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YZF-R1P YZF-R1PC SERVICE MANUAL LIT-11616-15-47 5PW-28197-10.
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EAS00000 YZF-R1P/YZF-R1PC SERVICE MANUAL ©2001 by Yamaha Motor Corporation, U.S.A. First edition, December 2001 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited.
EAS00003 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily fo r use by Yamaha deal- ers and their qualified mechanics. It is not possib le to include all the knowledge of a mechanic in one manual.
EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read refer ence book for the mechanic. Comprehensive explanations of all installation , removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order.
EAS00008 SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 General info rmation 2 Specifications 3 Periodic checks and ad justments 4 Chassis 5 Engine 6 Cooling system 7 Fuel injection system 8 Electrical system 9 Troubleshooting Symbols 0 to G indicate the following.
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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 E.
CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ................................................ .................1-1 VEHICLE IDENTIFICATION NUMBER ............................................. ....... 1-1 MODEL LABEL .........................
TIGHTENING TORQUES ........................................ .....................................2-17 GENERAL TIGHTENING TORQUE SPECIFICATIONS ........................ 2-17 ENGINE TIGHTENING TORQUES ....................................................
ENGINE ............................................................................... ............................3-9 ADJUSTING THE VALVE CLEARANCE ................................. .................3-9 SYNCHRONIZING THE THROTTLE BODIES .............
CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISCS .................... .......................................4-1 FRONT WHEEL ....................................... .................................................4-2 REMOVING THE FRONT WHEEL ...........
HANDLEBARS ........................................................ .....................................4-56 REMOVING THE HANDLEBARS ............................................ ...............4-58 CHECKING THE HANDLEBARS ............................
CYLINDER HEAD .............................. ........................................... ............... 5-19 REMOVING THE CYLINDER HEAD ......................................................5-20 CHECKING THE CYLINDER HEAD ............................
OIL PAN AND OIL PUMP .................................................. ..........................5-51 OIL PUMP ................................................................................ ............... 5-53 REMOVING THE OIL PAN ................
CHAPTER 6 COOLING SYSTEM RADIATOR .................................................... .................................................6-1 CHECKING THE RADIATOR .................................................. .................6-3 INSTALLING THE RADIATOR .
AIR INDUCTION SYSTEM ....... ..................................................... ...............7-37 AIR INDUCTION ..................................................................................... 7-37 AIR CUT-OFF VALVE .................. ......
COOLING SYSTEM .................. ..................................................... ............... 8-41 CIRCUIT DIAGRAM ...............................................................................8-41 TROUBLESHOOTING ..........................
FAULTY FRONT FORK LEGS ........... ..................................................... ....... 9-5 LEAKING OIL ...........................................................................................9-5 MALFUNCTION ...............................
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 head pipe. EAS00018 MODEL LABEL The model label 1 is affixed to the frame.
1 - 2 GEN INFO FEATURES FEATURES OUTLINE OF FI SYSTEM The main function of a fuel supply system is to provide fue l to the combustion chamber at the opti- mum air-fuel ratio in accordance with the en gine operating conditions and the atmospheric tempera- ture.
1 - 3 GEN INFO FEATURES FI SYSTEM The fuel pump delivers fuel to the inje ctor via the fuel filter. The pressure regulator mainta ins the fuel 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.
1 - 4 GEN INFO FEATURES Fuel control block The fuel control block consists of the fo llowing main components: An engine trouble warning light is provided on meter p anel.
1 - 5 GEN INFO FEATURES COMPONENTS ECU (Electronic Control Unit) The ECU is mounted underneath the seat. The main fun ctions of the ECU are ignitio n control, fuel control, self-diagnosis, and lo ad control.
1 - 6 GEN INFO FEATURES • Ignition control The ignition control function of th e ECU controls the ignition timing and the duration of ignition energizing.
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 it to the injector. A filter that is provided in the fuel pump prevents any debris in the fuel tank from entering the fu el system downstream of the pump.
1 - 8 GEN INFO FEATURES Pressure regulator It regulates the fuel pressure that is applied to the in jectors that are provided in th e cylinders in order to maintain a constant pressure d ifference with the pressure in the intake manifold.
1 - 9 GEN INFO FEATURES Fuel injector Upon receiving injection signals from the ECU, the fuel injector injects fuel. In the normal state, the core is pressed downward by t he force of the spring, as illustrated. The plunger tha t is integrated with the bottom of the core keeps the fuel pa ssage closed.
1 - 10 GEN INFO FEATURES Crankshaft position sensor The crankshaft position sensor uses the signals of the pickup co il that is mounted on the right side of the crankshaft.
1 - 11 GEN INFO FEATURES Cylinder identification sensor The cylinder identification sensor is mounted on the middle of exhaust side head cover. When the exhaust camshaft rotates, the sensor generates a signal and sends it to the ECU.
1 - 12 GEN INFO FEATURES Throttle position sensor The throttle position sensor measures the intake air volume by detectin g the position of the throt tle valve. It detects th e mechanical angle of the throttle valve through the posit ional relationship between the moving contact that moves in unison with the throttle shaft and the resistor boa rd.
1 - 13 GEN INFO FEATURES Intake air pressure sensor and atmos pheric pressure sensor • Intake air pressure se nsor The intake air pressure sensor is used for measuring the intake air volume. The intake air volume of every intake stroke is proportionate to th e intake air pressure.
1 - 14 GEN INFO FEATURES Coolant temperature sensor The signals from the coolant tempe rature sensor are used primarily for making fuel volume compen- sations during starting and warm-up. The coolan t temperature sensor converts the temperature of the coolant into electrical signals and sends them to the ECU.
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.
1 - 16 GEN INFO FEATURES FUEL INJECTION SYSTEM Operation and control The fuel injection timing, injection duration, ignitio n timing, and the coil energizing duration are con- trolled by the ECU.
1 - 17 GEN INFO FEATURES Determining the final injection duration The intake air volume determines the basic injection duration. Ho wever, at a given intake air vol- ume, the volume of fuel that is required varies by th e engine operating conditions such a s accelera- tion or deceleration, or by weather conditions.
1 - 18 GEN INFO FEATURES Reactive injection duration: A lag is created between the time the ECU outputs a fuel injection signal to the injector and the time the injector actually opens. Therefore, the ECU ca lculates this lag in advance before se nding the actuation signal to the injector.
1 - 19 GEN INFO FEATURES THREE-WAY CATALYTIC CONVERTER SYSTEM System outline This is a highly efficient exhaust gas cleaning system that effects air-fuel cont rol through a joint effort by the FI system and the three-way cata lytic converter system.
1 - 20 GEN INFO FEATURES INSTRUMENT FUNCTION Multi-function display The multi-function display is equipped with the following: • a speedometer (which shows the riding speed) • an odometer (which s.
1 - 21 GEN INFO FEATURES Display brightness and engine speed indi- cator light control mode This mode cycles through five control func- tions, allowing you to make the following set- tings in the order listed below.
1 - 22 GEN INFO FEATURES T o set the engine speed indicator light activ ation fun ction NOTE: _ The indicator light activation function can be set between 7,000 and 12 ,000 r/min in increments of 500 r/min. 1. Push the “ RESET ” button to sele ct the desired engine speed f or activating the indicator ligh t.
1 - 23 GEN INFO IMPORTANT INFORMATION EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Bef ore remo v al and disassemb ly , remov e all dir t, mud, dust and f oreign material. 2. Use only the proper tools and cleaning equipment.
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 lock tabs along a flat of the bolt or nut.
1 - 25 GEN INFO CHECKING THE CONNECTIONS EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Chec k: • lead • coupler • connector Moisture → Dry with an air blower.
1 - 26 GEN INFO SPECIAL TOOLS EAS00027 SPECIAL TOOLS The following special tools are necessary for complete an d accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damag e caused by the use of inappropri- ate tools or improvised techniques.
1 - 27 GEN INFO SPECIAL TOOLS YU-38411 Oil filter wrench This tool is needed t o loosen or tighten the oil filter cart ridge. YM-01434 Rod holder This tool is used to support the damper adjusting rod. Rod puller YM-01437 Rod puller These tools are used to pull up the front fork dampe r rod.
1 - 28 GEN INFO SPECIAL TOOLS Middle driven shaft bearing driver YM-4058-1 Mechanical se al installer YM-33221 Middle driven shaf t bearing driver Mechanical seal installer These tools are used t o install the water pump seal .
1 - 29 GEN INFO SPECIAL TOOLS YM-03112 Pocket tester This instrument is needed f or checking the engine oil temperatur e. YB-35956 Mity vac This tool used to measure th e vacuum pressure. YM-8037 Piston ring compressor This tool is used to compress t he piston rings when installing the piston into the cylinder.
2 - 1 SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5PW4 USA 5PW5 California 5PW6 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.
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.
2 - 3 SPEC ENGINE SPECIFICATIONS Oil filter Oil filter type Cartridge (paper) ---- Bypass valve opening pressure 80 ~ 120 kPa (0.8 ~ 1.2 kg/cm 2 , 11.6 ~ 17.4 psi) ---- Oil pump Oil pump type Trochoid ---- Inner-rotor-to-outer-rotor-tip clearance 0.01 ~ 0.
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-ca mshaft- cap clearance 0.
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.
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.
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.
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.
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.
2 - 10 SPEC ENGINE SPECIFICATIONS Air filter type Wet element ---- Fuel pump Pump type Electrical ---- Model (manufacturer) 5PW (DENSO) ---- Output pressure 94 kPa (2.
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.
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.
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.
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.
2 - 15 SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V ---- Ignition system Ignition system type Transistorized coil ignition (digital) ---- Ignition t.
2 - 16 SPEC ELECTRICAL SPECIFICATIONS Electric starting system System type Constant mesh ---- Starter motor Model (manufacturer) 5JJ (YAMAHA) ---- Power output 0.9 kW ---- Brushes Overall length 10.8 mm (0.43 in) 3.65 mm (0.14 in) Spring force 5.28 ~ 7.
2 - 17 SPEC CONVERSION TABLE/TIGHTENING TORQUES EAS00028 CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data.
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 + 12 1 ° (50) 2.0 + 121 ° (5.0) 14 + 121 ° (36) E Cylinder head Nut M10 6 20 + 10 5 ° (50) 2.
