Yamaha CP 250 V '06 - Service Manual

CP250V
SERVICE MANUAL
LIT-11616-19-48 1B7-28197-10
EAS20050
CP250V
SERVICE MANUAL
©2006 by Yamaha Motor Corporation, U.S.A.
First edition, August 2005
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-19-48
EAS20070
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-
cle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
NOTE:
● This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
● Designs and specifications are subject to change without notice.
EAS20080
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY
IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to

WARNING
the vehicle operator, a bystander or a person checking or repairing the vehicle.
A CAUTION indicates special precautions that must be taken to avoid damage to

CAUTION:
the vehicle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

EAS20090
HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
● The manual is divided into chapters and each chapter is divided into sections. The current section
title is shown at the top of each page “1”.
● Sub-section titles appear in smaller print than the section title “2”.
● To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section “3”.
● Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassem-
bly step “4”.

● Symbols indicate parts to be lubricated or replaced “5”.
Refer to “SYMBOLS”.
● A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc “6”.

● Jobs requiring more information (such as special tools and technical data) are described sequentially
“7”.
1
4
7
2
EAS20100
1. Serviceable with engine mounted
SYMBOLS
2. Filling fluid
The following symbols are used in this manual 3. Lubricant
for easier understanding. 4. Special tool
NOTE: 5. Tightening torque
The following symbols are not relevant to every 6. Wear limit, clearance
vehicle. 7. Engine speed
8. Electrical data
9. Engine oil
1 2 3
10. Gear oil
11. Molybdenum-disulfide oil
12. Wheel-bearing grease
13. Lithium-soap-based grease
4 5 6
14. Molybdenum-disulfide grease
15. Apply locking agent (LOCTITE®)
16. Replace the part
T.
R.
7 8
9 10 11
E G M
12 13 14
B LS M
15 16
LT New
EAS20110
TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
COOLING SYSTEM 6
FUEL SYSTEM 7
ELECTRICAL SYSTEM 8
TROUBLESHOOTING 9
GENERAL INFORMATION
IDENTIFICATION ........................................................................................ 1-1
VEHICLE IDENTIFICATION NUMBER .................................................. 1-1
MODEL LABEL ....................................................................................... 1-1
ENGINE SERIAL NUMBER .................................................................... 1-1
FEATURES ................................................................................................. 1-2
OUTLINE OF THE FI SYSTEM .............................................................. 1-2
1
FI SYSTEM ............................................................................................. 1-3
Multi-function display .............................................................................. 1-4
IMPORTANT INFORMATION ..................................................................... 1-7
PREPARATION FOR REMOVAL AND DISASSEMBLY ........................ 1-7
2
REPLACEMENT PARTS ........................................................................ 1-7
GASKETS, OIL SEALS AND O-RINGS.................................................. 1-7
LOCK WASHERS/PLATES AND COTTER PINS .................................. 1-7
BEARINGS AND OIL SEALS ................................................................. 1-8
CIRCLIPS ............................................................................................... 1-8
3
CHECKING THE CONNECTIONS.............................................................. 1-9
SPECIAL TOOLS........................................................................................ 1-10

4
9
IDENTIFICATION
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the right side of the down tube.
1
EAS20150
MODEL LABEL
The model label “1” is affixed to the frame. This
information will be needed to order spare parts.
EAS20160
ENGINE SERIAL NUMBER

The engine serial number “1” is stamped into the
elevated part of the left rear section of the en-
gine.
1-1
FEATURES
EAS20170
FEATURES
EAS1B710
OUTLINE OF THE FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum
air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In
the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion
chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the
respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating con-
ditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the
fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-fu-
el ratio can be achieved to accommodate the constant changes in the operating conditions of the en-
gine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases increase,
it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accom-
modate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place
of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by
the engine at all times by using a microprocessor that regulates the fuel injection volume according to
the engine operating conditions detected by various sensors. The adoption of the FI system has result-
ed in a highly precise fuel supply, improved engine response, better fuel economy, and reduced ex-
haust emissions.
5
4
9 10
8 11
3
7
6 12
2
19 18 17 16 15 14 13
1. ECU (engine control unit) 11. Intake air temperature sensor
2. Lean angle sensor 12. Air filter case
3. Fuel injection system relay 13. Catalytic converter
4. Battery 14. Crankshaft position sensor
5. Engine trouble warning light 15. Ignition coil
6. Fuel hose 16. Coolant temperature sensor
7. Intake air pressure sensor 17. Spark plug
8. Fuel injector 18. Fuel tank
9. Throttle position sensor 19. Fuel pump
10. ISC (idle speed control valve)
1-2
FEATURES
EAS1B711
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at only 250 kPa (2.5 kg/cm2, 35.6 psi). Accordingly, when
the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel
to be injected into the intake manifold only during the time the passage remains open. Therefore, the
longer the length of time the fuel injector is energized (injection duration), the greater the volume of fuel
that is supplied. Conversely, the shorter the length of time the fuel injector is energized (injection dura-
tion), the lesser the volume of fuel that is supplied. The injection duration and the injection timing are
controlled by the ECU. Signals that are input from the throttle position sensor, crankshaft position sen-
sor, intake air pressure sensor, intake temperature sensor and coolant temperature sensor enable the
ECU to determine the injection duration. The injection timing is determined through the signals from the
crankshaft position sensor. As a result, the volume of fuel that is required by the engine can be supplied
at all times in accordance with the driving conditions.
13
12
C
4
2
A
1 3
11 5
B
10
9
8 6
1. Fuel pump 11. Air filter case

2. Fuel injector 12. Throttle position sensor
3. Ignition coil 13. ISC (idle speed control valve)
4. ECU (engine control unit)
A. Fuel system
5. Catalytic converter
B. Air system
6. Coolant temperature sensor
C. Control system
7. Crankshaft position sensor
8. Intake air pressure sensor
9. Throttle bodies
10. Intake air temperature sensor
1-3
FEATURES
EAS1B701
started flashing)
Multi-function display
EWA12311
● a self-diagnosis device
WARNING ● a clock
Be sure to stop the vehicle before making ● an oil change indicator
any setting changes to the multi-function ● a V-belt replacement indicator
display. NOTE:
● Be sure to turn the key to “ON” before using
3 4 the “SELECT” and “RESET” buttons.
● When the key is turned to “ON”, all of the dis-
play segments of the multi-function display
will appear one after the other and then disap-
pear, in order to test the electrical circuit.
● To switch the speedometer and odometer/
tripmeter displays between miles and kilome-
ters, press the “SELECT” button for at least
1 2 5 two seconds.
1. “SELECT” button Tachometer
2. “RESET” button The tachometer allows the rider to monitor the
3. Odometer/tripmeter/clock engine speed and keep it within the ideal power
4. Tachometer range.
ECA11630
5. Speedometer
CAUTION:
● Do not operate the engine above 9000 r/
1 2 3 4 min.
● This model is equipped with an engine
speed limiter, which prevents the engine
speed from exceeding approximately 9000
r/min.
Odometer, clock and tripmeter modes
Pushing the “SELECT” button switches the dis-
play between the odometer mode “ODO”, clock
1. Oil change indicator “OIL” mode and the tripmeter modes “TRIP” in the fol-
2. V-belt replacement indicator “V-BELT” lowing order:
3. Fuel level warning indicator “ ” ODO → CLOCK → TRIP (A) → TRIP (B) →
4. Fuel meter ODO
When approximately 4 L (1.06 US gal) (0.88
The multi-function display is equipped with the
Imp.gal) of fuel remains in the fuel tank, the fuel
following:
meter and fuel level warning indicator will start
● a speedometer (which shows the riding
flashing, and the display will automatically
speed)
change to the fuel reserve tripmeter mode “F
● a tachometer (which shows engine speed)
TRIP” and start counting the distance traveled
● a fuel meter
from that point. In that case, pushing the “SE-
● an odometer (which shows the total distance
LECT” button switches the display between the
traveled)
various tripmeter, clock and odometer modes in
● two tripmeters (which show the distance trav-
the following order:
eled since they were last set to zero)
F TRIP → TRIP (A) → TRIP (B) → ODO →
● a fuel reserve tripmeter (which shows the dis-
CLOCK → F TRIP
tance traveled since the bottom segment of
the fuel meter and fuel level warning indicator
1-4
FEATURES
change indicator. Refer to “CHANGING THE
ENGINE OIL” on page 3-9.
If the engine oil is changed before the oil change
indicator comes on (i.e. before the periodic oil
change interval has been reached), the indicator
must be reset after the oil change for the next
periodic oil change to be indicated at the correct
time. Refer to “CHANGING THE ENGINE OIL”
1 on page 3-9.
The electrical circuit of the indicator can be
1. Fuel reserve tripmeter checked according to the following procedure.
To reset a tripmeter, select it by pushing the 1. Set the engine stop switch to “ ” and turn
“SELECT” button until “TRIP” or “F TRIP” begins the key to “ON”.
flashing (“TRIP” or “F TRIP” will only flash for five 2. Check that the indicator comes on for a few
seconds). While “TRIP” or “F TRIP” is flashing, seconds and then goes off.
push the “RESET” button for at least one sec- 3. If the indicator does not come on, check the
ond. If you do not reset the fuel reserve tripmeter electrical circuit. Refer to “SIGNALING
manually, it will reset itself automatically and the SYSTEM” on page 8-19.
display will return to the prior mode after refuel- NOTE:
ing and traveling 5 km (3 mi). The oil change indicator may flash when the en-
NOTE: gine is revved with the vehicle on the center-
The display cannot be changed back to “F TRIP” stand, but this does not indicate a malfunction.
after pushing the “RESET” button. V-belt replacement indicator “V-BELT”
Clock mode This indicator flashes every 20000 km (12500
To set the clock: mi) when the V-belt needs to be replaced. Refer
1. Push the “SELECT” button and “RESET” to “V-BELT AUTOMATIC TRANSMISSION” on
button together for at least two seconds. page 5-29
2. When the hour digits start flashing, push the V-belt replacement indicator is possible to reset
“RESET” button to set the hours. by the coupler in the upper cover. After replacing
3. Push the “SELECT” button, and the minute the V-belt, disconnect the V-belt replacement re-
digits will start flashing. set coupler “1” for more than 3 seconds. And
4. Push the “RESET” button to set the minutes. then, connect the V-belt replacement reset cou-
5. Push the “SELECT” button and then release pler, the V-belt replacement indicator will come
it to start the clock. on for 1.4 seconds. And the V-belt replacement
Fuel meter indicator will go off.
With the key in the “ON” position, the fuel meter The electrical circuit of the indicator can be
indicates the amount of fuel in the fuel tank. The checked according to the following procedure.
display segments of the fuel meter disappear to- 1. Turn the key to “ON” and make sure that the
wards “E” (Empty) as the fuel level decreases. engine stop switch is set to “ ”.
When the fuel level reaches the bottom segment 2. If the indicator does not come on, check the
near “E”, fuel meter and the fuel level warning in- electrical circuit. Refer to “SIGNALING
dicator will start flashing. Refuel as soon as pos- SYSTEM” on page 8-19.
sible.
Oil change indicator “OIL”
This indicator flashes at the initial 1000 km (625
mi), then at 5000 km (3125 mi) and every 5000
km (3125 mi) thereafter to indicate that the en-
gine oil should be changed.
After changing the engine oil, reset the oil
1-5
FEATURES
Self-diagnosis device
This model is equipped with a self-diagnosis de-
vice for various electrical circuits.
If any of those circuits are defective, the
multi-function display will indicate a two-digit er-
ror code (e.g., 12, 13, 14).
If the multi-function display indicates such an er-
ror code, note the code number, and then check
the vehicle. Refer to “FUEL INJECTION
SYSTEM” on page 8-29.
ECA11790
CAUTION:
If the multi-function display indicates an er-
ror code, the vehicle should be checked as
soon as possible in order to avoid engine
damage.
1-6
IMPORTANT INFORMATION
EAS20180
EAS20190
PREPARATION FOR REMOVAL AND

DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
EAS20210
GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket sur-
faces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
2. Use only the proper tools and cleaning parts and bearings and lubricate the oil seal
equipment. lips with grease.
Refer to “SPECIAL TOOLS” on page 1-10.
3. When disassembling, always keep mated
parts together. This includes gears, cylin-
ders, pistons and other parts that have been 2 2
“mated” through normal wear. Mated parts 3
must always be reused or replaced as an as- 1
sembly. 4
1. Oil
2. Lip
3. Spring
4. Grease
EAS20220
LOCK WASHERS/PLATES AND COTTER

4. During disassembly, clean all of the parts PINS
and place them in trays in the order of disas- After removal, replace all lock washers/plates
sembly. This will speed up assembly and al- “1” and cotter pins. After the bolt or nut has been
low for the correct installation of all parts. tightened to specification, bend the lock tabs
5. Keep all parts away from any source of fire. along a flat of the bolt or nut.
EAS20200
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
1-7
EAS20230
BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manu-
facturer’s marks or numbers are visible. When
installing oil seals “1”, lubricate the oil seal lips
with a light coat of lithium-soap-based grease.
Oil bearings liberally when installing, if appropri-
ate.
ECA13300
CAUTION:
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.
EAS20240
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.
1-8
CHECKING THE CONNECTIONS
EAS20250
(with the pocket tester)
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for Pocket tester
stains, rust, moisture, etc. 90890-03112
1. Disconnect: Analog pocket tester
YU-03112-C
● Lead
● Coupler NOTE:
● Connector ● If there is no continuity, clean the terminals.
2. Check: ● When checking the wire harness, perform
● Lead steps (1) to (3).
● Coupler ● As a quick remedy, use a contact revitalizer
● Connector available at most part stores.
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect sev-
eral times.
3. Check:
● All connections
Loose connection → Connect properly.

