Yamaha YZF-R6R - Manuals

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

CHASSIS 3-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT BRAKE 3-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE 3-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE...

REAR SHOCK ABSORBER ASSEMBLY 4-68 . . . . . . . . . . . . . . . . . . . . . . . . HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER 4-70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER 4-70 . . . . . . . . . ...

1-1 1 MOTORCYCLE IDENTIFICATION 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 head pipe. EAS00018 MODEL LABEL The model label 1 is affixed to the frame. This in...

1-2 FEATURES GEN INFO 8 Intake air pressuresensor 9 Throttle position sen-sor 10 Fuel injector 11 Catalytic converter 12 Crankshaft positionsensor 13 Coolant temperaturesensor 14 Spark plug 15 Cylinder identificationsensor 16 Pressure regulator 17 Battery 18 ECU 19 Atmospheric pressuresensor 20 Fuel...

1-3 FEATURES GEN INFO Illustration is for reference only. 6 Throttle position sen-sor 7 Intake air pressuresensor 8 ECU 9 Atmospheric pressuresensor 10 Coolant temperaturesensor 11 Cylinder identificationsensor 12 Crankshaft positionsensor A Fuel systemB Air system C Control system 1 Fuel pump 2 Pre...

1-4 FEATURES GEN INFO 1 Multi-function display2 “SELECT” button3 “RESET” button4 Engine trouble warning light NOTE: INSTRUMENT FUNCTIONMulti-function display The multi-function display is equipped with thefollowing: S a speedometer (which shows the ridingspeed) S an odometer (which shows the total d...

1-6 FEATURES GEN INFO NOTE: NOTE: To set the shift timing indicator light activation function S The indicator light activation function can be set between 10,000 and 16,000 r / min. S From 10,000 r / min to 12,000 r / min, the indicatar light can be set in increments of 500 r / min. S From 12,000 r ...

1-7 spring lip oil grease lip IMPORTANT INFORMATION GEN INFO EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment.Refer to the “SPECIAL TOOLS”. 3....

1-8 IMPORTANT INFORMATION GEN INFO CAUTION: EAS00023 LOCK WASHERS / PLATES AND COTTERPINS After removal, replace all lock washers / plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabsalong a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS ...

1-9 CHECKING THE CONNECTIONS GEN INFO NOTE: NOTE: NOTE: EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors forstains, rust, moisture, etc.1. Disconnect: S lead S coupler S connector 2. Check: S lead S coupler S connectorMoisture ! Dry with an air blower. Rust / stains ! Conn...

1-10 SPECIAL TOOLS GEN INFO NOTE: EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use onlythe appropriate special tools as this will help prevent damage caused by the use of inappropriate toolsor improvised techniques. Special tools, p...

1-13 SPECIAL TOOLS GEN INFO Tool No. Tool name / Function Illustration 90890-06756YB-35956 Vacuum/pressure pump gauge set This tool used to measure the vacuum pres-sure. 90890-85505ACC-11001-05-01 Yamaha bond No. 1215 This bond is used to seal two mating surfaces(e.g., crankcase mating surfaces).

2-1 GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5SL3 (USA except for CAL)5SL4 (CAL)5SL7 (USA except for CAL)5SL8 (CAL) SSS Dimensions Overall lengthOverall widthOverall heightSeat heightWheelbaseMinimum ground clearanceMinimum turning radius 2,025...

2-2 2 ENGINE SPECIFICATIONS SPEC ENGINE SPECIFICATIONS Item Standard Limit Engine Engine typeDisplacementCylinder arrangementBore stroke Compression ratioEngine idling speedVacuum pressure at engine idlingspeedStandard compression pressure(at sea level) Liquid-cooled, 4-stroke, DOHC600 cm 3 (36.61 c...

2-4 ENGINE SPECIFICATIONS SPEC Item Standard Limit Camshafts Drive systemCamshaft cap inside diameterCamshaft journal diameterCamshaft-journal-to-camshaft-cap clearanceIntake camshaft lobe dimensions Measurement A Measurement B Exhaust camshaft lobe dimensions Measurement A Measurement B Max. camsha...

2-6 ENGINE SPECIFICATIONS SPEC Item Standard Limit Valve springs Free length Intake (inner) Intake (outer) Exhaust Installed length (valve closed) Intake (inner) Intake (outer) Exhaust Compressed spring force(installed) Intake (inner) (outer) Exhaust Spring tilt Intake (inner) Intake (outer) Exhaust...

2-7 ENGINE SPECIFICATIONS SPEC Item Standard Limit Piston Piston-to-cylinder clearance Diameter D Height HPiston pin bore (in the piston) Diameter OffsetOffset direction Piston pins Outside diameter Piston-pin-to-piston-pin-boreclearance Piston rings Top ring Ring typeDimensions (B T) End gap (insta...

2-8 ENGINE SPECIFICATIONS SPEC Item Standard Limit Connecting rods Crankshaft-pin-to-big-end-bearingclearanceBearing color code 0.028 X 0.052 mm (0.0011 X 0.0020 in) 1 = Blue 2 = Black 3 = Brown 4 = Green 0.09 mm(0.0035 in) SSS Crankshaft Width AWidth BMax. runout C Big end side clearance DBig end r...

2-9 ENGINE SPECIFICATIONS SPEC Item Standard Limit Transmission Transmission typePrimary reduction systemPrimary reduction ratioSecondary reduction systemSecondary reduction ratioOperationGear ratios 1st gear2nd gear3rd gear4nd gear5th gear6th gear Max. main axle runout Max. drive axle runout Consta...

2-10 ENGINE SPECIFICATIONS SPEC Item Standard Limit Throttle position sensor ResistanceOutput voltage (at idle) 4.85 X 5.15 k Ω at 20 _ C (68 _ F) 0.63 X 0.73 V SSS Throttle bodies Model (manufacturer) quantity Intake vacuum pressureThrottle cable free play (at the flange 38EIS (MIKUNI) 4 24 kPa (18...

2-11 CHASSIS SPECIFICATIONS SPEC CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame typeCaster angleTrail Diamond24 _ 86 mm (3.39 in) SSS SSS SSS Front wheel Wheel typeRim SizeMaterial Wheel travelWheel runout Max. radial wheel runoutMax. lateral wheel runout Cast wheel 17 M / C MT3.50 Aluminum1...

2-12 CHASSIS SPECIFICATIONS SPEC Item Standard Limit Rear tire Tire typeSizeModel (manufacturer) Tire pressure (cold) 0 X 90 kg (0 X 198 lb) 90 X 193 kg (198 X 426 lb) (USA except for CAL)90 X 192 kg (198 X 423 lb) (CAL) High-speed riding Min. tire tread depth Tubeless180 / 55 ZR17 M / C (73W)Pilot ...

2-13 CHASSIS SPECIFICATIONS SPEC Item Standard Limit Front suspension Suspension typeFront fork typeFront fork travelSpring Free length Spacer lengthInstalled lengthSpring rate (K1)Spring stroke (K1) Inner tube outer diameterInner tube bending limit Optional spring availableFork oil Recommended oilQ...

2-14 CHASSIS SPECIFICATIONS SPEC Item Standard Limit Steering Steering bearing type Angular bearing SSS Rear suspension Suspension typeRear shock absorber assemblytypeRear shock absorber assemblytravelSpring Free lengthInstalled lengthSpring rate (K1)Spring stroke (K1) Optional spring availableStand...

2-15 ELECTRICAL SPECIFICATIONS SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V SSS Ignition system Ignition system typeIgnition timing Crankshaft position sensorresistance / colorCDI unit model (manufacturer) DC. CDI10 _ BTDC at 1,300 r / min (USA except for CAL)5 _ BTDC at 1,...

2-16 ELECTRICAL SPECIFICATIONS SPEC Item Standard Limit Indicator light(voltage / wattage quantity) Neutral indicator lightHigh beam indicator lightOil level indicator lightTurn signal indicator lightFuel level warning lightCoolant temparture indicator lightEngine trouble warning lightShift timing i...

2-17 ELECTRICAL SPECIFICATIONS SPEC Item Standard Limit Fuses (amperage quantity) Main fuseFuel injection system fuseHeadlight fuseSignaling system fuseIgnition fuseRadiator fan motor fuseBackup fuse (odometer and clock)Reserve fuse 40 A 1 15 A 1 20 A 1 15 A 1 15 A 1 15 A 1 10 A 1 40 A, 20 A, 15 A, ...

2-18 EAS00030 GENERAL TIGHTENING TORQUESPECIFICATIONS This chart specifies tightening torques for stan-dard fasteners with a standard ISO threadpitch. Tightening torque specifications for spe-cial components or assemblies are providedfor each chapter of this manual. To avoid war-page, tighten multi-...

2-19 TIGHTENING TORQUES SPEC TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Item Fastener Thread Q’ty Tightening torque Remarks Item Fastener size Q ty Nm m S kg ft S lb Remarks Spark plugsCylinder head Camshaft capsCylinder head coverCamshaft cap oil check boltReed valve coverAir-cut valve stayCamsha...

2-22 TIGHTENING TORQUES SPEC CHASSIS TIGHTENING TORQUES Item Thread Tightening Remarks Item size Nm m S kg ft S lb Remarks Upper bracket and front forkSteering stem nutHandlebar and front forkHandlebar and upper bracketLower ring nutUnder bracket pinch boltMain switch and upper bracketFront brake ma...

2-24 LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Crankshaft pins Piston surfaces Piston pins Connecting rod bolts and nuts Crankshaft journals Camshaft lobes Camshaft journals Valve stem...

2-25 LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00032 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Front wheel oil seal (right and left) Rear wheel oil seal Front axle shaft Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear axle s...

2-26 COOLING SYSTEM DIAGRAMS SPEC 1 Radiator 2 Oil cooler COOLING SYSTEM DIAGRAMS

2-30 ENGINE OIL LUBRICATION CHART SPEC ENGINE OIL LUBRICATION CHART

2-31 LUBRICATION DIAGRAMS SPEC 1 Oil level switch 2 Oil cooler 3 Relief valve LUBRICATION DIAGRAMS

2-37 CABLE ROUTING SPEC A Pass the right handlebar switch lead inside the front brake hoses and over the throttle cables. B Install the throttle cables to the hook so that the pull- ing side of the throttle cables is routed downward. C Pass the clutch cable through the guide.D Plastic locking tie sh...

2-49 CABLE ROUTING SPEC 1 Fuel pump assembly 2 Canister hose 3 Canister 4 Breather hose 5 Blance hose 6 Fuel tank drain hose A Install the roll over valve until it contacts with the fuel tank’s nipple. B Install the O-ring with its lip pointed upward. C Install the clip with its tab pointed in the u...

3-1 3 INTRODUCTION /PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM / GENERAL MAINTENANCE AND LUBRICATION CHART CHK ADJ EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. Iffollowed, these pr...

3-2 GENERAL MAINTENANCE AND LUBRICATION CHART CHK ADJ NOTE: NOTE: INITIAL ODOMETER READINGS NO. ITEM REMARKS 600 mi (1,000 km) or 1 month 4,000mi (7,000 km) or 6 months 8,000 mi (13,000 km) or 12 months 12,000 mi (19,000 km) or 18 months 16,000 mi (25,000 km) or 24 months 20,000 mi (31,000 km) or 30...

