Yamaha YZF-R1- Manuals

EAS00008 SYMBOLS The following symbols are not relevant toevery vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Fuel injection system 8 Electrical system 9 Troubleshooting Sym...

EAS00012 TABLE OF CONTENTS GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 CHASSIS CHAS 4 ENGINE ENG 5 COOLING SYSTEM COOL 6 FUEL INJECTION SYSTEM FI 7 ELECTRICAL SYSTEM ELEC 8 TROUBLESHOOTING TRBL SHTG 9 – +

CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISCS ...........................................................4-1 FRONT WHEEL ........................................................................................4-2REMOVING THE FRONT WHEEL ...........................................................4-3C...

HANDLEBARS .............................................................................................4-56 REMOVING THE HANDLEBARS ...........................................................4-58CHECKING THE HANDLEBARS ...........................................................4-58INSTALLING THE HA...

CHAPTER 6 COOLING SYSTEM RADIATOR .....................................................................................................6-1 CHECKING THE RADIATOR ...................................................................6-3INSTALLING THE RADIATOR ................................................

1 - 1 GEN INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering headpipe. EAS00018 MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to...

1 - 2 GEN INFO FEATURES FEATURES OUTLINE OF FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti-mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera-ture.In the conventional carburetor system, the a...

1 - 3 GEN INFO FEATURES FI SYSTEM The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains thefuel pressure that is applied to the injector at only 284 kPa (2.84 kg/cm 2 , 40.4 psi) higher than the intake manifold pressure. Accordingly, when the energizing si...

1 - 4 GEN INFO FEATURES Fuel control block The fuel control block consists of the following main components: An engine trouble warning light is provided on meter panel. Component Function Control block ECU Total FI system control Throttle body Air volume control Pressure regulator Fuel pressure dete...

1 - 5 GEN INFO FEATURES COMPONENTSECU (Electronic Control Unit) The ECU is mounted underneath the seat. The main functions of the ECU are ignition control, fuelcontrol, self-diagnosis, and load control.• ECU’s internal construction and functions The main components and functions of the ECU can be br...

1 - 7 GEN INFO FEATURES Fuel pump The fuel pump, which is mounted in the fuel tank, draws the fuel directly from the tank and pumps itto the injector.A filter that is provided in the fuel pump prevents any debris in the fuel tank from entering the fuelsystem downstream of the pump.The pump consists ...

1 - 8 GEN INFO FEATURES Pressure regulator It regulates the fuel pressure that is applied to the injectors that are provided in the cylinders in orderto maintain a constant pressure difference with the pressure in the intake manifold.The fuel that is delivered by the fuel pump fills the fuel chamber...

1 - 9 GEN INFO FEATURES Fuel injector Upon receiving injection signals from the ECU, the fuel injector injects fuel. In the normal state, thecore is pressed downward by the force of the spring, as illustrated. The plunger that is integratedwith the bottom of the core keeps the fuel passage closed.Wh...

1 - 10 GEN INFO FEATURES Crankshaft position sensor The crankshaft position sensor uses the signals of the pickup coil that is mounted on the right sideof the crankshaft. When the rotation of the pickup rotor that is attached to the crankshaft causes theprojections on the rotor to pass by the pickup...

1 - 12 GEN INFO FEATURES Throttle position sensor The throttle position sensor measures the intake air volume by detecting the position of the throttlevalve. It detects the mechanical angle of the throttle valve through the positional relationshipbetween the moving contact that moves in unison with ...

1 - 13 GEN INFO FEATURES Intake air pressure sensor and atmospheric pressure sensor • Intake air pressure sensor The intake air pressure sensor is used for measuring the intake air volume. The intake air volumeof every intake stroke is proportionate to the intake air pressure. Therefore, the intake ...

1 - 14 GEN INFO FEATURES Coolant temperature sensor The signals from the coolant temperature sensor are used primarily for making fuel volume compen-sations during starting and warm-up. The coolant temperature sensor converts the temperature ofthe coolant into electrical signals and sends them to th...

1 - 15 GEN INFO FEATURES Lean angle cut-off switch The lean angle cut-off switch stops the supply of fuel to the engine in case the motorcycle overturns.When the motorcycle is in the normal state, the cut-off switch outputs a constant voltage of approxi-mately 1.0 V (low level). When the motorcycle ...

1 - 16 GEN INFO FEATURES FUEL INJECTION SYSTEMOperation and control The fuel injection timing, injection duration, ignition timing, and the coil energizing duration are con-trolled by the ECU. To determine the basic injection timing, the ECU calculates the intake air volumethrough the signals from t...

1 - 17 GEN INFO FEATURES Determining the final injection duration The intake air volume determines the basic injection duration. However, at a given intake air vol-ume, the volume of fuel that is required varies by the engine operating conditions such as accelera-tion or deceleration, or by weather ...

1 - 19 GEN INFO FEATURES THREE-WAY CATALYTIC CONVERTER SYSTEMSystem outline This is a highly efficient exhaust gas cleaning system that effects air-fuel control through a jointeffort by the FI system and the three-way catalytic converter system. By effecting comprehensivecontrol of the air-fuel rati...

1 - 20 GEN INFO FEATURES INSTRUMENT FUNCTIONMulti-function display The multi-function display is equipped with thefollowing: • a speedometer (which shows the riding speed) • an odometer (which shows the total dis- tance traveled) • two tripmeters (which show the distance traveled since they were las...

1 - 22 GEN INFO FEATURES To set the engine speed indicator light activation function NOTE: _ The indicator light activation function can be set between 7,000 and 12,000 r/min in increments of500 r/min. 1. Push the “RESET” button to select the desired engine speed for activating the indicator light.2...

1 - 23 GEN INFO IMPORTANT INFORMATION EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS”. 3. When disassembling, a...

1 - 24 GEN INFO IMPORTANT INFORMATION EAS00023 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 locktabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install b...

1 - 25 GEN INFO CHECKING THE CONNECTIONS EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors forstains, rust, moisture, etc.1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains → Connect and disconne...

1 - 26 GEN INFO SPECIAL TOOLS EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Useonly the appropriate special tools as this will help prevent damage caused by the use of inappropri-ate tools or improvised techniques. Special tools, par...

2 - 1 SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5PW4 USA5PW5 California5PW6 Canada ------------ Dimensions Overall length 2,040 mm (80.3 in) ---- Overall width 705 mm (27.8 in) ---- Overall height 1,105 mm (43.5 in) ---- Seat height 820 mm (32.3 in) ---- Wheelbase 1,3...

2 - 2 SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, DOHC ---- Displacement 998 cm 3 (60.9 cu.in) ---- Cylinder arrangement Forward-inclined parallel 4-cylinder ---- Bore × stroke 74 × 58 mm (2.91 × 2.28 in) ---- Compression ratio 11....

2 - 4 SPEC ENGINE SPECIFICATIONS Camshafts Drive system Chain drive (right) ---- Camshaft cap inside diameter 24.500 ~ 24.521 mm (0.9646 ~ 0.9654 in) ---- Camshaft journal diameter 24.459 ~ 24.472 mm (0.9630 ~ 0.9635 in) ---- Camshaft-journal-to-camshaft-cap clearance 0.028 ~ 0.062 mm (0.0011 ~ 0.00...

2 - 5 SPEC ENGINE SPECIFICATIONS Timing chain Model/number of links RH2015/130 ---- Tensioning system Automatic ---- Valves, valve seats, valve guides Valve clearance (cold) Intake 0.11 ~ 0.20 mm (0.0043 ~ 0.0079 in) ---- Exhaust 0.21 ~ 0.27 mm (0.0083 ~ 0.0106 in) ---- Valve dimensions Valve head d...

2 - 6 SPEC ENGINE SPECIFICATIONS Valve stem runout ---- 0.01 mm (0.0004 in) Valve seat width Intake 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) ---- Exhaust 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) ---- Valve springs Free length Intake 38.9 mm (1.53 in) 37.0 mm (1.46 in) Exhaust 40.67 mm (1.60 in) 38.6 mm (1.52 in) ...

2 - 7 SPEC ENGINE SPECIFICATIONS Cylinders Cylinder arrangement Forward-inclined, parallel 4-cylinder ---- Bore × stroke 74 × 58 mm (2.91 × 2.28 in) ---- Compression ratio 11.8 : 1 ---- Bore 74.00 ~ 74.01 mm (2.9134 ~ 2.9138 in) ---- Max. taper ---- 0.05 mm (0.0020 in) Max. out-of-round ---- 0.05 mm...

2 - 8 SPEC ENGINE SPECIFICATIONS 2nd ring Ring type Taper ---- Dimensions (B × T) 0.8 × 2.8 mm (0.03 × 0.11 in) ---- End gap (installed) 0.43 ~ 0.58 mm (0.017 ~ 0.023 in) 0.93 mm (0.037 in) Ring side clearance 0.020 ~ 0.055 mm (0.0008 ~ 0.0022 in) 0.115 mm (0.0045 in) Oil ring Dimensions (B × T) 1.5...

2 - 9 SPEC ENGINE SPECIFICATIONS Clutch Clutch type Wet, multiple disc ---- Clutch release method Outer pull, rack and pinion pull ---- Clutch release method operation Cable operation ---- Operation Left-hand operation ---- Clutch cable free play (at the end of the clutch lever) 10 ~ 15 mm (0.4 ~ 0....

2 - 10 SPEC ENGINE SPECIFICATIONS Air filter type Wet element ---- Fuel pump Pump type Electrical ---- Model (manufacturer) 5PW (DENSO) ---- Output pressure 94 kPa (2.94 kg/cm 2 , 42.6 psi) ---- Throttle position sensor Resistance 4.85 ~ 5.15 k Ω at 20 °C (68 °F) ---- Output voltage (at idle) Adjust...

2 - 11 SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Diamond ---- Caster angle 24° ---- Trail 103 mm (4.06 in) ---- Front wheel Wheel type Cast wheel ---- Rim Size 17 M/C × MT3.50 ---- Material Aluminum ---- Wheel travel 120 mm (4.72 in) ---- Wheel runout Ma...