NOTE:
If the pin “1” on the terminal is flattened, bend it
up.
4. Connect:
● Lead
● Coupler
● Connector
NOTE:
Make sure all connections are tight.
5. Check:
● Continuity
1-9
SPECIAL TOOLS
EAS20260
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
NOTE:
For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
For others, use part number starting with “90890-”.
Reference
Tool name/Tool No. Illustration
pages
Rotor holding tool 5-32, 5-36
90890-01235
Universal magneto & rotor holder
YU-01235
Ring nut wrench 3-22, 4-51

90890-01268
Spanner wrench
YU-01268
Radiator cap tester 6-2

90890-01325
Radiator pressure tester
YU-24460-01
YU-24460-01
Radiator cap tester adapter 6-2

90890-01352
Radiator pressure tester adapter
YU-33984
YU-33984
T-handle 4-44, 4-46

90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
1-10
SPECIAL TOOLS
Reference
pages
Damper rod holder 4-44, 4-46
90890-01460
Locknut wrench 5-32, 5-36

90890-01348
YM-01348
Flywheel puller 5-41

90890-01362
Heavy duty puller
YU-33270-B
Flywheel puller attachment 5-41

90890-04089
Crankshaft protector
YM-33282
Fork seal driver weight 4-46, 4-47

90890-01367
Replacement hammer
YM-A9409-7
YM-A9409-7/YM-A5142-4
Fork seal driver attachment (ø33) 4-46

90890-01368
Replacement 33 mm
YM-A9409-4
Oil seal guide (ø41) 5-35

90890-01396
1-11
SPECIAL TOOLS
Reference
pages
Steering nut wrench 3-21, 3-22
90890-01403
Spanner wrench
YU-33975
Sheave holder 5-32, 5-36,

90890-01701 5-40, 5-41
Primary clutch holder
YS-01880-A
Cylinder cup installer 4-23, 4-36

90890-01996
Thickness gauge 3-4

90890-03079
Narrow gauge set
YM-34483
Compression gauge 3-8

90890-03081
Engine compression tester
YU-33223
Extension 3-8
90890-04082
Pocket tester 1-9, 8-63, 8-64,

90890-03112 8-65, 8-69,
Analog pocket tester 8-70, 8-71,
YU-03112-C 8-72, 8-73,
8-74, 8-75,
8-77, 8-78
Pressure gauge 7-6
90890-03153
YU-03153
1-12
SPECIAL TOOLS
Reference
pages
Fuel pressure adapter 7-6
90890-03181
Digital circuit tester 5-48, 8-73, 8-76

90890-03174
Model 88 Multimeter with tachometer
YU-A1927
Valve spring compressor 5-17, 5-22

90890-04019
YM-04019
Valve spring compressor attachment 5-17, 5-22

90890-04108
Valve spring compressor adapter 22 mm
YM-04108
Middle driven shaft bearing driver 6-7

90890-04058
Bearing driver 40 mm
YM-04058
Mechanical seal installer 6-7

90890-04145
Valve lapper 3-5, 5-20

90890-04101
Valve lapping tool
YM-A8998
Valve guide remover (ø4.5) 5-19

90890-04116
Valve guide remover (4.5 mm)
YM-04116
Valve guide installer (ø4.5) 5-19

90890-04117
Valve guide installer (4.5 mm)
YM-04117
1-13
SPECIAL TOOLS
Reference
pages
Valve guide reamer (ø4.5) 5-19
90890-04118
Valve guide reamer (4.5 mm)
YM-04118
Sheave spring compressor 5-33, 5-35

90890-04134
YM-04134
Sheave fixed block 5-33, 5-35

90890-04135
Sheave fixed bracket
YM-04135
Plane bearing installer 5-56, 5-58

90890-04146
Ignition checker 8-71

90890-06754
Opama pet-4000 spark checker
YM-34487
Digital tachometer 3-6, 8-73

90890-06760
Yamaha bond No. 1215 5-42, 5-53

(Three Bond No. 1215®)
90890-85505
1-14
SPECIAL TOOLS
1-15
SPECIFICATIONS
GENERAL SPECIFICATIONS .................................................................... 2-1
ENGINE SPECIFICATIONS........................................................................ 2-2
CHASSIS SPECIFICATIONS...................................................................... 2-8
ELECTRICAL SPECIFICATIONS............................................................... 2-10

1
TIGHTENING TORQUES............................................................................ 2-13
GENERAL TIGHTENING TORQUE SPECIFICATIONS ........................ 2-13
ENGINE TIGHTENING TORQUES ........................................................ 2-13
CHASSIS TIGHTENING TORQUES ...................................................... 2-16
2
LUBRICATION POINTS AND LUBRICANT TYPES .................................. 2-19
ENGINE .................................................................................................. 2-19
CHASSIS ................................................................................................ 2-21 3
COOLING SYSTEM DIAGRAMS................................................................ 2-23
CABLE ROUTING....................................................................................... 2-27
9
GENERAL SPECIFICATIONS
EAS20280
GENERAL SPECIFICATIONS
Model
Model 1B72
Dimensions
Overall length 2370 mm (93.3 in)
Overall width 825 mm (32.5 in)
Overall height 1050 mm (41.3 in)
Seat height 655 mm (25.8 in)
Wheelbase 1615 mm (63.6 in)
Ground clearance 105 mm (4.13 in)
Minimum turning radius 2800 mm (110.2 in)
Weight
With oil and fuel 200.0 kg (441 lb)
Maximum load 190 kg (419 lb)
2-1
ENGINE SPECIFICATIONS
EAS20290
Engine
Engine type Liquid cooled 4-stroke, DOHC
Displacement 250.0 cm3 (15.26 cu.in)
Cylinder arrangement Forward-inclined single cylinder
Bore × stroke 66.0 × 73.0 mm (2.60 × 2.87 in)
Compression ratio 10.80 :1
Standard compression pressure (at sea level) 1800 kPa/400 r/min (256.0 psi/400 r/min) (18.0 kgf/
cm2/400 r/min)
Starting system Electric starter
Fuel
Recommended fuel Unleaded gasoline only
Fuel tank capacity 14.0 L (3.70 US gal) (3.08 Imp.gal)
Engine oil
Lubrication system Wet sump
Type YAMALUBE 4, SAE10W30 or SAE20W40
Recommended engine oil grade API service SE, SF, SG type or higher
Engine oil quantity
Total amount 1.70 L (1.80 US qt) (1.50 Imp.qt)
Without oil filter element replacement 1.50 L (1.59 US qt) (1.32 Imp.qt)
With oil filter element replacement 1.70 L (1.80 US qt) (1.50 Imp.qt)
Final transmission oil
Type SAE10W30 type SE motor oil
Quantity 0.25 L (0.26 US qt) (0.22 Imp.qt)
Oil pump
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance 0.100–0.340 mm (0.0039–0.0134 in)
Limit 0.40 mm (0.0157 in)
Outer-rotor-to-oil-pump-housing clearance 0.013–0.036 mm (0.0005–0.0014 in)
Limit 0.150 mm (0.0059 in)
Oil-pump-housing-to-inner-and-outer-rotor clearance 0.04–0.09 mm (0.0016–0.0035 in)
Limit 0.15 mm (0.0059 in)
Cooling system
Radiator capacity (including all routes) 1.57 L (1.66 US qt) (1.38 Imp.qt)
Radiator capacity 0.45 L (0.48 US qt) (0.40 Imp.qt)
Coolant reservoir capacity (up to the maximum 0.25 L (0.26 US qt) (0.22 Imp.qt)
level mark)
Radiator cap opening pressure 110.0–140.0 kPa (16.0–20.3 psi) (1.10–1.40 kgf/cm2)
Thermostat
Model/manufacturer 5RU/NIPPON THERMOSTAT
Valve opening temperature 70.5–73.5 °C (158.90–164.30 °F)
Valve full open temperature 85.0 °C (185.00 °F)
Valve lift (full open) 3.0 mm (0.12 in)
Radiator core
Width 260.0 mm (10.24 in)
Height 148.0 mm (5.83 in)
Depth 24.0 mm (0.94 in)
Water pump
Water pump type Single suction centrifugal pump
Reduction ratio (1.00)
2-2
Spark plug (s)
Manufacturer/model NGK/CPR7EA-9
Spark plug gap 0.8–0.9 mm (0.031–0.035 in)
Cylinder head
Volume 15.06–15.86 cm3 (0.92–0.97 cu.in)
Warpage limit 0.03 mm (0.0012 in)
Camshaft
Drive system Chain drive (right)
Camshaft lobe dimensions
Intake A 33.250–33.350 mm (1.3091–1.3130 in)
Intake B 24.950–25.050 mm (0.9823–0.9862 in)
Exhaust A 33.250–33.350 mm (1.3091–1.3130 in)
Exhaust B 24.950–25.050 mm (0.9823–0.9862 in)
AA
B
B
Timing chain
Model/number of links DID SCR-0409 SDH
Tensioning system Automatic
Valve, valve seat, valve guide
Valve clearance (cold)
Intake 0.15–0.20 mm (0.0059–0.0079 in)
Exhaust 0.25–0.30 mm (0.0098–0.0118 in)
Valve dimensions
Valve head diameter A (intake) 24.90–25.10 mm (0.9803–0.9882 in)
Valve head diameter A (exhaust) 21.90–22.10 mm (0.8622–0.8701 in)
A
Valve face width B (intake) 1.484–2.192 mm (0.0584–0.0863 in)
Valve face width B (exhaust) 1.484–2.192 mm (0.0584–0.0863 in)
Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in)

Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)
2-3
Valve margin thickness D (intake) 0.15–0.20 mm (0.0059–0.0079 in)
Valve margin thickness D (exhaust) 0.25–0.30 mm (0.0098–0.0118 in)
Valve stem diameter (intake) 4.475–4.490 mm (0.1762–0.1768 in)

Limit 4.445 mm (0.1750 in)
Valve stem diameter (exhaust) 4.460–4.475 mm (0.1756–0.1762 in)
Limit 4.430 mm (0.1744 in)
Valve guide inside diameter (intake) 4.500–4.512 mm (0.1772–0.1776 in)
Limit 4.550 mm (0.1791 in)
Valve guide inside diameter (exhaust) 4.500–4.512 mm (0.1772–0.1776 in)
Limit 4.550 mm (0.1791 in)
Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in)
Limit 0.100 mm (0.0039 in)
Cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in)
Limit 1.6 mm (0.06 in)
Cylinder head valve seat width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)
Valve spring
Free length (intake) 43.68 mm (1.72 in)
Limit 41.50 mm (1.63 in)
Free length (exhaust) 43.68 mm (1.72 in)
Limit 41.50 mm (1.63 in)
Installed length (intake) 33.70 mm (1.33 in)
Installed length (exhaust) 33.70 mm (1.33 in)
Spring rate K1 (intake) 14.75 N/mm (84.22 lb/in) (1.50 kgf/mm)
Spring rate K2 (intake) 19.15 N/mm (109.35 lb/in) (1.95 kgf/mm)
Spring rate K1 (exhaust) 14.75 N/mm (84.22 lb/in) (1.50 kgf/mm)
Spring rate K2 (exhaust) 19.15 N/mm (109.35 lb/in) (1.95 kgf/mm)
Installed compression spring force (intake) 279.40–321.40 N (62.81–72.25 lb) (28.49–32.77 kgf)
Installed compression spring force (exhaust) 279.40–321.40 N (62.81–72.25 lb) (28.49–32.77 kgf)
Spring tilt (intake) 2.5 °/1.9 mm
Spring tilt (exhaust) 2.5 °/1.9 mm
Winding direction (intake) Clockwise

Winding direction (exhaust) Clockwise
Cylinder
Bore 66.000–66.010 mm (2.5984–2.5988 in)
Warp limit 0.05 mm (0.0020 in)
2-4
Piston
Piston-to-cylinder clearance 0.025–0.058 mm (0.0010–0.0023 in)
Limit 0.15 mm (0.0059 in)
Diameter D 65.952–65.975 mm (2.5965–2.5974 in)
Height H 9.0 mm (0.35 in)
H
D
Offset 0.50 mm (0.0197 in)

Offset direction Intake side
Piston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in)
Limit 16.043 mm (0.6316 in)
Piston pin outside diameter 15.991–16.000 mm (0.6296–0.6299 in)
Limit 15.975 mm (0.6289 in)
Piston ring
Top ring
Ring type Barrel
Dimensions (B × T) 0.80 × 2.45 mm (0.03 × 0.10 in)
B
T
End gap (installed) 0.15–0.25 mm (0.0059–0.0098 in)

Limit 0.40 mm (0.0157 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Limit 0.100 mm (0.0039 in)
2nd ring
Ring type Taper
B
T

Limit 0.65 mm (0.0256 in)
Limit 0.100 mm (0.0039 in)
Oil ring
B
T

2-5
Crankshaft
Width A 63.95–64.00 mm (2.518–2.520 in)
Runout limit C 0.030 mm (0.0012 in)
Big end side clearance D 0.350–0.850 mm (0.0138–0.0335 in)
C C
E
D
A
Big end radial clearance E 0.010–0.022 mm (0.0004–0.0009 in)