3-3 Order Job / Part Q’ty Remarks 12 Removing the seats Passenger seatRider seat 11 Remove the parts in the order listed. For installation, reverse the removal procedure. 7 Nm (0.7 m S kg, 5.1 ft S lb) SEATS CHK ADJ EAS00039 SEATS

3-4 Order Job / Part Q’ty Remarks 123456789 Removing the fuel tank Rider seatFuel hose connector coverFuel hoseFuel return hoseFuel sender couplerFuel pump couplerFuel tank overflow hoseFuel tank breather hoseFuel tankFuel pump 111111111 Remove the parts in the order listed.Refer to “SEATS”. Disconn...

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

3-6 FUEL TANK CHK ADJ 4 Nm (0.4 m S kg, 2.9 ft S lb) NOTE: CAUTION: INSTALLING THE FUEL PUMP 1. Install: S fuel pump S Do not damage the installation surfaces of thefuel tank when installing the fuel pump. S Always use a new fuel pump gasket. S Install the fuel pump as shown in the illustra-tion. S ...

3-7 Order Job / Part Q’ty Remarks 1234 56789 10 11 Removing the cowlings Rider and passenger seatsFront cowling inner panel (left and right)Front turn signal light lead couplersSide cowlings (left and right)Side cowlings inner panels (left and right)Bottom cowlings (left and right)Bottom cowling fro...

3-8 COWLINGS CHK ADJ NOTE: NOTE: REMOVAL 1. Remove: S rear cowling S side cowlings To remove the quick fastener, push its centerwith a screwdriver, then pull the fastener out. INSTALLATION 1. Install: S side cowlings S rear cowling To install the quick fastener, push its pin so that itprotrudes from...

3-9 Order Job / Part Q’ty Remarks 1234567 Removing the air filter case Rider seatFuel tankAir intake ductIntake temperature sensor couplerThrottle body hoseAir induction system hoseClampAir filter caseCrankcase breather hose 2121411 Remove the parts in the order listed.Refer to “SEATS”.Refer to “FUE...

3-10 ADJUSTING THE VALVE CLEARANCE CHK ADJ NOTE: EAS00045 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of thevalves. S Valve clearance adjustment should be madeon a cold engine, at room temperature. S When the valve clearance is to be measured oradjusted, the piston mu...

3-11 ADJUSTING THE VALVE CLEARANCE CHK ADJ NOTE: NOTE: 4. Measure: S valve clearanceOut of specification ! Adjust. Valve clearance (cold) Intake valve0.13 X 0.20 mm (0.0051 X 0.0079 in) Exhaust valve0.23 X 0.30 mm (0.0091 X 0.0118 in) a. Turn the crankshaft counterclockwise.b. When piston #1 is at T...

3-13 ADJUSTING THE VALVE CLEARANCE CHK ADJ NOTE: NOTE: c. Round off the original valve pad number ac- cording 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 (0.058 in))Rounded value = 150d. Locate the rounded number of ...

3-15 ADJUSTING THE VALVE CLEARANCE CHK ADJ VALVE CLEARANCE (cold): 0.13 X 0.20 mm (0.0051 X 0.0079 in) Example: Installed is 175 Measured clearance is 0.27 mm (0.0106 in)Replace 175 pad with 185 pad Pad number: (example) Pad No.175 = 1.75 mm (0.0689 in) Pad No.185 = 1.85 mm (0.0728 in) MEASURED CLEA...

3-16 ADJUSTING THE VALVE CLEARANCE / SYNCHRONIZING THE THROTTLE BODIES CHK ADJ NOTE: NOTE: NOTE: 7. Install: S all removed parts For installation, reverse the removal procedure. SYNCHRONIZING THE THROTTLE BODIES Prior to synchronizing the throttle bodies, thevalve clearance and the engine idling spe...

3-17 SYNCHRONIZING THE THROTTLE BODIES CHK ADJ NOTE: CAUTION: NOTE: 5. Install: S air filter caseRefer to “AIR FILTER CASE”. S fuel tankRefer to “FUEL TANK”. 6. Start the engine and let it warm up for several minutes. 7. Measure: S engine idling speedOut of specification ! Adjust. Refer to “ADJUSTIN...

3-18 SYNCHRONIZING THE THROTTLE BODIES / ADJUSTING THE ENGINE IDLING SPEED CHK ADJ NOTE: 9. Measure: S engine idling speedOut of specification ! Adjust. Make sure that the vacuum pressure is withinspecification. 10. Stop the engine and remove the measuring equipment. 11. Adjust: S throttle cable fre...

3-19 ADJUSTING THE ENGINE IDLING SPEED / ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ a b NOTE: 4. Adjust: S engine idling speed a. Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained. Direction Engine idling speed is increased. Direction Engine i...

3-20 ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ NOTE: a b NOTE: a b WARNING 3. Adjust: S throttle cable free play When the throttle is opened, the acceleratorcable 1 is pulled. Throttle body side a. Loosen the locknut 2 on the decelerator cable. b. Turn the adjusting nut 3 in direction a or b to...

3-21 ADJUSTING THE THROTTLE CABLE FREE PLAY / CHECKING THE SPARK PLUGS CHK ADJ CAUTION: 4. Install: S left frame side coverRefer to “COWLINGS”. S air filter caseRefer to “AIR FILTER CASE”. S fuel tankRefer to “FUEL TANK”. S rider seatRefer to “SEATS”. EAS00059 CHECKING THE SPARK PLUGS The following ...

3-22 CHECKING THE SPARK PLUGS / MEASURING THE COMPRESSION PRESSURE CHK ADJ 13 Nm (1.3 m S kg, 9.4 ft S lb) NOTE: NOTE: 6. Measure: S spark plug gap a (with a wire Thickness gauge)Out of specification ! Regap. Spark plug gap 0.6 X 0.7 mm (0.0236 X 0.0276 in) 7. Install: S spark plug Before installing...

3-23 MEASURING THE COMPRESSION PRESSURE CHK ADJ CAUTION: WARNING NOTE: Before removing the spark plugs, use com-pressed air to blow away any dirt accumu-lated in the spark plug wells to prevent itfrom falling into the cylinders. 5. Install: S compression gauge 1 S adapter Compression gauge 90890-030...

3-24 MEASURING THE COMPRESSION PRESSURE / CHECKING THE ENGINE OIL LEVEL CHK ADJ 13 Nm (1.3 m S kg, 9.4 ft S lb) NOTE: d. If the compression pressure is below the minimum specification, pour a teaspoonful ofengine oil into the spark plug bore and mea-sure again.Refer to the following table. Compressi...

3-25 CHECKING THE ENGINE OIL LEVEL / CHANGING THE ENGINE OIL CHK ADJ NOTE: NOTE: Recommended oil At 5 _ C (40 _ F) or higher A Yamalube 4 (20W40) orSAE 20W40 type SE motoroil At 15 _ C (60 _ F) or lower B Yamalube 4 (10W30) orSAE 10W30 type SE motoroil Before checking the engine oil level, wait a fe...

3-26 CHANGING THE ENGINE OIL CHK ADJ CAUTION: 43 Nm (4.3 m S kg, 31 ft S lb) 6. 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...

3-27 CHANGING THE ENGINE OIL / MEASURING THE ENGINE OIL PRESSURE CHK ADJ CAUTION: WARNING 10. Install: S engine oil filler cap S coolant reservoir tankRefer to “CHANGING THE COOLANT”. S bottom cowlingRefer to “COWLINGS”. 11. Start the engine, warm it up for several min- utes, and then turn it off. E...

3-28 MEASURING THE ENGINE OIL PRESSURE CHK ADJ NOTE: 8 Nm (0.8 m S kg, 5.8 ft S lb) 6. Measure: S engine oil pressure(at the following conditions) Engine oil pressure 240 kPa(2.4 kg / cm 2 , 2.4 bar, 34.1 psi) Engine speed Approx. 6,600 r / min Engine oil temperature 96 _ C (205 _ F) Regarding the o...

3-29 ADJUSTING THE CLUTCH CABLE FREE PLAY CHK ADJ c b NOTE: a b EAS00078 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: S clutch cable free play a Out of specification ! Adjust. Clutch cable free play (at the end of the clutch lever) 10 X 15 mm (0.39 X 0.59 in) 2. Adjust: S clutch cable free play Ha...

3-30 CLEANING THE AIR FILTER ELEMENT CHK ADJ CAUTION: NOTE: EAS00086 CLEANING THE AIR FILTER ELEMENT 1. Remove: S rider seatRefer to “SEATS”. S fuel tankRefer to “FUEL TANK”. 2. Remove: S air filter case cover 1 S air filter element 3. Clean: S air filter element 1 Use solvent to clean the air filte...

3-31 CLEANING THE AIR INTAKE SYSTEM SURGE TANKS / CHECKING THE THROTTLE BODY JOINTS CHK ADJ EAS00092 CLEANING THE AIR INTAKE SYSTEM SURGE TANKS The following procedure applies to both air in-take system surge tanks.1. Remove: S front cowlingRefer to “COWLINGS”. 2. Remove: S air intake system surge t...

3-32 CHECKING THE FUEL AND BREATHER HOSES / CHECKING THE CRANKCASE BREATHER HOSE CHK ADJ NOTE: CAUTION: EAS00096 CHECKING THE FUEL AND BREATHER HOSES The following procedure applies to all of the fueland breather hoses.1. Remove: S rider seatRefer to “SEATS”. S fuel tankRefer to “FUEL TANK”. 2. Chec...

3-33 CHECKING THE EXHAUST SYSTEM / CHECKING THE COOLANT LEVEL CHK ADJ NOTE: EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex-haust pipes and gaskets.1. Remove: S bottom cowlingRefer to “COWLINGS”. S radiatorRefer to “RADIATOR” in chapter 6. 2. Check: S exhaust pi...

3-34 CHECKING THE COOLANT LEVEL / CHECKING THE COOLING SYSTEM CHK ADJ CAUTION: NOTE: 2. Check: S coolant levelThe coolant level should be between themaximum level mark a and minimum level mark b . Below the minimum level mark ! Add the recommended coolant to the proper level. S Adding water instead ...

3-35 CHECKING THE COOLING SYSTEM / CHANGING THE COOLANT CHK ADJ 2. Check: S radiator 1 S radiator inlet hose 2 S radiator outlet hose 3 S oil cooler 4 S oil cooler inlet hose 5 S oil cooler outlet hose 6 S water jacket outlet joint 7 S water jacket hose 8 S water pump outlet pipe 9 S water pump outl...

3-36 CHANGING THE COOLANT CHK ADJ CAUTION: 10 Nm (1.0 m S kg, 7.2 ft S lb) 3. Disconnect: S coolant reservoir cap 1 4. Drain: S coolant(from the coolant reservoir tank) 5. Remove: S radiator cap 1 A hot radiator is under pressure. Therefore,do not remove the radiator cap when the en-gine is hot. Sca...

3-37 CHANGING THE COOLANT CHK ADJ WARNING CAUTION: 10. Install: S coolant reservoir tank 11. Connect: S coolant reservoir hose 12. Fill: S cooling system(with the specified amount of the recom-mended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosioninhibito...