2 - 12 SPEC CHASSIS SPECIFICATIONS Front brakes Brake type Dual disc brake ---- Operation Right hand operation ---- Recommended fluid DOT 4 ---- Brake lever free play 2.3 ~ 11.5 mm (0.09 ~ 0.45 in) ---- Brake discs Diameter × thickness 298 × 5 mm (11.73 × 0.20 in) ---- Min. thickness ---- 4.5 mm (0....

2 - 13 SPEC CHASSIS SPECIFICATIONS Front suspension Suspension type Telescopic fork ---- Front fork type Coil spring/oil damper ---- Front fork travel 120 mm (4.72 in) ---- Spring Free length 251 mm (9.88 in) 246 mm (9.69 in) Spacer length 74 mm (2.91 in) ---- Installed length 244 mm (9.61 in) ---- ...

2 - 14 SPEC CHASSIS SPECIFICATIONS Rear suspension Suspension type Swingarm (link suspension) ---- Rear shock absorber assembly type Coil spring/gas-oil damper ---- Rear shock absorber assembly travel 65 mm (2.56 in) ---- Spring Free length 176.5 mm (6.95 in) ---- Installed length 162.5 mm (6.4 in) ...

2 - 15 SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V ---- Ignition system Ignition system type Transistorized coil ignition (digital) ---- Ignition timing 5° BTDC at 1,050 r/min ---- Crankshaft position sensor resistance/color 248 ~ 372 Ω at 20 °C (...

2 - 17 SPEC CONVERSION TABLE/TIGHTENING TORQUES EAS00028 CONVERSION TABLE All specification data in this manual are listedin SI and METRIC UNITS. Use this table to convert METRIC unit data toIMPERIAL unit data. CONVERSION TABLE TIGHTENING TORQUES EAS00029 GENERAL TIGHTENING TORQUE SPECIFICATIONS Thi...

2 - 18 SPEC TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Item Fastener Thread size Q’ty Tightening torque Remarks Nm m·kg ft·lb Spark plugs — M10 4 13 1.3 9.4 Cylinder head Nut M10 2 20 + 121° (50) 2.0 + 121° (5.0) 14 + 121° (36) E Cylinder head Nut M10 6 20 + 105° (50) 2.0 + 105° (5.0) 14 + 105° (3...

2 - 21 SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Item Thread size Tightening Remarks Nm m·kg ft·lb Upper bracket and front fork M8 26 2.6 19 Steering stem nut M28 115 11.5 83 Handlebar and front fork M6 13 1.3 9.4 Handlebar and upper bracket M6 13 1.3 9.4 Lower ring nut M30 9 0.9 6.5 See NO...

2 - 23 SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Oil seal lips LS O-rings LS Bearings E Crankshaft pins E Piston surfaces E Piston pins E Connecting rod bolts and nuts M Crankshaft journals E Camshaft lobes M Camsha...

2 - 24 SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lower) LS Front wheel oil seal (right and left) LS Rear wheel oil seal LS Rear wheel drive hub oil seal LS Rear wheel drive hub mating surface LS Rear brake ...

2 - 25 SPEC COOLING SYSTEM DIAGRAMS EAS00033 COOLING SYSTEM DIAGRAMS 1 Radiator fan 2 Radiator 3 Water pump

2 - 29 SPEC ENGINE OIL LUBRICATION CHART ENGINE OIL LUBRICATION CHART Exhaust camshaft Intake camshaft Piston cooler Main gallery Oil filter Oilcooler Reliefvalve Oil pump Strainer Main axle Mission cooler Drive axle

2 - 30 SPEC LUBRICATION DIAGRAMS EAS00034 LUBRICATION DIAGRAMS 1 Intake camshaft 2 Exhaust camshaft 3 Oil filter cartridge 4 Oil level switch

2 - 35 SPEC CABLE ROUTING EAS00035 CABLE ROUTING 1 Headlight drain plug È Make sure to securely insertthe coupler and boot. É The headlight lead can berouted by either of the head-light or the boss. Do not catchthe headlight lead whenassembling the front cowling. Ê Do not make the lead stretchtoo mu...

2 - 45 SPEC for California 1 Canister 2 Roll over valve assembly 3 Hose (fuel tank breather – canister) 4 Hose (canister – roll over valve) 5 Hose (roll over valve – throttle body) È To throttle body É To atomosphere CABLE ROUTING

3 - 1 CHK ADJ EAS00036 PERIODIC CHECKS AND ADJUSTMENTS 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, alonger service life and reduce the need...

3 - 2 CHK ADJ * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi(7,000 km) or 6 months. NOTE: ● Air filter • This model’s air filter is ...

3 - 3 CHK ADJ SEATS EAS00039 SEATS T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order Job/Part Q’ty Remarks Removing the seats Remove the parts in the order listed. 1 Passenger seat 1 2 Rider seat 1 For installation, reverse the removal procedure.

3 - 4 CHK ADJ FUEL TANK EAS00040 FUEL TANK T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 4 Nm (0.4 m • kg, 2.9 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Rider seat Refer to “SEATS”. 1 Bolt 1 2 Bolt 1 3 F...

3 - 5 CHK ADJ FUEL TANK REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel return hose• fuel hose CAUTION: Although the fuel has been removed fromthe fuel tank be careful when removing thefuel hoses, since there may be fuel remain-ing...

3 - 6 CHK ADJ FUEL TANK INSTALLING THE FUEL PUMP 1. Install: • fuel pump NOTE: • Do not damage the installation surfaces of the fuel tank when installing the fuel pump. • Always use a new fuel pump gasket.• Install the fuel pump as shown in the illustra- tion. • Tighten the fuel pump bolts in stages...

3 - 7 CHK ADJ COWLINGS EAS00042 COWLINGS Order Job/Part Q’ty Remarks Removing the cowlings Remove the parts in the order listed. Rider and passenger seats Refer to “SEATS”. 1 Tail cowling 1 2 Bottom cowling 1 3 Front cowling inner panel (left) 1 4 Front cowling inner panel (right) 1 5 Left side cowl...

3 - 8 CHK ADJ AIR FILTER CASE EAS00043 AIR FILTER CASE T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) 3 Nm (0.3 m • kg, 2.2 ft • Ib) T R . . Order Job/Part Q’ty Remarks Removing the air filter case Remove the parts in the order listed. Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK”. 1 Crankcase ...

3 - 9 CHK ADJ ADJUSTING THE VALVE CLEARANCE EAS00045 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of thevalves. 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 pist...

3 - 10 CHK ADJ ADJUSTING THE VALVE CLEARANCE 4. Measure: • valve clearance Out of specification → Adjust. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the TDC mark a on the pickup rotor with the cra...

3 - 11 CHK ADJ ADJUSTING THE VALVE CLEARANCE 5. Remove: • camshaft NOTE: _ • Refer to “DISASSEMBLING THE ENGINE—CAMSHAFT AND CYLINDERHEAD” in chapter 5. • When removing the timing chain and cam- shafts, fasten the timing chain with a wire toretrieve it if it falls into the crankcase. 6. Adjust: • va...

3 - 12 CHK ADJ ADJUSTING THE VALVE CLEARANCE c. Round off the original valve pad number according to the following table. Last digit Rounded value 0 or 2 0 5 5 8 10 EXAMPLE: Original valve pad number = 148 (thickness =1.48 mm) Rounded value = 150d. Locate the rounded number of the original valve pad...

3 - 13 CHK ADJ ADJUSTING THE VALVE CLEARANCE VALVE PAD SELECTION TABLEINTAKE EXHAUST Measured clearance INSTALLED PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195...

3 - 14 CHK ADJ ADJUSTING THE VALVE CLEARANCE/ SYNCHRONIZING THE THROTTLE BODIES NOTE: @ • Refer to “ASSEMBLING AND ADJUSTING THE ENGINE—CYLINDER HEAD ANDCAMSHAFT” in chapter 5. • Lubricate the camshaft bearings, camshaft lobes and camshaft journals. • First, install the exhaust camshaft. • Align the...

3 - 15 CHK ADJ SYNCHRONIZING THE THROTTLE BODIES 4. Install: • carburetor syncronizer 1 (onto the synchronizing hose) • digital tachometer (near the spark plug) 5. Install: • fuel tank Refer to “FUEL TANK”. 6. Star t the engine and let it warm up for sev- eral minutes. 7. Measure: • engine idling sp...

3 - 16 CHK ADJ SYNCHRONIZING THE THROTTLE BODIES/ ADJUSTING THE ENGINE IDLING SPEED NOTE: @ The difference in vacuum pressure betweentwo throttle bodies should not exceed 1.33 kPa(10 mmHg, 0.39 inHg). ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 9. Measure: • engine idling speed Out of specific...

3 - 17 CHK ADJ ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY 2. Install: • digital tachometer (onto the spark plug lead of cylinder #1) 3. Check: • engine idling speed Out of specification → Adjust. 4. Adjust: • engine idling speed ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ...

3 - 18 CHK ADJ ADJUSTING THE THROTTLE CABLE FREE PLAY 2. Remove: • rider seat Refer to “SEATS”. • fuel tank Refer to “FUEL TANK”. • air filter case Refer to “AIR FILTER CASE”. 3. Adjust: • throttle cable free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ NOTE: _ When the throttle is opened,...

3 - 19 CHK ADJ ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS d. Tighten the locknut. WARNING _ After adjusting the throttle cable free play,start the engine and turn the handlebars tothe right and to the left to ensure that thisdoes not cause the engine idling speed tochange. ▲▲▲ ...

3 - 20 CHK ADJ CHECKING THE SPARK PLUGS/ MEASURING THE COMPRESSION PRESSURE 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) 6. Me...

3 - 21 CHK ADJ MEASURING THE COMPRESSION PRESSURE 1. Measure: • valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEAR-ANCE”. 2. Star t the engine, warm it up for several min- utes, and then turn it off. 3. Remove: • rider seat Refer to “SEATS”. • fuel tank Refer to “FUEL...