2 - 19 SPEC TIGHTENING TORQUES Exhaust pipe and exhaust valve Bolt M6 4 10 1.0 7.2 Exhaust valve and housing Bolt M6 3 10 1.0 7.2 EXUP pulley and arm shaft Bolt M5 2 5 0.5 3.6 Exhaust joint Bolt M4 4 3 0.3 2.2 Exhaust valve pipe Bolt M8 1 20 2.0 14 Air induction system pipe Clamp — 4 3.
2 - 20 SPEC TIGHTENING TORQUES NOTE: 1. First, tighten the bolt to appro ximately 20 Nm (2.0 m • kg, 14 ft • lb) with a torque wrench. 2. Retighten the bolt to 20 Nm (2.0 m • kg, 14 ft • lb), and tighten ano ther 41 ~ 46 ° with a angle gauge or 32 Nm (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.
2 - 22 SPEC TIGHTENING TORQUES NOTE: 1.First, tighten the ring nut to appro ximately 50 Nm (5.0 m • kg, 36 ft • lb) with a torque wrench, t hen loosen the ring nut completely . 2.Retighten the low er ring nut to specification. Coolant reservoir and radiato r M6 5 0.
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 su.
2 - 24 SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lo wer) LS Front wheel oil seal (right and left) LS Rear .
2 - 25 SPEC COOLING SYSTEM DIAGRAMS EAS00033 COOLING SYSTEM DIAGRAMS 1 Radiator fa n 2 Radiator 3 Water pump.
2 - 26 SPEC COOLING SYSTEM DIAGRAMS 1 Thermostat 2 Radiator ca p 3 Coolant reserv oir 4 Radiator 5 Oil cooler 6 Water jacket joint.
2 - 27 SPEC COOLING SYSTEM DIAGRAMS 1 Water pump 2 Radiator ca p 3 Thermostat 4 Thermostat hou sing.
2 - 28 SPEC COOLING SYSTEM DIAGRAMS 1 Radiator.
2 - 29 SPEC ENGINE OIL LUBRICATION CHART ENGINE OIL LUBRICATION CHART Exhaust camshaft Intake ca mshaft Piston cooler Main gallery Oil filter Oil cooler Relief valve Oil pump Strainer Main axle Missio.
2 - 30 SPEC LUBRICATION DIAGRAMS EAS00034 LUBRICATION DIAGRAMS 1 Intake camsha ft 2 Exhaust camshaft 3 Oil filter cartridge 4 Oil level switch.
2 - 31 SPEC LUBRICATION DIAGRAMS 1 Intake camsha ft 2 Exhaust camshaft 3 Crankshaft 4 Oil cooler 5 Oil pipe 6 Oil strainer 7 Oil pump.
2 - 32 SPEC LUBRICATION DIAGRAMS 1 Oil cooler 2 Oil filter cartridge 3 Oil level switch 4 Oil strainer 5 Oil pump 6 Oil pipe.
2 - 33 SPEC LUBRICATION DIAGRAMS 1 Main axle 2 Oil delivery pipe 3 Drive axle.
2 - 34 SPEC LUBRICATION DIAGRAMS 1 Cylinder head 2 Crankshaft.
2 - 35 SPEC CABLE ROUTING EAS00035 CABLE ROUTING 1 Headlight drain pl ug È Make sure to securely insert the coupler and boot . É The headlight lead can be routed by either of the head- light or the boss. Do not catch the headlight lead when assembling the front cowling.
2 - 36 SPEC CABLE ROUTING 1 Handlebar switch (left) 2 Main switch 3 Throttle position sensor lead 4 Guide-air 5 Handlebar switch (right) 6 Wiring section ! 7 AC magneto lead 8 Speed sensor lead 9 ( .
2 - 37 SPEC CABLE ROUTING È Route the horn lead under the rib of bracke t horn positionin g the stepped part of prot ector outside the ri b. É Make the horn lead face the outside. Ê Route the handlebar switch le ad along the groove of the guide-air.
2 - 38 SPEC CABLE ROUTING Ú Route under t he wire harness to the asse mbling point ! . Û Insert the holding clamp of the wire harness to th e frame. Ü Fasten the wire harn ess with the clamp inserted to t he frame. Ý Route the radiat or fan motor lead above the wire harness.
2 - 39 SPEC CABLE ROUTING Pass the filter of thrott le body through th e hole of rub ber baffle and releas e it under the ignition coil plate. Route the sub lead coupler behind the ignitio n coil. Pass the camshaft p osition sensor lead through the hole of COVER 1 and connect it.
2 - 40 SPEC CABLE ROUTING 1 Turn signal light lead 2 Radiator hose 3 Reservoir tank brea ther hose (L = 440) 4 Clutch cable 5 Crankshaft p osition sens or lead 6 Rear brake switch lead 7 Wiring sectio.
2 - 41 SPEC CABLE ROUTING Ô To turn signal light Õ In this area, pass the han dlebar switch (ri ght) lead behind of th e throttle cable. Ö Route the coola nt temperature senso r lead between the engine and the radiator hose. × Route the clut ch cable through the inside of radiator hose and fa sten it with the clamp to th e radiator.
2 - 42 SPEC CABLE ROUTING 1 Ignition coil plate 2 Rubber baffle 3 Assembling point ± 4 Assembling point ! 5 To wiring section ± 6 To wiring sections ± , # 7 Oil level switch lead 8 Sidestand switch.
2 - 43 SPEC CABLE ROUTING Ê Clamp the air cleaner drain hose, fuel tan k breather hose, drain hose, AI system hose, AI system lead a nd AC magneto. Route the air cleaner drain hose, fuel tan k breather ho se and drain hose outsid e the AI system hose, AI system lead and AC magneto lea d.
2 - 44 SPEC CABLE ROUTING Õ Point the tip of th e band to the inner side. Ö Routing position of each hose except the AI system hose is not regulated in th e clamp.
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 thrott.
3 - 1 CHK ADJ EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information ne cessary to perform recommended checks and ad justments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work.
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 mainte nance intervals starting from 4,000 mi (7,000 km) or 6 months.
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 th e order listed.
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.
3 - 5 CHK ADJ FUEL TANK REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank throug h the fuel tank cap with a pump . 2. Remo v e: • fuel return hose • fuel hose CAUTION: Although the fuel has been removed from the fuel tank be careful when removing the fuel hoses, since there may be fuel remain- ing in it.
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 in stalling the fuel pump. • Always use a new fuel pump gasket. • Install the fuel pump as shown in the illustra- tion.
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 ” .
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 ” an d “ FUEL TANK ” .
3 - 9 CHK ADJ ADJUSTING THE VALVE CLEARANCE EAS00045 ENGINE ADJUSTING THE VALV E CLEARANCE The following procedure applies to all of the valves. NOTE: _ • Valve clearance adjustment should be made on a cold engine, at room temperature.
3 - 10 CHK ADJ ADJUSTING THE VALVE CLEARANCE 4. Measure: • valve clearance Out of specification → Adjust. ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. T urn the crankshaft cloc kwise.
3 - 11 CHK ADJ ADJUSTING THE VALVE CLEARANCE 5. Remo v e: • camshaft NOTE: _ • Refer to “ DISASSEMBLING THE ENGINE — CAMSHAFT AND CYLINDER HEAD ” in chapter 5. • When removing the timing chain and cam- shafts, fasten the timing chain with a wire to retrieve it if it falls into the crankcase.
3 - 12 CHK ADJ ADJUSTING THE VALVE CLEARANCE c. Round off the original valv e pad number according to the f ollo wing tab le . Last digit Rounded value 0 or 2 0 55 81 0 EXAMPLE: Original valve pad number = 148 (thickness =1.48 mm) Rounded value = 150 d.
3 - 13 CHK ADJ ADJUSTING THE VALVE CLEARANCE VALVE PAD SELECTION TABLE INTAKE EXHAUST Measured clearance INSTALLED PAD NUMBER 120 125 130 135 140 145 150 155 160 165 17 0 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.
3 - 14 CHK ADJ ADJUSTING THE VALVE CLEARANC E/ SYNCHRONIZING THE THROTTLE BODIES NOTE: @ • Refer to “ ASSEMBLING AND ADJUSTING THE ENGINE — CYLINDER HEAD AND CAMSHAFT ” in chapter 5. • Lubricate the camshaft bea rings, camshaft lobes and camshaft journals.
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 war m up f or se v- eral min utes.
3 - 16 CHK ADJ SYNCHRONIZING THE THROTTLE BODIES/ ADJUSTING THE ENGINE IDLING SPEED NOTE: @ The difference in vacuum pressure between two throttle bodies should not exce ed 1.33 kPa (10 mmHg, 0.39 inHg). ▲▲▲ ▲ ▲ ▲▲▲ ▲▲ ▲ ▲ ▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 9.
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 cylind er #1) 3.
3 - 18 CHK ADJ ADJUSTING THE THROTTLE CABLE FREE PLAY 2. Remo v e: • rider seat Refer to “ SEATS ” . • fuel tank Refer to “ FUEL TANK ” . • air filter case Refer to “ AIR FILTER CASE ” .
3 - 19 CHK ADJ ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS d. Tighten the loc kn ut. W ARNING _ After adjusting the throttle cable free p lay, start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change.
3 - 20 CHK ADJ CHECKING THE SPARK PLUGS/ MEASURING THE COMPRESSION PRESSURE 4. Chec k: • electrode 1 Damage/wear → Rep lace the spark plug. • insulator 2 Abnormal color → Replace the spa rk plug. Normal color is medium-to-light tan. 5. Clean: • spark plug (with a spark plug cleaner or wire brush) 6.
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, w ar m it up f or se v er al min- utes, and t hen tur n it off .
3 - 22 CHK ADJ MEASURING THE COMPRESSION PRESSURE ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Set the main s w itch to “ ON ” . b . With the throttle wide open, crank the engine until the reading on the compression gauge stabiliz es.
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 ” .
3 - 24 CHK ADJ CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL 4. Star t the engine, w ar m it up f or se v er al min- utes, and t hen tur n it off . 5. Chec k the engine oil le vel again. NOTE: _ Before checking the engine oil level, wait a few minutes until the oil has settled.
3 - 25 CHK ADJ CHANGING THE ENGINE OIL c. Tighten th e ne w oil filter car tr idge to specifi- cation with an oil filter wrench. ▲▲▲ ▲ ▲ ▲▲▲ ▲▲ ▲ ▲ ▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ T R . .
3 - 26 CHK ADJ CHANGING THE ENGINE OIL/ ADJUSTING THE CLUTCH CABLE FREE PLAY 13.Chec k: • engine oil pressure ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Slightly loosen the oil gallery bolt 1 .