3-38 CHANGING THE COOLANT CHK ADJ NOTE: S Use only distilled water. However, if dis-tilled water is not available, soft water maybe used. S If coolant comes into contact with paintedsurfaces, immediately wash them with wa-ter. S Do not mix different types of antifreeze. 13. Install: S radiator cap 1...

3-39 ADJUSTING THE FRONT BRAKE CHK ADJ NOTE: a a WARNING CAUTION: EAS00107 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: S brake lever position(distance a from the throttle grip to the brake lever) S While pushing the brake lever forward, turn theadjusting dial 1 until the brake lever is in the desir...

3-40 ADJUSTING THE REAR BRAKE CHK ADJ a b WARNING WARNING CAUTION: EAS00110 ADJUSTING THE REAR BRAKE 1. Check: S brake pedal position(distance a bottom of the footrest bracket) Out of specification ! Adjust. Brake pedal position (below the bottom of the footrest bracket) 7 X 11 mm (0.28 X 0.43 in) 2...

3-41 A B ADJUSTING THE REAR BRAKE / CHECKING THE BRAKE FLUID LEVEL CHK ADJ NOTE: WARNING 3. Adjust: S rear brake light switchRefer to “ADJUSTING THE REAR BRAKELIGHT SWITCH”. EAS00115 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. S Place the motorcycle on a suitable stand...

3-43 B A B A CHECKING THE FRONT AND REAR BRAKE PADS ā / CHECKING THE FRONT AND REAR BRAKE HOSES CHK ADJ EAS00122 CHECKING THE FRONT AND REAR BRAKE PADS The following procedure applies to all of thebrake pads.1. Operate the brake. 2. Check: S front brake pad S rear brake padBrake pad wear limit a , b...

3-44 A B BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ WARNING NOTE: NOTE: EAS00135 BLEEDING THE HYDRAULIC BRAKE SYSTEM Bleed the hydraulic brake system whenev-er: S the system is disassembled. S a brake hose is loosened, disconnected orreplaced. S the brake fluid level is very low. S brake operation ...

3-46 ADJUSTING THE DRIVE CHAIN SLACK CHK ADJ NOTE: CAUTION: WARNING NOTE: EAS00140 ADJUSTING THE DRIVE CHAIN SLACK The drive chain slack must be checked at thetightest point on the chain. A drive chain that is too tight will overloadthe engine and other vital parts, and one thatis too loose can skip...

3-47 ADJUSTING THE DRIVE CHAIN SLACK / LUBRICATING THE DRIVE CHAIN CHK ADJ a b NOTE: Direction Drive chain is tightened. Direction Drive chain is loosened. To maintain the proper wheel alignment, adjustboth sides evenly. d. Tighten both locknuts to specification. Locknut 16 Nm (1.6 m S kg, 12 ft S l...

3-48 CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ WARNING NOTE: NOTE: EAS00146 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the motorcycle on a level surface. Securely support the motorcycle so thatthere is no danger of it falling over. Place the motorcycle on a suitable stand so thatthe fr...

3-49 CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ WARNING NOTE: NOTE: c. Loosen the lower ring nut 4 completely, then tighten it to specification. Do not overtighten the lower ring nut. Lower ring nut (final tightening torque) 14 Nm (1.4 m S kg, 10 ft S lb) d. Check the steering head for loosene...

3-50 CHECKING AND ADJUSTING THE STEERING HEAD / CHECKING THE FRONT FORK CHK ADJ WARNING Steering head tension 200 X 500 g e. Repeat the above procedure on the opposite handlebar. f. If the steering head tension is out of specifi- cation (both handlebars should be withinspecification), remove the upp...

3-51 ADJUSTING THE FRONT FORK LEGS CHK ADJ WARNING CAUTION: a b CAUTION: EAS00155 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of thefront fork legs. S Always adjust both front fork legs evenly.Uneven adjustment can result in poor han-dling and loss of stability. S Securely ...

3-53 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY CHK ADJ WARNING CAUTION: a b CAUTION: EAS00158 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Securely support the motorcycle so thatthere is no danger of it falling over. Spring preload Never go beyond the maximum or minimumadjustment positions. 1. Adjust...

3-55 CHECKING THE TIRES CHK ADJ WARNING WARNING EAS00162 CHECKING THE TIRES The following procedure applies to both of thetires.1. Check: S tire pressureOut of specification ! Regulate. S The tire pressure should only be checkedand regulated when the tire temperatureequals the ambient air temperatur...

3-57 CHECKING THE TIRES / CHECKING THE WHEELS CHK ADJ WARNING NOTE: WARNING NOTE: Front tire Manufacturer Size Model DUNLOP 120 / 60ZR 17 M / C (55W) D208FL MICHELIN 120 / 60ZR 17 M / C (55W) Pilot SPORTS N Rear tire Manufacturer Size Model DUNLOP 180 / 55ZR 17 M / C (73W) D208L MICHELIN 180 / 55ZR ...

3-59 CHECKING AND CHARGING THE BATTERY CHK ADJ WARNING CAUTION: EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY Batteries generate explosive hydrogen gasand contain electrolyte which is made of poi-sonous and highly caustic sulfuric acid.Therefore, always follow these preventivemeasures...

3-60 Relationship between the open-circuit voltageand the charging time at 20 _ C Open-circuit voltage (V) These values vary with the temperature, the condition ofthe battery plates, and the electrolyte level. 13.0 12.5 12.0 11.5 5 6.5 10 Charging time (hours) Ambienttemperature20 _ C Open-circuit v...

3-61 Charging Ambient temperature 20 _ C Open-circuit voltage (V) Check the open-circuitvoltage. Time (minutes) CHECKING AND CHARGING THE BATTERY CHK ADJ WARNING CAUTION: 5. Charge: S battery(refer to the appropriate charging method il-lustration) Do not quick charge a battery. S Never remove the MF...

3-62 CHECKING AND CHARGING THE BATTERY CHK ADJ Measure the open-circuitvoltage prior to charging. Connect a charged andAMP meter to the batteryand start charging. Make sure that the currentis higher than the standardcharging current written onthe battery. By turning the chargingvoltage adjust dial, ...

3-64 CHECKING AND CHARGING THE BATTERY / CHECKING THE FUSES CHK ADJ CAUTION: CAUTION: NOTE: 6. Install: S battery 7. Connect: S battery leads(to the battery terminals) First, connect the positive battery lead 1 , and then the negative battery lead 2 . 8. Check: S battery terminalsDirt ! Clean with a...

3-65 CHECKING THE FUSES CHK ADJ WARNING Pocket tester 90890-03112, YU-3112 b. If the pocket tester indicates “ ∞ ”, replace the fuse. 3. Replace: S blown fuse a. Set the main switch to “OFF”.b. Install a new fuse of the correct amperage rating. c. Set on the switches to verify if the electrical circ...

3-66 REPLACING THE HEADLIGHT BULBS CHK ADJ WARNING CAUTION: EAS00183 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of theheadlight bulbs.1. Remove: S front cowling inner panelsRefer to “COWLINGS”. 2. Disconnect: S headlight bulb cover S headlight coupler 1 3. Remove: S headli...

3-67 ADJUSTING THE HEADLIGHT BEAMS CHK ADJ a b a b EAS00185 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of theheadlights.1. Remove: S front cowling inner panelsRefer to “COWLINGS”. 2. Adjust: S headlight beam (vertically) a. Turn the adjusting screw 1 in direction a or b . ...

4-1 Order Job / Part Q’ty Remarks 123456789 Removing the front wheel and brakediscs Brake hose holder (left and right)Front brake caliper (left and right)Front wheel axle pinch boltFront wheel axle boltFront wheel axleCollar (left and right)Oil seal cover (left and right)Front wheelFront brake disc ...

4-2 4 Order Job / Part Q’ty Remarks Disassembling the front wheel Oil seal (left and right)Wheel bearing (left and right)Spacer 221 Remove the parts in the order listed. For assembly, reverse the disassembly procedure. 123 FRONT WHEEL AND BRAKE DISCS CHAS EAS00518

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

4-5 FRONT WHEEL AND BRAKE DISCS CHAS NOTE: EAS00533 CHECKING THE BRAKE DISCS The following procedure applies to all of thebrake discs.1. Check: S brake discsDamage / galling ! Replace. 2. Measure: S brake disc deflectionOut of specification ! Correct the brake disc deflection or replace the brake di...

4-6 FRONT WHEEL AND BRAKE DISCS CHAS NOTE: NOTE: Brake disc bolt Front: 18 Nm (1.8 m S kg, 13 ft S lb) Rear: 30 Nm (3.0 m S g, 22 ft S lb) LOCTITE  d. Measure the brake disc deflection.e. If out of specification, repeat the adjustment steps until the brake disc deflection is withinspecification. f....

4-7 FRONT WHEEL AND BRAKE DISCS CHAS NOTE: NOTE: 8. Tighten wheel axle pinch bolt 2 , and then pinch bolt 1 to specified torque. 9. Retighten pinch bolt 2 to the specified torque. Wheel axle pinch bolt: 18 Nm (1.8 m S kg, 13 ft S lb) 10. Tap the outer side of the left fork leg with a rubber mallet t...

4-9 Order Job / Part Q’ty Remarks 123456789 10 Removing the rear wheel Rear brake caliperLocknut (left and right)Adjusting bolt (left and right)Wheel axle nutWasherRear wheel axleLeft adjusting blockRight adjusting blockRear wheelRear brake caliper bracket 1221111111 Remove the parts in the order li...

4-10 Order Job / Part Q’ty Remarks 123456789 Removing the rear brake disc andrear wheel sprocket Rear brake discRear wheel sprocketCollarOil sealBearingRear wheel drive hubRear wheel drive hub damperCollarRear wheel 111121611 Remove the parts in the order listed. For installation, reverse the remova...

4-11 Order Job / Part Q’ty Remarks Disassembling the rear wheel CollarBearingSpacerOil sealCirclipBearing 111111 Disassemble the parts in the order listed. For installation, reverse the disassemblyprocedure. 123456 REAR WHEEL AND BRAKE DISC CHAS EAS00560

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

4-13 REAR WHEEL AND BRAKE DISC CHAS EAS00565 CHECKING THE REAR WHEEL 1. Check: S wheel axle S rear wheel S wheel bearings S oil sealsRefer to “CHECKING THE FRONTWHEEL”. 2. Check: S tire S rear wheelDamage / wear ! Replace. Refer to “CHECKING THE TIRES” and“CHECKING THE WHEELS” in chapter 3. 3. Measu...

4-14 REAR WHEEL AND BRAKE DISC CHAS NOTE: 110 Nm (11 m S kg, 80 ft S lb) 28 Nm (2.8 m S kg, 20 ft S lb) 23 Nm (2.3 m S kg, 17 ft S lb) 2. Replace: S 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 s...

4-16 Order Job / Part Q’ty Remarks 123456 Removing the front brake pads Front brake caliperBrake pad clipBrake pad pinBrake pad springBrake padBleed screw 121121 Remove the parts in the order listed. The following procedure applies to both ofthe front brake calipers. For installation, reverse the re...