Automatic centrifugal clutch
Clutch type Dry, centrifugal automatic
Clutch shoe thickness 3.3 mm (0.13 in)
Wear limit 2.0 mm (0.08 in)
Clutch shoe spring free length 33.5 mm (1.32 in)
Clutch housing inside diameter 145.0 mm (5.71 in)
Limit 145.5 mm (5.73 in)
Compression spring free length 102.4 mm (4.03 in)
Limit 90.0 mm (3.54 in)
Weight outside diameter 25.0 mm (0.98 in)
Limit 24.5 mm (0.96 in)
Clutch-in revolution 2050–2650 r/min
Clutch-stall revolution 4000–5000 r/min
Transmission
Transmission type V-belt automatic
Primary reduction system Helical gear
Primary reduction ratio 36/14 (2.571)
Secondary reduction system Helical gear
Secondary reduction ratio 50/14 (3.571)
Operation Centrifugal automatic type
Single speed automatic 2.290–0.744 :1
Air filter
Air filter element Oil-coated paper element
Air filter oil grade Foam air-filter oil or SAE10W30SE
Fuel pump
Pump type Electrical
Model/manufacturer 1B7/AISAN
Output pressure 242.0–176.0 kPa (35.1–25.5 psi) (2.42–1.76 kgf/cm2)
Fuel injection
Model/quantity 1100-87C70-A/1
Manufacturer AISAN
2-6
Throttle body
Manufacturer AISAN
ID mark 1B71 00
Idling condition
Engine idling speed 1450 r/min
Intake vacuum 33.0–39.0 kPa (9.7–11.5 inHg) (248–293 mmHg)
Water temperature 75.0–85.0 °C (167.00–185.00 °F)
Oil temperature 75.0–85.0 °C (167.00–185.00 °F)
Throttle cable free play 3.0–5.0 mm (0.12–0.20 in)
2-7
CHASSIS SPECIFICATIONS
EAS20300
Chassis
Frame type Steel tube backbone
Caster angle 28.00 °
Trail 103.0 mm (4.06 in)
Front wheel
Wheel type Cast wheel
Rim size 13M/C x MT3.50
Rim material Aluminum
Wheel travel 100.0 mm (3.94 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Wheel axle bending limit 0.55 mm (0.02 in)
Rear wheel
Wheel type Cast wheel
Rim size 13M/C x MT3.50
Rim material Aluminum
Wheel travel 75.0 mm (2.95 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Front tire
Type Tubeless
Size 120/70-13M/C 53P
Manufacturer/model DUNLOP/D305F
Wear limit (front) 0.8 mm (0.03 in)
Rear tire
Type Tubeless
Size 130/70-13M/C 63P
Manufacturer/model DUNLOP/D305
Wear limit (rear) 0.8 mm (0.03 in)
Tire air pressure (measured on cold tires)
Loading condition 0–90 kg (0–198 lb)
Front 200 kPa (29 psi) (2.00 kgf/cm2) (2.00 bar)
Rear 225 kPa (33 psi) (2.25 kgf/cm2) (2.25 bar)
Loading condition 90 kg - maximum load
Front 200 kPa (29 psi) (2.00 kgf/cm2) (2.00 bar)
Rear 250 kPa (36 psi) (2.50 kgf/cm2) (2.50 bar)
Front brake
Type Single disc brake
Operation Right hand operation
Front disc brake
Disc outside diameter × thickness 245.0 × 5.0 mm (9.65 × 0.20 in)
Brake disc thickness limit 4.5 mm (0.18 in)
Brake disc deflection limit 0.15 mm (0.0059 in)
Brake pad lining thickness (inner) 6.0 mm (0.24 in)
Brake pad lining thickness (outer) 6.0 mm (0.24 in)
Master cylinder inside diameter 12.70 mm (0.50 in)
Caliper cylinder inside diameter 25.40 mm (1.00 in)
2-8
Recommended fluid DOT 4
Rear brake
Type Single disc brake
Operation Left hand operation
Rear disc brake
Disc outside diameter × thickness 245.0 × 5.0 mm (9.65 × 0.20 in)
Brake disc thickness limit 4.5 mm (0.18 in)
Brake disc deflection limit 0.15 mm (0.0059 in)
Brake pad lining thickness (inner) 7.3 mm (0.29 in)
Brake pad lining thickness (outer) 7.3 mm (0.29 in)
Master cylinder inside diameter 14.0 mm (0.55 in)
Recommended fluid DOT 4
Steering
Steering bearing type Angular bearing
Lock to lock angle (left) 40.0 °
Lock to lock angle (right) 40.0 °
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 100.0 mm (3.94 in)
Fork spring free length 278.2 mm (10.95 in)
Limit 272.6 mm (10.73 in)
Installed length 265.2 mm (10.44 in)
Spring rate K1 12.73 N/mm (72.69 lb/in) (1.30 kgf/mm)
Spring stroke K1 0.0–50.0 mm (0.00–1.97 in)
Inner tube outer diameter 33.0 mm (1.30 in)
Inner tube bending limit 0.2 mm (0.01 in)
Optional spring available No
Recommended oil Fork oil 10W or equivalent
Quantity 149.0 cm3 (5.04 US oz) (5.26 Imp.oz)
Level 91.0 mm (3.58 in)
Rear suspension
Type Unit swing
Spring/shock absorber type Coil spring/oil damper
Rear shock absorber assembly travel 96.0 mm (3.78 in)
Spring free length 223.0 mm (8.78 in)
Limit 218.5 mm (8.60 in)
Installed length 220.5 mm (8.68 in)
Optional spring available No
Swingarm
Swingarm end free play limit (radial) 1.0 mm (0.04 in)
Swingarm end free play limit (axial) 1.0 mm (0.04 in)
2-9
ELECTRICAL SPECIFICATIONS
EAS20310
Voltage
System voltage 12 V
Ignition system
Ignition system Transistorized coil ignition (digital)
Advancer type Digital
Ignition timing (B.T.D.C.) 5.0 °/1450 r/min
Transistorized coil ignition
Pickup coil resistance 248–372 ΩR-W
TCI unit model/manufacturer 1B7/YAMAHA
Ignition coil
Model/manufacturer 1B7/YAMAHA
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 2.16–2.64 Ω
Secondary coil resistance 8.64–12.96 kΩ
Spark plug cap
Material Resin
Resistance 10.0 kΩ
AC magneto
Model/manufacturer 1B7/YAMAHA
Standard output 14.0 V27.5 A5000 r/min
Stator coil resistance 0.19–0.27 ΩW-W
Rectifier/regulator
Regulator type Semi conductor-short circuit
Model/manufacturer SH678-11/SHINDENGEN
No load regulated voltage (DC) 14.1–14.9 V
Rectifier capacity (DC) 22.0 A
Withstand voltage 200.0 V
Battery
Model YTZ10S
Voltage, capacity 12 V, 8.6 Ah
Specific gravity 1.310
Manufacturer GS YUASA
Ten hour rate amperage 0.80 A
Headlight
Bulb type Halogen bulb
Bulb voltage, wattage × quantity
Low beam headlight 12 V, 55.0 W × 1
High beam headlight 12 V, 55.0 W × 1
Tail/brake light LED
Front turn signal/position light 12 V, 27 W/8.0 W × 2
Rear turn signal light 12 V, 21.0 W × 2
License plate light 12 V, 5.0 W × 1
Meter lighting LED
Indicator light
Turn signal indicator light LED
2-10
High beam indicator light LED
Coolant temperature warning light LED
Engine trouble warning light LED
Electric starting system
System type Constant mesh
Starter motor
Model/manufacturer SM-13/MITSUBA
Power output 0.65 kW
Armature coil resistance 0.0012–0.0022 Ω
Brush overall length 12.0 mm (0.47 in)
Limit 4.00 mm (0.16 in)
Brush spring force 7.65–10.01 N (27.54–36.03 oz) (780–1021 gf)
Commutator diameter 28.0 mm (1.10 in)
Limit 27.0 mm (1.06 in)
Mica undercut (depth) 0.70 mm (0.03 in)
Starter relay
Model/manufacturer 2768102-A/JIDECO
Amperage 180.0 A
Coil resistance 4.18–4.62 Ω
Horn
Horn type Plane
Quantity 1 pcs
Model/manufacturer HF-12/NIKKO
Maximum amperage 3.0 A
Performance 108–116 dB/2m
Turn signal/hazard relay
Relay type Full transistor
Model/manufacturer FE246BH/DENSO
Built-in, self-canceling device No
Turn signal blinking frequency 75.0–95.0 cycles/min
Wattage 27+21 W+3.4 W
Fuel gauge
Model/manufacturer 1B7/AISAN
Sender unit resistance (full) 19.0–21.0 Ω
Sender unit resistance (empty) 137.0–143.0 Ω
Starting circuit cut-off relay
Model/manufacturer ACA12115-4/MATSUSHITA
Diode Yes
Radiator fan
Model/manufacturer STD/YAMAMOTO DENKI
Running rpm 4500 r/min
Thermo unit
Model/manufacturer 5PS/DENSO
Resistance at 80°C 310.0–326.0 Ω
Resistance at 100°C 183.6 Ω
2-11
Fuses
Main fuse 30.0 A
Headlight fuse 15.0 A
Taillight fuse 10.0 A
Signaling system fuse 10.0 A
Ignition fuse 10.0 A
Radiator fan fuse 10.0 A
Auxiliary DC connector fuse 10.0 A
Fuel injection system fuse 10.0 A
Backup fuse 10.0 A
Reserve fuse 30.0 A
Reserve fuse 15.0 A
Reserve fuse 10.0 A
2-12
TIGHTENING TORQUES
EAS20320
TIGHTENING TORQUES
EAS20330
GENERAL TIGHTENING TORQUE

SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch.
Tightening torque specifications for special com-
ponents or assemblies are provided for each
chapter of this manual. To avoid warpage, tight-
en multi-fastener assemblies in a crisscross pat- A. Distance between flats
tern and progressive stages until the specified B. Outside thread diameter
tightening torque is reached. Unless otherwise
specified, tightening torque specifications re- General tightening
A (nut) B (bolt) torques
quire clean, dry threads. Components should be
at room temperature. Nm m•kg ft•lb
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
EAS20340
ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Camshaft cap bolt M6 8 10 Nm (1.0 m•kg, 7.2 ft• lb)
Cylinder head plug M12 2 28 Nm (2.8 m•kg, 20 ft• lb)
Exhaust pipe stud bolt M8 2 13 Nm (1.3 m•kg, 9.4 ft• lb)
Spark plug M10 1 13 Nm (1.3 m•kg, 9.4 ft• lb)
Cylinder head timing chain cavity
M6 2 10 Nm (1.0 m•kg, 7.2 ft• lb)
bolt
Cylinder head and cylinder (nut) M10 2 40 Nm (4.0 m•kg, 29 ft• lb)
Cylinder head and cylinder (cap
M10 2 52 Nm (5.2 m•kg, 37 ft• lb)
nut)
Cylinder head cover bolt M6 9 10 Nm (1.0 m•kg, 7.2 ft• lb)
Oil gallery bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft• lb)
Cylinder and crankcase M6 1 10 Nm (1.0 m•kg, 7.2 ft• lb)
Air induction passage plate M6 2 12 Nm (1.2 m•kg, 8.6 ft• lb)
Eliminate
the oil and
Pickup coil rotor nut M18 1 130 Nm (13.0 m•kg, 94 ft• lb)
grease on
the rotor.
Camshaft sprocket bolt M7 2 20 Nm (2.0 m•kg, 14 ft• lb)
Timing chain guide bolt M6 3 10 Nm (1.0 m•kg, 7.2 ft• lb)
2-13
TIGHTENING TORQUES
Thread
size
Timing chain tensioner bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft• lb)
Timing chain tensioner cap bolt M6 1 7 Nm (0.7 m•kg, 5.1 ft• lb)
Water pump cover bolt M6 3 10 Nm (1.0 m•kg, 7.2 ft• lb)
Joint M6 1 10 Nm (1.0 m•kg, 7.2 ft• lb)
Thermostat cover bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft• lb)
Radiator filler hose M5 1 5 Nm (0.5 m•kg, 3.6 ft• lb)
Radiator pipe M6 3 7 Nm (0.7 m•kg, 5.1 ft• lb)
Heat exchanger bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft• lb)
Heat exchanger cover bolt M6 3 10 Nm (1.0 m•kg, 7.2 ft• lb)
Coolant drain bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft• lb)
Drain stopper bolt M5 1 6 Nm (0.6 m•kg, 4.3 ft• lb)
Oil pump cover screw M3 1 1 Nm (0.1 m•kg, 0.7 ft• lb)
Oil pump bolt M6 2 7 Nm (0.7 m•kg, 5.1 ft• lb)
Oil strainer cover M35 1 32 Nm (3.2 m•kg, 23 ft• lb)
Oil filter element cover bolt M6 3 10 Nm (1.0 m•kg, 7.2 ft• lb)
Until
Throttle body clamp hose M5 1 3 Nm (0.3 m•kg, 2.2 ft• lb) touching
the collar
Intake manifold bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft• lb)
Throttle body joint M6 2 10 Nm (1.0 m•kg, 7.2 ft• lb)
Fuel injector bolt M6 1 12 Nm (1.2 m•kg, 8.6 ft• lb)
Intake air pressure sensor and
M6 1 10 Nm (1.0 m•kg, 7.2 ft• lb)
stay
Fuel hose stay M5 3 7 Nm (0.7 m•kg, 5.1 ft• lb)
Air filter case cap screw M5 5 1.2 Nm (0.12 m•kg, 0.9 ft• lb)
Throttle body clamp screw M4 0.7 3 Nm (0.3 m•kg, 2.2 ft• lb)
Air filter case bolt M6 3 9 Nm (0.9 m•kg, 6.5 ft• lb)
Muffler joint M8 1 14 Nm (1.4 m•kg, 10 ft• lb)
Muffler protector bolt M6 2 8 Nm (0.8 m•kg, 5.8 ft• lb) LT
Protector plate bolt M6 4 7 Nm (0.7 m•kg, 5.1 ft• lb) LT
Exhaust pipe (nut) M8 2 20 Nm (2.0 m•kg, 14 ft• lb)

Air induction pipe bolt M5 3 1.2 Nm (0.12 m•kg, 0.9 ft• lb)
Air induction assembly M6 2 10 Nm (1.0 m•kg, 7.2 ft• lb)
Muffler (bolt) M10 3 53 Nm (5.3 m•kg, 38 ft• lb)
Air duct M6 4 7 Nm (0.7 m•kg, 5.1 ft• lb) LT
Crankcase 1, 2 M6 7 10 Nm (1.0 m•kg, 7.2 ft• lb)

Crankcase 1, 2 M8 7 16 Nm (1.6 m•kg, 12 ft• lb)
2-14
TIGHTENING TORQUES
Thread
size
Upper
Crankcase 1, 2 M8 1 30 Nm (3.0 m•kg, 22 ft• lb) side of the
oil filter
cover
Cylinder stud bolt M10 4 13 Nm (1.3 m•kg, 9.4 ft• lb)
With gas-
Transmission oil drain bolt M8 1 20 Nm (2.0 m•kg, 14 ft• lb)
ket
Bearing plate M6 1 10 Nm (1.0 m•kg, 7.2 ft• lb) LT
Crankcase cover 2 and crankcase

M8 7 16 Nm (1.6 m•kg, 12 ft• lb)
1
M8 1 22 Nm (2.2 m•kg, 16 ft• lb)
1
M6 9 10 Nm (1.0 m•kg, 7.2 ft• lb)
1
Air duct and crankcase cover 3 M6 6 4 Nm (0.4 m•kg, 2.9 ft• lb)
Element and crankcase cover 3 M6 4 4 Nm (0.4 m•kg, 2.9 ft• lb)
M6 6 7 Nm (0.7 m•kg, 5.1 ft• lb)
1
Cover stay 1 and cover 1 M6 2 7 Nm (0.7 m•kg, 5.1 ft• lb)
Cover 1 and crankcase 2 M6 11 10 Nm (1.0 m•kg, 7.2 ft• lb)
Oil plug M6 1 10 Nm (1.0 m•kg, 7.2 ft• lb)
Primary fixed sheave nut M18 1 83 Nm (8.3 m•kg, 60 ft• lb)
With
Timing plug M16 1 8 Nm (0.8 m•kg, 5.8 ft• lb)
O-ring
With gas-
Engine oil drain bolt M12 1 20 Nm (2.0 m•kg, 14 ft• lb)
ket
Clutch housing nut M14 1 60 Nm (6.0 m•kg, 43 ft• lb)
Starter one way bolt M8 6 30 Nm (3.0 m•kg, 22 ft• lb)
Clutch carrier nut M36 1 90 Nm (9.0 m•kg, 65 ft• lb)
Stator coil assembly M6 3 10 Nm (1.0 m•kg, 7.2 ft• lb) LT
Crank shaft position sensor M6 2 10 Nm (1.0 m•kg, 7.2 ft• lb) LT
Starting motor assembly M6 2 12 Nm (1.2 m•kg, 8.6 ft• lb)