3 - 22 CHK ADJ MEASURING THE COMPRESSION PRESSURE ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Set the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compressiongauge stabilizes. WARNING _ To prevent sparking, ground all spark plugleads before ...

3 - 23 CHK ADJ MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL 7. Install: • spark plug • ignition coil 8. Install: • rubber baffle• ignition coil plates• air filter case Refer to “AIR FILTER CASE”. • fuel tank Refer to “FUEL TANK”. • rider seat Refer to “SEATS”. T R . . 13 Nm (1.3...

3 - 24 CHK ADJ CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL 4. Star t the engine, warm it up for several min- utes, and then turn it off. 5. Check the engine oil level again. NOTE: _ Before checking the engine oil level, wait a fewminutes until the oil has settled. EAS00073 CHANGING THE EN...

3 - 25 CHK ADJ CHANGING THE ENGINE OIL c. Tighten the new oil filter cartridge to specifi- cation with an oil filter wrench. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ T R . . Oil filter cartridge 17 Nm (1.7 m · kg, 12 ft · lb) 6. Check: • engine oil drain bolt gasket Damage → Replace. 7. Ins...

3 - 26 CHK ADJ CHANGING THE ENGINE OIL/ ADJUSTING THE CLUTCH CABLE FREE PLAY 13.Check: • engine oil pressure ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Slightly loosen the oil gallery bolt 1 . b. Star t the engine and keep it idling until engine oil star ts to seep from the oil gallerybolt...

3 - 27 CHK ADJ ADJUSTING THE CLUTCH CABLE FREE PLAY 2. Adjust: • clutch cable free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ Handlebar side a. Turn the adjusting dial 1 in direction a or b until the specified clutch cable free play is obtained. NOTE: _ If the specified clutch cable free...

3 - 28 CHK ADJ REPLACING THE AIR FILTER ELEMENT EAS00086 REPLACING THE AIR FILTER ELEMENT 1. Remove: • rider seat Refer to “SEATS”. • fuel tank Refer to “FUEL TANK”. 2. Remove: • air filter case cover 1 3. Check: • air filter element 1 Damage → Replace. NOTE: Replace the air filter element at period...

3 - 29 CHK ADJ CHECKING THE FUEL AND BREATHER HOSES/ CHECKING THE CRANKCASE BREATHER HOSE EAS00096 CHECKING THE FUEL AND BREATHER HOSES The following procedure applies to all of thefuel and breather hoses.1. Remove: • rider seat Refer to “SEATS”. • fuel tank Refer to “FUEL TANK”. 2. Check: • breathe...

3 - 30 CHK ADJ CHECKING THE CRANKCASE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM 3. Install: • fuel tank Refer to “FUEL TANK”. • rider seat Refer to “SEATS”. EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of theexhaust pipes and gaskets.1. Remove: • radiator Refer to “RA...

3 - 31 CHK ADJ ADJUSTING THE EXUP CABLES EAS00101 ADJUSTING THE EXUP CABLES 1. Remove: • bottom cowling Refer to “COWLINGS”. 2. Remove: • EXUP valve pulley cover 1 3. Check: • EXUP system operation ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the main switch ON.b. Check that the EXUP va...

3 - 32 CHK ADJ ADJUSTING THE EXUP CABLES/ CHECKING THE COOLANT LEVEL 7. Install: • bottom cowling Refer to “COWLINGS”. EAS00102 CHECKING THE COOLANT LEVEL 1. Stand the motorcycle on a level surface. NOTE: _ • Place the motorcycle on a suitable stand. • Make sure the motorcycle is upright. 2. Check: ...

3 - 33 CHK ADJ CHECKING THE COOLING SYSTEM EAS00104 CHECKING THE COOLING SYSTEM 1. Remove: • bottom cowling• side cowlings Refer to “COWLINGS”. 2. 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 j...

3 - 34 CHK ADJ CHANGING THE COOLANT EAS00105 CHANGING THE COOLANT 1. Remove: • side cowling• bottom cowling Refer to “COWLINGS”. 2. Disconnect: • coolant reservoir hose 1 3. Drain: • coolant (from the coolant reservoir) 4. Remove: • radiator cap 1 WARNING _ A hot radiator is under pressure. Therefor...

3 - 35 CHK ADJ CHANGING THE COOLANT 10.Fill: • cooling system (with the specified amount of the recom-mended coolant) Handling notes for coolant Coolant is potentially harmful and should behandled with special care. WARNING _ • If coolant splashes in your eyes, thor- oughly wash them with water and ...

3 - 36 CHK ADJ CHANGING THE COOLANT 11.Install: • radiator cap 12.Fill: • coolant reservoir (with the recommended coolant to the maxi-mum level mark a ) 13.Install: • coolant reservoir cap 14.Start the engine, warm it up for several min- utes, and then stop it. 15.Check: • coolant level Refer to “CH...

3 - 37 CHK ADJ ADJUSTING THE FRONT BRAKE EAS00107 CHASSIS ADJUSTING THE FRONT 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. • ...

3 - 38 CHK ADJ ADJUSTING THE REAR BRAKE EAS00110 ADJUSTING THE REAR BRAKE 1. Check: • brake pedal position (distance a from the top of the brake pedal to the bottom of the rider footrest bracket) Out of specification → Adjust. 2. Adjust: • brake pedal position ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...

3 - 39 CHK ADJ ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL 3. Adjust: • rear brake light switch Refer to “ADJUSTING THE REAR BRAKELIGHT SWITCH”. EAS00115 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: _ • Place the motorcycle on a suitable stand. • Make...

3 - 40 CHK ADJ CHECKING THE FRONT AND REAR BRAKE PADS/ ADJUSTING THE REAR BRAKE LIGHT SWITCH EAS00122 CHECKING THE FRONT AND REAR BRAKE PADS The following procedure applies to all of thebrake pads.1. Operate the brake. 2. Check: • front brake pad • rear brake pad Wear indicator groove 1 almost disap...

3 - 41 CHK ADJ CHECKING THE FRONT AND REAR BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00131 CHECKING THE FRONT AND REAR BRAKE HOSES The following procedure applies to all of thebrake hoses and brake hose clamps.1. Check: • brake hose Cracks/damage/wear → Replace. 2. Check: • brake hose clam...

3 - 42 CHK ADJ BLEEDING THE HYDRAULIC BRAKE SYSTEM 1. Bleed: • hydraulic brake system ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. b. Install the brake fluid reservoir diaphragm. c. Connect a clear plastic h...

3 - 43 CHK ADJ ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK EAS00136 ADJUSTING THE SHIFT PEDAL 1. Check: • shift pedal position (distance a from the bottom of the rider footrest bracket to the top of the shift pedal) Out of specification → Adjust. 2. Adjust: • shift pedal position ▼▼▼ ...

3 - 44 CHK ADJ ADJUSTING THE DRIVE CHAIN SLACK 3. Check: • drive chain slack a Out of specification → Adjust. T R . . Drive chain slack 40 ~ 50 mm (1.57 ~ 1.97 in) 4. Adjust: • drive chain slack ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loosen the wheel axle nut 1 . b. Loosen both locknut...

3 - 45 CHK ADJ LUBRICATING THE DRIVE CHAIN/ CHECKING AND ADJUSTING THE STEERING HEAD EAS00142 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interactingparts. If the drive chain is not maintained prop-erly, it will wear out quickly. Therefore, thedrive chain should be serviced, especia...

3 - 46 CHK ADJ CHECKING AND ADJUSTING THE STEERING HEAD 3. Remove: • upper bracket Refer to “HANDLEBARS” and “STTERLINGHEAD” in chapter 4. 4. Adjust: • steering head ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the lock washer 1 , the upper ring nut 2 , and the rubber washer 3 . b. Lo...

3 - 47 CHK ADJ CHECKING AND ADJUSTING THE STEERING HEAD 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 neces-sary, hold the lower ring nut and tighten theupper ring nut until their slots are align...

3 - 48 CHK ADJ CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK g. Reinstall the upper bracket and measure the steering head tension again as describedabove. h. Repeat the above procedure until the steer- ing head tension is within specification. i. Grasp the bottom of the front for...

3 - 49 CHK ADJ ADJUSTING THE FRONT FORK LEGS EAS00155 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of thefront fork legs. WARNING _ • Always adjust both front fork legs evenly. Uneven adjustment can result in poorhandling and loss of stability. • Securely support the motorcy...

3 - 51 CHK ADJ ADJUSTING THE FRONT FORK LEGS/ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ Direction a Compression damping is increased (suspen-sion is harder). Direction b Compression damping is decreased (suspen-sion is softer). Adjusting positions Mi...

3 - 52 CHK ADJ ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ Rebound damping CAUTION: _ Never go beyond the maximum or mini-mum adjustment positions. Direction a Spring preload is increased (suspension is harder). Direction b Spring preload is decreased...

3 - 54 CHK ADJ CHECKING THE TIRES * Total weight of rider, passenger, cargo and acces- sories WARNING _ It is dangerous to ride with a worn-out tire.When the tire tread reaches the wear limit,replace the tire immediately. Basic weight (with oil and a full fuel tank) For USA, Canada 193 kg (426 lb) F...

3 - 56 CHK ADJ CHECKING THE TIRES/ CHECKING THE WHEELS Front tire Rear tire WARNING _ New tires have a relatively low grip on theroad surface until they have been slightlyworn. Therefore, approximately 100 kmshould be traveled at normal speed beforeany high-speed riding is done. NOTE: _ For tires wi...

3 - 57 CHK ADJ CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS AND PEDALS/LUBRICATING THE SIDESTAND/LUBRICATING THE REAR SUSPENSION EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of theinner and outer cables. WARNING _ Damaged outer cable may cause th...

3 - 58 CHK ADJ CHECKING AND CHARGING THE BATTERY EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING _ Batteries generate explosive hydrogen gasand contain electrolyte which is made ofpoisonous and highly caustic sulfuric acid. Therefore, always follow these preventivemeasures: • We...