4-17 Order Job / Part Q’ty Remarks 123456 Removing the rear brake pads Screw plugBrake pad pinRear brake caliperBrake pad shimBrake padBleed screw 121421 Remove the parts in the order listed. For installation, reverse the removal procedure. 6 Nm (0.6 m S kg, 4.3 ft S lb) 28 Nm (2.8 m S kg, 20 ft S l...

4-18 FRONT AND REAR BRAKES CHAS CAUTION: WARNING NOTE: EAS00579 Disc brake components rarely require disas-sembly.Therefore, always follow these preventivemeasures: S Never disassemble brake components un-less absolutely necessary. S If any connection on the hydraulic brakesystem is disconnected, th...

4-20 FRONT AND REAR BRAKES CHAS NOTE: 40 Nm (4.0 m S kg, 29 ft S lb) a. Connect a clear plastic hose 1 tightly to the bleed screw 2 . Put the other end of the hose into an open container. b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper withyour finger. c. Tighten ...

4-21 FRONT AND REAR BRAKES CHAS NOTE: NOTE: EAS00583 REPLACING THE REAR BRAKE PADS When replacing the brake pads, it is not neces-sary to disconnect the brake hose or disas-semble the brake caliper. 1. Remove: S screw plug 1 S brake pad pin S brake caliper 2 2. Remove: S brake pad spring 3. Remove: ...

4-22 FRONT AND REAR BRAKES CHAS 28 Nm (2.8 m S kg, 20 ft S lb) 23 Nm (2.3 m S kg, 17 ft S lb) a. Connect a clear plastic hose 1 tightly to the bleed screw 2 . Put the other end of the hose into an open container. b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper wit...

4-23 Order Job / Part Q’ty Remarks 123456789 10 11 121314 Removing the front brake master cylinder Brake fluid StopperBrake fluid reservoir capBrake fluid reservoir diaphragm holderBrake fluid reservoir diaphragmBrake fluid reservoir tankBrake fluid reservoir hoseDust coverCirclipHose jointBrake lev...

4-26 Order Job / Part Q’ty Remarks 123456789 10 Removing the rear brake mastercylinder Brake fluid Brake fluid reservoir capBrake fluid reservoir diaphragm holderBrake fluid reservoir diaphragmBrake fluid reservoir tankBrake fluid reservoir hoseHose jointUnion boltCopper washerBrake hoseBrake master...

4-29 B A A B A B FRONT AND REAR BRAKES CHAS EAS00593 CHECKING THE FRONT AND REAR BRAKEMASTER CYLINDERS The following procedure applies to both of thebrake master cylinders.1. Check: S brake master cylinder Damage / scratches / wear ! Replace. S brake fluid delivery passages (brake master cylinder bo...

4-32 FRONT AND REAR BRAKES CHAS 30 Nm (3.0 m S kg, 22 ft S lb) CAUTION: WARNING 6. Check: S brake fluid levelBelow the minimum level mark a ! Add the recommended brake fluid to the proper level.Refer to “CHECKING THE BRAKE FLUIDLEVEL” in chapter 3. 7. Check: S brake lever operationSoft or spongy fee...

4-33 FRONT AND REAR BRAKES CHAS WARNING CAUTION: S Use only the designated brake fluid. Otherbrake fluids may cause the rubber seals todeteriorate, causing leakage and poorbrake performance. S Refill with the same type of brake fluid thatis already in the system. Mixing brakefluids may result in a h...

4-34 Order Job / Part Q’ty Remarks 1234 Removing the front brake calipers Brake fluidUnion boltCopper washerBrake hoseBrake caliper 1211 Remove the parts in the order listed. The following procedure applies to bothof the front brake calipers. Drain. For installation, reverse the removal procedure. N...

4-36 Order Job / Part Q’ty Remarks 1234 Removing the rear brake caliper Brake fluidUnion boltCopper washerBrake hoseBrake caliper 1211 Remove the parts in the order listed.Drain. For installation, reverse the removal procedure. 30 Nm (3.0 m S kg, 22 ft S lb) 23 Nm (2.3 m S kg, 17 ft S lb) 28 Nm (2.8...

4-37 Order Job / Part Q’ty Remarks Disassembling the rear brake caliper Screw plugBrake pad pinBrake padBrake pad shimBrake pad springBrake caliper pistonBrake caliper piston sealBleed screw 11241121 Disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 123 6 Nm...

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

4-41 FRONT AND REAR BRAKES CHAS WARNING 40 Nm (4.0 m S kg, 29 ft S lb) 30 Nm (3.0 m S kg, 22 ft S lb) 7 Nm (0.7 m S kg, 5.1 ft S lb) WARNING CAUTION: EAS00640 ASSEMBLING AND INSTALLING THEFRONT BRAKE CALIPERS The following procedure applies to both of thebrake calipers. S Before installation, all in...

4-45 Order Job / Part Q’ty Remarks 123456 Removing the front fork legs Front wheelFront brake calipersFront cowling inner panelsFront fenderCap boltHandlebar pinch boltUpper bracket pinch boltUnder bracket pinch boltFront fork leg 111121 Remove the parts in the order listed. Refer to “FRONT AND REAR...

4-46 Order Job / Part Q’ty Remarks Disassembling the front fork legs Cap boltO-ringDamper adjusting rodNutWasherSpacerWasherFork springDust sealOil seal clipDamper rod assembly boltCopper washer 111111111111 Disassemble the parts in the order listed. The following the procedure applies toboth of the...

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

4-49 FRONT FORK CHAS NOTE: CAUTION: NOTE: EAS00655 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of thefront fork legs.1. Loosen: S nut 1 2. Remove: S cap bolt 2 (from the damper rod assembly) 3. Remove: S damper adjusting rod 1 S washer 2 S spacer 3 S fork spring 4. Drai...

4-50 FRONT FORK CHAS WARNING Damper rod holder 90890-01473 7. Remove: S damper rod assembly 8. Remove: S inner tube S oil seal S inner tube bushing a. Hold the front fork leg horizontally.b. Slowly push A the inner tube into the outer tube and just before it bottoms out, pull B the inner tube back q...

4-51 FRONT FORK CHAS CAUTION: WARNING NOTE: S The front fork leg has a built-in damper ad-justing rod and a very sophisticated inter-nal construction, which are particularlysensitive to foreign material. S When disassembling and assembling thefront fork leg, do not allow any foreign ma-terial to ent...

4-52 FRONT FORK CHAS WARNING CAUTION: 40 Nm (4.0 m S kg, 29 ft S lb) NOTE: Always use new copper washers. Allow the damper rod assembly to slideslowly down the inner tube 1 until it pro- trudes from the bottom of the inner tube. Becareful not to damage the inner tube. 2. Lubricate: S inner tube’s ou...

4-53 FRONT FORK CHAS CAUTION: NOTE: NOTE: 5. Install: S washer S oil seal 1 (with the fork seal driver weight and fork sealdriver attachment) Make sure the numbered side of the oil sealfaces up. S Before installing the oil seal, lubricate its lipswith lithium-soap-based grease. S Lubricate the outer...

4-56 FRONT FORK CHAS WARNING NOTE: 23 Nm (2.3 m S kg, 17 ft S lb) 26 Nm (2.6 m S kg, 19 ft S lb) 23 Nm (2.3 m S kg, 17 ft S lb) e. Install the cap bolt and finger tighten it. S Before installing the cap bolt, apply greaseonto the O-ring. S Always use a new cap bolt O-ring. f. Hold the cap bolt and t...

4-57 FRONT FORK CHAS 33 Nm (3.3 m S kg, 24 ft S lb) 13 Nm (1.3 m S kg, 9.4 ft S lb) WARNING 5. Install: S handlebar S handlebar pinch bolt 1 S handlebar bolt 2 Make sure the brake hoses are routed prop-erly. 6. Adjust: S spring preload S rebound damping S compression dampingRefer to “ADJUSTING THE F...

4-58 Order Job / Part Q’ty Remarks 123456789 10 11 121314 Removing the handlebars Grip endHandlebar gripClutch switch connectorLeft handlebar switchClutch cableClutch leverRight handlebar switchThrottle gripThrottle cablesFront brake light switch connectorFront brake master cylinder holderFront brak...

4-59 HANDLEBARS CHAS WARNING NOTE: WARNING EAS00667 REMOVING THE HANDLEBARS 1. Stand the motorcycle on a level surface. Securely support the motorcycle so thatthere is no danger of it falling over. 2. Remove: S grip end S handlebar grip Blow compressed air between the left handle-bar and the handleb...

4-60 HANDLEBARS CHAS WARNING NOTE: 33 Nm (3.3 m S kg, 24 ft S lb) 13 Nm (1.3 m S kg, 9.4 ft S lb) 13 Nm (1.3 m S kg, 9.4 ft S lb) CAUTION: NOTE: EAS00674 INSTALLING THE HANDLEBARS 1. Stand the motorcycle on a level surface. Securely support the motorcycle so thatthere is no danger of it falling over...

4-63 Order Job / Part Q’ty Remarks 1234567 Removing the under bracket Front wheelFront brake calipersFront fork legsFront fenderHandlebarsFuel tankAir filter case Main switch couplerSteering stem nutWasherUpper bracketUnder bracket panelLock washerUpper ring nut 2111111 Remove the parts in the order...

4-65 STEERING HEAD CHAS WARNING NOTE: WARNING EAS00679 REMOVING THE UNDER BRACKET 1. Stand the motorcycle on a level surface. Securely support the motorcycle so thatthere is no danger of it falling over. 2. Remove: S steering stem nut S washer S upper bracket S lock washer S rubber washer S ring nut...

4-66 STEERING HEAD CHAS CAUTION: NOTE: 3. Replace: S bearings S bearing races a. Remove the bearing races 1 from the steer- ing head pipe with a long rod 2 and hammer. b. Remove the bearing race 3 from the under bracket with a floor chisel 4 and hammer. c. Install a new rubber seal and new bearing r...

4-67 STEERING HEAD CHAS 113 Nm (11.3 m S kg, 82 ft S lb) NOTE: NOTE: 3. Install: S upper bracket S washer S steering stem nut Temporarily tighten the steering stem nut. 4. Install: S front fork legsRefer to “INSTALLING THE FRONT FORKLEGS”. Temporarily tighten the upper and under brack-et pinch bolts...

4-68 Order Job / Part Q’ty Remarks 1 2 34 5 67 8 Removing the rear shock absorber assembly Rear wheel Self-locking nut / bolt (Relay arm – rear shock absorber)Self-locking nut / bolt(Rear shock absorber upper)Rear shock absorberSelf-locking nut / bolt(Relay arm – swingarm)Self-locking nut / bolt(Rel...

4-69 REAR SHOCK ABSORBER ASSEMBLY CHAS Order Job / Part Q’ty Remarks 9 10 11 Oil seal / bearing / collarOil seal / bearing / collarBracket 6/3/3 2/1/1 1 For installation, reverse the removal procedure. 52 Nm (5.2 m S kg, 38 ft S lb) 44 Nm (4.4 m S kg, 32 ft S lb) 44 Nm (4.4 m S kg, 32 ft S lb)

4-70 REAR SHOCK ABSORBER ASSEMBLY CHAS WARNING WARNING EAS00687 HANDLING THE REAR SHOCK ABSORBERAND GAS CYLINDER This rear shock absorber and gas cylindercontain highly compressed nitrogen gas.Before handling the rear shock absorber orgas cylinder, read and make sure you under-stand the following in...