Coolant temperature sensor M12 1 18 Nm (1.8 m•kg, 13 ft• lb)
2-15
TIGHTENING TORQUES
Camshaft cap tightening sequence:
6 4 2 8
7 1 3 5
Cylinder head tightening sequence:

6 5
4 1
2 3
EAS20350
CHASSIS TIGHTENING TORQUES

Thread
size
Frame and engine bracket (left/
M12 4 45 Nm (4.5 m•kg, 32 ft• lb)
right)
Engine bracket and engine M12 1 65 Nm (6.5 m•kg, 47 ft• lb)
Engine bracket (left/right) and
M10 4 56 Nm (5.6 m•kg, 40 ft• lb) LT
engine bracket (center)
Frame and rear footrest bracket M8 2 30 Nm (3.0 m•kg, 22 ft• lb)
Frame and front under bracket M8 4 30 Nm (3.0 m•kg, 22 ft• lb)
Sidestand bolt M10 1 45 Nm (4.5 m•kg, 32 ft• lb)
Front cowling stay and frame
M10 2 23 Nm (2.3 m•kg, 19 ft• lb)
(upper)
Front cowling stay and frame
M10 2 23 Nm (2.3 m•kg, 19 ft• lb)
(lower)
Coolant reservoir tank M6 1 7 Nm (0.7 m•kg, 5.1 ft• lb)
Battery box M6 5 7 Nm (0.7 m•kg, 5.1 ft• lb)
Main switch assembly M6 2 7 Nm (0.7 m•kg, 5.1 ft• lb)
Throttle cable adjusting nut M6 1 4 Nm (0.4 m•kg, 2.9 ft• lb)
Ignition coil M6 2 7 Nm (0.7 m•kg, 5.1 ft• lb)
Horn and stay M6 1 7 Nm (0.7 m•kg, 5.1 ft• lb)
Rectifier/regulator M6 2 7 Nm (0.7 m•kg, 5.1 ft• lb)
Battery bracket M6 2 7 Nm (0.7 m•kg, 5.1 ft• lb)
Swingarm and engine M10 2 57 Nm (5.7 m•kg, 41 ft• lb)
2-16
TIGHTENING TORQUES
Thread
size
Rear shock absorber (upper) M10 2 34 Nm (3.4 m•kg, 26 ft• lb)
Rear shock absorber (lower) M8 2 29 Nm (2.9 m•kg, 21 ft• lb)
Brake hose holder and swingarm M6 1 10 Nm (1.0 m•kg, 7.2 ft• lb)
Swingarm and rear brake hose
M6 3 10 Nm (1.0 m•kg, 7.2 ft• lb)
cover
See
Lower bracket and upper ring nut M30 1 90 Nm (9.0 m•kg, 65 ft• lb)
NOTE.
Upper bracket and lower bracket M25 1 165 Nm (16.5 m•kg, 119 ft• lb)
Upper bracket and upper handle-
M8 4 23 Nm (2.3 m•kg, 19 ft• lb)
bar holder
Brake hose and brake master cyl-
M10 2 30 Nm (3.0 m•kg, 22 ft• lb)
inder (left/right)
Brake master cylinder M6 4 10 Nm (1.0 m•kg, 7.2 ft• lb)
Inner tube and lower bracket M8 4 23 Nm (2.3 m•kg, 19 ft• lb)
Fuel pump bolt M5 6 4 Nm (0.4 m•kg, 2.9 ft• lb)
Seat assembly M8 2 30 Nm (3.0 m•kg, 22 ft• lb)
Grab bar bolt M8 4 30 Nm (3.0 m•kg, 22 ft• lb)
Document box bolt M6 4 7 Nm (0.7 m•kg, 5.1 ft• lb)
Seat lock assembly bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft• lb)
Seat lock cable and main switch M5 1 7 Nm (0.7 m•kg, 5.1 ft• lb)
Seat lock cable adjusting nut M6 1 4 Nm (0.4 m•kg, 2.9 ft• lb)
Trunk stay and frame M8 4 42 Nm (4.2 m•kg, 30 ft• lb)
Rear trunk box and stay M6 4 11 Nm (1.1 m•kg, 7.9 ft• lb)
Lock assembly trunk — 4 2 Nm (0.2 m•kg, 1.4 ft• lb)
Resin
Windshield M5 4 0.4 Nm (0.04 m•kg, 0.03 ft• lb)
screw
Headlight assembly and front cowl-
M6 5 7 Nm (0.7 m•kg, 5.1 ft• lb)
ing
Mud guard and trunk M6 2 10 Nm (1.0 m•kg, 7.2 ft• lb)
Stay 2 and frame M8 2 30 Nm (3.0 m•kg, 22 ft• lb)
Front wheel axle M14 1 70 Nm (7.0 m•kg, 50 ft• lb)
Front brake caliper bracket bolt M10 2 35 Nm (3.5 m•kg, 25 ft• lb)
Rear brake caliper bolt M10 2 40 Nm (4.0 m•kg, 29 ft• lb)
Brake hose union bolt M10 2 30 Nm (3.0 m•kg, 22 ft• lb)
Brake caliper bleed screw M7 1 6 Nm (0.6 m•kg, 4.3 ft• lb)
Brake disc and wheel M8 8 23 Nm (2.3 m•kg, 19 ft• lb)
Rear wheel axle nut M14 1 135 Nm (13.5 m•kg, 97 ft• lb)
NOTE:
1. Tighten the lower steering ring nut 36 Nm (3.6 m•kg, 26 ft•lb) with a torque wrench and the steering
nut wrench.
2. Turn the steering shaft to left or right several times and make sure the steering shaft turns smoothly
2-17
TIGHTENING TORQUES
3. Loosen the nut completely, and then tighten the lower steering ring nut 18 Nm (1.8 m•kg, 13 ft• lb)
with a torque wrench and the steering nut wrench.
4. Install the rubber washer.
5. Finger tighten the center steering ring nut, align the slots of both steering ring nuts.
6. Install the lock washer.
7. Hold the lower and center steering ring nuts, and then tighten the upper steering ring nut 90 Nm (9.0
m•kg, 65 ft•lb) with a torque wrench and the steering nut wrench.
4 5
3
2
1. Lower ring nut

2. Rubber washer
3. Center ring nut
4. Lock washer
5. Upper ring nut
2-18
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20360

EAS20370
ENGINE
Lubrication point Lubricant
Oil seal lips LS
Bearings E
O-rings LS
Cylinder head stud bolt E
Cylinder head nut E
Camshaft cap bolt E
Cylinder inner surface E
Crankshaft pin E
Connecting rod big end thrust surface E
Balancer drive gear inner surface E
Crankshaft thrust surface E
Crankshaft journals E
Crankshaft end (generator rotor side) E
Pickup coil rotor nut and washer E
Piston and piston rings E
Piston pin E
Connecting rod small end E
Buffer boss E
Balancer impeller shaft end E
Balancer weight gear assembly E
Camshaft lobes and camshaft journals M
Valve stems (intake and exhaust) M
Valve guides (intake and exhaust) E
Valve stem ends (intake and exhaust) E
Oil pump assembly E
Oil pump shafts E
O-ring and gasket (fuel injector assembly) Silicone oil

Primary sheave collar Shell BT grease 3®
Primary sheave O-ring Shell BT grease 3®
2-19
Primary drive gear Shell BT grease 3®
Secondary sheave O-ring Shell BT grease 3®
Secondary sheave collar Shell BT grease 3®
Crankcase left holder, union collar outer surface LS
Crankcase left plain bearing outer surface E
Starter clutch idle gear E
Starter clutch idle gear and shaft 1 E
Starter clutch gear E
Main axle thrust surfaces E
Main and drive axle serration E

or LS
Primary driven gear E

or LS
Drive axle wheel LS
Drive axle serration E

or LS
1st wheel gear E

or LS
Drive axle bearing LS
BEL-RAY assembly
Primary sheave bushing inner surface
lube®
BEL-RAY assembly
Primary sheave collar inner surface
lube®
BEL-RAY assembly
Primary sheave oil seal inner surface
lube®
Yamaha bond No.
Cylinder head cover (guide stopper mating surface) 1215 (Three Bond No.
1215®)
Yamaha bond No.
Cylinder head straight screw plug, semicircular plug 1215 (Three Bond No.
1215®)
Housing union cover LT
Yamaha bond No.