3 - 27 CHK ADJ ADJUSTING THE CLUTCH CABLE FREE PLAY 2. Adjust: • clutch cable free play ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ Handlebar side a. T ur n the adjusting dial 1 in direction a or b until the specified clutch cab le free pla y is obtained.
3 - 28 CHK ADJ REPLACING THE AIR FILTER ELEMEN T EAS00086 REPLACING THE AIR FILTER ELEMENT 1. Remo v e: • rider seat Refer to “ SEATS ” . • fuel tank Refer to “ FUEL TANK ” . 2. Remo v e: • air filter case cover 1 3. Chec k: • air filter element 1 Damage → Replace.
3 - 29 CHK ADJ CHECKING THE FUEL AND B REATHER HOSES/ CHECKING THE CRANKCASE BREATHER HOSE EAS00096 CHECKING THE FUEL AND BREATHER HOSES The following procedure applies to all of the fuel and breather hoses. 1. Remo v e: • rider seat Refer to “ SEATS ” .
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 the exhaust pipes and gaskets.
3 - 31 CHK ADJ ADJUSTING THE EXUP CABLES EAS00101 ADJUSTING THE EXUP CABLES 1. Remo v e: • bottom cowling Refer to “ COWLINGS ” . 2. Remo v e: • EXUP valve pulley cov er 1 3. Chec k: • EXUP system operation ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a.
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 le vel surf ace. NOTE: _ • Place the motorcycle on a suitable stand.
3 - 33 CHK ADJ CHECKING THE COOLING SYSTEM EAS00104 CHECKING THE COOLING SYSTEM 1. Remo v e: • bottom cowling • side cowlings Refer to “ COWLINGS ” .
3 - 34 CHK ADJ CHANGING THE COOLANT EAS00105 CHANGING THE COOLANT 1. Remo v e: • side cowling • bottom cowling Refer to “ COWLINGS ” . 2. Disconnect: • coolant reservoir hose 1 3. Drain: • coolant (from the coolant reservoir) 4. Remo v e: • radiator cap 1 W ARNING _ A hot radiator is under pressure.
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 be handled with special care. W ARNING _ • If coolant splashes in your eyes, thor- oughly wash them with water a nd consult a doctor.
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.Star t the engine, wa r m it up f or se veral min- utes, and t hen stop it.
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. Chec k: • brake pedal position (distance a from the top of the brake pedal to the bottom of the rider footrest bracket) Out of specification → Adjust.
3 - 39 CHK ADJ ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL 3. Adjust: • rear brake light switch Refer to “ ADJUSTING THE REAR BRAKE LIGHT SWITCH ” . EAS00115 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a le vel surf ace.
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 the brake pads.
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 the brake hoses and brake hose clamps. 1. Chec k: • brake hose Cracks/damage/wear → Replace .
3 - 42 CHK ADJ BLEEDING THE HYDRAULIC BRAKE SYSTEM 1. Bleed: • hydraulic brake system ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Fill the brak e fluid reservoir to the proper le v el with the recommended br ak e fluid.
3 - 43 CHK ADJ ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK EAS00136 ADJUSTING THE SHIFT PEDAL 1. Chec k: • shift pedal position (distance a from the bottom of the rider footrest bracket to the top of the shift pedal) Out of specification → Adjust.
3 - 44 CHK ADJ ADJUSTING THE DRIVE CHAIN SLACK 3. Chec k: • 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.
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 interacting parts.
3 - 46 CHK ADJ CHECKING AND ADJUSTING THE STEERING HEAD 3. Remo v e: • upper bracket Refer to “ HANDLEBARS ” and “ STTERLING HEAD ” in chapter 4. 4. Adjust: • steering head ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a.
3 - 47 CHK ADJ CHECKING AND ADJUSTING THE STEERING HEAD e. Install the rubber w asher 3 . f . Install th e upper ring nut 2 . g. Finger tigh ten the upper ring nut 2 , then align the slots of both ring nuts. If nece s- sar y , hold the lo wer ring nut and tighten the upper ring nut until their slots are aligned.
3 - 48 CHK ADJ CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK g. Reinstall the upper brack et and measure the steering head tension again as descr ibed abov e . h. Repeat the abo v e procedure until the steer- ing head tension is within specification.
3 - 49 CHK ADJ ADJUSTING THE FRONT FORK LEGS EAS00155 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. W ARNING _ • Always adjust both front fork legs evenly. Uneven adjustment can result in poor handling and loss of stability.
3 - 50 CHK ADJ ADJUSTING THE FRONT FORK LEGS Rebound damping CAUTION: _ Never go beyond the maximum or mini- mum adjustment positions. 1. Adjust: • rebound damping ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a.
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).
3 - 52 CHK ADJ ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ▲▲▲ ▲ ▲ ▲▲▲ ▲▲ ▲ ▲ ▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ Rebound damping CAUTION: _ Never go beyond the maximum or mini- mum adjustment positions.
3 - 53 CHK ADJ ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/CHECKING THE TIRES 1. Adjust: • compression damping ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. T urn the adjusting scre w 1 in direction a or b .
3 - 54 CHK ADJ CHECKING THE TIRES * Total weight of ride r, passenger, cargo and acces- sories W ARNING _ It is dangerous to ride with a worn-out tire.
3 - 55 CHK ADJ CHECKING THE TIRES W ARNING _ • Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. • When using a tube tire, be sure to install the correct tube. • Always replace a new tube tire and a new tube as a set.
3 - 56 CHK ADJ CHECKING THE TIRES/ CHECKING THE WHEELS Front tire Rear tire W ARNING _ New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done.
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 the inner and outer cables.
3 - 58 CHK ADJ CHECKING AND CHARGING THE BATTERY EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY W ARNING _ Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid.
3 - 59 CHK ADJ CHECKING AND CHARGING THE BATTERY NOTE: _ Since MF batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
3 - 60 CHK ADJ CHECKING AND CHARGING THE BATTERY 5. Charge: • battery (refer to the appropriate chargin g method illustration) W ARNING _ Do not quick charge a battery.
3 - 61 CHK ADJ CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) c harger Measure the open- circuit voltage prior to charging. Connect a charge r and AMP meter to th e battery and start char ging. Make sure that th e current is higher than th e standard charging current writt en on the battery.
3 - 62 CHK ADJ CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger Measure the open- circuit voltage prior to charging. Connect a char ger and AMP meter to the ba ttery and start charging. NO YES Make sure that the current is higher than the standard charging current wr itten on the battery.
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. Chec k: • battery terminals Dirt → Clean with a wire b rush.
3 - 64 CHK ADJ CHECKING THE FUSES 3. Replace: • blown fuse ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Set the main s w itch to “ OFF ” . b . Install a ne w fuse of the correct a mperage rating.
3 - 65 CHK ADJ REPLACING THE HEADLIGHT BULBS EAS00183 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Disconnect: • headlight coupler 1 2. Remo v e: • headlight bulb cover 2 3. Remo v e: • headlight bulb holder 1 4.
3 - 66 CHK ADJ ADJUSTING THE HEADLIGHT BEAM EAS00184 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: • headlight beam (vertically) ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. T urn the adjusting scre w 1 in direction a or b .
4 - 1 CHAS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS Order Job/Part Q ’ ty Remarks Removing the front wheel an d brake discs Remove the parts in the order listed. NOTE: _ Place the motorcycle on a suitable stand so that the front wheel is elevated.
4 - 2 CHAS FRONT WHEEL AND BRAKE DISCS EAS00518 FRONT WHEEL Order Job/Part Q ’ ty Remarks Disassembling the fron t 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 le vel surf ace. W ARNING _ Securely support the motorcycle so that there is no danger of it falling over. NOTE: _ Place the motorcycle on a suitable stand so that the front wheel is elevated.
4 - 4 CHAS FRONT WHEEL AND BRAKE DISCS 3. Measure: • radial wheel runout 1 • lateral wheel runout 2 Over the specified limits → Replace. Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) 4. Chec k: • wheel bearings Front wheel turns roughly or is loose → Replace the wheel b earings.
4 - 5 CHAS FRONT WHEEL AND BRAKE DISCS EAS00533 CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs. 1. Chec k: • brake disc Damage/galling → Repla ce. 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 brak e disc deflect ion. e. If out of specification, repeat the adjustment steps until the br ak e disc deflection is with in specification. f . If the br ak e disc deflection ca nnot be brought within specification, re place the brak e disc.
4 - 7 CHAS FRONT WHEEL AND BRAKE DISCS 8. Tighten wheel axle pinch bolt 1 , and then pinch bolt 2 to the specified t orque. 9. T ap the outer side of the right f ork leg with a rubber mallet to align it with the end of the wheel axle . 10.Tighten wheel axle pinch bo lt 3 , and then pinch bolt 4 to the specified t orque.
4 - 8 CHAS FRONT WHEEL AND BRAKE DISCS ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Spin the front wh eel. b . When the front wheel stops , put an “ X 1 ” mark at the bottom of the wheel.
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.
4 - 10 CHAS REAR WHEEL AND BRAKE DISC EAS00560 REAR WHEEL Order Job/Part Q ’ ty Remarks Disassembling the rear whe el 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 - 11 CHAS REAR WHEEL AND BRAKE DISC T R . . 18 Nm (1.8 m • kg, 13 ft • Ib) T R . . 100 Nm (10 m • kg, 72 ft • lb) Order Job/Part Q ’ ty Remarks Remove the brake disc and rear wheel sprocket Remove the parts in the order listed.
4 - 12 CHAS REAR WHEEL AND BRAKE DISC EAS00561 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a le vel surf ace. W ARNING _ Securely support the motorcycle so that there is no danger of it falling over. NOTE: _ Place the motorcycle on a suitable stand so that the rear wheel is elevated.
4 - 13 CHAS REAR WHEEL AND BRAKE DISC 5. Remo v e: • left collar 1 • rear wheel drive hub 2 • rear wheel drive hub damper • right collar EAS00565 CHECKING THE REAR WHEEL 1. Chec k: • wheel axle • rear wheel • wheel bearings • oil seals Refer to “ CHECKING THE FRONT WHEEL ” .
4 - 14 CHAS REAR WHEEL AND BRAKE DISC EAS00568 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Chec k: • 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.
4 - 15 CHAS REAR WHEEL AND BRAKE DISC 2. Adjust: • drive chain slack Refer to “ ADJUSTING THE DRIVE CHAIN SLACK ” in ch apter 3. 3. Tighten: • wheel axle nut • brake caliper bolts W ARNING _ Make sure the brake hose is routed prop- erly. CAUTION: _ Do not loosen the wheel axle nut after tight- ening it to the specified torque.