4-72 REAR SHOCK ABSORBER ASSEMBLY CHAS NOTE: 44 Nm (4.4 m S kg, 32 ft S lb) 44 Nm (4.4 m S kg, 32 ft S lb) S springDamage / wear ! Replace the rear shock ab- sorber assembly. S gas cylinderDamage / gas leaks ! Replace. S bushingsDamage / wear ! Replace. S dust sealsDamage / wear ! Replace. S boltsBe...

4-73 Order Job / Part Q’ty Remarks 123456789 Removing the swingarm and drive chain Rear wheel Rear shock absorber assembly Relay arms and connecting rod Drive sprocket coverAdjusting boltLocknutRear fenderPivot shaft nut / washerPivot shaftSwingarmDrive chainDrive chain guideDust cover 221 1 / 1 111...

4-75 SWINGARM AND DRIVE CHAIN CHAS WARNING NOTE: EAS00703 REMOVING THE SWINGARM 1. Stand the motorcycle on a level surface. Securely support the motorcycle so thatthere is no danger of it falling over. Place the motorcycle on a suitable stand so thatthe rear wheel is elevated. 2. Remove: S rear whee...

4-76 SWINGARM AND DRIVE CHAIN CHAS WARNING NOTE: WARNING EAS00704 REMOVING THE DRIVE CHAIN 1. Stand the motorcycle on a level surface. Securely support the motorcycle so thatthere is no danger of it falling over. Place the motorcycle on a suitable stand so thatthe rear wheel is elevated. 2. Remove: ...

4-77 SWINGARM AND DRIVE CHAIN CHAS NOTE: 4. Check: S dust covers 1 S spacer 2 Damage / wear ! Replace. S bearingsDamage / pitting ! Replace. EAS00709 CHECKING THE DRIVE CHAIN 1. Measure: S ten-link section a of the drive chain Out of specification ! Replace the drive chain. Ten-link drive chain sect...

4-78 SWINGARM AND DRIVE CHAIN CHAS CAUTION: This motorcycle has a drive chain with smallrubber O-rings 1 between the drive chain side plates. Never use high-pressure wateror air, steam, gasoline, certain solvents(e.g., benzine), or a coarse brush to clean thedrive chain. High-pressure methods couldf...

4-79 SWINGARM AND DRIVE CHAIN CHAS 6 Nm (0.6 m S kg, 4.3 ft S lb) 95 Nm (9.5 m S kg, 69 ft S lb) NOTE: 44 Nm (4.4 m S kg, 32 ft S lb) 44 Nm (4.4 m S kg, 32 ft S lb) NOTE: EAS00711 INSTALLING THE SWINGARM 1. Lubricate: S bearings S spacers S dust covers S pivot shaft Recommended lubricant Lithium-soa...

5-1 5 Order Job / Part Q’ty Remarks 12345678 Removing the drive sprocket Bottom cowlingSide cowlingsDrive chain Lock nutShift rodShift armDrive sprocket coverNutLock washerChain guideDrive sprocket 21111111 Remove the parts in the order listed. Loosen.Refer to “ADJUSTING THE DRIVE CHAIN” in chapter ...

5-2 ENGINE ENG 20 Nm (2.0 m S kg, 15 ft S lb) 20 Nm (2.0 m S kg, 15 ft S lb) 20 Nm (2.0 m S kg, 15 ft S lb) Order Job / Part Q’ty Remarks 123 Removing the exhaust pipe Bottom cowlingSide cowlingsMufflerExhaust pipe assemblyExhaust pipe gasket 114 Remove the parts in the order listed. For installatio...

5-3 Order Job / Part Q’ty Remarks 12 Disconnecting the leads and hoses Air filter caseThrottle body assembly Engine oilOil filter cartridge Oil coolerAir cut-off valve Starter motor Battery negative leadBattery positive lead 11 Disconnect the parts in the order listed.Refer to “AIR FILTER CASE” in c...

5-5 Order Job / Part Q’ty Remarks 123456789 Removing the engine Drive chain guideRight front engine mounting boltLeft front engine mounting boltSelf-locking nutRear engine mounting boltEngine bracket boltEngine bracketEngine mounting adjust boltEngine 122222121 Removing the parts in the order listed...

5-6 ENGINE ENG 45 Nm (4.5 m S kg, 33 ft S lb) NOTE: 45 Nm (4.5 m S kg, 33 ft S lb) NOTE: 7 Nm (0.7 m S kg, 5.1 ft S lb) NOTE: EAS00192 INSTALLING THE ENGINE 1. Install: S engine bracket 1 (to the engine) S engine mounting adjust bolts (temporary tighten) 2. Install: S rear engine mounting bolts 1 S ...

5-7 ENGINE ENG 45 Nm (4.5 m S kg, 33 ft S lb) NOTE: 45 Nm (4.5 m S kg, 33 ft S lb) NOTE: 10 Nm (1.0 m S kg, 7.2 ft S lb) NOTE: 7 Nm (0.7 m S kg, 5.1 ft S lb) Pivot shaft wrench 90890-01471, YM-01471 Pivot shaft wrench adapter 90890-01476 5. Tighten: S nuts 1 (rear engine mounting bolts) First tighte...

5-8 Order Job / Part Q’ty Remarks 123456 Removing the cylinder head cover Throttle body assembly Radiator assemblyAir cut-off valve Ignition coilSpark plugCylinder head coverCylinder head cover gasketTiming chain guide (top side)Cylinder identification sensor 441111 Remove the parts in the order lis...

5-9 Order Job / Part Q’ty Remarks 123456789 10 11 12 Removing the camshafts Pickup rotor cover Camshaft sprocket boltTiming chain tensionerTiming chain tensioner gasketTiming chain guide (exhaust side)Intake camshaft capDowel pinExhaust camshaft capDowel pinIntake camshaftExhaust camshaftPinTiming c...

5-10 CAMSHAFTS ENG NOTE: CAUTION: EAS00198 REMOVING THE CAMSHAFTS 1. Remove: S pickup rotor coverRefer to “CRANKSHAFT POSITION SEN-SOR AND PICKUP ROTOR”. 2. Align: S “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 ...

5-11 CAMSHAFTS ENG NOTE: 7. Remove: S intake camshaft 1 S exhaust camshaft 2 To prevent the timing chain from falling into thecrankcase, fasten it with a wire a . 8. Remove: S camshaft sprockets EAS00204 CHECKING THE CAMSHAFTS 1. Check: S camshaft lobesBlue discoloration / pitting / scratches ! Re- ...

5-12 CAMSHAFTS ENG NOTE: 3. Measure: S camshaft runoutOut of specification ! Replace. Camshaft runout limit 0.06 mm (0.0024 in) 4. Measure: S camshaft-journal-to-camshaft-cap clear-anceOut of specification ! Measure the camshaft journal diameter. Camshaft-journal-to-camshaft-cap clearance 0.028 X 0....

5-13 CAMSHAFTS ENG NOTE: EAS00208 CHECKING THE TIMING CHAIN, CAMSHAFTSPROCKETS, AND TIMING CHAIN GUIDES The following procedure applies to all of thecamshaft sprockets and timing chain guides.1. Check: S timing chain 1 Damage / stiffness ! Replace the timing chain and camshaft sprockets as a set. 2....

5-14 CAMSHAFTS ENG NOTE: b. Remove the screwdriver and slowly release the timing chain tensioner rod. c. Make sure that the timing chain tensioner rod comes out of the timing chain tensionerhousing smoothly. If there is rough move-ment, replace the timing chain tensioner. 3. Check: S cap bolt S copp...

5-15 CAMSHAFTS ENG NOTE: 10 Nm (1.0 m S kg, 7.2 ft S lb) NOTE: CAUTION: NOTE: 3. Install: S dowel pins S exhaust camshaft caps S intake cmashaft caps S Make sure each camshaft cap is installed in itsoriginal place. S Make sure the arrow mark a on each cam- shaft cap points towards the right side of ...

5-16 CAMSHAFTS ENG WARNING 24 Nm (2.4 m S kg, 17 ft S lb) CAUTION: 6. Install: S timing chain tensioner a. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod ful-ly clockwise with a thin screwdriver 1 . b. With the timing chain tensioner rod turned all the way in...

5-18 Order Job / Part Q’ty Remarks 123 Removing the cylinder head Intake and exhaust camshaftEngine bracketCylinder headCylinder head gasketDowel pin 112 Remove the parts in the order listed.Refer to “CAMSHAFTS”.Refer to “ENGINE”. For installation, reverse the removal procedure. 12 Nm (1.2 m S kg, 8...

5-19 CYLINDER HEAD ENG NOTE: NOTE: NOTE: EAS00222 REMOVING THE CYLINDER HEAD 1. Remove: S cylinder head bolts S Loosen the bolts in the proper sequence asshown. S Loosen each bolt 1 / 2 of a turn at a time. Afterall of the bolts are fully loosened, removethem. EAS00229 CHECKING THE CYLINDER HEAD 1. ...

5-20 CYLINDER HEAD ENG NOTE: 19 Nm (1.9 m S kg, 14 ft S lb) 50 Nm (5.0 m S kg, 36 ft S lb) 12 Nm (1.2 m S kg, 8.7 ft S lb) NOTE: EAS00233 INSTALLING THE CYLINDER HEAD 1. Install: S gasket New 1 S dowel pins 2 2. Install: S cylinder head Pass the timing chain through the timing chain cavity. 3. Tight...

5-21 Order Job / Part Q’ty Remarks 123456789 10 11 1213 Remove the valves and valve springs Cylinder headIntake valve lifterIntake valve padIntake valve cotterIntake valve upper spring seatIntake valve spring outerIntake valve spring innerIntake valve oil sealIntake valve lower spring seatIntake val...

5-23 VALVES AND VALVE SPRINGS ENG NOTE: NOTE: NOTE: NOTE: EAS00238 REMOVING THE VALVES The following procedure applies to all of thevalves and related components. Before removing the internal parts of the cylin-der head (e.g., valves, valve springs, valveseats), make sure the valves properly seal. 1...

5-24 VALVES AND VALVE SPRINGS ENG NOTE: Valve spring compressor 90890-04019, YM-04019 Valve spring compressor attachment 90890-04108, YM-01253 4. Remove: S upper spring seat 1 S valve spring outer 2 S valve spring inner (intake only) 3 S valve 4 S oil seal 5 S lower spring seat 6 Identify the positi...

5-26 VALVES AND VALVE SPRINGS ENG NOTE: 5. Measure: S valve margin thickness a Out of specification ! Replace the valve. Valve margin thickness 0.6 X 0.8 mm (0.0236 X 0.0315 in) <Limit>: 0.5 mm (0.02 in) 6. Measure: S valve stem runoutOut of specification ! Replace the valve. S When installing...

5-28 VALVES AND VALVE SPRINGS ENG j. Measure the valve seat width c again. If the valve seat width is out of specification, refaceand lap the valve seat. EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of thevalve springs.1. Measure: S valve spring free length a Out of spe...