Crankcase mating surface 1215 (Three Bond No.
1215®)
Yamaha bond No.
Pickup coil rotor cover (grommet mating surface) 1215 (Three Bond No.
1215®)
Yamaha bond No.
Left crankcase cover and cover stay 1215 (Three Bond No.
1215®)
2-20
EAS20380
CHASSIS
Engine mounting bolt LS
Swingarm, oil seal LS
Steering bearings and oil seal LS
Throttle grip inner surface and throttle cables LS
Brake lever pivoting point and metal-to-metal moving parts (left and right) LS
Rear brake lock lever cable and rear brake lock lever (cable connection area) LS
Front wheel oil seal LS
Speed sensor oil seal LS
Rear wheel axle LS
Sidestand pivoting point, metal-to-metal moving parts and collar outer surface LS
Mainstand shaft pivoting point and metal-to-metal moving parts LS
Mainstand stopper pivoting point LS
Mainstand spring hook metal-to-metal moving parts LS
Sidestand spring hook metal-to-metal moving parts LS
Sidestand switch contact point LS
Fuel tank lid hinge and stopper LS
Rear trunk hinge pin LS
Seat lock assembly contact point LS
2-21
2-22
COOLING SYSTEM DIAGRAMS
EAS20420
2-23
1. Radiator hose (OUT)
2. Radiator
3. Radiator cap
4. Coolant reservoir hose
5. Radiator filler hose
6. Radiator hose (IN)
7. Radiator pipes
2-24
2-25
1. Radiator pipes
2. Hose (heat exchanger–OUT)
3. Heat exchanger cover
4. Hose (water pump–OUT)
5. Water pump cover
6. Hose (water pump–IN)
7. Hose (thermostat–IN)
8. Air bleed hose
9. Hose (thermostat–OUT)
10. Thermostat
11. Thermostat cover
12. Pipe (water jacket–IN)
13. Heat exchanger
2-26
CABLE ROUTING
EAS20430
CABLE ROUTING
2-27
CABLE ROUTING
1. Rear brake lock cable
2. Throttle cable (pull side)
3. Throttle cable (return side)
4. Front brake hose
5. Right handlebar switch
6. Clamp
7. Left handlebar switch
8. Rear brake hose
A. Pass the handlebar switch lead through
the steering cover left hole.
B. Route the brake hose and rear brake lock
cable as illustration. Do not touch to the
steering cover hole front side. (Refer to
A-A.)
C. Pass the right handlebar switch lead
through the steering cover right hole.
D. Clamp the right handlebar switch lead at
the front side of the handlebar R-shape
parts (upper and lower). Face the clamp
ends outward of the vehicle. Also, route
the leads so as not to get in between rear
brake lock cable, throttle cable and han-
dlebar.
E. Route the throttle cable to the front side
of handle.
F. Route the rear brake lock cable to the
front side of handle.
G. When installing the clamp, do not touch
the brake hose and rear brake lock lever
to the handle lower holder. Also, fasten
the clamp touching to the lower surface
of the handle lower holder.
H. Fasten the brake hoses and cables with a
clamp as shown. Adjust the length of the
clamp end in 60–80mm, and then cut off
end in 10–20mm. Face the clamp end
rightward, also clamp position is rear side
than rear brake lock cable and brake
hose.
2-28
CABLE ROUTING
2-29
CABLE ROUTING
1. Speed sensor lead
2. Clamp
3. Hose holder
4. Speed sensor
5. Cable guide
6. Front brake hose
A. Route the speed sensor lead to the front
side of the brake hose from the rear side
of the brake hose rounding it, and then
clamp the speed sensor lead on the
white paint side. When turning the han-
dlebar to the left and right several times,
speed sensor lead so as not to get
between the head pipe and steering
stopper, and not to touch to the other
part.
B. Clamp the speed sensor lead along the
rear side of the front brake hose.
C. Install the hose holder that aligning the
stopper of the hose holder to the outer
tube boss.
D. Route the speed sensor lead to the
inside of the front brake hose.
E. Make sure the slot in the speed sensor
fits over the stopper on the outer tube.
F. Make sure the brake hose touches the
projection on the brake caliper.
G. Clamp the speed sensor lead along
inside of the front brake hose.
H. Install the hose holder that inserting the
stopper of the hose holder in the hole of
the lower bracket.
I. Pass the speed sensor lead through the
cable guide.
J. Clamp the speed sensor lead facing it
rearward.
2-30
CABLE ROUTING
2-31
CABLE ROUTING
1. Handlebar switch couplers K. Pass the hoses and cables through the
2. Left handlebar switch lead upper cable guide of the cowling stay as
3. Right handlebar switch lead shown.
4. Horn L. Cut the end of the clamp in 2–4mm.
5. Starter motor lead M. Insert the frame hole.
6. Stay 1 N. Route the starting motor cable and bat-
tery negative lead to the upper side of
7. Front right turn signal lead
the frame hole.
8. Front right turn signal light
O. Clamp the wireharness on the white tap-
9. Front left turn signal light ing part and the battery negative lead on
10. Front left turn signal lead the yellow taping part.
11. Front cowling P. To the battery box.
12. Headlight
13. Stay 2
15. Cowling stay cable guide
17. Rear brake hose
18. Throttle cable (pull side)
19. Throttle cable (return side)
20. Front brake hose
21. Battery negative lead
22. Wire harness
23. Frame
24. Rectifier/regulator
A. Clamp the handlebar switch leads and
meter lead.
B. Route the right handlebar switch lead to
rear of the head pipe.
C. Route the throttle cable to the inside of
the wireharness.
D. Route the throttle cable to inside of the
wireharness. Also, route the return side
upon the pull side.
E. Fasten the grommet part of the throttle
cable. However, fasten the cable that
marked the white paint (pull side) to the
front side.
F. Route the turn signal leads between the
front cowling and the pipe of the stay 1.
G. Route the headlight lead between the
front cowling and pipe of stay 1.
H. Pass the front brake hose through the
cowling stay cable guide (lower).
I. Route the rear brake hose and rear brake
lock cable to the outside of the front
brake hose.
J. Route the throttle cable to the most rear
side of the rear brake lock cable and
brake hose.
2-32
CABLE ROUTING
2-33
CABLE ROUTING
1. Box light coupler L. Pass the right turn signal light lead
2. Box light switch coupler through the hole of trunk stay (left can-
3. Sidestand switch coupler ter).
4. Pickup coil rotor coupler1, 2 M. Store the turn signal light couplers,
license light coupler tail light coupler.
5. Box light manual switch coupler
N. After connecting, insert the sub lead wire
6. Rear left turn signal light
coupler to the bracket hole from the
7. License plate light lead inside.
8. Taillight lead O. Connect the large connector of the igni-
9. High tension code tion coil to the upper side, connect the
10. Ignition coil small connector to the lower side. Also
11. Sidestand switch face the connectors outward.
12. Pipe 2 P. Fasten the throttle cable with a clamp.
13. Inner fender Q. Fasten the sidestand switch lead with a
14. Radiator fan motor coupler clamp.
15. Wire harness (to horn) R. Fasten the wireharness, battery negative
lead, starting motor lead and sidestand
16. Wire harness (to rectifier/regulator)
switch lead with a clamp. Face the
17. Frame engage part of the clamp outside.
18. Radiator fan motor lead S. Fasten the wireharness, battery negative
19. Starter motor lead lead, starting motor lead and box light
20. Battery negative lead lead with a clamp. Face the engage part
21. Wire harness of the clamp inside.
22. Box light switch lead T. Clamp the wireharness to the outside
23. Box light lead from the down tube upper side. Fasten
with the frame hole, also face downward.
A. Clamp the wireharness, battery negative U. Pass the radiator fan motor lead through
lead and starting motor lead. the notch of the inner fender 2.
B. Fasten the throttle cable with a clamp. V. Fasten with the frame hole, also face the
C. Fasten the throttle cable with the clamp end of the clamp downward.
of frame. W. Position the box light switch lead and the
D. Position the coupler to the outside of the box light lead to the upper side. Also
wireharness. clamp the white tape part fasten with the
E. Install the tank mold aligning the R-shape frame hole, and then face the end of the
of the member 3. clamp downward.
F. Position the sidestand switch coupler to X. Cut off the end of the clamp in 2–4mm.
the outside of the wireharness. Y. Position the sidestand switch lead out-
G. Store the pickup coil rotor coupler 1, 2 to ward. Also clamp the protector part.
the inside of the cover after connecting. Z. Set the hose to the clamp of the inner
H. Insert the clamp to the hole of the frame. fender 2 facing the paint upward.
I. Fasten the wireharness with a clamp. AA. Set to the clamp of the inner fender 2.
J. Fasten the wireharness with a clamp at AB. Route to the outside of the guide.
the wireharness protector part. Face the AC. Set to the clamp of the inner fender 2.
open side of the clamp to the outside. AD. Face the paint mark side outward. Possi-
Also, store the wireharness in the rib that ble to use synthetic detergent or water as
prevent to come out clamp lubricant during installing.
K. Fasten the right turn signal light lead, AE. Clamp the sidestand switch lead on the
license plate light lead and tail/brake light protector part.
lead. Face the open side of the clamp
facing upward.
2-34
CABLE ROUTING
2-35
CABLE ROUTING
1. Protector 1
2. Main switch
4. Right footboard
5. Frame
6. Rear brake hose
8. Seat lock cable
9. Clamp
10. Rear brake hose grommet
11. Rear brake cable grommet
A. Route the rear brake hose and rear brake
lock cable to the outside of the frame
tank rail as shown. (Route the rear brake
lock cable to the lower side.)
B. Fasten the rear brake hose and rear
brake lock cable with a clamp. Position
the rear brake lock cable to the lower
side.
C. Route the main switch lead to the inside
of the cowling stay pipe.
D. Clamp with the frame hole, facing the
end downward.
E. Clamp with the frame tank rail, facing the
end downward.
F. Position the white paint mark of the seat
lock cable upon the band of fastening the
protector 1.
G. Cut off the end of the clamp in 2–4mm.
2-36
CABLE ROUTING
2-37
CABLE ROUTING
1. Positive battery lead A. Route the main switch lead to the outside
2. Battery of the battery.
3. Front right turn signal light lead B. Store the right turn signal light coupler to
4. Speed sensor lead the battery box after connecting it.
5. Meter lead C. Route the main switch lead to the inside
of the stay 1.
6. Fuel pump coupler
D. Fasten the rear brake hose and rear
7. Plug cap
brake lock cable. Face the engage part
8. Throttle body outward.
9. Rear right turn signal light E. Fasten the rear brake hose and rear
10. Right trunk stay brake lock cable with a clamp.
11. Rear trunk F. Pass the rear brake hose and rear brake
12. Seat lock lock cable to the cable guide of the
13. Starter motor engine bracket routing the rear brake
14. High tension code lock cable to the outside.
15. Fuel hose G. Route the rear right turn signal light to
the upper side of the right trunk stay.
16. Fuel overflow hose
H. Set the seat lock cable end to the notch.
17. Left handlebar switch lead
I. Pass the fuel hose to the cable guide of
18. Speed sensor coupler
the frame from upward.
19. Fuse box
J. Fasten the protector at the high tension
20. Front left turn signal coupler cord with the clamp of the cylinder head
21. Starter motor lead cover.
22. Battery negative lead K. Route the box light switch lead and box
23. ECU light lead to the lower side of the seat
24. Battery negative lead coupler bracket and the upper side of the wire-
25. Relay assembly harness.
26. Lean angle sensor L. Route the wireharness, battery negative
27. Headlight coupler lead and starting motor lead to the inside
of the member and the lower side of the
28. Headlight lead
seat bracket as shown.
29. Main switch coupler
M. Store the speed sensor lead to the bat-
30. Battery box tery box after connecting it.
31. Wire harness N. Route the starting motor lead to the out-
32. Main switch lead side of the battery box.
33. Wire harness (to the front left turn signal O. Position the front left turn signal light cou-
light) pler to the lower side of the fuse box after
34. Wire harness (to fuse box) connecting it.
35. Option lead P. Install the cover to the starting motor lead
36. Engine bracket after connecting the coupler.
37. Wire sub harness Q. Install the cover to the battery positive
38. Pickup coil rotor lead lead after connecting the connector.
39. Rear right turn signal lead R. Pass the battery positive lead to the
lower side of the cowling stay pipe.
40. Pickup coil rotor lead marking
S. Fasten the battery positive lead with a
41. Frame
clamp.
42. Wire sub lead marking
T. Insert the wireharness to the battery box.
43. Battery negative lead marking
U. Cut off the end of the clamp in 2–4mm.
44. Starting motor lead marking
45. Clamp
2-38
CABLE ROUTING
2-39
CABLE ROUTING
V. Pass the sub lead wire, pickup coil rotor
lead, battery negative lead and starting
motor lead to the cable guide of the
engine bracket. Also position the battery
negative lead and pickup coil rotor lead
to the lower side.
W. Fasten the rear right turn signal light lead
with a clamp. Face the open side for-
ward.
X. Pass the speed sensor lead to the lower
side of the main switch lead. (do not step
over main switch lead.)
Y. The starter motor lead may intersect with
the battery negative lead while routing it.
Z. Fasten the handlebar switch leads (left/
right) and meter lead with a clamp. Face
the end of the clamp rearward.
AA. Store the empty coupler of the battery
box into the battery box so as not to float.
AB. Fasten the clamp so as not to float the
leads.
AC. Route the speed sensor lead and right
turn signal light lead to the front side of
the battery bolt, and then store them into
the battery box.
AD. Cut off the end of the clamp in 2–4mm.
AE. Clamp the battery negative lead with the
hole of pulling out water of the battery
box. Face the end of the clamp down-
ward.
AF. Clamp the yellow taping part of the wire
sub harness, battery negative lead, start-
ing motor cable and pickup coil rotor
lead.
AG. Store the joint coupler in the battery box.
AH. Store the option connector coupler and
V-belt reset coupler in the battery box.
2-40
CABLE ROUTING
2-41
CABLE ROUTING
1. Sidestand switch lead
2. Hose (canister to throttle body)
3. Hose (rollover valve to canister)
4. Rollover valve
5. Canister
6. Hose (fuel tank to rollover valve)
7. Frame
A. When installing the hose (rollover valve
to canister), face the paint mark upward.
B. Install the clamp on the frame (T stud).
Also, clamp the hose (canister to throttle
body) between the stopper on the hose.
C. Be careful the face of clamp. Also, align
the clamp position to the center of the
white paint on the hose (canister to throt-
tle body).
D. Pass the hose (canister to throttle body)
through the outside of the sidestand
switch lead.
E. Fasten the hose (rollover valve to canis-
ter) with the frame guide.
F. Possible to use synthetic detergent or
water as lubricant during installing the
hose. Do not use the oil. Also, install the
hose (rollover valve to canister) and hose
(canister to throttle body) onto the canis-
ter, making sure they contact the canister
body.
G. Install the hose (fuel tank to rollover
valve) onto the pipe, making sure that
contact the R-shape of the pipe.
H. Install the hose (canister to throttle body)
onto the throttle body, making sure that
contact the throttle body.
I. Install the hose (fuel tank to rollover
valve) onto the rollover valve, making
sure that contact the rollover valve.
J. Fasten the hose (fuel tank to rollover
valve) with a clamp, making sure clamp
contact the frame bracket.
K. Install the hose (rollover valve to canis-
ter) onto the rollover valve, making sure
that contact the rollover valve.
L. Fasten the hose (fuel tank to rollover
valve) to the frame pipe protector area
with a clamp. Also, be careful the hose so
as not to collapse.
2-42
CABLE ROUTING
2-43
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE........................................................................ 3-1
INTRODUCTION .................................................................................... 3-1
Periodic maintenance chart for the emission control system.................. 3-1
General maintenance and lubrication chart ............................................ 3-1
ENGINE ....................................................................................................... 3-4
ADJUSTING THE VALVE CLEARANCE ................................................ 3-4
1
CHECKING THE ENGINE IDLING SPEED ............................................ 3-6
ADJUSTING THE THROTTLE CABLE FREE PLAY .............................. 3-6
CHECKING THE SPARK PLUG ............................................................. 3-7
MEASURING THE COMPRESSION PRESSURE ................................. 3-7
CHECKING THE ENGINE OIL LEVEL ................................................... 3-8
2
CHANGING THE ENGINE OIL ............................................................... 3-9
CHANGING THE TRANSMISSION OIL ................................................. 3-11
REPLACING THE AIR FILTER ELEMENT............................................. 3-12
CLEANING THE V-BELT CASE AIR FILTER ELEMENT....................... 3-12
CHECKING THE THROTTLE BODY JOINT AND INTAKE
3
MANIFOLD ............................................................................................ 3-13
CHECKING THE FUEL LINE.................................................................. 3-13
CHECKING THE CRANKCASE BREATHER HOSE.............................. 3-13
CHECKING THE EXHAUST SYSTEM ................................................... 3-14
CHECKING THE COOLANT LEVEL ...................................................... 3-14
CHECKING THE COOLING SYSTEM ................................................... 3-15
4
CHANGING THE COOLANT .................................................................. 3-15
CHASSIS..................................................................................................... 3-18
CHECKING THE BRAKE FLUID LEVEL ................................................ 3-18
CHECKING THE FRONT BRAKE PADS ............................................... 3-18
5
CHECKING THE REAR BRAKE PADS .................................................. 3-18
CHECKING THE FRONT BRAKE HOSE ............................................... 3-19
CHECKING THE REAR BRAKE HOSE ................................................. 3-19
ADJUSTING THE REAR BRAKE LOCK LEVER CABLE ....................... 3-19
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-20
6
CHECKING AND ADJUSTING THE STEERING HEAD ........................ 3-21
CHECKING THE FRONT FORK ............................................................ 3-22
CHECKING THE TIRES ......................................................................... 3-22
CHECKING THE WHEELS..................................................................... 3-24
CHECKING AND LUBRICATING THE CABLES .................................... 3-24
7
LUBRICATING THE LEVER ................................................................... 3-25
LUBRICATING THE SIDESTAND .......................................................... 3-25
LUBRICATING THE CENTERSTAND.................................................... 3-25
ELECTRICAL SYSTEM .............................................................................. 3-26 8
CHECKING AND CHARGING THE BATTERY ...................................... 3-26
CHECKING THE FUSES ........................................................................ 3-26
REPLACING THE HEADLIGHT BULBS................................................. 3-26
ADJUSTING THE HEADLIGHT BEAMS ................................................ 3-27
9
PERIODIC MAINTENANCE
EAS20450
EAS20460
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a long-
er service life and reduce the need for costly overhaul work. This information applies to vehicles already
in service as well as to new vehicles that are being prepared for sale. All service technicians should be
familiar with this entire chapter.
EAS17580
Periodic maintenance chart for the emission control system

INITIAL ODOMETER READINGS
7000 mi 10000 mi 13000 mi 16000 mi

No. ITEM ROUTINE 600 mi 4000 mi
(11000 (16000 (21000 (26000
(1000 km) (6000 km)
km) km) km) km)
or or
or or or or
1 month 6 months
12 months 18 months 24 months 30 months
● Check fuel hoses for cracks or

1 * Fuel line damage. √ √ √ √ √
● Replace if necessary.
● Check condition.
● Adjust gap and clean.
2 Spark plug √ √ Replace. √ √
● Replace every 10000 mi (16000
km) or 18 months.
● Check and adjust valve clear-
3 * Valve clearance Every 26600 mi (42000 km)
ance when engine is cold.
● Check breather hose for cracks
Crankcase breather
4 * or damage. √ √ √ √ √
system
5 * Fuel injection ● Check engine idle speed. √ √ √ √ √ √
Evaporative emis- ● Check control system for dam-

6 * sion control system age. √ √
(For California only) ● Replace if necessary.
● Check the air cut-off valve, reed

Air induction sys-
7 * valve, and hose for damage. √
tem
● Replace any damaged parts.
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
EAS32162
General maintenance and lubrication chart

7000 mi 10000 mi 13000 mi 16000 mi

(11000 (16000 (21000 (26000
(1000 km) (6000 km)
km) km) km) km)
or or
or or or or
1 month 6 months
● Check condition and damage.

1 * Air filter element √ √ √ √ √
V-belt case air filter ● Clean.

2 √ √ √ √ √
element
● Check operation, fluid level, and
3 * Front brake for fluid leakage. √ √ √ √ √ √
● Replace brake pads if necessary.
3-1
7000 mi 10000 mi 13000 mi 16000 mi

(11000 (16000 (21000 (26000
(1000 km) (6000 km)
km) km) km) km)
or or
or or or or
1 month 6 months
● Check operation, fluid level, and

4 * Rear brake for fluid leakage. √ √ √ √ √ √
● Replace brake pads if necessary.
● Check for cracks or damage. √ √ √ √ √

5 * Brake hoses
● Replace. Every 4 years
● Check operation.
6 Rear brake lock √ √ √ √ √ √
● Adjust.
● Check runout and for damage.