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.
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 th e order listed.
4 - 18 CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: _ Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: W ARNING • Never disassemble brake components unless absolutely necessary.
4 - 19 CHAS FRONT AND REAR BRAKES 2. Remo v e: • brake pad clips 1 • brake pad pins 2 • brake pad spring 3 3. Remo v e: • 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.
4 - 20 CHAS FRONT AND REAR BRAKES ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose 1 tightly to the ble ed scre w 2 . Put the other end of the hose into an open contain er .
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 disa s- semble the brake caliper. 1. Remo v e: • brake caliper 1 2. Remo v e: • brake pads 1 (along with the brake pad shims) 3.
4 - 22 CHAS FRONT AND REAR BRAKES ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose 1 tightly to the ble ed scre w 2 . Put the other end of the hose into an open contain er .
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.
4 - 24 CHAS FRONT AND REAR BRAKES 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 13 Br ake hos e 1 14 Brake master cylinder bracke t 1 15 Brake master cylinder 1 16 Front brake switch 1 For installation, reverse the removal procedure.
4 - 25 CHAS FRONT AND REAR BRAKES EAS00585 Order Job/Part Q ’ ty Remarks Disassembling the front brake master cylinder Remove the parts in the order listed. 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder 1 For assembly, reverse the disassembly procedure.
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.
4 - 27 CHAS FRONT AND REAR BRAKES EAS00587 T R . . 16 Nm (1.6 m • kg, 12 ft • Ib) Order Job/Part Q ’ ty Remarks Disassembling the rear brake master cylinder Remove the parts in the order listed. 1 Brake master cylinder kit 1 2 Brake master cylinder 1 For assembly, reverse the disassembly procedure.
4 - 28 CHAS FRONT AND REAR BRAKES EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: _ Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect: • brake switch coupler 1 (from the brake switch) 2.
4 - 29 CHAS FRONT AND REAR BRAKES EAS00593 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to both of the brake master cylinders. 1. Chec k: • brake master cylinder Damage/scratches/wear → Replace. • brake fluid delivery passages (brake master cylinder body) Obstruction → Blow out with compressed air.
4 - 30 CHAS FRONT AND REAR BRAKES EAS00607 ASSEMBLING AND INSTALLIN G THE FRONT BRAKE MASTER CYLINDER W ARNING _ • Before installation, all internal brake com- ponents should be cleaned and lub ricated with clean or new brake fluid. • Never use solvents on internal brake components.
4 - 31 CHAS FRONT AND REAR BRAKES 3. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) W ARNING _ • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
4 - 32 CHAS FRONT AND REAR BRAKES EAS00610 ASSEMBLING THE REAR BRAK E MASTER CYLINDER 1. Install: • copper washers • brake hose • union bolt CAUTION: _ When installing the brake hose onto the brake master cylinder, make sure that the brake pipe touches the projection a on the brake master cylinder.
4 - 33 CHAS FRONT AND REAR BRAKES 3. Bleed: • brake system Refer to “ BLEEDING THE HYDRAULIC BRAKE SYSTEM ” in chapter 3. 4. Chec k: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “ CHECKING THE BRAKE FLUID LEVEL ” in chapter 3.
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 Re move the parts in the order listed.
4 - 35 CHAS FRONT AND REAR BRAKES EAS00615 T R . . 6 Nm (0.6 m • kg, 4.3 ft • Ib) Order Job/Part Q ’ ty Remarks Disassembling the front brake calipers Remove the parts in the order listed. The following procedure applies to both of the front brake calipers.
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.
4 - 37 CHAS FRONT AND REAR BRAKES EAS00617 T R . . 6 Nm (0.6 m • kg, 4.3 ft • Ib) Order Job/Part Q ’ ty Remarks Disassembling the rear brake caliper Remove the parts in the order listed. 1 Brake caliper piston 2 2 Brake caliper piston seal 4 3 Bleed screw 1 For assembly, reverse the disassembly procedure.
4 - 38 CHAS FRONT AND REAR BRAKES EAS00625 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. NOTE: _ Before disassembling the brake caliper, drain the brake fluid from the entire b rake system.
4 - 39 CHAS FRONT AND REAR BRAKES EAS00627 DISASSEMBLING THE REAR BRAKE CALIPER NOTE: _ Before disassembling the brake caliper, drain the brake fluid from the entire b rake system. 1. Remo v e: • union bolt 1 • copper washers 2 • brake hose NOTE: _ Put the end of the brake hose into a container and pump out the brake fluid carefully.
4 - 40 CHAS FRONT AND REAR BRAKES EAS00633 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every four years Brake fluid Every two years and whenever the brake is disassem- bled 1.
4 - 41 CHAS FRONT AND REAR BRAKES EAS00640 ASSEMBLING AND INSTALLIN G THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. W ARNING _ • Before installation, all internal brake com- ponents should be cleaned and lub ricated with clean or new brake fluid.
4 - 42 CHAS FRONT AND REAR BRAKES 4. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) W ARNING _ • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
4 - 43 CHAS FRONT AND REAR BRAKES ASSEMBLING AND INSTALLIN G THE REAR BRAKE CALIPER W ARNING @ • Before installation, all internal brake com- ponents should be cleaned and lub ricated with clean or new brake fluid. • Never use solvents on internal brake components as they will cause the piston seals to swell and distort.
4 - 44 CHAS FRONT AND REAR BRAKES 4. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) W ARNING _ • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
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 .
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.
4 - 47 CHAS FRONT FORK T R . . 40 Nm (4.0 m • kg, 29 ft • Ib) Order Job/Part Q ’ ty Remarks C Damper rod assembly bolt 1 D Copper washer 1 E Damper rod assembly 1 F Inner tube 1 For assembly, reverse the disassembly procedure.
4 - 48 CHAS FRONT FORK EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a le vel surf ace. W ARNING _ Securely support the motorcycle so that there is no danger of it falling over.
4 - 49 CHAS FRONT FORK NOTE: @ Use the side of the rod holder that is marked “ B ” . c. Loosen the nut. d. Remov e the cap bolt. e. Remov e the rod holder and f ork spr ing com- pressor . W ARNING _ The fork spring is compressed. f . Remo v e the spacer and nut.
4 - 50 CHAS FRONT FORK EAS00656 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Chec k: • inner tube 1 • outer tube 2 Bends/damage/scratches → Repla ce. W ARNING @ Do not attempt to straighten a bent inner tube as this may dangerously weaken it.
4 - 51 CHAS FRONT FORK EAS00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. W ARNING _ • Make sure the oil levels in both front fork legs are equal. • Uneven oil levels can result in poor han- dling and a loss of stability.
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 o f the oil seal faces out side. NOTE: _ • Before installing the oil seal, lubricate its lips with lithium-soap-based grea se.
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 f ork leg up and down to distribute the fork oil.
4 - 54 CHAS FRONT FORK d. Press down on the spacer with the f or k spring compressor 1 . e. Pull up the rod puller and in stall the rod holder 2 between the n ut 3 and the spacer 4 . NOTE: _ Use the side of the rod holder that is marked “ B ” . f .
4 - 55 CHAS FRONT FORK EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: • front fork leg Temporarily tighten the upper and lower bracket pinch bolts. NOTE: _ Make sure the inner fork tube is flush with the top of the handlebar holder.
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 - 57 CHAS 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 - 58 CHAS HANDLEBARS EAS00667 REMOVING THE HANDLEBARS 1. Stand the motorcycle on a le vel surf ace. W ARNING _ Securely support the motorcycle so that there is no danger of it falling over.
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.
4 - 60 CHAS HANDLEBARS 6. Install: • left handlebar switch 1 NOTE: _ Align the projection a on the left handlebar switch with the hole b in the left handlebar. 7. Install: • handlebar grip ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a.
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 - 62 CHAS 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 .
4 - 63 CHAS STEERING HEAD EAS00677 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a le vel surf ace. W ARNING _ Securely support the motorcycle so that there is no danger of it falling over. 2. Remo v e: • ring nut 1 (with the steering nut wrench 2 ) W ARNING _ Securely support the lower bracket so that there is no danger of it falling.
4 - 64 CHAS STEERING HEAD b . Remo v e the bearing r ace 3 from the lo wer brac k et with a floor chisel 4 and h ammer . c. Install a ne w rubber seal and ne w bearing rac es. CAUTION: _ If the bearing race is not installed properly, the steering head pipe could be damaged .
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 listed.
4 - 66 CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00687 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER W ARNING _ This rear shock absorber and gas c ylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and m ake sure you understand the following information.
4 - 67 CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00690 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the motorcycle on a le vel surf ace. W ARNING _ Becurely support the motorcycle so that there is no danger of it falling over. NOTE: _ Place the motorcycle on a suitable stand so that the rear wheel is elevated.
4 - 68 CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00695 CHECKING THE REAR SHOCK ABSORB ER ASSEMBLY 1. Chec k: • rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly. • rear shock absorber Gas leaks/oil leaks → Replace the rear shock absorber assembly.
4 - 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 . . 1 05 Nm (1 0.5 m • kg, 76 ft • lb) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R .
4 - 70 CHAS 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 . . 1 05 Nm (1 0.5 m • kg, 76 ft • lb) T R .
4 - 71 CHAS SWINGARM AND DRIVE CHAIN EAS00703 REMOVING THE SWINGARM 1. Stand the motorcycle on a le vel surf ace. W ARNING _ Securely support the motorcycle so that there is no danger of it falling over. NOTE: _ Place the motorcycle on a suitable stand so that the rear wheel is elevated.
4 - 72 CHAS SWINGARM AND DRIVE CHAIN EAS00704 REMOVING THE DRIVE CHAIN 1. Stand the motorcycle on a le vel surf ace. W ARNING _ Securely support the motorcycle so that there is no danger of it falling over. NOTE: _ Place the motorcycle on a suitable stand so that the rear wheel is elevated.
4 - 73 CHAS SWINGARM AND DRIVE CHAIN 3. W ash: • pivot shaft • dust covers • spacer • washers • bearings Recommended cleaning solvent Kerosene 4. Chec k: • dust covers 1 • spacer 2 Damage/wear → Replace. • bearings 3 Damage/pitting → Replace.
4 - 74 CHAS SWINGARM AND DRIVE CHAIN 2. Chec k: • drive chain Stiffness → Clean and lubricate o r replace. 3. Clean: • drive chain ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a.