5-29 VALVES AND VALVE SPRINGS ENG 3. Measure: S valve spring tilt a Out of specification ! Replace the valve spring. Spring tilt limit Intake valve spring (inner) 2.5 _ / 1.6 mm (0.06 in) (outer)2.5 _ / 1.8 mm (0.07 in) Exhaust valve spring2.5 _ / 1.8 mm (0.07 in) EAS00242 CHECKING THE VALVE LIFTERS...

5-31 Order Job / Part Q’ty Remarks 12345 Removing the stator coil assembly Rider seat and fuel tank Buttom cowlingLeft side cowlingCoolantCoolant reservoir tank Engine oil Stator coil assembly couplerGenerator rotor coverGenerator rotor cover gasketDowel pinStator coil assembly lead holder 11121 Rem...

5-33 STARTER CLUTCH AND GENERATOR ENG NOTE: NOTE: EAS00347 REMOVING THE GENERATOR 1. Remove: S rider seat and fuel tankRefer to “SEATS” and “FUEL TANK” in chap-ter 3. S buttom cowling S left side cowlingRefer to “COWLINGS” in chapter 3. 2. Drain: S coolantRefer to “CHANGING THE COOLANT” inchapter 3....

5-34 STARTER CLUTCH AND GENERATOR ENG CAUTION: NOTE: NOTE: 5. Remove: S generator rotor 1 (with the flywheel puller 2 and flywheel pull- er attachment) S woodruff key To protect the end of the crankshaft, placean appropriate sized socket between the fly-wheel puller set’s center bolt and the crank-s...

5-35 STARTER CLUTCH AND GENERATOR ENG 32 Nm (3.2 m S kg, 23 ft S lb) LOCTITIE R NOTE: EAS00351 CHECKING THE STARTER CLUTCH 1. Check: S starter clutch rollers 1 Damage / wear ! Replace. 2. Check: S starter clutch idle gear 1 S starter clutch drive gear 2 Burrs / chips / roughness / wear ! Replace the...

5-37 STARTER CLUTCH AND GENERATOR ENG NOTE: Tighten the generator rotor cover bolts in stagesand in a crisscross pattern. 6. Fill: S engine oilRefer to “CHANGING THE ENGINE OIL” inchapter 3. S coolantRefer to “CHANGING THE COOLANT” inchapter 3. 7. Install: S left side cowling S buttom cowlingRefer t...

5-38 Order Job / Part Q’ty Remarks 123456789 10 Removing the shift shaft and stopperlever Coolant reservoir tankCoolant Drive sprocket coverShift shaft coverShift shaft cover gasketDowel pinOil sealShift shaftShift shaft springCollarStopper lever springCirclipWasher 1111111111 Remove the parts in th...

5-40 SHIFT SHAFT ENG 22 Nm (2.2 m S kg, 16 ft S lb) NOTE: NOTE: EAS00328 CHECKING THE SHIFT SHAFT 1. Check: S shift shaft 1 Bends / damage / wear ! Replace. S shift shaft spring 2 Damage / wear ! Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: S stopper lever 1 Bends / damage ! Replace. Rolle...

5-41 Order Job / Part Q’ty Remarks 12345 Removing the crankshaft positionsensor and pickup rotor Rider seatFuel tankRight side cowlingBottom cowlingEngine oil Generator cover Clutch cableCrankshaft position sensor lead couplerPickup rotor coverPickup rotor cover gasketDowel pin 11112 Remove the part...

5-43 CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR ENG NOTE: NOTE: NOTE: REMOVING THE PICKUP ROTOR 1. Remove: S clutch cable holder 1 S pickup rotor cover 2 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. 2. Remov...

5-45 Order Job / Part Q’ty Remarks 12345 Removing the clutch cover Bottom cowlingRight side cowlingEngine oil Coolant Coolant hoseClutch cableClutch coverClutch cover gasketDowel pin 11112 Removing the parts in the order listed. Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.Drain.Refer to “CH...

5-46 CLUTCH ENG Order Job / Part Q’ty Remarks Disassembling the clutch cover CirclipWasherPull leverPull lever springOil sealBearing 221112 Disassemble the parts in the order listed. For assembly, reverse the disassemblyprocedure. 123456

5-47 Order Job / Part Q’ty Remarks 123456789 10 11 12 Removing the clutch Compression springPressure platePull rodBearingFriction plate (Brown)Clutch plate (t=2.0 mm, 0.08 in)Friction plate (Purple)Clutch plate (t=2.3 mm, 0.09 in)Clutch boss nutLock plateClutch bossThrust plate 611167211111 Remove t...

5-48 CLUTCH ENG NOTE: NOTE: EAS00276 REMOVING THE CLUTCH 1. Remove: S clutch cover 1 S gasket 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: S compression spring bolts 1 S compression springs S pressu...

5-49 CLUTCH ENG NOTE: 2. Measure: S friction plate thicknessOut of specification ! Replace the friction plates as a set. Measure the friction plate at four places. Friction plate thickness 2.9 X 3.1 mm (0.114 X 0.122 in) <Limit>: 2.8 mm (0.110 in) EAS00281 CHECKING THE CLUTCH PLATES The follow...

5-50 CLUTCH ENG NOTE: NOTE: 2. Measure: S clutch spring free length a Out of specification ! Replace the clutch springs as a set. Clutch spring free length 50 mm (1.97 in)<Limit>: 49 mm (1.93 in) EAS00284 CHECKING THE CLUTCH HOUSING 1. Check: S clutch housing dogs Damage / pitting / wear ! Deb...

5-51 CLUTCH ENG 70 Nm (7.0 m S kg, 51 ft S lb) NOTE: EAS00287 CHECKING THE PULL LEVER SHAFT ANDPULL ROD 1. Check: S pull lever shaft pinion gear teeth a S pull rod teeth b Damage / wear ! Replace the pull rod and pull lever shaft pinion gear as a set. 2. Check: S pull rod bearing Damage / wear ! Rep...

5-54 Order Job / Part Q’ty Remarks 12345678 Removing the oil pan and oil pump Engine oil Coolant Exhaust pipe assemblyWater pumpOil level switch couplerOil level switchOil level switch lead holderOil panOil pan gasketDowel pinOil strainerOil strainer gasket 11111211 Remove the parts in the order lis...

5-57 OIL PAN AND OIL PUMP ENG NOTE: EAS00362 REMOVING THE OIL PAN 1. Remove: S oil level switch 1 S oil pan 2 S oil pan gasket S dowel pins 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 O...

5-58 OIL PAN AND OIL PUMP ENG 3. Check: S oil pump operationRough movement ! Repeat steps (1) and (2) or replace the defective part(s). EAS00365 CHECKING THE RELIEF VALVE 1. Check: S relief valve body 1 S relief valve 2 S spring 3 S O-ring 4 Damage / wear ! Replace the defective part(s). EAS00367 CH...

5-59 OIL PAN AND OIL PUMP ENG 12 Nm (1.2 m S kg, 8.7 ft S lb) NOTE: 12 Nm (1.2 m S kg, 8.7 ft S lb) CAUTION: EAS00374 ASSEMBLING THE OIL PUMP 1. Lubricate: S inner rotor S outer rotor S oil pump shaft(with the recommended lubricant) Recommended lubricant Engine oil 2. Install: S oil pump housing 1 S...

5-60 OIL PAN AND OIL PUMP ENG NOTE: 12 Nm (1.2 m S kg, 8.7 ft S lb) 10 Nm (1.0 m S kg, 7.2 ft S lb) 43 Nm (4.3 m S kg, 31 ft S lb) WARNING NOTE: EAS00378 INSTALLING THE OIL STRAINER 1. Install: S oil strainer 1 S relief valve 2 Make sure to check the arrow mark a located on the oil strainer housing ...

5-61 Order Job / Part Q’ty Remarks 12345 Removing the crankcase EngineCylinder headStarter clutch and generator Shift shaftCrankshaft position sensor and pickuprotorClutchWater pump assemblyOil pan and oil pumpTiming chainOil pump drive chainOil pump drive chain guideLower crankcaseDowel pin 11113 R...

5-63 CRANKCASE ENG NOTE: CAUTION: NOTE: EAS00384 DISASSEMBLING THE CRANKCASE 1. Place the engine upside down.2. Remove: S crankcase bolts S 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. S Loosen the bolts in d...

5-64 CRANKCASE ENG 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: S crankcaseCracks / damage ! Replace. S oil delivery passagesObstruction ! Blow out with compressed air. ...

5-65 CRANKCASE ENG NOTE: CAUTION: NOTE: Do not allow any sealant to come into contactwith the oil gallery or crankshaft journal bear-ings. Do not apply sealant to within 2 X 3 mm of the crankshaft journal bearings. 3. Install: S dowel pin 4. Set the shift drum assembly and transmis- sion gears in th...

5-66 Order Job / Part Q’ty Remarks 123456789 10 Removing the connecting rods andpistons Lower crankcaseConnecting rod capBig end lower bearingBig end upper bearingPiston pin clipPiston pinPistonConnecting rodTop ring2nd ringOil ring 4448444444 Remove the parts in the order listed. Refer to “CRANKCAS...

5-67 CONNECTING RODS AND PISTONS ENG NOTE: CAUTION: NOTE: NOTE: EAS00393 REMOVING THE CONNECTING RODS ANDPISTONS The following procedure applies to all of theconnecting rods and pistons.1. Remove: S connecting rod cap 1 S big end bearings Identify the position of each big end bearing sothat it can b...

5-68 CONNECTING RODS AND PISTONS ENG NOTE: NOTE: EAS00387 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: S crankshaft assembly S crankshaft journal upper bearings(from the upper crankcase)Refer to “CRANKSHAFT”. Identify the position of each crankshaft journalupper bearing so that it can be reinstalled ...

5-70 CONNECTING RODS AND PISTONS ENG NOTE: NOTE: Piston ring side clearance Top ring 0.030 X 0.065 mm (0.0012 X 0.0026 in) <Limit>: 0.115 mm (0.0045 in) 2nd ring 0.030 X 0.065 mm (0.0012 X 0.0026 in) <Limit>: 0.125 mm (0.0049 in) 2. Install: S piston ring(into the cylinder) Level the pis...

5-71 CONNECTING RODS AND PISTONS ENG 2. Measure: S piston pin outside diameter a Out of specification ! Replace the piston pin. Piston pin outside diameter 15.991 X 16.000 mm (0.6296 X 0.6299 in) <Limit>: 15.971 mm (0.6288 in) 3. Measure: S piston pin bore inside diameter b Out of specificatio...

5-73 CONNECTING RODS AND PISTONS ENG CAUTION: WARNING CAUTION: NOTE: e. Tighten the connecting rod nuts. Connecting rod nut 15 Nm (1.5 m S kg, 11 ft S lb) + 150 _ f. Replace the connecting rod bolts and nuts with new ones. Tighten the connecting rod bolts using theplastic-region tightening angle met...

5-74 CONNECTING RODS AND PISTONS ENG NOTE: NOTE: 2. Select: S big end bearings (P1 X P4) S The numbers A stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacementbig end bearing sizes. S “P1” X “P4” refer to the bearings shown in the crankshaft il...