7 * Wheels √ √ √ √ √
● Check tread depth and for dam-

age.
8 * Tires ● Replace if necessary. √ √ √ √ √
● Check air pressure.
● Correct if necessary.
● Check bearings for smooth oper-

9 * Wheel bearings ation. √ √ √ √ √
● Check bearing assemblies for

√ √ √ √ √ √
looseness.
10 * Steering bearings
● Moderately repack with lith-
Every 12000 mi (19000 km)
ium-soap-based grease.
● Check all chassis fitting and fas-
11 * Chassis fasteners teners. √ √ √ √ √
● Correct if necessary.
Front and rear brake ● Apply lithium-soap-based grease

12 √ √ √ √ √
lever pivot (all-purpose grease) lightly.
● Check operation.
Centerstand and
13 ● Apply lithium-soap-based grease √ √ √ √ √
sidestand pivots
(all-purpose grease) lightly.
● Check operation and replace if
14 * Sidestand switch √ √ √ √ √ √
necessary.
● Check operation and for oil leak-
15 * Front fork age. √ √ √ √ √
● Check operation and for oil leak-

Shock absorber
16 * age. √ √ √ √ √
assemblies
● Change. When the oil change indicator flashes (every 3125 mi

√
(5000 km))
17 Engine oil
● Check oil level and vehicle for oil
Every 3125 mi (5000 km)
leakage.
Engine oil filter ele- ● Replace.

18 √ Every 12500 mi (20000 km)
ment
● Check coolant level and vehicle
√ √ √ √ √
19 * Cooling system for coolant leakage.
● Change. Every 3 years
Final transmission ● Check vehicle for oil leakage.

20 √ √ √
oil ● Change.
3-2
7000 mi 10000 mi 13000 mi 16000 mi

(11000 (16000 (21000 (26000
(1000 km) (6000 km)
km) km) km) km)
or or
or or or or
1 month 6 months
● Replace. When the V-belt replacement indicator flashes every (12500 mi

21 * V-belt
(20000 km))
Front and rear brake ● Check operation.

22 * √ √ √ √ √ √
switches
● Check operation and free play.
● Adjust the throttle cable free play
Throttle grip hous-
23 * if necessary. √ √ √ √ √
ing and cable
● Lubricate the throttle grip hous-
ing and cable.
Lights, signals and ● Check operation.
24 * √ √ √ √ √ √
switches ● Adjust headlight beam.
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
NOTE:
From 19000 mi (31000 km) or 36 months, repeat the maintenance intervals starting from 7000 mi
(11000 km) or 12 months.
EAS38260
NOTE:
● The air filter and V-belt filter need more frequent service if you are riding in unusually wet or dusty
areas.
● Hydraulic brake service
● After disassembling the brake master cylinders and calipers, always change the fluid. Regularly
check the brake fluid levels and fill the reservoirs as required.
● Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.

● Replace the brake hoses every four years and if cracked or damaged.
3-3
ENGINE
EAS20470
ENGINE
EAS20510
ADJUSTING THE VALVE CLEARANCE

The following procedure applies to all of the
valves.
NOTE:
● Valve clearance adjustment should be made
on a cold engine, at room temperature.
● When the valve clearance is to be measured
or adjusted, the piston must be at top dead NOTE:
center (TDC) on the compression stroke. ● TDC on the compression stroke can be found
when the camshaft lobes are turned away
1. Remove:
from each other.
● Left side cover
● In order to be sure that the piston is at TDC,
● Document box
the punch marks “c” on the intake camshaft
● Trunk
sprocket and the punch marks “d” on the ex-
● V-belt case filter cover“1”
haust camshaft sprocket must align with the
● V-belt case air filter element
cylinder head mating surface as shown in the
1 illustration.
2. Remove:
● Timing plug
● Spark plug c. Measure the valve clearance with a thick-

● Cylinder head cover ness gauge “1”.
● Cylinder head cover gasket
3. Measure:
● Valve clearance
Out of specification → Adjust.
Valve clearance (cold)

Intake
0.15–0.20 mm (0.0059–0.0079 in)
1
Exhaust
0.25–0.30 mm (0.0098–0.0118 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ NOTE:
a. Turn the crankshaft counterclockwise by If the valve clearance is incorrect, record the
turning the primary sheave nut. measured reading.
b. When the piston is at TDC on the compres-
sion stroke, align the mark “a” on the pickup
coil rotor with the mark “b” on the crankcase ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
cover. 4. Remove:
● Camshaft cap
3-4
ENGINE
● Intake camshaft 1.20–2.40 mm
Exhaust camshaft Valve pad thickness
● (0.047–0.094 in)
NOTE:
25 thicknesses in 0.05
● Refer to “CAMSHAFTS” on page 5-5.
Available valve pads mm (0.002 in) incre-
● When removing the timing chain and cam- ments
shafts, fasten the timing chain with a wire to
retrieve it if it falls into the crankcase. NOTE:
● The thickness of each valve pad is marked in
5. Adjust: hundredths of millimeters on the side that
● Valve clearance
touches the valve lifter.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ● Since valve pads of various sizes are original-
a. Remove the valve lifter “1” and the valve pad ly installed, the valve pad number must be
“2” with a hand valve lapper “3”. rounded in order to reach the closest equiva-
lent to the original.
● The new valve pad number is only an approx-
imation. The valve clearance must be mea-
sured again and the above steps should be
repeated if the measurement is still incorrect.
c. Install the new valve pad “1” and the valve
lifter “2”.
Valve lapper
90890-04101
Valve lapping tool
YM-A8998 2
1
NOTE:
● Cover the timing chain opening with a rag to
prevent the valve pad from falling into the
crankcase. NOTE:
● Make a note of the position of each valve lifter ● Lubricate the valve pad with molybdenum dis-
“1” and valve pad “2” so that they can be in- ulfide grease.
stalled in the correct place. ● Lubricate the valve lifter with molybdenum
disulfide oil.
● The valve lifter must turn smoothly when ro-
tated by hand.
● Install the valve lifter and the valve pad in the
correct place.
d. Install the exhaust and intake camshafts, tim-
ing chain and the camshaft caps.
Camshaft cap bolt
10 Nm (1.0 m•kg, 7.2 ft•lb)
T.
R.
b. Select the proper valve pad from the follow-

NOTE:
ing table.
● Refer to “CAMSHAFTS” on page 5-5.
Valve pad range No. 120–240 ● Lubricate the camshaft bearings, camshaft
lobes and camshaft journals.
● First, install the exhaust camshaft.
3-5
ENGINE
● Align the camshaft sprocket marks with the EAS20640
ADJUSTING THE THROTTLE CABLE FREE

edge of the cylinder head.
PLAY
● Turn the crankshaft counterclockwise several
NOTE:
full turns to seat the parts. Prior to adjusting the throttle cable free play, the
e. Measure the valve clearance again. engine idling speed should be adjusted properly.
f. If the valve clearance is still out of specifica- 1. Check:
tion, repeat all of the valve clearance adjust- ● Throttle cable free play “a”
ment steps until the specified clearance is Out of specification → Adjust.
obtained.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
● Cylinder head cover gasket
● Cylinder head cover a

● Spark plug
● Timing plug
7. Install:
● V-belt case filter cover
● Trunk
Throttle cable free play
● Document box
3.0–5.0 mm (0.12–0.20 in)
● Left side cover
2. Adjust:
EAS20620
● Throttle cable free play
CHECKING THE ENGINE IDLING SPEED
NOTE: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Prior to checking the engine idling speed, the air a. Loosen the locknut “1”.
filter element should be clean, and the engine b. Turn the adjusting nut “2” in direction “a” or
should have adequate compression. “b” until the specified throttle cable free play
is obtained.
1. Start the engine and let it warm up for several
minutes. Direction “a”
2. Remove: Throttle cable free play is increased.
● Trunk Direction “b”
Refer to “GENERAL CHASSIS” on page 4-1. Throttle cable free play is decreased.
3. Install:
● Digital tachometer c. Tighten the locknut.
(onto the spark plug lead of cylinder #1)
Digital tachometer
90890-06760
4. Check: 2
a
● Engine idling speed
Out of specification → Replace the throttle

body.
b
Engine idling speed 1
1450 r/min EWA12920
WARNING
5. Install: After adjusting the throttle cable free play,
● Trunk start the engine and turn the handlebars to
Refer to “GENERAL CHASSIS” on page 4-1. the right and to the left to ensure that this
3-6
ENGINE
does not cause the engine idling speed to Out of specification → Regap.
change.
Spark plug gap
0.8–0.9 mm (0.031–0.035 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS20690
CHECKING THE SPARK PLUG

1. Remove:
● Document box
● Trunk
Refer to “GENERAL CHASSIS” on page 4-1.

2. Disconnect:
● Spark plug cap
3. Remove:
8. Install:
● Spark plug
ECA13330 ● Spark plug
CAUTION:
Spark plug
Before removing the spark plug, blow away
13 Nm (1.3 m•kg, 9.4 ft•lb)
any dirt accumulated in the spark plug well
T.
R.
with compressed air to prevent it from falling NOTE:
into the cylinder. Before installing the spark plug, clean the spark
4. Check: plug and gasket surface.
● Spark plug type
9. Connect:
Incorrect → Change. ● Spark plug cap
Manufacturer/model 10.Install:
NGK/CPR7EA-9 ● Trunk
● Document box
5. Check: Refer to “GENERAL CHASSIS” on page 4-1.

● Electrode “1”
EAS20710
Damage/wear → Replace the spark plug. MEASURING THE COMPRESSION

● Insulator “2” PRESSURE
Abnormal color → Replace the spark plug. The following procedure applies to all of the cyl-
Normal color is medium-to-light tan. inders.
NOTE:
● Insufficient compression pressure will result in
a loss of performance.
● Before measuring compression pressure,
valve clearance is proper. Refer to “ADJUST-
ING THE VALVE CLEARANCE” on page 3-4.
1. Remove:
● Document box
● Trunk
6. Clean: Refer to “GENERAL CHASSIS” on page 4-1.

● Spark plug
2. Start the engine, warm it up for several min-
(with a spark plug cleaner or wire brush) utes, and then turn it off.
7. Measure: 3. Disconnect:
● Spark plug cap
● Spark plug gap “a”
(with a wire thickness gauge)
3-7
ENGINE
4. Remove: ed in the spark plug wells to prevent it from
● Spark plug falling into the cylinders.
ECA13340
CAUTION: c. If the compression pressure is above the

Before removing the spark plugs, use com- maximum specification, check the cylinder
pressed air to blow away any dirt accumulat- head, valve surfaces and piston crown for
ed in the spark plug wells to prevent it from carbon deposits.
falling into the cylinders. Carbon deposits → Eliminate.
d. If the compression pressure is below the
5. Install: minimum specification, pour a teaspoonful of
● Compression gauge “1”
engine oil into the spark plug bore and mea-
Compression gauge sure again.
90890-03081 Refer to the following table.
Engine compression tester Compression pressure (with oil applied into the
YU-33223 cylinder)
Extension
90890-04082 Reading Diagnosis
Piston ring(s) wear or
Higher than without oil
damage → Repair.
1 Piston, valves, cylin-

der head gasket or
Same as without oil
piston possibly defec-
tive → Repair.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Install:
● Spark plug
6. Measure:
● Compression pressure
Spark plug
Out of specification → Refer to steps (c) and 13 Nm (1.3 m•kg, 9.4 ft•lb)
T.
(d).
R.
8. Connect:
Standard compression pressure
● Spark plug cap
(at sea level)
1800 kPa/400 r/min (256.0 psi/400 9. Install.
● Trunk
r/min) (18.0 kgf/cm2/400 r/min)
● Document box
Maximum compression pressure
2020 kPa/400 r/min (293 psi/400 r/ Refer to “GENERAL CHASSIS” on page 4-1.
min) (20.2 kgf/cm2/400 r/min) EAS20730
Minimum compression pressure CHECKING THE ENGINE OIL LEVEL

1570 kPa/400 r/min (228 psi/400 r/ 1. Stand the vehicle on a level surface.
min) (15.7 kgf/cm2/400 r/min) NOTE:
● Place the vehicle on the mainstand.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
● Make sure the vehicle is upright.
a. Set the main switch to “ON”.
b. With the throttle wide open, crank the engine 2. Start the engine, warm it up for several min-
until the reading on the compression gauge utes, and then turn it off.
stabilizes. 3. Remove:
ECA13340
● Right rear mat“1”
CAUTION:
● Oil level gauge cover“2”
Before removing the spark plugs, use com-
pressed air to blow away any dirt accumulat-
3-8
ENGINE
NOTE:
● Check the engine oil filler cap without screw-
ing it in.
● Before checking the engine oil level, wait a
few minutes until the oil has settled.
1 5. Start the engine, warm it up for several min-

utes, and then turn it off.
2 6. Check the engine oil level again.
EAS20810
4. Check: CHANGING THE ENGINE OIL

● Engine oil level
1. Remove:
● Trunk
Remove the engine oil filler cap “1” the en-
gine oil level should be between the mini- Refer to “GENERAL CHASSIS” on page 4-1.
mum level mark “a” and maximum level mark 2. Start the engine, warm it up for several min-
“b”. utes, and then turn it off.
Below the minimum level mark → Add the 3. Place a container under the engine oil drain
recommended engine oil to the proper level. bolt.
4. Remove:
1 ● Rear mat
1 ● Engine oil filler cap “1”
● Engine oil drain bolt “2”
(along with the gasket)
1
1
b
a
Type
YAMALUBE 4, SAE10W30 or
SAE20W40
Recommended engine oil grade
API service SE, SF, SG type or
higher 2
ECA1B703
CAUTION:
Do not allow foreign materials to enter the
crankcase.
0 10 30 50 70 90 110 130 F
YAMALUBE 4 (10W30)
or SAE 10W30
5. Drain:
YAMALUBE 4 (20W40) ● Engine oil
or SAE 20W40
(completely from the crankcase)
-20 -10 0 10 20 30 40 50 C 6. If the oil filter element is also to be replaced,
perform the following procedure.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the oil filter element cover “1” and oil
filter element “2”.
3-9
ENGINE
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1 8. Install:
● Engine oil drain bolt
(along with the new gasket)
Engine oil drain bolt