4 - 75 CHAS SWINGARM AND DRIVE CHAIN 6. Chec k: • 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 SWINGARM 1.
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 spro cket Remove the parts in the order listed.
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 parts in the order listed.
5 - 3 ENG ENGINE 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 7 Exhaust valve pipe 1 8 Muffler 1 For installation, reverse the removal procedure.
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 th e order listed. Air filter case Refer to “ AIR FILTER CASE ” in chapter 3.
5 - 5 ENG ENGINE 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 3 Clutc h cable 1 4 Crankcase breather hose 1 5 Starter motor lead 1 Disconnect. 6 Ground lead 1 Disconnect. 7 Starter motor 1 8 Stator coil assembly coupler 1 Disconnect.
5 - 6 ENG ENGINE EAS00191 ENGINE T R . . 50 Nm (5.0 m • kg, 36 ft • Ib) 45 Nm (4.5 m • kg, 33 ft • Ib) T R . . T R . . 45 Nm (4.5 m • kg, 33 ft • Ib) T R . . 50 Nm (5.0 m • kg, 36 ft • Ib) T R . . 24 Nm (2.4 m • kg, 17 ft • Ib) 6 T R .
5 - 7 ENG ENGINE EAS00192 INSTALLING THE ENGINE 1. Install: • engine mounting adjust bolts 1 • rear mounting bolts 2 • self-locking nuts 3 • left front mounting bolt 4 • right front mounting bolt 5 • pinch bolt 6 NOTE: _ • Lubricate the rear mounting bolt thread s with lithium soap base grease.
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.
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 parts in the order listed.
5 - 10 ENG CAMSHAFT 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 .
5 - 11 ENG CAMSHAFT EAS00198 REMOVING THE CAMSHAFTS 1. Align: • TDC mark on the pickup coil rotor (with the crankcase mating surf ace) ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a.
5 - 12 ENG CAMSHAFT 6. Remo v e: • timing chain guide (exhaust side) 1 • camshaft caps • dowel pins CAUTION: _ To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in.
5 - 13 ENG CAMSHAFT 3. Measure: • camshaft runout Out of specification → Replace. 4. Measure: • camshaft-journal-to-camshaft-cap clear- ance Out of speci fication → Measure the cam- shaft journal diameter. Camshaft runout limit 0.03 mm (0.0012 in) Camshaft-journal-to-camshaft- cap clearance 0.
5 - 14 ENG CAMSHAFT 5. Measure: • camshaft journal diameter a Out of specification → Replace the cam- shaft. Within specification → Repla ce the cylinder head and the camshaft caps as a set. Camshaft journal diameter 24.459 ~ 24.472 mm (0.9630 ~ 0.
5 - 15 ENG CAMSHAFT EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Chec k: • timing chain tensioner Cracks/damage → Replace. 2. Chec k: • one-way cam operation Rough movement → Replace the timing chain tensioner housing.
5 - 16 ENG CAMSHAFT CAUTION: _ The camshaft cap bolts must be tightened evenly or damage to the cylinder h ead, camshaft caps, and camshafts wil l result. 4. Install: • intake camshaft sprocket • exhaust camshaft sprocket ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a.
5 - 17 ENG CAMSHAFT 6. Install: • timing chain tensioner ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. While lightly pressing the timing chain ten- sioner rod b y hand, turn the tensioner rod fully cloc kwise with a thin scre wdriver 1 .
5 - 18 ENG CAMSHAFT 9. Tighten: • camshaft sprocket bolts CAUTION: _ Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine. 10.Install: • timing chain guide (top side) 11.
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.
5 - 20 ENG CYLINDER HEAD EAS00222 REMOVING THE CYLINDER HEAD 1. Remo v e: • cylinder head nuts • cylinder head bolts NOTE: _ • Loosen the nuts in t he proper sequence as shown. • Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.
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 cha in cavity.
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.
5 - 23 ENG VALVES AND VALVE SPRINGS Order Job/Part Q ’ ty Remarks 10 Exhaust valve lifter 8 11 Exhaust valve pad 8 12 Exhaust valve cotter 16 13 Exhaust valve upper spring seat 8 14 Exhaust valve sp.
5 - 24 ENG VALVES AND VALVE SPRINGS EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: _ Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal.
5 - 25 ENG VALVES AND VALVE SPRINGS 4. Remo v e: • upper spring seat 1 • valve spring 2 • valve stem seal 3 • lower spring seat 4 • valve 5 NOTE: _ Identify the position of e ach part very carefully so that it can be reinstalled in its origin al place.
5 - 26 ENG VALVES AND VALVE SPRINGS ▲▲▲ ▲ ▲ ▲▲▲ ▲▲ ▲ ▲ ▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Eliminate: • carbon deposits (from the valve face and valve seat) 4. Chec k: • valve face Pitting/wear → Grind the valve face.
5 - 27 ENG VALVES AND VALVE SPRINGS EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. 1. Eliminate: • carbon deposits (from the valve face and valve seat) 2. Chec k: • valve seat Pitting/wear → Replace the cylinder head.
5 - 28 ENG VALVES AND VALVE SPRINGS ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply a coarse lapping compound a to the val ve fa c e. CAUTION: _ Do not let the lapping compound en ter the gap between the valve stem an d the valve guide.
5 - 29 ENG VALVES AND VALVE SPRINGS 2. Measure: • compressed valve spring force a Out of specification → Replace the valve spring. b Installed length Compressed valve spring forc e (installed) Intake valve spring 82 ~ 96 N (8.2 ~ 9.6 kg, 18.43 ~ 21.
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.
5 - 31 ENG VALVES AND VALVE SPRINGS 5. T o secure the v alv e cotters onto the v alv e stem, lightly tap the v alv e tip with a soft-f ace hammer . CAUTION: _ Hitting the valve tip with excessive force could damage the valve.
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.
5 - 33 ENG GENERATOR REMOVING THE GENERATOR 1. Remo v e: • generator rotor cover 1 NOTE: @ Loosen each bolt 1/4 of a turn a t a time, in stages and in a crisscross p attern.
5 - 34 ENG GENERATOR CAUTION: • Clean the tapered portion of the crank- shaft and the generator rotor hub with lacquer thinner. • Lubricate the generator roto r bolt threads with engine oil. 3. Tighten: • generator rotor bolt 1 NOTE: @ While holding the generator rotor 2 with the rotor holding tool 3 , tighten the generator rotor bolt.
5 - 35 ENG GENERATOR W ARNING When the bolt are tightened more than the specified angle, do not loosen the bolt and then retighten it. Replace the bolt with a new one a nd per- form the procedure again. CAUTION: • Do not use a torque wrench to tighten the bolt to the specified angle.
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 listed.
5 - 37 ENG 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 7 Crankshaft position sensor coupler 1 Disconnect.
5 - 38 ENG PICKUP COIL REMOVING THE PICKUP COIL ROTOR 1. Remo v e: • clutch cable holder 1 • pickup coil lead holder 2 • pickup coil rotor cover 3 NOTE: @ Loosen each bolt 1/4 of a turn a t a time, in stages and in a crisscross p attern. After all of the bolts are f ully loosened, remove them.
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.
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 co wling Refer to “ COWLINGS ” in chapter 3.
5 - 41 ENG CLUTCH PULL LEVER SHAFT Order Job/Part Q ’ ty Remarks Removing the pull lever shaf t Remove the parts in the order listed. 1C i r c l i p 2 2 Pull lever 1 3 Pull lever spring 1 4 Pull lever shaft 1 5O i l s e a l 1 6B e a r i n g 2 For installation, reverse the removal procedure.
5 - 42 ENG CLUTCH EAS00274 CLUTCH T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) T R . . 105 Nm (10.5 m • kg, 76 ft • lb) T R . . 8 Nm (0.8 m • kg, 5.8 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the clutch Remove the parts in the order listed.
5 - 43 ENG CLUTCH T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) T R . . 105 Nm (10.5 m • kg, 76 ft • lb) T R . . 8 Nm (0.8 m • kg, 5.8 ft • Ib) Order Job/Part Q ’ ty Remarks 15 Thrust was her .
5 - 44 ENG CLUTCH EAS00277 REMOVING THE CLUTCH 1. Straigh ten the loc k w asher 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.
5 - 45 ENG CLUTCH EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Chec k: • clutch plate Damage → Replace the clutch plates as a set. 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge 1 ) Out of specification → Replace the clutch plates as a set.
5 - 46 ENG CLUTCH EAS00286 CHECKING THE PRESSURE PLATE 1. Chec k: • pressure plate 1 Cracks/damage → Replace. • bearing 2 Damage/wear → Replace.
5 - 47 ENG CLUTCH 2. Chec k: • starter clutch operation ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the star ter clutch drive ge ar onto the star ter clutch and hold the star ter clutch.
5 - 48 ENG CLUTCH 5. Install: • friction plates • clutch plates NOTE: _ First, install a friction plate and then alternate between a clutch plate and a friction plat e.
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.
5 - 50 ENG SHIFT SHAFT CHECKING THE SHIFT SHAFT 1. Chec k: • shift shaft 1 Bends/damage/wear → Replace. • shift shaft spring 2 Damage/wear → Replace. CHECKING THE STOPPER LEVER 1. Chec k: • stopper lever 1 Bends/damage → Replace. Roller turns roughly → Replace the stopper lever.
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.
5 - 52 ENG 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 .
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.
5 - 54 ENG OIL PAN AND OIL PUMP EAS00362 REMOVING THE OIL PAN 1. Remo v e: • oil level switch 1 • oil pan 2 • gasket • dowel pins NOTE: _ Loosen each bolt 1/4 of a turn a t a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
5 - 55 ENG OIL PAN AND OIL PUMP 3. Chec k: • oil pump operation Rough movement → Repeat steps (1) and (2) or replace the defective part(s). EAS00365 CHECKING THE RELIEF VALVE 1. Chec k: • relief valve body 1 • relief valve 2 • spring 3 • O-ring 4 Damage/wear → Replace the defective part(s).
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.
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 engin e. T R . . 10 Nm (1.0 m · kg, 7.2 ft · lb) EAS00380 INSTALLING THE OIL PAN 1.
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 ” .
5 - 59 ENG 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 6W a s h e r 1 7 Oil/water pump assembly drive sprocket 1 8W a s h e r 1 9P l a t e 1 10 Lower crankcase 1 11 Dowel pin 3 For installation, reverse the removal procedure.