3 - 60 CHK ADJ CHECKING AND CHARGING THE BATTERY 5. Charge: • battery (refer to the appropriate charging methodillustration) WARNING _ Do not quick charge a battery. CAUTION: _ • Never remove the MF battery sealing caps. • Do not use a high-rate battery charger since it forces a high-amperage curren...

3 - 61 CHK ADJ CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger Measure the open-circuitvoltage prior to charging. Connect a charger and AMP meter to the battery and start charging. Make sure that the currentis higher than the standardcharging current writ...

3 - 62 CHK ADJ CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger Measure the open-circuitvoltage prior to charging. Connect a charger and AMP meter to the battery and start charging. NO YES Make sure that the currentis higher than the standardcharging current written...

3 - 63 CHK ADJ CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) CAUTION: _ First, connect the positive battery lead 1 , and then the negative battery lead 2 . 8. Check: • battery terminals Dirt → Clean with a wire brus...

3 - 64 CHK ADJ CHECKING THE FUSES 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 bl...

3 - 65 CHK ADJ REPLACING THE HEADLIGHT BULBS EAS00183 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of theheadlight bulbs.1. Disconnect: • headlight coupler 1 2. Remove: • headlight bulb cover 2 3. Remove: • headlight bulb holder 1 4. Remove: • headlight bulb 2 WARNING _ Sinc...

3 - 66 CHK ADJ ADJUSTING THE HEADLIGHT BEAM EAS00184 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: • headlight beam (vertically) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting screw 1 in direction a or b . ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Adjust: • headlight be...

4 - 1 CHAS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS Order Job/Part Q’ty Remarks Removing the front wheel and brake discs Remove the parts in the order listed. NOTE: _ Place the motorcycle on a suitable standso that the front wheel is elevated. 1 Brake hose holder (left and right) 2 2 Brake calip...

4 - 2 CHAS FRONT WHEEL AND BRAKE DISCS EAS00518 FRONT WHEEL Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the order listed. 1 Oil seal (left and right) 2 2 Wheel bearing (left and right) 2 3 Spacer 1 For assembly, reverse the disassembly procedure.

4 - 3 CHAS FRONT WHEEL AND BRAKE DISCS EAS00521 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. WARNING _ Securely support the motorcycle so thatthere is no danger of it falling over. NOTE: _ Place the motorcycle on a suitable stand sothat the front wheel is elevated. 2. Remove:...

4 - 5 CHAS FRONT WHEEL AND BRAKE DISCS EAS00533 CHECKING THE BRAKE DISCS The following procedure applies to all of thebrake discs.1. Check: • brake disc Damage/galling → Replace. 2. Measure: • brake disc deflection Out of specification → Correct the brake disc deflection or replace the brake disc. ▼...

4 - 6 CHAS FRONT WHEEL AND BRAKE DISCS d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is withinspecification. f. If the brake disc deflection cannot be brought within specification, replace thebrake disc. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ...

4 - 7 CHAS FRONT WHEEL AND BRAKE DISCS 8. Tighten wheel axle pinch bolt 1 , and then pinch bolt 2 to the specified torque. 9. Tap the outer side of the right fork leg with a rubber mallet to align it with the end of thewheel axle. 10.Tighten wheel axle pinch bolt 3 , and then pinch bolt 4 to the spe...

4 - 9 CHAS REAR WHEEL AND BRAKE DISC EAS00551 REAR WHEEL AND BRAKE DISC T R . . 27 Nm (2.7 m • kg, 20 ft • Ib) T R . . 150 Nm (15.0 m • kg, 108 ft • lb) Order Job/Part Q’ty Remarks Removing the rear wheel Remove the parts in the order listed. NOTE: @ Place the motorcycle on a suitable standso that t...

4 - 10 CHAS REAR WHEEL AND BRAKE DISC EAS00560 REAR WHEEL Order Job/Part Q’ty Remarks Disassembling the rear wheel Remove the parts in the order listed. 1 Spacer 1 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Circlip 1 6 Bearing 1 For installation, reverse the disassembly procedure.

4 - 12 CHAS REAR WHEEL AND BRAKE DISC EAS00561 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. WARNING _ Securely support the motorcycle so thatthere is no danger of it falling over. NOTE: _ Place the motorcycle on a suitable stand sothat the rear wheel is elevated. 2. Remove: • ...

4 - 13 CHAS REAR WHEEL AND BRAKE DISC 5. Remove: • left collar 1 • rear wheel drive hub 2 • rear wheel drive hub damper • right collar EAS00565 CHECKING THE REAR WHEEL 1. Check: • wheel axle • rear wheel • wheel bearings • oil seals Refer to “CHECKING THE FRONTWHEEL”. 2. Check: • tire • rear wheel D...

4 - 14 CHAS REAR WHEEL AND BRAKE DISC EAS00568 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: •...

4 - 15 CHAS REAR WHEEL AND BRAKE DISC 2. Adjust: • drive chain slack Refer to “ADJUSTING THE DRIVE CHAINSLACK” in chapter 3. 3. Tighten: • wheel axle nut • brake caliper bolts WARNING _ Make sure the brake hose is routed prop-erly. CAUTION: _ Do not loosen the wheel axle nut after tight-ening it to ...

4 - 16 CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS T R . . 6 Nm (0.6 m • kg, 4.3 ft • Ib) T R . . 6 Nm (0.6 m • kg, 4.3 ft • Ib) T R . . 40 Nm (4.0 m • kg, 29 ft • Ib) Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. The f...

4 - 17 CHAS FRONT AND REAR BRAKES REAR BRAKE PADS T R . . 6 Nm (0.6 m • kg, 4.3 ft • Ib) T R . . 27 Nm (2.7 m • kg, 20 ft • Ib) Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. 1 Brake caliper 1 2 Brake pad 2 3 Brake pad shim 2/2 4 Brake pad spring 2 5 B...

4 - 18 CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: _ Disc brake components rarely require dis-assembly. Therefore, always follow these preventivemeasures: WARNING • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the...

4 - 19 CHAS FRONT AND REAR BRAKES 2. Remove: • brake pad clips 1 • brake pad pins 2 • brake pad spring 3 3. Remove: • brake pads 1 (along with the brake pad shims) 4. Measure: • brake pad wear limit Out of specification → Replace the brake pads as a set. 5. Install: • brake pad shims (onto the brake...

4 - 21 CHAS FRONT AND REAR BRAKES EAS00583 REPLACING THE REAR BRAKE PADS NOTE: _ When replacing the brake pads, it is not neces-sary to disconnect the brake hose or disas-semble the brake caliper. 1. Remove: • brake caliper 1 2. Remove: • brake pads 1 (along with the brake pad shims) 3. Measure: • b...

4 - 23 CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER T R . . 30 Nm (3.0 m • kg, 22 ft • Ib) T R . . 9 Nm (0.9 m • kg, 6.5 ft • Ib) Order Job/Part Q’ty Remarks Removing the front brake master cylinder Remove the parts in the order listed. Brake fluid Drain. 1 Brake fluid reservoir c...

4 - 26 CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER T R . . 18 Nm (1.8 m • kg, 13 ft • Ib) T R . . 30 Nm (3.0 m • kg, 22 ft • Ib) T R . . 3 Nm (0.3 m • kg, 2.2 ft • Ib) Order Job/Part Q’ty Remarks Removing the rear brake master cylinder Remove the parts in the order listed. Brake f...

4 - 30 CHAS FRONT AND REAR BRAKES EAS00607 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING _ • Before installation, all internal brake com- ponents should be cleaned and lubricatedwith clean or new brake fluid. • Never use solvents on internal brake components. Recommended brake fl...

4 - 32 CHAS FRONT AND REAR BRAKES EAS00610 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 1. Install: • copper washers • brake hose• union bolt CAUTION: _ When installing the brake hose onto thebrake master cylinder, make sure that thebrake pipe touches the projection a on the brake master cylinder. WARN...

4 - 34 CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS T R . . 6 Nm (0.6 m • kg, 4.3 ft • Ib) T R . . 40 Nm (4.0 m • kg, 29 ft • Ib) T R . . 30 Nm (3.0 m • kg, 22 ft • Ib) Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. The following proce...

4 - 36 CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER T R . . 30 Nm (3.0 m • kg, 22 ft • Ib) T R . . 27 Nm (2.7 m • kg, 20 ft • Ib) Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain. 1 Union bolt 1 2 Copper washer 2 3 Brake ho...

4 - 38 CHAS FRONT AND REAR BRAKES EAS00625 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of thebrake calipers. NOTE: _ Before disassembling the brake caliper, drainthe brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hose...

4 - 39 CHAS FRONT AND REAR BRAKES EAS00627 DISASSEMBLING THE REAR BRAKE CALIPER NOTE: _ Before disassembling the brake caliper, drainthe brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hose NOTE: _ Put the end of the brake hose into a containerand pump ...

4 - 41 CHAS FRONT AND REAR BRAKES EAS00640 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of thebrake calipers. WARNING _ • Before installation, all internal brake com- ponents should be cleaned and lubricatedwith clean or new brake fluid. • Never use solv...

4 - 45 CHAS FRONT FORK EAS00647 FRONT FORK T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 6 Nm (0.6 m • kg, 4.3 ft • Ib) T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 13 Nm (1.3 m • kg, 9.4 ft • Ib) T R . . 26 Nm (2.6 m • kg, 19 ft • Ib) Order Job/Part Q’ty Remarks Removing the front fork legs Remo...

4 - 46 CHAS FRONT FORK EAS00648 T R . . 40 Nm (4.0 m • kg, 29 ft • Ib) Order Job/Part Q’ty Remarks Disassembling the front fork legs Remove the parts in the order listed. 1 Cap bolt 1 2 O-ring 1 3 Spacer 1 4 Nut 1 5 Spring seat 1 6 Fork spring 1 7 Damper adjusting rod 1 8 Outer tube 1 9 Dust seal 1 ...