20 Nm (2.0 m•kg, 14 ft•lb)
T.
R.
9. Fill:
b. Install new O-rings “3”. ● Crankcase
(with the specified amount of the recom-

mended engine oil)
Engine oil quantity

Total amount
1.70 L (1.80 US qt) (1.50 Imp.qt)
Without oil filter element replace-
1 3 2 3 ment
1.50 L (1.59 US qt) (1.32 Imp.qt)
With oil filter element replacement
1.70 L (1.80 US qt) (1.50 Imp.qt)
c. Install the new oil filter element and the oil fil-
ter element cover. 10.Install:
● Engine oil filler cap
Oil filter element cover bolt (M10)
10 Nm (1.0 m•kg, 7.2 ft•lb) 11.Start the engine, warm it up for several min-
T.
R.
12.Check:
● Engine
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ (for engine oil leaks)

7. If the oil strainer is also to be cleaned, per- 13.Check:
form the following procedure. ● Engine oil level
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Refer to “CHECKING THE ENGINE OIL

a. Remove the oil strainer cover “1” and oil LEVEL” on page 3-8.
strainer “2”. 14.Check:
b. Install new O-ring “3”. ● Engine oil pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slightly loosen the oil gallery bolt “1”.
2
1
1 1
c. Install the oil strainer cover.
Oil strainer cover

b. Start the engine and keep it idling until en-
32 Nm (3.2 m•kg 23 ft•lb)
gine oil starts to seep from the oil gallery bolt.
T.
R.
If no engine oil comes out after one minute,
3-10
ENGINE
turn the engine off so that it will not seize. EAS20830
CHANGING THE TRANSMISSION OIL

c. Check the engine oil passages, the oil filter
1. Stand the vehicle on a level surface.
cartridge and the oil pump for damage or
NOTE:
leakage. Refer to “OIL PUMP” on page 5-43.
d. Start the engine after solving the problem(s)
● Make sure that the vehicle up right.
and check the engine oil pressure again.
e. Tighten the oil gallery bolt to specification. 2. Start the engine, warm it up for several min-
Oil gallery bolt 3. Place a container under the transmission.
10 Nm (1.0 m•kg, 7.2 ft•lb) 4. Remove:
T.
R.
● Oil filler cap
● Transmission oil drain bolt “1”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Completely drain the transmission oil.

15.Reset:
● Engine oil change indicator
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the key to “ON”.
b. Hold the reset button “1” pushed for more 1
than 3 seconds.
5. Install:
● Transmission oil drain bolt
Transmission oil drain bolt

20 Nm 2.0 m•kg, 14 ft•lb)
T.
1
R.
6. Fill:
c. Release the reset button and the engine oil ● Transmission oil
change indicator will go off. (with the specified amount of the recom-
NOTE: mended transmission oil)
If the engine oil is changed before the engine oil
change indicator comes on (i.e. before the peri- Type
odic engine oil change interval has been SAE10W30 type SE motor oil
reached), the indicator must be reset after the Quantity
engine oil change for the next periodic engine oil 0.25 L (0.26 US qt) (0.22 Imp.qt)
change to be indicated at the correct time. To re- 7. Install:
set the engine oil change indicator before the ● Oil filler cap “1”
periodic engine oil change interval has been ● O-ring “2” New
reached, follow the above procedure, but note

that the indicator will come on for 1.4 seconds 1 1
after releasing the reset button, otherwise re-
peat the procedure. 2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
16.Install:
● Trunk

3-11
ENGINE
8. Start the engine for several minutes to warm formance and possible overheating.
it up and check for the oil leakage. NOTE:
EAS20960 When installing the air filter element into the air
REPLACING THE AIR FILTER ELEMENT filter case cover, make sure that the sealing sur-
1. Remove: faces are aligned to prevent any air leaks.
● Document box
Refer to “GENERAL CHASSIS” on page 4-1. EAS20980
● Air filter case cover“1” CLEANING THE V-BELT CASE AIR FILTER
● Air filter element“2”
ELEMENT
1. Remove:
● Left side cover

● V-belt case air filter cover “1”
● V-belt case air filter cover seal
1 1
2. Clean:
● V-belt case air filter element “1”
Blow the compressed air to the engine side

of the V-belt case air filter element.
2. Check:
● Air filter element
Damage → Replace.
NOTE: 1
● Replace the air filter element every 20000 km
(1200 mi) of operation.
● The air filter needs more frequent service if it
is used in unusually wet or dusty areas.
3. Install:
● Air filter element
3. Check:
● Air filter case cover
● Document box
Damage → Replace.
Refer to “GENERAL CHASSIS” on page 4-1. ECA13440
ECA1B706
CAUTION:
CAUTION:
Since the V-belt case air filter element is a
Never operate the engine without the air filter dry type, do not let grease or water contact it.
element installed. Unfiltered air will cause
rapid wear of engine parts and may damage 4. Install:
the engine. Operating the engine without the
● V-belt case air filter cover seal
air filter element will also affect carburetor
● V-belt case air filter cover
synchronization, leading to poor engine per-
3-12
ENGINE
● V-belt case air filter cover screw
● Left side cover 1
V-belt case air filter cover screw

4 Nm (0.4 m•kg, 2.9 ft•lb)
T.
R.
EAS21020
CHECKING THE THROTTLE BODY JOINT

AND INTAKE MANIFOLD
1. Remove:
● Document box 3. Install:
● Trunk
● Trunk
Refer to “GENERAL CHASSIS” on page 4-1. Refer to “GENERAL CHASSIS” on page 4-1.
2. Check: EAS21070
● Throttle body joint “1” CHECKING THE CRANKCASE BREATHER

● Intake manifold “2” HOSE
Cracks/damage → Replace. 1. Remove:
● Document box
● Trunk

1
2. Check:
● Crankcase breather hose “1”
● Transmission breather hose “2”
Cracks/damage → Replace.
2 Loose connection → Connect properly.
1
3. Install:
● Trunk
● Document box

EAS21030
CHECKING THE FUEL LINE

The following procedure applies to all of the fuel,
vacuum and breather hoses.
1. Remove:
● Trunk

2. Check: 2
● Fuel hose “1”
ECA14940
CAUTION:
Make sure the fuel tank breather hose is
ECA1B707
routed correctly.
CAUTION:
Make sure the breather hoses are routed cor-
rectly.
3-13
ENGINE
3. Install: ● Right side cover
● Trunk Refer to “GENERAL CHASSIS” on page 4-1.
● Document box
EAS21110
Refer to “GENERAL CHASSIS” on page 4-1. CHECKING THE COOLANT LEVEL

EAS21080
CHECKING THE EXHAUST SYSTEM NOTE:
The following procedure applies to all of the ex- ● Place the vehicle on the mainstand.
haust pipes and gaskets. ● Make sure the vehicle is upright.
1. Remove:
2. Remove:
● Right side cover
● Upper cover
● Right footboard
Refer to “GENERAL CHASSIS” on page 4-1. 3. Check:
2. Check:
● Coolant level
● Exhaust pipe “1”
The coolant level should be between the
● Muffler “2”
minimum level mark “a” and maximum level
Cracks/damage → Replace. mark “b”.
● Gasket
Below the minimum level mark → Add the
Exhaust gas leaks → Replace. recommended coolant to the proper level.
3. Check:
● Tightening torque
Exhaust pipe nut “3”

20 Nm (2.0 m•kg, 14 ft•lb)
T.
Exhaust pipe and muffler bolt “4”

R.
14 Nm (1.4 m•kg, 10 ft•lb)

Muffler and muffler bracket bolt
“5” b
53 Nm (5.3 m•kg, 38 ft•lb) a
ECA13470
CAUTION:
3 ● Adding water instead of coolant lowers the
antifreeze content of the coolant. If water
is used instead of coolant check, and if
1 necessary, correct the antifreeze concen-
tration of the coolant.
● Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
5 4. Start the engine, warm it up for several min-
5. Check:
● Coolant level
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.
5
4 6. Install:
2 5
● Upper cover
4. Install: Refer to “GENERAL CHASSIS” on page 4-1.
● Right footboard
3-14
ENGINE
EAS21120
●Front cowling
CHECKING THE COOLING SYSTEM
1. Remove:
● Coolant reservoir tank
● Trunk
● Coolant reservoir hose
● Left footboard/right footboard
Refer to “RADIATOR” on page 6-1.
● Radiator cover
2. Disconnect:
2. Check:
● Radiator “1”
3. Drain:
● Radiator inlet hose “2”
● Coolant
● Radiator outlet hose “3”
(from the coolant reservoir)
● Radiator filler hose “4”
4. Remove:
● Oil cooler outlet hose
● Radiator cap “1”
● Hose (water pump-IN) “5”
● Hose (water pump-OUT) “6”

1
● Hose (thermostat-IN) “7”
● Hose (thermostat-OUT)
Refer to “RADIATOR” on page 6-1, “THER-
MOSTAT” on page 6-4 and “WATER PUMP”
on page 6-6.
4
EWA13030
WARNING
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may
2
be blown out, which could cause serious in-
3 jury. When the engine has cooled, open the
1
radiator cap as follows:
Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap counter-
clockwise toward the detent to allow any re-
sidual pressure to escape. When the hissing
sound has stopped, press down on the radi-
ator cap and turn it counterclockwise to re-
7
move.
6 5 The following procedure applies to all of the
coolant drain bolts and copper washers.
3. Install: 5. Remove:
● Coolant drain bolt (engine) “1”
● Radiator cover
● Left footboard/right footboard

(along with the copper washer)
● Trunk

EAS21130
CHANGING THE COOLANT

1. Remove:
● Upper cover
3-15
ENGINE
Recommended antifreeze
High-quality ethylene glycol anti-
1 freeze containing corrosion inhibi-
tors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Radiator capacity (including all
routes)
1.57 L (1.66 US qt) (1.38 Imp.qt)
Coolant reservoir capacity (up to
6. Drain: the maximum level mark)
● Coolant 0.25 L (0.26 US qt) (0.22 Imp.qt)
(from the engine and radiator) EWA13040
7. Check: WARNING
● Copper washer (coolant drain bolt-engine)
● If coolant splashes in your eyes, thorough-
Damage → Replace. ly wash them with water and consult a
8. Connect: doctor.
● If coolant splashes on your clothes, quick-
9. Remove: ly wash it away with water and then with
● Bleed screw“1”
soap and water.
● If coolant is swallowed, induce vomiting
and get immediate medical attention.
ECA13480
CAUTION:
● Adding water instead of coolant lowers
the antifreeze content of the coolant. If wa-
ter is used instead of coolant check, and if
necessary, correct the antifreeze concen-
1 tration of the coolant.
● Use only distilled water. However, if dis-
10.Install:
tilled water is not available, soft water may
● Coolant drain bolt (engine)
be used.
Coolant drain bolt (engine) ● If coolant comes into contact with painted
10 Nm (1.0 m•Kg, 7.2 ft•lb) surfaces, immediately wash them with wa-
T.
ter.
R.
11.Fill: ● Do not mix different types of antifreeze.

● Cooling system
12.Install:
● Bleed screw
mended coolant)
Handling notes for coolant Bleed screw
Coolant is potentially harmful and should be 6 Nm (0.6 m•kg 4.3 ft•lb)
T.
R.
handled with special care.

13.Install:
● Radiator cap
● Coolant reservoir tank
● Coolant reservoir cap

14.Fill:
● Coolant reservoir
3-16
ENGINE
(with the recommended coolant to the maxi-
mum level mark “a”)
15.Start the engine, warm it up for several min-

utes, and then stop it.
16.Check:
● Coolant level
Refer to “CHECKING THE COOLANT LEV-

EL” on page 3-14.
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant has settled.
17.Install:
● Upper cover
3-17
CHASSIS
EAS21140
tion, leading to poor brake performance.
CHASSIS ● When refilling, be careful that water does
EAS21240 not enter the brake fluid reservoir. Water
CHECKING THE BRAKE FLUID LEVEL will significantly lower the boiling point of
1. Stand the vehicle on a level surface. the brake fluid and could cause vapor
NOTE: lock.
ECA13540
● Make sure the vehicle is upright. CAUTION:
● In order to ensure a correct reading of the
Brake fluid may damage painted surfaces
brake fluid level, make sure the top of the
and plastic parts. Therefore, always clean up
brake fluid reservoir is horizontal.
any spilt brake fluid immediately.
2. Check:
EAS21250
● Brake fluid level
CHECKING THE FRONT BRAKE PADS
Below the minimum level mark “a” → Add the
recommended brake fluid to the proper level.
brake pads.
Recommended fluid 1. Operate the brake.
DOT 4 2. Check:
● Front brake pad
Wear indicator groove almost disappeared

A a “1” → Replace the brake pads as a set.
Refer to “FRONT BRAKE” on page 4-13.
B
a
EAS21260
CHECKING THE REAR BRAKE PADS

brake pads.
1. Operate the brake.
2. Check:
● Rear brake pad
A. Front brake Wear indicators almost touch the brake disc

B. Rear brake “1” → Replace the brake pads as a set.
EWA13090 Refer to “REAR BRAKE” on page 4-25.
WARNING
● Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
● Refill with the same type of brake fluid that
is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
3-18
CHASSIS
EAS21270
3. Check:
CHECKING THE FRONT BRAKE HOSE ● Brake hose clamp
1. Check:
Loose Connection → Tighten the clamp bolt.
● Brake hose “1”
4. Hold the vehicle upright and apply the rear
Cracks/damage/wear → Replace.
brake several times.
5. Check:
1 ● Brake hose
Brake fluid leakage → Replace the damaged

hose.
Refer to “REAR BRAKE” on page 4-25.
6. Install:

EAS21320
2. Check: ADJUSTING THE REAR BRAKE LOCK

● Brake hose clamp
LEVER CABLE
EWA1B701
Loose Connection → Tighten the clamp bolt. WARNING
3. Hold the vehicle upright and apply the front Do not apply the rear brake lock lever when
brake several times. riding.
4. Check:
● Brake hose
NOTE:
Brake fluid leakage → Replace the damaged ● Place the vehicle on the mainstand.
hose. ● Before adjusting the rear brake lock lever,
Refer to “FRONT BRAKE” on page 4-13. check the rear brake fluid level.
EAS21290
1. Remove:
CHECKING THE REAR BRAKE HOSE ● Right side cover
1. Remove: Refer to “GENERAL CHASSIS” on page 4-1.

● Right side cover 2. Measure:
Refer to “GENERAL CHASSIS” on page 4-1. ● Rear brake lock lever cable length “a”
2. Check: Out of specification → Adjust.