5 - 60 ENG CRANKCASE EAS00384 DISASSEMBLING THE CRANKCASE 1. Place the engine upside do wn. 2. Remo v e: • crankcase bolts NOTE: _ • Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
5 - 61 ENG CRANKCASE EAS00399 CHECKING THE CRANKCASE 1. Thoroughly w ash the crankcase halv es in a mild solv ent. 2. Thoroughly clean all the gask et surf aces and crankcase mating surf aces. 3. Chec k: • crankcase Cracks/damage → Replace. • oil delivery passages Obstruction → Blow out with compressed air.
5 - 62 ENG CRANKCASE EAS00414 ASSEMBLING THE CRANKCAS E 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 conta ct with the oil gallery or crankshaft journal bear- ings.
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 is turned by hand. 7. Install: • crankcase bolts NOTE: _ • Lubricate the bolt threads with e ngine oil.
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.
5 - 65 ENG CONNECTING RODS AND PISTONS EAS00393 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the connecting rods and pistons. 1. Remo v e: • connecting rod 1 • big end bearings NOTE: _ Identify the position of each big end bearing so that it can be reinstalled in its original place.
5 - 66 ENG CONNECTING RODS AND PISTONS 3. Remo v e: • top ring • 2nd ring • oil ring NOTE: _ When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown. EAS00387 REMOVING THE CRANKSHAFT ASSEMBLY 1.
5 - 67 ENG CONNECTING RODS AND PISTONS b . If out of specification, replace the cylinder , and the pistons and piston rings as a set. Cylinder bore “ C ” 74.00 ~ 74.01 mm (2.9134 ~ 2.9138 in) Wear limit 74.06 mm (2.9157 in) Taper limit “ T ” 0.
5 - 68 ENG CONNECTING RODS AND PISTONS EAS00263 CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance Out of specification → Replace the piston and piston rings as a set. NOTE: _ Before measuring the piston ring side clear- ance, eliminate any carbon deposits f rom the piston ring grooves and piston rings.
5 - 69 ENG CONNECTING RODS AND PISTONS CHECKING THE PISTON PINS The following procedure applies to all of the piston pins. 1. Chec k: • piston pin Blue discoloration/grooves → Replace the piston pin and then check the lubrication system. 2. Measure: • piston pin outside diameter a Out of specification → Replace the piston pin.
5 - 70 ENG CONNECTING RODS AND PISTONS ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ The following procedure applies to all of the connecting rods. CAUTION: @ Do not interchange the big end bearings and connecting rods.
5 - 71 ENG CONNECTING RODS AND PISTONS e. Tighten the connecting rod n uts . f . Replace the connecting rod bolts and n uts with ne w ones . CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts and nuts.
5 - 72 ENG CONNECTING RODS AND PISTONS 2. Select: • big end bearings (P1 ~ P4) NOTE: @ • The numbe rs È stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes. •“ P1 ” ~ “ P4 ” refer to the bearings shown in the crankshaft illustration.
5 - 73 ENG CONNECTING RODS AND PISTONS 2. Install: • piston 1 (onto the respective connecting rod 2 ) • piston pin 3 • piston pin clip 4 NOTE: @ • Apply engine oil onto the piston p in. • Make sure that the “ Y ” mark a on the con- necting rod faces left when the arrow mark b on the piston is pointing up.
5 - 74 ENG CONNECTING RODS AND PISTONS 6. Install: • big end bearings • connecting rod assembly (into the cylinder and onto the crankshaft pin). • connecting rod cap (onto the connecting rod) NOTE: @ • Align the projections on the big end bearings with the notches in the connecting rod s and connecting rod caps.
5 - 75 ENG CONNECTING RODS AND PISTONS e. Tighten the nut fur ther to reach the speci- fied angle (120 ° ). W ARNING When the nut is tightened more than the specified angle, do not loos en the nut and then retighten it. Replace the bolt with a new one a nd per- form the procedure again.
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 ” .
5 - 77 ENG CRANKSHAFT EAS00395 CHECKING THE CRANKSHAFT 1. Measure: • crankshaft runout Out of specification → Replace the crank- shaft. 2. Chec k: • crankshaft journal surfaces • crankshaft pin surfaces • bearing surfaces Scratches/wear → Replace the crankshaft.
5 - 78 ENG CRANKSHAFT c. Install th e crankshaft journal upper bearings 1 and the cra nkshaft into the upper cr ank- case. NOTE: _ Align the projections a on the crankshaft jour- nal upper bearings with the notches b in the upper crankcase. d. Put a piece of Plastigauge ® 2 on each crankshaft journal.
5 - 79 ENG CRANKSHAFT g. Remov e the lower cr ankcase and the crank- shaft journal lower bearings . h. Measure the compressed Plastigauge ® width c on each cr ankshaft jour nal. If the crankshaft-journal-to-crankshaft-jour- nal-bearing clearance is out of specification, select replacement crankshaft journal bear- ings.
5 - 80 ENG CRANKSHAFT EAS00407 INSTALLING THE CRANKSHAFT 1. Install: • crankshaft journal upper bearin gs 1 (into the upper crankcase) NOTE: _ • Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase.
5 - 81 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 fork s Remove the parts in the order listed.
5 - 82 ENG 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 10 Shift dr um assembly 1 11 Shift fork “ C ” 1 12 Main axle assembly 1 For installation, reverse the removal procedure.
5 - 83 ENG TRANSMISSION Order Job/Part Q ’ ty Remarks Disassembling the main axle assembly Disassembly the parts in the order listed. 1 2nd pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washe.
5 - 84 ENG TRANSMISSION Order Job/Part Q ’ ty Remarks A Main axle/1st pinion gear 1 B Bearing 1 C Main axle bearing housing 1 For assembly, reverse the disassembly procedure.
5 - 85 ENG TRANSMISSION Order Job/Part Q ’ ty Remarks Disassembling the drive axle assembly Disassembly the parts in the order listed. 1 Washer 1 2 1st wheel gear 1 3 Spacer 1 4 5th wheel gear 1 5 C.
5 - 86 ENG TRANSMISSION Order Job/Part Q ’ ty Remarks A 4th wheel gear 1 B 6th wheel gear 1 C 2nd wheel gear 1 D Spacer 1 E Drive axle 1 F Bearing 1 G Spacer 1 For assembly, reverse the disassembly procedure.
5 - 87 ENG TRANSMISSION EAS00420 REMOVING THE TRANSMISSION 1. Remo v e: • main axle assembly 1 (with the Torx ® wrench T30) ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a.
5 - 88 ENG TRANSMISSION EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Chec k: • 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.
5 - 89 ENG TRANSMISSION 4. Chec k: • transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmission axle assemblies. 5. Chec k: • transmission gear movement Rough movement → Repla ce the defective part(s).
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 ” in chapter 3. Air filter case and rubber cover Refer to “ AIR FILTER CASE ” in chapter 3.
6 - 2 COOL RADIATOR Order Job/Part Q ’ ty Remarks 3 Radiator inlet hose 1 4 Radiator outlet hose 1 5 Water pump breather hose 1 6R a d i a t o r 1 7 Radiator fan 1 8 Water pump inlet pipe 1 For installation, reverse the removal procedure.
6 - 3 COOL RADIATOR EAS00455 CHECKING THE RADIATOR 1. Chec k: • 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.
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 ” in chapter 3. 2. Chec k: • cooling system Leaks → Repair or replace any faulty part.
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 th e order listed.
6 - 6 COOL OIL COOLER EAS00458 CHECKING THE OIL COOLER 1. Chec k: • oil cooler Cracks/damage → Replace. 2. Chec k: • oil cooler inlet hose • oil cooler outlet hose Cracks/damage/wear → Replace .
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 ” an d “ FUEL TANK ” in chapter 3.
6 - 8 COOL 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 5 Thermostat assembly 1 6 Thermostat assembly inlet pipe (left) 1 For installation, reverse the removal procedure.
6 - 9 COOL THERMOSTAT EAS00461 ‘ T R . . 18 Nm (1.8 m • kg, 13 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q ’ ty Remarks Disassembling the thermostat housing Remove the parts in the order listed. 1 Thermostat housing cover 1 2 Thermostat 1 3 Thermostat housing 1 For assembly, reverse the disassembly procedure.
6 - 10 COOL THERMOSTAT EAS00462 CHECKING THE THERMOSTAT 1. Chec k: • thermostat Does not open at 71 ~ 85 ° C (160 ~ 185 ° F) → Replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a.
6 - 11 COOL THERMOSTAT EAS00464 ASSEMBLING THE THERMOSTAT ASSEMBLY 1. Install: • thermostat housing 1 • thermostat 2 • O-ring 3 • thermostat housing cover 4 NOTE: _ Install the thermostat with its breather hole a facing up.
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 Re move the parts in the order listed. NOTE: • The water pump and oil pump are com- bined into one unit (oil/water pump assembly).
6 - 13 COOL WATER PUMP T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q ’ ty Remarks 5 Water pump seal 1 6O i l s e a l 1 7B e a r i n g 1 For installation, reverse the removal procedure.
6 - 14 COOL WATER PUMP EAS00471 DISASSEMBLING THE WATER PUMP 1. Remo v e: • water pump seal 1 NOTE: _ Tap out the water pump seal from the inside of the water pump housing. 2 Water pump housing 2. Remo v e: • oil seal 1 • bearing 2 NOTE: _ Tap out the bearing and oil seal from the out- side of the water pump housing.
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 dia meter.
6 - 16 COOL WATER PUMP 4. Measure: • impeller shaft tilt Out of specification → Repeat steps (3) and (4). CAUTION: _ Make sure the ru bber damper and rubber damper holder are flush with the imp eller. 1 Straightedge 2 Impeller Impeller shaft tilt limit 0.
7 - 1 FI FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 Ignition coil 2 Air filter case 3 Intake temper ature sensor 4 Fuel delivery hose 5 Fuel tank 6 Fuel pump 7 Fuel return hose 8 Intake air pressur.
7 - 2 FI FUEL INJECTION SYSTEM WIRING DIAGRAM OFF RUN L / R R / Y Br / W P / W Y B / L (BLACK) (BLACK) Y B / L Br / W P / W (BLACK) G / W B R / L B CORD HEAD LIGHT MAIN HARNESS A WIRE SUB LEAD 4 MAIN .
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 eng ine control sys- tem is operating normally.
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 ECU illumin.
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.
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 actuators.
7 - 7 FI FUEL INJECTION SYSTEM Diagnostic fault code table Fault Code No. Symptom Probable cause of malfunction Code of diagnostic mode 11 No nor mal signals are received from the cylinder identification sensor .