4 - 48 CHAS FRONT FORK EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of thefront fork legs.1. Stand the motorcycle on a level surface. WARNING _ Securely support the motorcycle so thatthere is no danger of it falling over. NOTE: _ Place the motorcycle on a suitable st...

4 - 49 CHAS FRONT FORK NOTE: @ Use the side of the rod holder that is marked“B”. c. Loosen the nut.d. Remove the cap bolt.e. Remove the rod holder and fork spring com- pressor. WARNING _ The fork spring is compressed. f. Remove the spacer and nut. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ Fo...

4 - 50 CHAS FRONT FORK EAS00656 CHECKING THE FRONT FORK LEGS The following procedure applies to both of thefront fork legs.1. Check: • inner tube 1 • outer tube 2 Bends/damage/scratches → Replace. WARNING @ Do not attempt to straighten a bent innertube as this may dangerously weaken it. 2. Measure: ...

4 - 52 CHAS FRONT FORK 4. Install: • dust seal 1 • oil seal clip 2 • oil seal 3 • washer 4 CAUTION: @ Make sure the numbered side of the oil sealfaces out side. NOTE: _ • Before installing the oil seal, lubricate its lips with lithium-soap-based grease. • Lubricate the outer surface of the inner tub...

4 - 53 CHAS FRONT FORK 8. Install: • rod puller 1 (onto the damper rod 2 ) Rod puller YM-01437 9. Fill: • front fork leg (with the specified amount of the recom-mended fork oil) NOTE: _ • While filling the front fork leg, keep it upright. • After filling, slowly pump the front fork leg up and down t...

4 - 54 CHAS FRONT FORK d. Press down on the spacer with the fork spring compressor 1 . e. Pull up the rod puller and install the rod holder 2 between the nut 3 and the spacer 4 . NOTE: _ Use the side of the rod holder that is marked“B”. f. Remove the rod puller and adapter.g. Install the nut 1 and p...

4 - 55 CHAS FRONT FORK EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of thefront fork legs.1. Install: • front fork leg Temporarily tighten the upper and lowerbracket pinch bolts. NOTE: _ Make sure the inner fork tube is flush with thetop of the handlebar holder. 2....

4 - 56 CHAS HANDLEBARS EAS00665 HANDLEBARS T R . . 9 Nm (0.9 m • kg, 6.5 ft • Ib) T R . . 13 Nm (1.3 m • kg, 9.4 ft • Ib) T R . . 26 Nm (2.6 m • kg, 19 ft • Ib) T R . . 115 Nm (11.5 m • kg, 83 ft • lb) T R . . 13 Nm (1.3 m • kg, 9.4 ft • Ib) T R . . 4 Nm (0.4 m • kg, 2.9 ft • Ib) Order Job/Part Q’ty...

4 - 58 CHAS HANDLEBARS EAS00667 REMOVING THE HANDLEBARS 1. Stand the motorcycle on a level surface. WARNING _ Securely support the motorcycle so thatthere is no danger of it falling over. 2. Remove: • handlebar grip NOTE: _ Blow compressed air between the left handle-bar and the handlebar grip, and ...

4 - 59 CHAS HANDLEBARS 2. Install: • right handlebar switch 1 NOTE: _ Align the projection a on the right handlebar switch with the hole b in the right handlebar. 3. Install: • brake master cylinder holder 1 CAUTION: _ • Install the brake master cylinder holder with the “UP” mark facing up. • First,...

4 - 61 CHAS STEERING HEAD EAS00676 STEERING HEAD T R . . 1st 50 Nm (5.0 m • kg, 36 ft • lb) 2nd 9 Nm (0.9 m • kg, 6.5 ft • lb) T R . . 115 Nm (11.5 m • kg, 83 ft • lb) T R . . 26 Nm (2.6 m • kg, 19 ft • Ib) T R . . 13 Nm (1.3 m • kg, 9.4 ft • Ib) Order Job/Part Q’ty Remarks Removing the lower bracke...

4 - 63 CHAS STEERING HEAD EAS00677 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. WARNING _ Securely support the motorcycle so thatthere is no danger of it falling over. 2. Remove: • ring nut 1 (with the steering nut wrench 2 ) WARNING _ Securely support the lower bracket so ...

4 - 64 CHAS STEERING HEAD b. Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer. c. Install a new rubber seal and new bearing races. CAUTION: _ If the bearing race is not installed properly,the steering head pipe could be damaged. NOTE: _ • Always replace the bearings ...

4 - 65 CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY T R . . 45 Nm (4.5 m • kg, 33 ft • Ib) T R . . 45 Nm (4.5 m • kg, 33 ft • Ib) T R . . 45 Nm (4.5 m • kg, 33 ft • Ib) 1 Order Job/Part Q’ty Remarks Removing the rear shock absorber assembly Remove the parts in the order li...

4 - 66 CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00687 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER WARNING _ This rear shock absorber and gas cylindercontain highly compressed nitrogen gas.Before handling the rear shock absorber orgas cylinder, read and make sure youunderstand the following informa...

4 - 67 CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00690 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the motorcycle on a level surface. WARNING _ Becurely support the motorcycle so thatthere is no danger of it falling over. NOTE: _ Place the motorcycle on a suitable stand sothat the rear wheel is el...

4 - 69 CHAS SWINGARM AND DRIVE CHAIN EAS00700 SWINGARM AND DRIVE CHAIN T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 5 Nm (0.5 m • kg, 3.6 ft • Ib) T R . . 105 Nm (10.5 m • kg, 76 ft • lb) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 4 Nm (0.4 m • kg, 2.9 ft • Ib) Order Job/Part Q’ty Remarks Remo...

4 - 71 CHAS SWINGARM AND DRIVE CHAIN EAS00703 REMOVING THE SWINGARM 1. Stand the motorcycle on a level surface. WARNING _ Securely support the motorcycle so thatthere is no danger of it falling over. NOTE: _ Place the motorcycle on a suitable stand sothat the rear wheel is elevated. 2. Remove: • rel...

4 - 72 CHAS SWINGARM AND DRIVE CHAIN EAS00704 REMOVING THE DRIVE CHAIN 1. Stand the motorcycle on a level surface. WARNING _ Securely support the motorcycle so thatthere is no danger of it falling over. NOTE: _ Place the motorcycle on a suitable stand sothat the rear wheel is elevated. 2. Remove: • ...

4 - 73 CHAS SWINGARM AND DRIVE CHAIN 3. Wash: • pivot shaft • dust covers • spacer • washers • bearings Recommended cleaning solvent Kerosene 4. Check: • dust covers 1 • spacer 2 Damage/wear → Replace. • bearings 3 Damage/pitting → Replace. 5. Check: • connecting arms 1 • relay arm 2 Damage/wear → R...

4 - 74 CHAS SWINGARM AND DRIVE CHAIN 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 t...

4 - 75 CHAS SWINGARM AND DRIVE CHAIN 6. Check: • drive sprocket • rear wheel sprocket More than 1/4 tooth a wear → Replace the drive chain sprockets as a set. Bent teeth → Replace the drive chain sprockets as a set. b Correct 1 Drive chain roller 2 Drive chain sprocket EAS00711 INSTALLING THE SWINGA...

5 - 1 ENG EAS00188 OVERHAULING THE ENGINE ENGINE DRIVE SPROCKET T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 85 Nm (8.5 m • kg, 61 ft • Ib) Order Job/Part Q’ty Remarks Removing the drive sprocket Remove the parts in the order listed. 1 Locknut 2 2 Shift rod 1 3 Drive sprocket cover 1 4 Lock washe...

5 - 2 ENG ENGINE EAS00189 EXHAUST PIPE T R . . 20 Nm (2.0 m • kg, 14 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 20 Nm (2.0 m • kg, 14 ft • Ib) T R . . 38 Nm (3.8 m • kg, 27 ft • Ib) T R . . 20 Nm (2.0 m • kg, 14 ft • Ib) Order Job/Part Q’ty Remarks Removing the exhaust pipe Remove the ...

5 - 4 ENG ENGINE LEADS AND HOSES T R . . 20 Nm (2.0 m • kg, 14 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q’ty Remarks Disconnecting the leads and hoses Disconnect the parts in the order listed. Air filter case Refer to “AIR FILTER CASE” in chapter 3. Throttle body assembly Refe...

5 - 8 ENG CAMSHAFT EAS00194 CAMSHAFT CYLINDER HEAD COVERS T R . . 13 Nm (1.3 m • kg, 9.4 ft • Ib) T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q’ty Remarks Removing the cylinder head covers Remove the parts in the order listed. Throttle body assembly...

5 - 9 ENG CAMSHAFT EAS00196 CAMSHAFTS T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 24 Nm (2.4 m • kg, 17 ft • Ib) Order Job/Part Q’ty Remarks Removing the camshafts Remove the pa...

5 - 11 ENG CAMSHAFT EAS00198 REMOVING THE CAMSHAFTS 1. Align: • TDC mark on the pickup coil rotor (with the crankcase mating surface) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the TDC mark a on t...

5 - 12 ENG CAMSHAFT 6. Remove: • timing chain guide (exhaust side) 1 • camshaft caps • dowel pins CAUTION: _ To prevent damage to the cylinder head,camshafts or camshaft caps, loosen thecamshaft cap bolts in stages and in a criss-cross pattern, working from the outside in. 7. Remove: • intake camsha...

5 - 13 ENG CAMSHAFT 3. Measure: • camshaft runout Out of specification → Replace. 4. Measure: • camshaft-journal-to-camshaft-cap clear- ance Out of specification → Measure the cam- shaft journal diameter. Camshaft runout limit 0.03 mm (0.0012 in) Camshaft-journal-to-camshaft-cap clearance 0.028 ~ 0....

5 - 14 ENG CAMSHAFT 5. Measure: • camshaft journal diameter a Out of specification → Replace the cam- shaft. Within specification → Replace the cylinder head and the camshaft caps as a set. Camshaft journal diameter 24.459 ~ 24.472 mm (0.9630 ~ 0.9635 in) EAS00208 CHECKING THE TIMING CHAIN, CAMSHAFT...