5-77 CONNECTING RODS AND PISTONS ENG WARNING CAUTION: NOTE: e. Tighten the nut further to reach the specified angle (150 _ ). When the nut is tightened more than the spe-cified angle, do not loosen the nut and thenretighten it.Replace the bolt with a new one and performthe procedure again. S Do not ...

5-78 Order Job / Part Q’ty Remarks 123 Removing the crankshaft Crankcase Connecting rod caps CrankshaftCrankshaft journal lower bearingCrankshaft journal upper bearing 155 Remove the parts in the order listed.Separate.Refer to “CRANKCASE”.Refer to “CONNECTING RODS AND PISTONS”. For installation, rev...

5-79 CRANKSHAFT ENG CAUTION: EAS00395 CHECKING THE CRANKSHAFT 1. Measure: S crankshaft runoutOut of specification ! Replace the crank- shaft. Crankshaft runout Less than 0.03 mm (0.0012 in) 2. Check: S crankshaft journal surfaces S crankshaft pin surfaces S bearing surfacesScratches / wear ! Replace...

5-82 CRANKSHAFT ENG NOTE: EAS00407 INSTALLING THE CRANKSHAFT 1. Install: S crankshaft journal upper bearings 1 (into the upper crankcase) S Align the projections a on the crankshaft jour- nal upper bearings with the notches b in the upper crankcase. S Be sure to install each crankshaft journal up-pe...

5-83 Order Job / Part Q’ty Remarks 123456789 10 11 Removing the transmission, shift drum assembly, and shift forks Crankcase lower Drive axle assemblyCirclipOil sealBearingShift drum retainerShift fork guide barSpringShift fork “L”Shift fork “R”Shift drum assemblyShift fork “C” 11111241111 Remove th...

5-89 TRANSMISSION ENG WARNING EAS00420 REMOVING THE TRANSMISSION 1. Remove: S main axle assembly 1 (with the Torx  wrench T30) a. Insert two bolts 2 of the proper size, as shown in the illustration, into the main axleassembly bearing housing. b. Tighten the bolts until they contact the crank- case ...

5-90 TRANSMISSION ENG EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: S shift drum groovesDamage / scratches / wear ! Replace the shift drum assembly. S shift drum segment 1 Damage / wear ! Replace the shift drum as- sembly. S shift drum bearing 2 Damage / pitting ! Replace the shift drum assemb...

5-91 TRANSMISSION ENG NOTE: NOTE: 4. Check: S transmission gear engagement(each pinion gear to its respective wheelgear)Incorrect ! Reassemble the transmission axle assemblies. 5. Check: S transmission gear movementRough movement ! Replace the defective part(s). 6. Check: S circlipsBends / damage / ...

6-1 6 Order Job / Part Q’ty Remarks 12345678 Removing the radiator Rider seatFuel tankAir filter caseSide cowlings and bottom cowlingCoolant Coolant reservoir hoseThrottle body hoseRadiator outlet hoseCoolant pipeRadiator inlet hoseOil cooler outlet hoseRadiatorRadiator fan 12111111 Remove the parts...

6-3 RADIATOR COOL NOTE: EAS00455 CHECKING THE RADIATOR 1. Check: S radiator finsObstruction ! Clean. Apply compressed air to the rear of the radia-tor.Damage ! Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: S radiator hoses S radiator pipesCracks / dam...

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

6-5 Order Job / Part Q’ty Remarks 123456789 10 11 Removing the oil cooler Radiator assemblyEngine oil Oil cooler outlet hoseUnion boltWasherOil coolerOil cooler inlet hoseOil cooler inlet pipeWater jacket joint hoseWater jacket jointO-ringO-ringWater pump hose 11111111112 Remove the parts in the ord...

6-6 OIL COOLER COOL 63 Nm (6.3 m S kg, 46 ft S lb) NOTE: EAS00458 CHECKING THE OIL COOLER 1. Check: S oil coolerCracks / damage ! Replace. 2. Check: S oil cooler inlet hose S oil cooler outlet hoseCracks / damage / wear ! Replace. EAS00459 INSTALLING THE OIL COOLER 1. Clean: S mating surfaces of the...

6-7 Order Job / Part Q’ty Remarks 123 Removing the thermostat Rider seatAir filter caseThrottle body assembly Coolant Radiator inlet hoseThermostat coverThermostat 111 Remove the parts in the order listed.Refer to “SEATS” chapter 3.Refer to “AIR FILTER CASE” in chapter 3.Refer to “THROTTLE BODIES” i...

6-8 1 THERMOSTAT COOL NOTE: NOTE: 12 Nm (1.2 m S kg, 8.7 ft S lb) NOTE: EAS00462 CHECKING THE THERMOSTAT 1. Check: S thermostat 1 Does not open at 71 X 85 _ C (160 X 185 _ F) ! Replace. a. Suspend the thermostat in a container filled with water. b. Slowly heat the water.c. Place a thermometer in the...

6-10 Remove the parts in the order listed.Refer to “COWLINGS” in chapter 3.Drain.Refer to “CHANGING THE COOLANT” inchapter 3. It is not necessary to remove the waterpump unless the coolant level is extremelylow or the coolant contains engine oil. For installation, reverse the removal procedure. NOTE...

6-11 Order Job / Part Q’ty Remarks Disassembling the water pump Water pump coverO-ringImpeller shaftCirclipWater pump sealOil sealBearingWater pump housing 11111111 Disassemble the parts in the order listed. For assembly, reverse the disassemblyprocedure. 1234567 10 Nm (1.0 m S kg, 7.2 ft S lb) 8 WA...

6-12 WATER PUMP COOL NOTE: NOTE: NOTE: NOTE: EAS00471 DISASSEMBLING THE WATER PUMP 1. Remove: S circlip S impeller shaft 2. Remove: S water pump seal 1 Remove the water pump seal from the outsideof the water pump housing. 2 Water pump housing 3. Remove: S oil seal 1 (with a thin, flat-head screwdriv...

6-13 WATER PUMP COOL NOTE: CAUTION: NOTE: EAS00473 CHECKING THE WATER PUMP 1. Check: S water pump housing 1 S water pump cover 2 S impeller 3 S rubber damper 4 S rubber damper holder 5 S water pump seals S oil seal Cracks / damage / wear ! Replace. 2. Check: S bearing Rough movement ! Replace. 3. Ch...

6-14 WATER PUMP COOL NOTE: CAUTION: Mechanical seal installer 90890-04078, YM-33221 4 Middle driven shaft bearing driver 90890-04058, YM-04058 5 Quick Gasket ACC-11001-05-01 Yamaha bond #1215 90890-85505 A Push down. 3. Install: S rubber damper New 1 S rubber damper holder New 2 Before installing th...

6-15 WATER PUMP COOL 12 Nm (1.2 m S kg, 8.7 ft S lb) NOTE: NOTE: INSTALLING THE WATER PUMP 1. Install: S water pump assembly Align the projection a at the oil pump shaft and water pump shaft groove b . 2. Install: S water pump outlet hose 1 S water pump inlet hose 2 S Install the inlet hose with yel...

7-1 FUEL INJECTION SYSTEM FI 19 Atmospheric pressuresensor 20 Fuel injection systemrelay 21 Engine trouble warninglight 22 Lean angle cut-offswitch 13 Coolant temperaturesensor 14 Spark plug 15 Cylinder identificationsensor 16 Pressure regulator 17 Battery 18 ECU 1 Ignition coil 2 Air filter case 3 ...

7-2 7 FUEL INJECTION SYSTEM FI 1 Main switch 5 Battery 6 Fuse (main) 9 Fuse (fuel injection) 10 Fuse (ignition) 11 Starting circuit cut-off relay 12 Sidestand switch 13 Fuel pump 14 ECU 15 Ignition coil 16 Spark plug 17 Fuel injector 19 Neutral switch 20 Crankshaft position sensor 21 Intake air temp...

7-3 30: Lean angle cut-off switch(latch up detected) 41: Lean angle cut-off switch(open or short circuit) 50: ECU internal malfunction(memory check error) FUEL INJECTION SYSTEM FI EAS00899 ECU’S SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the ...

7-4 FUEL INJECTION SYSTEM FI EAS00902 ALTERNATE INSTRUCTIONS OPERATION CONTROL (FAIL-SAFE ACTION) If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi-nates the engine trouble warning light and provides the engine with alternate operating instructions...

7-5 Engine operation is not normal or the engine trouble warning light is on. * Engine trouble warning light may not come on even if the engine operation is not normal. The engine trouble warning light comes on. Check the fault code number displayed on the me-ter. Identify the system with the malfun...

7-6 FUEL INJECTION SYSTEM FI NOTE: NOTE: EAS00905 DIAGNOSTIC MODE Setting the diagnostic mode1. Turn the main switch to “OFF” and set the en- gine stop switch to “ON”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “SE- LECT” and “RESET” buttons, turn...

7-7 FUEL INJECTION SYSTEM FI NOTE: This code appears if no normal sig-nals from the start switch is turnedON. Fault code table Fault code No. Symptom Probable cause of malfunction Diagnostic code 11 No normal signals are received fromthe cylinder identification sensor whenthe engine is started or wh...

7-9 FUEL INJECTION SYSTEM FI NOTE: EAS00907 Diagnostic mode table Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to“DIAGNOSTIC MODE”. S Check the intake temperature and coolant temperature as close as possible to the intake temperaturesensor and t...

7-12 FUEL INJECTION SYSTEM FI Cylinder identification sensoroutput voltage When sensor is on 4.8 V or more When sensor is off 0.8 V or less Tester positive probe ! white Tester negative probe ! black / blue 1 2 EAS00908 TROUBLESHOOTING DETAILS This section describes the countermeasures per fault cod...

7-27 Order Job / Part Q’ty Remarks 12345 Removing the throttle bodies Seats / fuel tank / rubber sheet Air filter caseCoolant Sub-wire harness couplerCoolant temp sensor couplerThrottle stop screwThrottle body joint clamp screwThrottle bodies 21141 Remove the parts in the order listed.Refer to “SEAT...

7-29 THROTTLE BODIES FI Order Job / Part Q’ty Remarks 123456789 Removing the injector Throttle position sensor couplerIntake air pressure sensorCylinder #1-injector couplerCylinder #2-injector couplerCylinder #3-injector couplerCylinder #4-injector couplerSub wire harness 2Negative pressure hosePres...

7-31 THROTTLE BODIES FI CAUTION: EAS00911 The throttle bodies should not be disas-sembled. EAS00912 CHECKING THE INJECTOR 1. Check: S injectorDamage ! Replace. EAS00913 CHECKING THE THROTTLE BODY 1. Check: S throttle bodyCracks / damage ! Replace the throttle bo- dies. 2. Check: S fuel passagesObstr...

7-32 THROTTLE BODIES FI NOTE: CHECKING THE PRESSURE REGULATOR 1. Check: S pressure regulatorDamage ! Replace. CHECKING THE FUEL PUMP AND PRES-SURE REGULATOR OPERATION 1. Check: S pressure regulator operation a. Remove the fuel tank. Refer to “FUEL TANK” in chapter 3. b. Disconnect the negative press...