7 - 8 FI FUEL INJECTION SYSTEM 33 Open circuit is detected in the primar y lead of the ignition coil (#1). • Open or short circuit in wiring harness. • Malfunction in ignition coil. • Malfunction in ECU. • Malfunction in a component of ignition cut-off circuit system.
7 - 9 FI FUEL INJECTION SYSTEM Diagnostic mode table Set the meter display from the regular mode to t he 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 mounted.
7 - 10 FI FUEL INJECTION SYSTEM 32 Ignition coil #3 After 1 second has elapsed from the time the engine stop s witch has been tur ned from OFF to ON, it actuates ignition coil #3 for fiv e times e v ery second and illuminates the en gine trouble w arning light .
7 - 11 FI FUEL INJECTION SYSTEM 52 Headlight relay 1 After 1 second has elapsed f rom the time the engine stop s witch has been turn ed from OFF to ON, it actuates the head- light rela y five times e v ery 5 seconds and illuminates the engine trouble warning light.
7 - 12 FI FUEL INJECTION SYSTEM TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter.Carry out check and maintenance on items or componen ts that could be a cause of malfunction in accordance with the order.
7 - 13 FI FUEL INJECTION SYSTEM Fault code No. 12 Symptom No normal signals are received from the crankshaft position sensor. Used diagnostic code No.-- Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Installed condition of sensor Check the installed area for looseness or pinching.
7 - 14 FI FUEL INJECTION SYSTEM Fault code No. 13 Symptom Intake air pressure sensor - open or short circuit detected. Used diagnostic code No. 03 (intake air pressure sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective intake air pressure sensor Replace if defective.
7 - 15 FI FUEL INJECTION SYSTEM Fault code No. 14 Symptom Intake air pressure sensor - hose system malfunction (clogged or detached hose). Used diagnostic code No.
7 - 16 FI FUEL INJECTION SYSTEM Fault code No. 17 Symptom EXUP servo motor potention circuit - open or short circuit detected. Used diagnostic code 53 Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective EXUP servo motor potention circuit.
7 - 17 FI FUEL INJECTION SYSTEM Fault code No. 18 Symptom EXUP servo motor is stuck. Used diagnostic code 53 Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective EXUP servo motor. Replace if defective.
7 - 18 FI FUEL INJECTION SYSTEM Fault code No. 19 Symptom Open circuit is detected in the input line from the sidestand switch to the ECU. Used diagnostic code No. 20 (sidestand switch) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective sidestand switch Replace if defective.
7 - 19 FI FUEL INJECTION SYSTEM Fault code No. 22 Symptom Open or short circuit detected from the intake temperature sensor. Used diagnostic code No. 05 (intake temperature sensor) Inspection operatio.
7 - 20 FI FUEL INJECTION SYSTEM Fault code No. 23 Symptom Open or short circuit detected from the atmospheric pressure sensor. Used diagnostic code No. 02 (atmospheric pressure sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective atmospheric pressure sensor.
7 - 21 FI FUEL INJECTION SYSTEM Fault code No. 30 Symptom The motorcycle has overturned. Used diagnostic code No. 08 (lean angle cut-off switch) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective lean angle cut-off switch Replace if defective.
7 - 22 FI FUEL INJECTION SYSTEM Fault code No. 33 Symptom Malfunction detected in the primary lead of the ignition coil (#1). Used diagnostic code No. 30 (ignition coil #1) Inspection operation item a.
7 - 23 FI FUEL INJECTION SYSTEM Fault code No. 36 Symptom Malfunction detected in the primary lead of the ignition coil (#4). Used diagnostic code No. 33 (ignition coil #4) Inspection operation item a.
7 - 24 FI FUEL INJECTION SYSTEM Fault code No. 42 Symptom 1 No normal signals are received from the speed sensor. 2 Open or short circuit is detected in the neutral switch.
7 - 25 FI FUEL INJECTION SYSTEM Fault code No. 43 Symptom The ECU is unable to monitor the battery voltage. Used diagnostic code No. 09 (fuel system voltage) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Malfunction in ECU Fuel injection system relay is on.
7 - 26 FI FUEL INJECTION SYSTEM Fault code No. 44 Symptom Error is detected while reading or writing on EEP-ROM. Used diagnostic No. 60 (EEP-ROM improper cylinder indication) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Malfunction in ECU Execute diagnostic code 60 * Check the faulty cylinder.
7 - 27 FI FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signal are received from the ECU. Used diagnostic code No. -- Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Open or short circuit in wiring harness and/or sub lead.
7 - 28 FI FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom Non-registered data has been received from the meter. Used diagnostic code No. -- Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Open or short circuit in wiring harness and/or sub lead.
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/ru bber sheet Refer to “ SEATS ” and “ FUEL TANK ” in chapter 3. Air filter case Refer to “ AIR FILTER CASE ” in chapter 3.
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.
7 - 32 FI THROTTLE BODIES Order Job/Part Q ’ ty Remarks 11 Intake air pressure sensor 1 12 Fuel distributor 1 13 Injector 4 14 Throttle position sensor 1 For installation, reverse the removal procedure.
7 - 33 FI THROTTLE BODIES CAUTION: The throttle bodies should not be disas- sembled unnecessarily. CHECKING THE INJECTOR 1. Chec k: • injector Damage → Replace. CHECKING THE THROTTLE BODY 1. Chec k: • throttle body Cracks/damage → Replace the throttle bodies.
7 - 34 FI THROTTLE BODIES CHECKING THE PRESSURE REGULATOR 1. Chec k: • pressure regulator Damage → Replace. CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 1. Chec k: • pressure regulator operation ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a.
7 - 35 FI THROTTLE BODIES Faulty → Replace the pressure regulato r. ▲▲▲ ▲ ▲ ▲▲▲ ▲▲ ▲ ▲ ▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ Increase the va.
7 - 36 FI THROTTLE BODIES f . While slo wly opening the throttle , chec k that the throttle position sensor resistance is within the specified rang e. The resistance does not change or it changes abruptly → Replace the throt tle position sensor. The slot is worn or broken → Replace the throttle position sensor.
7 - 37 FI AIR INDUCTION SYSTEM EAS00507 AIR INDUCTION SYSTEM AIR INDUCTION The air induction system burns unburned exhaust gases by injecting fresh air (second- ary air) into the exhaust port, reducing the emission of hydrocarbons.
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. Chec k: • hoses Loose connection → Connect properly. Cracks/damage → Replace. • pipes Cracks/damage → Replace. 2. Chec k: • reed valve 1 • reed valve stopper • reed valve seat Cracks/damage → Replace the reed valve.
7 - 40 FI AIR INDUCTION SYSTEM 5. Chec k • Al system soleno id ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remo v e the AI system solenoid coup ler from the wire harness. b . Connect the poc k et tester ( Ω × 1) to the AI system solenoid ter minal as shown.
8 - 1 – + ELEC EAS00729 ELECTRICAL ELECTRICAL COMPONENTS 1 Fuse box 2 Front brake swit ch 3 Clutch switch 4 Battery 5 Starter relay 6 Fuel injection system fuse 7 Main fuse 8 Neutral switch 9 Rear b.
8 - 2 – + ELEC ELECTRICAL COMPONENTS 1 Coolant temp erature sensor 2 Intake air temp erature sensor 3 Intake air pressure se nsor 4 Lean angle cut -off switch 5 Atmospheric pre ssure sensor 6 ECU 7 .
8 - 3 – + ELEC CHECKING SWITCH CONTINUITY EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket 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- pler terminal slots 1 .
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.
8 - 5 – + ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connectio ns, and also fo r con- tinuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.
8 - 6 – + ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remo v e: • bulb W ARNING _ Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
8 - 7 – + ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Chec k: • bulb socket (for continu ity) (with the pocket tester) No continuity → Re place.
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 (BLACK) (BLACK) Y B / L Br / W P / W (BLACK) G / W.
8 - 9 – + ELEC IGNITION SYSTEM EAS00737 TROUBLESHOOTING Check: 1. main and ignition fuses 2. batter y 3. spark plugs 4. ignition spark gap 5. ignition coil resistance 6. crankshaft posit ion sensor resistance 7. main s witch 8. engine stop s witch 9.
8 - 10 – + ELEC IGNITION SYSTEM EAS00743 EAS00 747 4. Ignition spark gap The following procedure applies to all of the spark plugs. • Disconnect the spark plug cap from the spark plug. • Connect the ignition checker 1 as shown. 2 Ignition coil • Set the main switch to “ ON ” .
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 as shown.
8 - 12 – + ELEC IGNITION SYSTEM EAS00753 EAS00 754 11.Star ting circuit cut-off rela y • Disconnect the starting circuit cut-off relay coupler from the wire harness. • Connect the pocket tester ( Ω × 1) to the starting circuit cut-off relay coupler as shown.
8 - 13 – + ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM L / R R / Y Br / W P / W Y B / L (BLACK) (BLACK) Y B / L Br / W P / W (BLACK) G / W B R / L B CORD HEAD LIG.
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 are clo.
8 - 15 – + ELEC ELECTRIC STARTING SYSTEM EAS00757 TROUBLESHOOTING Check: 1. main and ignition fuses 2. batter y 3. star ter motor 4. star ting circuit cut-off relay 5. star ter rela y 6. main s witch 7. engine stop s witch 8. neutral s witch 9. sidestand s witch 10.
8 - 16 – + ELEC EAS00759 EAS00761 EAS00749 EAS00750 EAS00751 4. Star ting circuit cut-off rela y • Disconnect the starting circuit cut-off relay coupler from the wire harness. • Connect the pocket tester ( Ω × 1) and bat- tery (12 V) to the starting circuit cut-off relay coupler as shown.
8 - 17 – + ELEC ELECTRIC STARTING SYSTEM EAS00752 EAS00763 EAS00764 EAS00766 9. Sidestand s witch • Check the sidestand switch for continuity. Refer to “ CHECKING THE SWITCHES ” . • Is the sidestand switch OK? YES NO Replace the side- stand switch.
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.
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 th e order listed.
8 - 20 – + ELEC ELECTRIC STARTING SYSTEM EAS00769 CHECKING THE STARTER MOTOR 1. Chec k: • commutator Dirt → Clean with 600-grit sa ndpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor.
8 - 21 – + ELEC ELECTRIC STARTING SYSTEM 5. Measure: • brush length a Out of specification → Re place 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.