5 - 15 ENG CAMSHAFT EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • timing chain tensioner Cracks/damage → Replace. 2. Check: • one-way cam operation Rough movement → Replace the timing chain tensioner housing. 3. Check: • cap bolt • copper washer • spring • one-way cam • gasket • timing ch...

5 - 17 ENG CAMSHAFT 6. Install: • timing chain tensioner ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rodfully clockwise with a thin screwdriver 1 . b. With the timing chain tensioner rod turned all the way i...

5 - 18 ENG CAMSHAFT 9. Tighten: • camshaft sprocket bolts CAUTION: _ Be sure to tighten the camshaft sprocketbolts to the specified torque to avoid thepossibility of the bolts coming loose anddamaging the engine. 10.Install: • timing chain guide (top side) 11.Measure: • valve clearance Out of specif...

5 - 19 ENG CYLINDER HEAD EAS00221 CYLINDER HEAD 2nd 140˚ or 65 Nm (6.5 m • kg, 47 ft • lb) T R . . 1st 20 Nm (2.0 m • kg, 14 ft • lb) 2nd 105˚ or 50 Nm (5.0 m • kg, 36 ft • lb) T R . . 1st 20 Nm (2.0 m • kg, 14 ft • lb) 2nd 121˚ or 50 Nm (5.0 m • kg, 36 ft • lb) T R . . 1st 20 Nm (2.0 m • kg, 14 ft ...

5 - 20 ENG CYLINDER HEAD EAS00222 REMOVING THE CYLINDER HEAD 1. 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, removethem. EAS00227 CHECKING THE CYLINDER...

5 - 21 ENG CYLINDER HEAD EAS00233 INSTALLING THE CYLINDER HEAD 1. Install: • gasket 1 • dowel pins 2 2. Install: • cylinder head NOTE: _ Pass the timing chain through the timing chaincavity. 3. Tighten: • cylinder head nuts 1 ~ 6 1st 2nd • cylinder head nuts 7 , 0 1st 2nd • cylinder head nuts 8 , 9 ...

5 - 22 ENG VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve springs Remove the parts in the order listed. Cylinder head Refer to “CYLINDER HEAD”. 1 Intake valve lifter 12 2 Intake valve pad 12 3 Intake valve cotter 24 4 Intake valve...

5 - 24 ENG VALVES AND VALVE SPRINGS EAS00237 REMOVING THE VALVES The following procedure applies to all of thevalves and related components. NOTE: _ Before removing the internal parts of the cylin-der head (e.g., valves, valve springs, valveseats), make sure the valves properly seal. 1. Remove: • va...

5 - 25 ENG VALVES AND VALVE SPRINGS 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 carefullyso that it can be reinstalled in its original place. EAS00239 CHECKING THE VALVES AND VALVE GUIDES The fo...

5 - 26 ENG VALVES AND VALVE SPRINGS ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 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 thanthe body of the valve stem → R...

5 - 27 ENG VALVES AND VALVE SPRINGS EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of thevalves 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 wi...

5 - 28 ENG VALVES AND VALVE SPRINGS ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply a coarse lapping compound a to the valve face. CAUTION: _ Do not let the lapping compound enter thegap between the valve stem and the valveguide. b. Apply molybdenum disulfide oil onto the valve stem. c. I...

5 - 30 ENG VALVES AND VALVE SPRINGS 2. Lubricate: • valve stem 1 • valve stem seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3. Install: • valve 1 • lower spring seat 2 • valve stem seal 3 • valve spring 4 • upper spring seat 5 (into the cylinder head) NOTE: _...

5 - 32 ENG GENERATOR T R . . 14 Nm (1.4 m • kg, 10 ft • Ib) T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) T R . . 65 Nm (6.5 m • kg, 47 ft • Ib) + 60˚ Order Job/Part Q’ty Remarks Removing the stator coil assembly Remove the parts in the order listed. Rider seat and fuel tank Refer to “SEATS” and “FUEL TAN...

5 - 35 ENG GENERATOR WARNING When the bolt are tightened more than thespecified angle, do not loosen the bolt andthen retighten it.Replace the bolt with a new one and per-form the procedure again. CAUTION: • Do not use a torque wrench to tighten the bolt to the specified angle. • Tighten the bolt un...

5 - 36 ENG PICKUP COIL PICKUP COIL T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) T R . . 15 Nm (1.5 m • kg, 11 ft • Ib) T R . . 60 Nm (6.0 m • kg, 43 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q’ty Remarks Removing the pickup coil and pickup coil rotor Remove the parts in the order li...

5 - 38 ENG PICKUP COIL REMOVING THE PICKUP COIL ROTOR 1. Remove: • clutch cable holder 1 • pickup coil lead holder 2 • pickup coil rotor cover 3 NOTE: @ Loosen each bolt 1/4 of a turn at a time, instages and in a crisscross pattern. After all of the bolts are fully loosened, removethem. 2. Remove: •...

5 - 39 ENG PICKUP COIL 2. Tighten: • pickup coil rotor bolt 1 NOTE: @ While holding the generator rotor 2 with the rotor holding tool 3 , tighten the pickup coil rotor bolt. Rotor holding tool YU-01235 T R . . 60 Nm (6.0 m · kg, 43 ft · lb) 3. Apply: • sealant (onto the crankshaft position sensor le...

5 - 40 ENG CLUTCH CLUTCH CLUTCH COVER T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) Order Job/Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Bottom cowling and right side cowling Refer to “COWLINGS” in chapter 3. Engine oil Drain.R...

5 - 41 ENG CLUTCH PULL LEVER SHAFT Order Job/Part Q’ty Remarks Removing the pull lever shaft Remove the parts in the order listed. 1 Circlip 2 2 Pull lever 1 3 Pull lever spring 1 4 Pull lever shaft 1 5 Oil seal 1 6 Bearing 2 For installation, reverse the removal procedure.

5 - 44 ENG CLUTCH EAS00277 REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Loosen: • clutch boss nut 1 NOTE: _ While holding the clutch boss 2 with the uni- versal clutch holder 3 , loosen the clutch boss nut. 3. Remove: • clutch boss nut 1 • lock washer 2 • clutch boss assembly 3 • thrust...

5 - 45 ENG CLUTCH EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of theclutch 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 c...

5 - 46 ENG CLUTCH EAS00286 CHECKING THE PRESSURE PLATE 1. Check: • pressure plate 1 Cracks/damage → Replace. • bearing 2 Damage/wear → Replace. EAS00287 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1. Check: • pull lever shaft pinion gear teeth 1 • pull rod teeth 2 Damage/wear → Replace the pull rod a...

5 - 47 ENG CLUTCH 2. Check: • starter clutch operation ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the star ter clutch drive gear onto the starter clutch and hold the starter clutch. b. When turning the starter clutch drive gear clockwise È , the star ter clutch and the starter clut...

5 - 49 ENG SHIFT SHAFT EAS00327 SHIFT SHAFT SHIFT SHAFT AND STOPPER LEVER T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) T R . . 22 Nm (2.2 m • kg, 16 ft • Ib) Order Job/Part Q’ty Remarks Removing the shift shaft and stop-per lever Remove the parts in the order listed. Drive sprocket cover Refer to “ENGINE...

5 - 50 ENG SHIFT SHAFT CHECKING THE SHIFT SHAFT 1. Check: • shift shaft 1 Bends/damage/wear → Replace. • shift shaft spring 2 Damage/wear → Replace. CHECKING THE STOPPER LEVER 1. Check: • stopper lever 1 Bends/damage → Replace. Roller turns roughly → Replace the stopper lever. INSTALLING THE SHIFT S...

5 - 51 ENG OIL PAN AND OIL PUMP EAS00356 OIL PAN AND OIL PUMP T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 43 Nm (4.3 m • kg, 31 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib)...

5 - 53 ENG OIL PAN AND OIL PUMP EAS00360 OIL PUMP T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 15 Nm (1.5 m • kg, 11 ft • Ib) Order Job/Part Q’ty Remarks Disassembling the oil pump Remove the parts in the order listed. 1 Oil/water pump assembly driven sprocket 1 2 Washer 1 3 Oil pump housing 1 4 ...

5 - 54 ENG OIL PAN AND OIL PUMP EAS00362 REMOVING THE OIL PAN 1. Remove: • oil level switch 1 • oil pan 2 • gasket • dowel pins NOTE: _ Loosen each bolt 1/4 of a turn at a time, instages and in a crisscross pattern. After all ofthe bolts are fully loosened, remove them. EAS00364 CHECKING THE OIL PUM...

5 - 55 ENG OIL PAN AND OIL PUMP 3. Check: • oil pump operation Rough movement → Repeat steps (1) and (2) or replace the defective part(s). EAS00365 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). EAS00367 C...

5 - 56 ENG OIL PAN AND OIL PUMP EAS00374 ASSEMBLING THE OIL PUMP 1. Lubricate: • inner rotor • outer rotor • oil pump shaft (with the recommended lubricant) 2. Install: • pin 1 • inner rotor 2 • outer rotor 3 • oil pump housing 4 • oil pump housing screw NOTE: _ When installing the inner rotor, alig...

5 - 57 ENG OIL PAN AND OIL PUMP EAS00378 INSTALLING THE OIL STRAINER 1. Install: • oil strainer housing 1 NOTE: _ The arrow mark a on the oil strainer housing must point towards the front of the engine. T R . . 10 Nm (1.0 m · kg, 7.2 ft · lb) EAS00380 INSTALLING THE OIL PAN 1. Install: • dowel pins ...

5 - 58 ENG CRANKCASE EAS00381 CRANKCASE T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q’ty Remarks Removing the crankcase Remove the parts in the order listed. Engine Refer to “ENGINE”. Cylinder head Refer to “CYLINDER HEAD”. Pickup coil and pickup co...