7-35 AIR INDUCTION SYSTEM FI EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned ex-haust gases by injecting fresh air (secondaryair) into the exhaust port, reducing the emissionof hydrocarbons.When there is negative pressure at the exhaustport, the reed valve opens, ...

7-36 AIR INDUCTION SYSTEM FI A To cylinder #1 and #2B To cylinder #3 and #4 1 Air cut-off valve2 Reed valve3 To air filter case EAS00509 AIR INDUCTION SYSTEM DIAGRAMS

7-37 AIR INDUCTION SYSTEM FI EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: S hosesLoose connection ! Connect properly. Cracks / damage ! Replace. S pipesCracks / damage ! Replace. 2. Check: S reed valve 1 S reed valve stopper S reed valve seatCracks / damage ! Replace the reed valve. 3. Measu...

7-38 AIR INDUCTION SYSTEM FI 5. Check S air induction system solenoid a. Remove the air induction system solenoid coupler from the wire harness. b. Connect the pocket tester ( Ω 1) to the air induction system solenoid terminal asshown. Tester positive probe ! orange 1 Tester negative probe ! green 2...

8-1 ELECTRICAL COMPONENTS ELEC 9 Sidestand switch 10 Oil level switch 11 Radiator fan motor 12 Horn 13 Ignition coil 14 Fuse box 1 Main switch 2 Front brake light switch 3 Clutch switch 4 Battery 5 Starter relay 6 Fuse (main) 7 Neutral switch 8 Rear brake light switch EAS00729 ELECTRICAL ELECTRICAL ...

8-3 CHECKING SWITCH CONTINUITY ELEC CAUTION: NOTE: NOTE: EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pockettester. If the continuity reading is incorrect,check the wiring connections and if necessary,replace the switch. Never insert the tester probes into the cou-pl...

8-4 11 Neutral switch 12 Rear brake light switch 13 Fuse box 1 Main switch 2 Horn switch 3 Dimmer switch 4 Turn signal switch 5 Clutch switch 6 Sidestand switch 7 Engine stop switch 8 Front brake light switch 9 Start switch 10 Oil level switch CHECKING THE SWITCHES ELEC EAS00731 CHECKING THE SWITCHE...

8-5 CHECKING THE BULBS AND BULB SOCKETS ELEC EAS00732 CHECKING THE BULBS ANDBULB SOCKETS Check each bulb and bulb socket for damage orwear, proper connections, and also for continu-ity between the terminals.Damage / wear ! Repair or replace the bulb, bulb socket or both.Improperly connected ! Proper...

8-7 CHECKING THE BULBS AND BULB SOCKETS ELEC NOTE: WARNING CHECKING THE CONDITION OF THE BULBSOCKETS The following procedure applies to all of the bulbsockets.1. Check: S bulb socket (for continuity)(with the pocket tester)No continuity ! Replace. Pocket tester 90890-03112, YU-3112 Check each bulb s...

8-8 1 Main switch 5 Battery 6 Fuse (main) 10 Fuse (ignition) 11 Starting circuit cut-off relay 12 Sidestand switch 14 ECU 15 Ignition coil 16 Spark plug 19 Neutral switch 20 Crankshaft position sensor 28 Lean angle cut-off switch 44 Engine stop switch 55 Clutch switch IGNITION SYSTEM ELEC EAS00735 I...

8-11 IGNITION SYSTEM ELEC 6. Crankshaft position sensor resistance S Disconnect the crankshaft position sensorcoupler from the wire harness. S Connect the pocket tester ( Ω 100) to the crankshaft position sensor coupler as shown. Positive tester probe ! gray Negative tester probe ! black 1 2 S Measu...

8-14 1 Main switch 5 Battery 6 Fuse (main) 7 Starter relay 8 Starter motor 10 Fuse (ignition) 11 Starting circuit cut-off relay 12 Sidestand switch 19 Neutral switch 44 Engine stop switch 45 Start switch 55 Clutch switch ELECTRIC STARTING SYSTEM ELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM

8-15 ELECTRIC STARTING SYSTEM ELEC 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: S The transmission is in n...

8-16 YES NO 3. Starter motor S Connect the positive battery terminal and starter motor lead with a jumper lead . Repair or replace thestarter motor. S A wire that is used as a jumper leadmust have at least the same capacity ormore as that of the battery lead, other-wise the jumper lead may burn. S T...

8-19 STARTER MOTOR ELEC Order Job / Part Q’ty Remarks 12 Removing the starter motor Rider seatFuel tankLeft side cowlingStarter motor leadStarter motor 11 Remove the parts in the order listed.Refer to “SEATS” in chapter 3.Refer to “FUEL TANK” in chapter 3.Refer to “COWLINGS” in chapter 3. For instal...

8-20 STARTER MOTOR ELEC Order Job / Part Q’ty Remarks Disassembling the starter motor O-ringFront coverLock washerOil sealBearingWasher setRear coverWasher setO-ringBrush holderArmature assemblyStarter motor yoke 111111112111 Disassembly the parts in the order listed. For assembly, reverse the disas...

8-22 STARTER MOTOR ELEC NOTE: NOTE: 5. Measure: S brush length a . Out of specification ! Replace the brushes as a set. Brush length wear limit 3.5 mm (0.14 in) 6. Measure: S brush spring forceOut of specification ! Replace the brush springs as a set. Brush spring force 7.16 X 9.52 N (730 X 971 gf, ...

8-23 2 A.C. magneto 3 Rectifier / regulator 5 Battery 6 Fuse (main) CHARGING SYSTEM ELEC EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM

8-26 LIGHTING SYSTEM ELEC EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM

8-33 SIGNALING SYSTEM ELEC EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM

8-35 YES NO S Clean the batteryterminals. S Recharge or re-place the battery. EAS00749 3. Main switch S Check the main switch for continuity.Refer to “CHECKING THE SWITCHES”. S Is the main switch OK? YES NO Replace the mainswitch. YES NO 1. Horn switch S Check the horn switch for continuity.Refer to...

8-42 1 Main switch 5 Battery 6 Fuse (main) 10 Fuse (ignition) 14 ECU 22 Coolant temperature sensor 48 Fuse (radiator fan motor) 49 Radiator fan motor relay 50 Radiator fan motor COOLING SYSTEM ELEC EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM

8-43 YES NO 2. Battery S Check the condition of the battery.Refer to “CHECKING AND CHARGINGTHE BATTERY” in chapter 3. Minimum open-circuit voltage 12.8 V or more at 20 _ C (68 _ F) S Is the battery OK? S Clean the batteryterminals. S Recharge or re-place the battery. EAS00739 EAS00749 3. Main switch...

8-45 COOLING SYSTEM ELEC S Remove the coolant temperature sensor. S Connect the pocket tester ( Ω 1k) to the coolant temperature sensor as shown. S Immerse the coolant temperature sensor ina container filled with coolant . Make sure the coolant temperature sensorterminals do not get wet. S Place a t...

8-46 1 Main switch 5 Battery 6 Fuse (main) 9 Fuse (fuel injection) 10 Fuse (ignition) 11 Starting circuit cut-off relay 13 Fuel pump 14 ECU 44 Engine stop switch FUEL PUMP SYSTEM ELEC EAS00814 FUEL PUMP SYSTEM CIRCUIT DIAGRAM

8-47 FUEL PUMP SYSTEM ELEC 1 Battery 2 Fuse (main) 3 Main switch 4 Fuse (ignition) 5 Engine stop switch 6 ECU 7 Fuse (fuel injection) 8 Starting circuit cut-off relay (fuel pump injection system relay) 9 Fuel pump EAS00815 FUEL PUMP SYSTEM The ECU includes the control unit for thefuel pump.

8-50 FUEL PUMP SYSTEM ELEC WARNING EAS00819 CHECKING THE FUEL PUMP Gasoline is extremely flammable and undercertain circumstances there can be a dangerof an explosion or fire. Be extremely carefuland note the following points: S Stop the engine before refueling. S Do not smoke, and keep away from op...

8-52 SELF-DIAGNOSIS ELEC Repair or replace thewire harness. NO 1. Wire harness S Check the wire harness for continuity.Refer to “CIRCUIT DIAGRAM”. S Is the wire harness OK? YES NO 2. Fuel sender S Check the fuel sender for continuity.Refer to “The fuel level indicator light fails tocome on”. S Is th...

8-53 SELF-DIAGNOSIS ELEC Replace the oil levelswitch. NO 2. Oil level switch S Check the oil level switch for continuity.Refer to “The oil level warning light fails tocome on”. S Is the oil level switch OK? YES Repair or replace thewire harness. NO 1. Wire harness S Check the wire harness for contin...

9-1 9 STARTING FAILURES TRBL SHTG NOTE: FUEL SYSTEMFuel tank S Empty fuel tank S Clogged fuel filter S Clogged fuel tank drain hose S Clogged rollover valve S Clogged rollover valve hose S Deteriorated or contaminated fuel Fuel pump S Faulty fuel pump S Faulty fuel pump relay Throttle body (-ies) S ...

9-2 Starting system S Faulty starter motor S Faulty starter relay S Faulty starting circuit cut-off relay S Faulty starter clutch STARTING FAILURES/INCORRECT ENGINE IDLING SPEED/ POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE TRBL SHTG ELECTRICAL SYSTEMSBattery S Discharged battery S Faulty battery Spark pl...

9-3 FAULTY GEAR SHIFTING / FAULTY CLUTCH TRBL SHTG JUMPS OUT OF GEARShift shaft S Incorrect shift pedal position S Improperly returned stopper lever Shift forks S Worn shift fork Shift drum S Incorrect axial play S Worn shift drum groove Transmission S Worn gear dog CLUTCH DRAGSClutch S Unevenly ten...

9-4 OVERHEATING / OVERCOOLING / POOR BRAKING PERFORMANCE TRBL SHTG FUEL SYSTEMThrottle body (-ies) S Damaged or loose throttle body joint Air filter S Clogged air filter element CHASSISBrake(s) S Dragging brake ELECTRICAL SYSTEMSSpark plug(s) S Incorrect spark plug gap S Incorrect spark plug heat ra...

9-5 FAULTY FRONT FORK LEGS / UNSTABLE HANDLING TRBL SHTG MALFUNCTION S Bent or damaged inner tube S Bent or damaged outer tube S Damaged fork spring S Worn or damaged outer tube bushing S Bent or damaged damper rod S Incorrect oil viscosity S Incorrect oil level Rear shock absorber assembly(-ies) S ...

9-6 FAULTY LIGHTING OR SIGNALING SYSTEM TRBL SHTG TURN SIGNAL DOES NOT COME ON S Faulty turn signal switch S Faulty turn signal relay S Burnt-out turn signal bulb S Incorrect connection S Damaged or faulty wire harness S Improperly grounded circuit S Faulty battery S Blown, damaged or incorrect fuse...

Rear turn signal light (right)Rear turn signal light (left)Front turn signal / position light (right)Front turn signal / position light (left)HeadlightLicense lightTail / brake light COLOR CODE B Black . . . . . . . Br Brown . . . . . . Ch Chocolate . . . . . Dg Dark green . . . . . G Green . . . . ...