8 - 22 – + ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM (BLACK) R Br / L R Br / L L / YL / B L / BL / Y R B (GRA Y) W W W ON OFF RW R / WL / W R / W L / W R R R R B B B B B R W R B .
8 - 23 – + ELEC CHARGING SYSTEM EAS00774 TROUBLESHOOTING Check: 1. main fuse 2. batter y 3. charging v oltage 4. stator coil resistance 5. wiring connections (of the entire charging system) NOTE: _ • Before troubleshooting, remove the following part(s): 1.
8 - 24 – + ELEC CHARGING SYSTEM EAS00776 EAS00779 4. Stator coil resistance • Remove the generator cover. • Connect the pocket tester ( Ω × 1) to the stator coils as shown.
8 - 25 – + ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM L / R R / Y Br / W P / W Y B / L (BLACK) (BLACK) Y B / L Br / W P / W (BLACK) G / W B R / L B CORD HEAD LIGHT MAIN HARNESS A .
8 - 26 – + ELEC LIGHTING SYSTEM 1 Main switch 5 Battery 6 Fuse (main ) C ECU X Hi beam indicator light [ Meter light c Dimmer switch l Auxiliary light m Headlight n License light o Taillight u Headl.
8 - 27 – + ELEC LIGHTING SYSTEM EAS00781 TROUBLESHOOTING Check: 1. main, signal and headlight fuses 2. batter y 3. main s witch 4. dimmer s witch 5. headlight rela y (on/off) 6. headlight rela y (dimmer) 7. wiring connections (of the entire lighting system) NOTE: _ • Before troubleshooting, remove the following part(s): 1.
8 - 28 – + ELEC LIGHTING SYSTEM YES NO YES NO EAS00787 5. Headlight rela y (on/off) • Disconnect the headlight relay (o n/off) from the coupler. • Connect the pocket tester ( Ω × 1) and bat- tery (12 V) to the he adlight relay (on/off) coupler as shown.
8 - 29 – + ELEC LIGHTING SYSTEM EAS00788 CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light f ail t o come on. YES NO YES NO 1.
8 - 30 – + ELEC LIGHTING SYSTEM EAS00789 2. The meter light f ails to come o n. EAS00790 3. The tail/brak e light f ails to come on. 1. Meter light b ulb and so ck et • Check the meter light bulb and socket for continuity.
8 - 31 – + ELEC LIGHTING SYSTEM EAS00791 4. The auxiliar y light f ails to come on. EAS00792 5. The license plate light f ails to come on. 1. A uxiliar y light bulb and sock et • Check the auxiliary light bulb and socket for continuity.
8 - 32 – + ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM L / R R / Y Br / W P / W Y B / L (BLACK) (BLACK) Y B / L Br / W P / W (BLACK) G / W B R / L B CORD HEAD LIGHT MAIN HARNESS .
8 - 33 – + ELEC SIGNALING SYSTEM 1 Main switch 4 Fuse (back up) 5 Battery 6 Fuse (main ) 0 Starting circuit c ut-off relay B Fuel pump C ECU I Speed sensor R Neutral switch S Fuel level warning ligh.
8 - 34 – + ELEC SIGNALING SYSTEM EAS00794 TROUBLESHOOTING Check: 1. main, ignition, signaling and bac k up fuses 2. batter y 3. main s witch 4. wiring connections (of the entire signaling system) NOTE: _ • Before troubleshooting, remove the following part(s): 1.
8 - 35 – + ELEC SIGNALING SYSTEM EAS00797 2. The tail/brak e light f ails to come on. 2. V oltage • Connect the po cket tester (DC 20 V) to the horn connector at th e horn terminal as shown. Positive tester probe → pink 1 Negative tester probe → ground • Set the main switch to “ ON ” .
8 - 36 – + ELEC SIGNALING SYSTEM EAS00799 3. The tur n signal light, turn signal indicator light or both f ail to b link. YES NO This circuit is OK. The wiring circuit from the main switch to the tail/brake light coupler is faulty and must be repaired.
8 - 37 – + ELEC SIGNALING SYSTEM EAS00801 4. The neutral indica tor light f ails to come on. Left turn signal light Positive tester probe → c hocolate 1 Negative tester pro be → ground Right turn signal light Positive tester probe → da rk green 2 Negative tester pro be → ground ÈÉ Ê • Set the main switch to “ ON ” .
8 - 38 – + ELEC SIGNALING SYSTEM EAS00802 5. The oil le v el w ar ning light f ails to come on. EAS00803 6. The fuel le vel indicator light f ails to come on. 1. Oil le v el w arning light bulb and soc k et • Check the oil level warning light bulb and socket for continuity.
8 - 39 – + ELEC SIGNALING SYSTEM EAS00806 7. The speedometer f ails to come on. 2. Fuel sender • Drain the fuel from the fuel tank and remove the fuel pump from the fuel tank. • Disconnect the fuel sender coupler from the wire harness. • Connect the pocket tester ( Ω × 1) to the fuel sender as shown.
8 - 40 – + ELEC SIGNALING SYSTEM 2. V oltage • Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown. Positive tester probe → yellow/blue 1 Negative tester probe → black/white 2 • Set the main switch to “ ON ” .
8 - 41 – + ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM L / R R / Y Br / W P / W Y B / L (BLACK) (BLACK) Y B / L Br / W P / W (BLACK) G / W B R / L B CORD HEAD LIGHT MAIN HARNESS A WI.
8 - 42 – + ELEC COOLING SYSTEM EAS00808 TROUBLESHOOTING Check: 1. main, ignition and radiator f an motor fuses 2. batter y 3. main s witch 4. radiator f an motor 5. radiator f an motor relay 6. coolant temper ature sensor 7. wiring connections (the entire cooling system) NOTE: _ • Before troubleshooting, remove the following part(s): 1.
8 - 43 – + ELEC COOLING SYSTEM EAS00809 YES NO 4. Radiator f an mot or • Disconnect the radiator fan moto r coupler from the wire harness. • Connect the battery (DC 12 V) as shown.
8 - 44 – + ELEC COOLING SYSTEM EAS00812 EAS00813 6. Coolant temperatur e 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 tempe rature sensor in a container filled with coo lant 2 .
8 - 45 – + ELEC FUEL PUMP SYSTEM FUEL PUMP SYSTEM CIRCUIT DIAGRAM L / R R / Y Br / W P / W Y B / L (BLACK) (BLACK) Y B / L Br / W P / W (BLACK) G / W B R / L B CORD HEAD LIGHT MAIN HARNESS A WIRE SU.
8 - 46 – + ELEC FUEL PUMP SYSTEM EAS00815 FUEL PUMP SYSTEM The ECU includes the co ntrol unit for the fuel pump. 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 ECU 7 Fuel.
8 - 47 – + ELEC FUEL PUMP SYSTEM EAS00816 TROUBLESHOOTING Check: 1. Main and fuel injection system fuses 2. Batter y 3. Main s witch 4. Engine stop s witch 5.
8 - 48 – + ELEC FUEL PUMP SYSTEM EAS00759 EAS00 817 EAS00818 5. Star ting circuit cut-off rela y • Disconnect the starting circuit cut-off relay coupler from the wire harness. • Connect the pocket tester ( Ω × 1) and bat- tery (12 V) to the starting circuit cut-off relay coupler as shown.
8 - 49 – + ELEC FUEL PUMP SYSTEM EAS00819 CHECKING THE FUEL PUMP W ARNING _ Gasoline is extremely flammable and under certain circumstances there can be a dan- ger of an explosion or fire. Be extremely careful and note the following points: • Stop the engine before refueling.
9 - 1 TRBL SHTG EAS00844 TROUBLESHOOTING NOTE: _ The following guide for trouble shooting does not cover all the possible cause s of trouble. It should be helpful, however, as a guide to basic troubleshooting . Refer to the relative procedure in this man- ual for checks, adjustments, and replacemen t of parts.
9 - 2 TRBL SHTG STARTING FAILURES/ INCORRECT ENGINE IDLING SPEED ELECTRICAL SYSTEMS Battery • Discharged battery • Faulty battery Fuse(s) • Blown, damaged or incorrect fuse • Improperly instal.
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 ” .
9 - 4 TRBL SHTG OVERHEATING/OVERCOOLING/ POOR BRAKING PERFORMANCE EAS00855 OVERHEATING ENGINE Clogged coolant passages • Cylinder head(s) and piston(s) • Heavy carbon buildup Engine oil • Incorr.
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 o.
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 chargi.
YZF-R1P/YZF-R1PC WIRING DIAGRAM 1 Main switch 2 AC magneto 3 Rectifier/regulator 4 Fuse (back up) 5 Battery 6 Fuse (main) 7 Fuse (fuel injection system) 8 Starter relay 9 Starter motor 0 Starting circ.
YZF-R1P/YZF-R1PC WIRING DIAGRAM Dark green Green Gray Black Blue Brown Chocolate COLOR CODE Orange Pink Red Sky blue Black / White Black / Yellow Blue / Black Blue / Red Blue / White Blue / Yellow Bro.
Y AMAHA MO T OR CO . , L TD . 2500 SHINGAI IW A T A SHIZUOKA JAP AN PRINTED IN U.S.A..
Ein wichtiger Punkt beim Kauf des Geräts Yamaha YZF-R1PC (oder sogar vor seinem Kauf) ist das durchlesen seiner Bedienungsanleitung. Dies sollten wir wegen ein paar einfacher Gründe machen:
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Wenn Sie aber schon Yamaha YZF-R1PC besitzen, und noch keine Gelegenheit dazu hatten, die Bedienungsanleitung zu lesen, sollten Sie es aufgrund der oben beschriebenen Gründe machen. Sie erfahren dann, ob Sie die zugänglichen Funktionen richtig genutzt haben, aber auch, ob Sie keine Fehler begangen haben, die den Nutzungszeitraum von Yamaha YZF-R1PC verkürzen könnten.
Jedoch ist die eine der wichtigsten Rollen, die eine Bedienungsanleitung für den Nutzer spielt, die Hilfe bei der Lösung von Problemen mit Yamaha YZF-R1PC. Sie finden dort fast immer Troubleshooting, also die am häufigsten auftauchenden Störungen und Mängel bei Yamaha YZF-R1PC gemeinsam mit Hinweisen bezüglich der Arten ihrer Lösung. Sogar wenn es Ihnen nicht gelingen sollte das Problem alleine zu bewältigen, die Anleitung zeigt Ihnen die weitere Vorgehensweise – den Kontakt zur Kundenberatung oder dem naheliegenden Service.