5 - 60 ENG CRANKCASE EAS00384 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 ofthe bolts are fully loosened, remove them. • Loosen the bolts in decreasing n...

5 - 61 ENG CRANKCASE EAS00399 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...

5 - 62 ENG CRANKCASE EAS00414 ASSEMBLING THE CRANKCASE 1. Lubricate: • crankshaft journal bearings (with the recommended lubricant) Recommended lubricant Engine oil 2. Apply: • sealant (onto the crankcase mating surfaces) NOTE: _ Do not allow any sealant to come into contactwith the oil gallery or c...

5 - 63 ENG CRANKCASE 6. Install: • lower crankcase 1 (onto the upper crankcase 2 ) CAUTION: _ Before tightening the crankcase bolts,make sure the transmission gears shift cor-rectly when the shift drum assembly isturned by hand. 7. Install: • crankcase bolts NOTE: _ • Lubricate the bolt threads with...

5 - 64 ENG CONNECTING RODS AND PISTONS EAS00382 CONNECTING RODS AND PISTONS T R . . 20 Nm (2.0 m • kg, 14 ft • Ib) + 120˚ Order Job/Part Q’ty Remarks Removing the connecting rods and pistons Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. 1 Connecting rod cap 4 2 Big ...

5 - 66 ENG CONNECTING RODS AND PISTONS 3. Remove: • top ring • 2nd ring • oil ring NOTE: _ When removing a piston ring, open the endgap with your fingers and lift the other side ofthe ring over the piston crown. EAS00387 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: • crankshaft assembly 1 • crankshaf...

5 - 69 ENG CONNECTING RODS AND PISTONS CHECKING THE PISTON PINS The following procedure applies to all of thepiston pins.1. Check: • piston pin Blue discoloration/grooves → Replace the piston pin and then check the lubricationsystem. 2. Measure: • piston pin outside diameter a Out of specification →...

5 - 72 ENG CONNECTING RODS AND PISTONS 2. Select: • big end bearings (P1 ~ P4) NOTE: @ • The numbers È stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacementbig end bearing sizes. • “P1” ~ “P4” refer to the bearings shown in the crankshaft illu...

5 - 75 ENG CONNECTING RODS AND PISTONS e. Tighten the nut further to reach the speci- fied angle (120°). WARNING When the nut is tightened more than thespecified angle, do not loosen the nut andthen retighten it.Replace the bolt with a new one and per-form the procedure again. CAUTION: • Do not use ...

5 - 76 ENG CRANKSHAFT CRANKSHAFT Order Job/Part Q’ty Remarks Removing the crankshaft assembly Remove the parts in the order listed. Crankcase Separate.Refer to “CRANKCASE”. Connecting rod caps Refer to “CONNECTING RODS AND PISTONS”. 1 Crankshaft 1 2 Crankshaft journal lower bearing 5 3 Crankshaft jo...

5 - 77 ENG CRANKSHAFT EAS00395 CHECKING THE CRANKSHAFT 1. Measure: • crankshaft runout Out of specification → Replace the crank- shaft. 2. Check: • crankshaft journal surfaces • crankshaft pin surfaces • bearing surfaces Scratches/wear → Replace the crankshaft. Crankshaft runout Less than 0.03 mm (0...

5 - 80 ENG CRANKSHAFT EAS00407 INSTALLING THE CRANKSHAFT 1. Install: • crankshaft journal upper bearings 1 (into the upper crankcase) 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 upp...

5 - 81 ENG TRANSMISSION EAS00419 TRANSMISSION T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q’ty Remarks Removing the transmission, shift drum assembly, and shift forks Remove the parts in the order listed. Crankcase Separate.Refer to “CRANKCASE”. Sto...

5 - 87 ENG TRANSMISSION EAS00420 REMOVING THE TRANSMISSION 1. Remove: • main axle assembly 1 (with the Torx ® wrench T30) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Inser t two bolts 2 of the proper size, as shown in the illustration, into the main axleassembly bearing housing. b. Tighten ...

5 - 88 ENG TRANSMISSION EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: • shift drum grooves Damage/scratches/wear → Replace the shift drum assembly. • shift drum segment 1 Damage/wear → Replace the shift drum assembly. • shift drum bearing 2 Damage/pitting → Replace the shift drum assembly. EAS...

5 - 89 ENG TRANSMISSION 4. Check: • transmission gear engagement (each pinion gear to its respective wheelgear) Incorrect → Reassemble the transmission axle assemblies. 5. Check: • transmission gear movement Rough movement → Replace the defective part(s). 6. Check: • circlips Bends/damage/looseness ...

6 - 1 COOL EAS00454 COOLING SYSTEM RADIATOR Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” inchapter 3. Air filter case and rubber cover Refer to “AIR FILTER CASE” in chapter3. Bottom cowling and side ...

6 - 3 COOL RADIATOR EAS00455 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction → Clean. Apply compressed air to the rear of the radi-ator. Damage → Repair or replace. NOTE: _ Straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: • radiator hoses • radiator pipes Crack...

6 - 4 COOL RADIATOR EAS00456 INSTALLING THE RADIATOR 1. Fill: • cooling system (with the specified amount of the recom-mended coolant) Refer to “CHANGING THE COOLANT” inchapter 3. 2. Check: • cooling system Leaks → Repair or replace any faulty part. 3. Measure: • radiator cap opening pressure Below ...

6 - 5 COOL OIL COOLER EAS00457 OIL COOLER T R . . 35 Nm (3.5 m • kg, 25 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q’ty Remarks Removing the oil cooler Remove the parts in the order listed. Radiator a...

6 - 6 COOL OIL COOLER EAS00458 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. EAS00459 INSTALLING THE OIL COOLER 1. Clean: • mating surfaces of the oil cooler and the crankcase (with a c...

6 - 7 COOL THERMOSTAT EAS00460 THERMOSTAT T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q’ty Remarks Removing the thermostat assembly Remove the parts in the order listed. Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in chapter 3. Air fil...

6 - 10 COOL THERMOSTAT EAS00462 CHECKING THE THERMOSTAT 1. Check: • thermostat Does not open at 71 ~ 85 °C (160 ~ 185 °F) → Replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the w...

6 - 12 COOL WATER PUMP EAS00468 WATER PUMP T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q’ty Remarks Removing the impeller shaft Remove the parts in the order listed. NOTE: • The water pump and oil pump are com- bined into one unit (oil/water pumpassembly). • It is not necessary to remove ...

6 - 14 COOL WATER PUMP EAS00471 DISASSEMBLING THE WATER PUMP 1. Remove: • water pump seal 1 NOTE: _ Tap out the water pump seal from the inside ofthe water pump housing. 2 Water pump housing 2. Remove: • oil seal 1 • bearing 2 NOTE: _ Tap out the bearing and oil seal from the out-side of the water p...

6 - 15 COOL WATER PUMP EAS00475 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. 2. Install: • water p...

6 - 16 COOL WATER PUMP 4. Measure: • impeller shaft tilt Out of specification → Repeat steps (3) and (4). CAUTION: _ Make sure the rubber damper and rubberdamper holder are flush with the impeller. 1 Straightedge 2 Impeller Impeller shaft tilt limit 0.15 mm (0.0059 in)

7 - 1 FI FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 Ignition coil 2 Air filter case 3 Intake temperature sensor 4 Fuel delivery hose 5 Fuel tank 6 Fuel pump 7 Fuel return hose 8 Intake air pressure sensor 9 Throttle position sensor 0 Fuel injector A Catalytic converter B Crankshaft position senso...

7 - 2 FI FUEL INJECTION SYSTEM WIRING DIAGRAM OFF R UN L / R R / Y Br / W P / W Y B / L (BLA CK) (BLA CK) Y B / L Br / W P / W (BLA CK) G / W B R / L B CORD HEAD LIGHT MAIN HARNESS A WIRE SUB LEAD 4 MAIN HARNESS G R / L L / B R / B O / B G / B L (BLA CK) G / B L R / B O / B R / L L / B R / B O / G O...

7 - 3 FI FUEL INJECTION SYSTEM ECU’S SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the engine control sys-tem is operating normally. If this function detects a malfunction in the system, it immediately oper-ates the engine under substitute chara...

7 - 4 FI FUEL INJECTION SYSTEM SUBSTITUTE CHARACTERISTICS OPERATION CONTROL (FAIL-SAFE ACTION) If the ECU detects an abnormal signal from a sensor while the motorcycle is being driven, the ECUilluminates the engine trouble warning light and provides the engine with substitute characteristicoperation...

7 - 5 FI FUEL INJECTION SYSTEM TROUBLESHOORING CHART “Engine runs irregularly.” or “Engine trouble warning light is illuminated.” * Engine trouble warning light may not be illuminated even if the engine runs irregularly. When the engine trouble warning light is illumi-nated Checking the self-diagnos...

7 - 6 FI FUEL INJECTION SYSTEM DIAGNOSTIC MODE • In this mode, diagnostic codes are input into the ECU in accordance with the number of times the start switch has been operated. • In accordance with the diagnostic codes, the ECU displays the values received from the sensors and actuates the actuator...

7 - 7 FI FUEL INJECTION SYSTEM Diagnostic fault code table Fault Code No. Symptom Probable cause of malfunction Code of diagnostic mode 11 No normal signals are received from the cylinder identification sensor. NOTE: This code number appears if the con-dition continued for 10 seconds inwhich the sta...

7 - 9 FI FUEL INJECTION SYSTEM Diagnostic mode table Set the meter display from the regular mode to the diagnosis mode. For the setting method, refer to“DIAGNOSTIC MODE”. NOTE: • Check the intake temperature and coolant temperature as close as possible to the area in which the respective sensor is m...

7 - 12 FI FUEL INJECTION SYSTEM TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter.Carry out checkand maintenance on items or components that could be a cause of malfunction in accordance withthe order.When the check and maintenance of malfunctio...

7 - 29 FI THROTTLE BODIES THROTTLE BODIES Order Job/Part Q’ty Remarks Removing the throttle bodies Remove the parts in the order listed. Seats/fuel tank/rubber sheet Refer to “SEATS” and “FUEL TANK” in chapter 3. Air filter case Refer to “AIR FILTER CASE” in chapter 3. Coolant Drain.Refer to “CHANGI...

7 - 30 FI THROTTLE BODIES Order Job/Part Q’ty Remarks 5 Throttle cable 2 Disconnect. 6 Plunger control unit hose 2 Disconnect. 7 Throttle body joint 4 For installation, reverse the removal procedure.

7 - 31 FI THROTTLE BODIES Order Job/Part Q’ty Remarks Removing the injector Remove the parts in the order listed. 1 Throttle position sensor coupler 1 Disconnect. 2 Intake air pressure sensor 1 Disconnect. 3 Cylinder #1-injector coupler 1 Disconnect. 4 Cylinder #2-injector coupler 1 Disconnect. 5 Cy...

7 - 33 FI THROTTLE BODIES CAUTION: The throttle bodies should not be disas-sembled unnecessarily. CHECKING THE INJECTOR 1. Check: • injector Damage → Replace. CHECKING THE THROTTLE BODY 1. Check: • throttle body Cracks/damage → Replace the throttle bodies. 2. Check: • fuel passages Obstruction → Cle...

7 - 34 FI THROTTLE BODIES CHECKING THE PRESSURE REGULATOR 1. Check: • pressure regulator Damage → Replace. CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 1. Check: • pressure regulator operation ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the fuel tank. Refer to “SEATS” and ...

7 - 37 FI AIR INDUCTION SYSTEM EAS00507 AIR INDUCTION SYSTEM AIR INDUCTION The air induction system burns unburnedexhaust gases by injecting fresh air (second-ary air) into the exhaust port, reducing theemission of hydrocarbons. When there is negative pressure at theexhaust port, the reed valve open...

7 - 38 FI AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Air cut-off valve 2 Reed valve 3 Air cleaner È To cylinder #1 É To cylinder #2 Ê To cylinder #3 Ë To cylinder #4

7 - 39 FI AIR INDUCTION SYSTEM EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: • hoses Loose connection → 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. 3. Measure...

8 - 1 – + ELEC EAS00729 ELECTRICAL ELECTRICAL COMPONENTS 1 Fuse box 2 Front brake switch 3 Clutch switch 4 Battery 5 Starter relay 6 Fuel injection system fuse 7 Main fuse 8 Neutral switch 9 Rear brake switch 0 Sidestand switch A Oil level switch B Radiator fan motor C Horn D Ignition coil ELECTRICA...

8 - 3 – + ELEC CHECKING SWITCH CONTINUITY EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with thepocket tester. If the continuity reading is incor-rect, check the wiring connections and if nec-essary, replace the switch. CAUTION: _ Never insert the tester probes into the cou-pl...

8 - 4 – + ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the ter-minals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect con...

8 - 5 – + ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damageor wear, proper connections, and also for con-tinuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both. Improperly connected →...

8 - 6 – + ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of thebulbs. 1. Remove: • bulb WARNING _ Since the headlight bulb gets extremelyhot, keep flammable products and yourhands away from the bulb until it hascooled down. CAUTION...

8 - 7 – + ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of thebulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) No continuity → Replace. NOTE: _ Check each bulb socket for continuity in thesame...

8 - 8 – + ELEC IGNITION SYSTEM EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM Y / B L / R B / R Ch Dg B / Y Y / L Sb / W L / R R / Y Br / W P / W Y B / L (BLA CK) (BLA CK) Y B / L Br / W P / W (BLA CK) G / W B R / L B CORD HEAD LIGHT MAIN HARNESS A WIRE SUB LEAD 4 MAIN HARNESS G R / L L / B R / B O / B G ...

8 - 11 – + ELEC IGNITION SYSTEM EAS00748 EAS00749 EAS00750 EAS00751 EAS00752 6. Crankshaft position sensor resistance • Disconnect the crankshaft position sensor coupler from the wire harness. • Connect the pocket tester ( Ω × 100) to the crankshaft position sensor coupler asshown. Positive tester p...

8 - 13 – + ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM L / R R / Y Br / W P / W Y B / L (BLA CK) (BLA CK) Y B / L Br / W P / W (BLA CK) G / W B R / L B CORD HEAD LIGHT MAIN HARNESS A WIRE SUB LEAD 4 MAIN HARNESS G R / L L / B R / B O / B G / B L (BLA CK) G / B L R...

8 - 14 – + ELEC ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches areclosed), the starter motor can only operate if atleast one of the following conditions is met: • The transmission i...

8 - 18 – + ELEC ELECTRIC STARTING SYSTEM EAS00767 STARTER MOTOR T R . . 5 Nm (0.5 m • kg, 3.6 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Rider seat Refer to “SEATS” in chapter 3. Fuel tank Refer to “FUE...

8 - 19 – + ELEC ELECTRIC STARTING SYSTEM EAS00768 T R . . 5 Nm (0.5 m • kg, 3.6 ft • Ib) Order Job/Part Q’ty Remarks Disassembling the starter motor Disassembly the parts in the order listed. 1 Starter motor rear cover 1 2 Bearing 1 3 Starter motor yoke 1 4 O-ring 2 5 Armature assembly 1 6 Brush 2 7...

8 - 21 – + ELEC ELECTRIC STARTING SYSTEM 5. Measure: • brush length a Out of specification → Replace the brushes as a set. Brush length wear limit 3.65 mm (0.14 in) 6. Measure: • brush spring force Out of specification → Replace the brush springs as a set. 7. Check: • gear teeth Damage/wear → Replac...

8 - 22 – + ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM (BLACK) R Br / L R Br / L L / Y L / B L / B L / Y R B (GRAY) W W W ON OFF R W R / W L / W R / W L / W R R R R B B B B B R W R B R B R WWW WW R W B R Br / L Br / L L / B R / W L / Y (RED) (RED) R R / G 1 2 3 4 5 8 6 7 9 w 2 AC m...

8 - 25 – + ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM L / R R / Y Br / W P / W Y B / L (BLA CK) (BLA CK) Y B / L Br / W P / W (BLA CK) G / W B R / L B CORD HEAD LIGHT MAIN HARNESS A WIRE SUB LEAD 4 MAIN HARNESS G R / L L / B R / B O / B G / B L (BLA CK) G / B L R / B O / B R / L L...

8 - 27 – + ELEC LIGHTING SYSTEM EAS00781 TROUBLESHOOTING Check: 1. main, signal and headlight fuses 2. battery 3. main switch 4. dimmer switch 5. headlight relay (on/off)6. headlight relay (dimmer)7. wiring connections (of the entire lighting system) NOTE: _ • Before troubleshooting, remove the foll...

8 - 32 – + ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM L / R R / Y Br / W P / W Y B / L (BLA CK) (BLA CK) Y B / L Br / W P / W (BLA CK) G / W B R / L B CORD HEAD LIGHT MAIN HARNESS A WIRE SUB LEAD 4 MAIN HARNESS G R / L L / B R / B O / B G / B L (BLA CK) G / B L R / B O / B R / L...

8 - 44 – + ELEC COOLING SYSTEM EAS00812 EAS00813 6. Coolant temperature sensor • Remove the coolant temperature sensor from the thermostat housing. • Connect the pocket tester ( Ω × 1k) to the coolant temperature sensor 1 as shown. • Immerse the coolant temperature sensor in a container filled with ...

8 - 45 – + ELEC FUEL PUMP SYSTEM FUEL PUMP SYSTEM CIRCUIT DIAGRAM L / R R / Y Br / W P / W Y B / L (BLA CK) (BLA CK) Y B / L Br / W P / W (BLA CK) G / W B R / L B CORD HEAD LIGHT MAIN HARNESS A WIRE SUB LEAD 4 MAIN HARNESS G R / L L / B R / B O / B G / B L (BLA CK) G / B L R / B O / B R / L L / B R ...

8 - 49 – + ELEC FUEL PUMP SYSTEM EAS00819 CHECKING THE FUEL PUMP WARNING _ Gasoline is extremely flammable and undercertain circumstances there can be a dan-ger of an explosion or fire. Be extremelycareful and note the following points: • Stop the engine before refueling. • Do not smoke, and keep aw...

9 - 1 TRBL SHTG EAS00844 TROUBLESHOOTING NOTE: _ The following guide for troubleshooting does not cover all the possible causes of trouble. It shouldbe helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this man-ual for checks, adjustments, and replacement of p...

9 - 2 TRBL SHTG STARTING FAILURES/ INCORRECT ENGINE IDLING SPEED ELECTRICAL SYSTEMSBattery • Discharged battery • Faulty battery Fuse(s) • Blown, damaged or incorrect fuse • Improperly installed fuse Spark plug(s) • Incorrect spark plug gap • Incorrect spark plug heat range • Fouled spark plug • Wor...

9 - 3 TRBL SHTG POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ FAULTY GEAR SHIFTING/FAULTY CLUTCH EAS00848 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING FAILURES”. ENGINEAir filter • Clogged air filter element FUEL SYSTEMFuel pump • Faulty fuel pump EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIF...

9 - 4 TRBL SHTG OVERHEATING/OVERCOOLING/ POOR BRAKING PERFORMANCE EAS00855 OVERHEATING ENGINEClogged coolant passages • Cylinder head(s) and piston(s) • Heavy carbon buildup Engine oil • Incorrect oil level • Incorrect oil viscosity • Inferior oil quality COOLING SYSTEMCoolant • Low coolant level Ra...

9 - 5 TRBL SHTG FAULTY FRONT FORK LEGS/ UNSTABLE HANDLING EAS00861 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 dam...

9 - 6 TRBL SHTG FAULTY LIGHTING OR SIGNALING SYSTEM EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT COME ON • Wrong headlight bulb • Too many electrical accessories • Hard charging • Incorrect connection • Improperly grounded circuit • Poor contacts (main switch) • Burnt-out headligh...