Rear brake lock lever cable length
“a”
45–47 mm (1.77–1.85 in)
3. Adjust:
● Rear brake lock lever cable length “a”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting nut “1” in direction “b” or
“c” until the rear brake lock lever cable length
3-19
CHASSIS
“a” is 42–44 mm (1.65–1.73 in) when the rear brake system, considerably lengthening the
brake lock lever is released. bleeding procedure.
b. Slowly apply the rear brake several times. ● If bleeding is difficult, it may be necessary to
c. Set the rear brake lock lever and wait more let the brake fluid settle for a few hours. Re-
than 5 minutes. peat the bleeding procedure when the tiny
d. Release the rear brake lock lever. bubbles in the hose have disappeared.
e. Turn the adjusting nut “1” in direction “b” or
1. Remove:
“c” until the rear brake lock lever cable length
“a” is 45–47 mm (1.77–1.85 in).
Direction “b” 2. Bleed:
Rear brake lock lever cable length is in- ● Hydraulic brake system
creased. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Direction “c” a. Fill the brake fluid reservoir to the proper lev-
Rear brake lock lever cable length is de- el with the recommended brake fluid.
creased. b. Install the diaphragm (brake master cylinder
reservoir or brake fluid reservoir).
a c. Connect a clear plastic hose “1” tightly to the
bleed screw “2”. And then place the other
1
end of the hose into a container.
b
A
2
c 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:

B 2
EAS21350
BLEEDING THE HYDRAULIC BRAKE

SYSTEM
EWA13100
WARNING
1
Bleed the hydraulic brake system whenever:
● the system is disassembled.
● a brake hose is loosened, disconnected or

replaced.
● the brake fluid level is very low. A. Front
● brake operation is faulty. B. Rear
NOTE: d. Slowly apply the brake several times.

● Be careful not to spill any brake fluid or allow e. Fully pull the brake lever or fully press down
the brake master cylinder reservoir or brake the brake pedal and hold it in position.
fluid reservoir to overflow. f. Loosen the bleed screw.
● When bleeding the hydraulic brake system, NOTE:
make sure there is always enough brake fluid Loosening the bleed screw will release the pres-
before applying the brake. Ignoring this pre- sure and cause the brake lever to contact the
caution could allow air to enter the hydraulic throttle grip or the brake pedal to fully extend.
3-20
CHASSIS
g. Tighten the bleed screw and then release the b. Loosen the lower ring nut “4” and then tight-
brake lever or brake pedal. en it to specification with the steering nut
h. Repeat steps (d) to (g) until all of the air bub- wrench “5”.
bles have disappeared from the brake fluid in NOTE:
the plastic hose. Set the torque wrench at a right angle to the
i. Tighten the bleed screw to specification. steering nut wrench.
Bleed screw
6 Nm (0.6 m•kg, 4.3 ft•lb)
T.
R.
j. Fill the brake fluid reservoir to the proper lev-

el with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-18.
EWA13110
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:

EAS21520
CHECKING AND ADJUSTING THE

STEERING HEAD
1. Stand the vehicle on a level surface. Steering nut wrench
EWA13120
90890-01403
WARNING
Spanner wrench
Securely support the vehicle so that there is
YU-33975
no danger of it falling over.
NOTE: Lower ring nut (initial tightening
Place the vehicle on the mainstand so that the torque)
T.
front wheel is elevated. 36 Nm (3.6 m•kg, 26 ft•lb)

R.
2. Check:
c. Check the steering head for looseness or
● Steering head
binding by turning the front fork all the way in
Grasp the bottom of the front fork legs and
both directions. If any binding is felt, remove
gently rock the front fork.
the lower bracket and check the upper and
Binding/looseness → Adjust the steering
lower bearings.
head.
Refer to “STEERING HEAD” on page 4-49.
3. Remove:
d. Loosen the lower ring nut “4” completely and
● Handlebar lower holder
then tighten it to specification with a steering
Refer to “STEERING HEAD” on page 4-49.
nut wrench.
4. Adjust:
● Steering head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the lock washer “2”, the upper ring
nut “1”, the center ring nut “3” and the rubber
washer.
3-21
CHASSIS
EAS21530
Lower ring nut (final tightening CHECKING THE FRONT FORK

T. torque) 1. Stand the vehicle on a level surface.
18 Nm (1.8 m•kg, 13 ft•lb) EWA13120
R.
WARNING
EWA13140 Securely support the vehicle so that there is
WARNING no danger of it falling over.
Do not overtighten the lower ring nut.
2. Check:
e. Install the rubber washer. ● Inner tube
f. Finger tighten the center ring nut, then align Damage/scratches → Replace.
the slots of both ring nuts. If necessary, hold ● Oil seal
the lower ring nut and tighten the center ring Oil leakage → Replace.
nut until their slots are aligned. 3. Hold the vehicle upright and apply the front
g. Install the lock washer “2”. brake.
NOTE: 4. Check:
Make sure the lock washer tabs “a” sit correctly ● Front fork operation
in the ring nut slots “b”. Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Rough movement → Repair.
Refer to “FRONT FORK” on page 4-42.
h. Hold the lower and center ring nuts with a

ring nut wrench and tighten the upper steer-
ing nut with a ring nut wrench.
Ring nut wrench EAS21660
90890-01268 CHECKING THE TIRES

Spanner wrench The following procedure applies to both of the
YU-01268 tires.
Steering nut wrench 1. Check:
90890-01403 ● Tire pressure
Spanner wrench Out of specification → Regulate.
YU-33975
Upper ring nut

90 Nm (9.0 m•kg, 65 ft•lb)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
Refer to “STEERING HEAD” on page 4-49. EWA13180
WARNING
● The tire pressure should only be checked
3-22
CHASSIS
and regulated when the tire temperature 1. Tire tread depth
equals the ambient air temperature. 2. Side wall
● The tire pressure and the suspension 3. Wear indicator
must be adjusted according to the total
weight (including cargo, rider, passenger Wear limit (front)
and accessories) and the anticipated 0.8 mm (0.03 in)
riding speed. Wear limit (rear)
● Operation of an overloaded vehicle could 0.8 mm (0.03 in)
cause tire damage, an accident or an inju-
EWA14080
ry.
WARNING
NEVER OVERLOAD THE VEHICLE.
● Do not use a tubeless tire on a wheel de-
Tire air pressure (measured on cold signed only for tube tires to avoid tire fail-
tires) ure and personal injury from sudden
Loading condition deflation.
0–90 kg (0–198 lb) ● When using a tube tire, be sure to install
Front the correct tube.
200 kPa (29 psi) (2.00 kgf/cm2) ● Always replace a new tube tire and a new
(2.00 bar) tube as a set.
Rear ● To avoid pinching the tube, make sure the
225 kPa (33 psi) (2.25 kgf/cm2) wheel rim band and tube are centered in
(2.25 bar)
the wheel groove.
Loading condition
● Patching a punctured tube is not recom-
90 kg–maximum load
Front mended. If it is absolutely necessary to do
200 kPa (29 psi) (2.00 kgf/cm2) so, use great care and replace the tube as
(2.00 bar) soon as possible with a good quality re-
Rear placement.
250 kPa (36 psi) (2.50 kgf/cm2)
(2.50 bar)
Maximum load
190 kg (419 lb)
* Total weight of rider, passenger, cargo
and accessories
EWA13190
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit, re-
place the tire immediately.
2. Check: A. Tire
● Tire surfaces B. Wheel
Damage/wear → Replace the tire.
Tube wheel Tube tire only
Tubeless wheel Tube or tubeless tire
EWA14090
WARNING
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufacturer
and of the same design. No guarantee con-
3-23
CHASSIS
cerning handling characteristics can be giv-
en if a tire combination other than one
approved by Yamaha is used on this vehicle.
Front tire
Size
120/70-13M/C 53P
Manufacturer/model
DUNLOP/D305F
Rear tire EAS21670
Size CHECKING THE WHEELS

130/70-13M/C 63P The following procedure applies to both of the
Manufacturer/model wheels.
DUNLOP/D305 1. Check:
● Wheel
EWA1B703
WARNING Damage/out-of-round → Replace.

EWA13260
● New tires have a relatively low grip on the WARNING
road surface until they have been slightly Never attempt to make any repairs to the
worn. Therefore, approximately 100 km wheel.
should be traveled at normal speed before
any high-speed riding is done. NOTE:
● After a tire has been repaired or replaced, After a tire or wheel has been changed or re-
be sure to tighten the tire air valve stem placed, always balance the wheel.
nut “1” and locknut “2” to specification. EAS21690
(rear tire only) CHECKING AND LUBRICATING THE
CABLES
2 The following procedure applies to all of the in-
1
A ner and outer cables.
EWA13270
WARNING
Damaged outer cable may cause the cable to
45˚ corrode and interfere with its movement. Re-
place damaged outer cable and inner cables
as soon as possible.
1. Check:
● Outer cable
A. Forward
Damage → Replace.
Tire air valve stem 2. Check:
Valve stem nut ● Cable operation
T.
2 Nm (0.2 m•kg, 1.4 ft•lb) Rough movement → Lubricate.

R.
Valve stem lock nut

3 Nm (0.3 m•kg, 2.2 ft•lb) Recommended lubricant
Engine oil or a suitable cable lu-
NOTE: bricant
For tires with a direction of rotation mark “3” in-
stall the tire with mark pointing in the direction of NOTE:
wheel rotation. Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubricating device.
3-24
CHASSIS
EAS21700
LUBRICATING THE LEVER

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

moving parts of the sidestand.
EAS21730
LUBRICATING THE CENTERSTAND

moving parts of the centerstand.
3-25
ELECTRICAL SYSTEM
EAS21750
ELECTRICAL SYSTEM A 1
EAS21760
CHECKING AND CHARGING THE BATTERY

Refer to “ELECTRICAL COMPONENTS” on
page 8-59.
EAS21770
CHECKING THE FUSES

Refer to “ELECTRICAL COMPONENTS” on
page 8-59.
EAS21790
B 2
REPLACING THE HEADLIGHT BULBS
The following procedure applies to both of the
headlight bulbs.
1. Remove:
● Front cowling

2. Remove:
● Headlight bulb cover “1”
Remove by turning in direction “a”.

A. Low beam
A a 1 B. High beam
4. Remove:
● Headlight bulb holder “1”
● Headlight bulb “2”
A
2
1
a
B
1 2
A. Low beam 1
B. High beam
3. Remove:
● Headlight coupler “1” (connector “2”)
A. Low beam
B. High beam
EWA13320
WARNING
Since the headlight bulb gets extremely hot,
3-26
ELECTRICAL SYSTEM
keep flammable products and your hands EAS21810
ADJUSTING THE HEADLIGHT BEAMS

away from the bulb until it has cooled down.
5. Install: headlights.
● Headlight bulb New 1. Adjust:
Secure the new headlight bulb with the head- ● Headlight beam (vertically)
light bulb holder. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

ECA13690
a. Turn the adjusting screw “1” in direction “a” or
CAUTION:
“b”.
Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise Direction “a”
the transparency of the glass, the life of the Headlight beam is raised.
bulb and the luminous flux will be adversely Direction “b”
affected. If the headlight bulb gets soiled, Headlight beam is lowered.
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
6. Install:
● Headlight bulb holder
b a
7. Connect: 1
● Headlight coupler
8. Install:
a b
● Headlight bulb cover“1”
1
Install by turning indirection “a”.
A a
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
● Headlight beam (horizontally)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw “2” in direction “a” or
“b”.
Direction “a”
B Headlight beam moves to the right.
Direction “b”
Headlight beam moves to the left.
a
b a
1
1
a b
1
A. Low beam
B. High beam
9. Install:
● Front cowling

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-27
CHASSIS
GENERAL CHASSIS .................................................................................. 4-1
FRONT WHEEL .......................................................................................... 4-5

REMOVING THE FRONT WHEEL ......................................................... 4-7
DISASSEMBLING THE FRONT WHEEL ............................................... 4-7
CHECKING THE FRONT WHEEL.......................................................... 4-7
ASSEMBLING THE FRONT WHEEL ..................................................... 4-8
1
ADJUSTING THE FRONT WHEEL STATIC BALANCE......................... 4-8
INSTALLING THE FRONT WHEEL........................................................ 4-9
REAR WHEEL............................................................................................. 4-11
CHECKING THE REAR WHEEL ............................................................ 4-12
2
ADJUSTING THE REAR WHEEL STATIC BALANCE ........................... 4-12
FRONT BRAKE........................................................................................... 4-13
INTRODUCTION .................................................................................... 4-17
CHECKING THE FRONT BRAKE DISC................................................. 4-17
3
REPLACING THE FRONT BRAKE PADS.............................................. 4-18
REMOVING THE FRONT BRAKE CALIPER ......................................... 4-19
DISASSEMBLING THE FRONT BRAKE CALIPER ............................... 4-20
CHECKING THE FRONT BRAKE CALIPER .......................................... 4-20
ASSEMBLING THE FRONT BRAKE CALIPER ..................................... 4-21 4
INSTALLING THE FRONT BRAKE CALIPER ........................................ 4-21
REMOVING THE FRONT BRAKE MASTER CYLINDER ...................... 4-22
CHECKING THE FRONT BRAKE MASTER CYLINDER ....................... 4-22
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER................... 4-23
INSTALLING THE FRONT BRAKE MASTER CYLINDER ..................... 4-23 5
REAR BRAKE............................................................................................. 4-25
INTRODUCTION .................................................................................... 4-30
CHECKING THE REAR BRAKE DISC ................................................... 4-30
REPLACING THE REAR BRAKE PADS ................................................ 4-30
REMOVING THE REAR BRAKE CALIPER............................................ 4-32
6
DISASSEMBLING THE REAR BRAKE CALIPER .................................. 4-32
CHECKING THE REAR BRAKE CALIPER ............................................ 4-33
ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-33
INSTALLING THE REAR BRAKE CALIPER .......................................... 4-34
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-35
7
CHECKING THE REAR BRAKE MASTER CYLINDER ......................... 4-35
ASSEMBLING THE REAR BRAKE MASTER CYLINDER ..................... 4-36
INSTALLING THE REAR BRAKE MASTER CYLINDER ....................... 4-36
HANDLEBAR .............................................................................................. 4-38 8
REMOVING THE HANDLEBARS ........................................................... 4-40
CHECKING THE HANDLEBAR .............................................................. 4-40
INSTALLING THE HANDLEBAR ............................................................ 4-40
FRONT FORK ............................................................................................. 4-42 9
REMOVING THE FRONT FORK LEGS ................................................. 4-44
DISASSEMBLING THE FRONT FORK LEGS ....................................... 4-44
CHECKING THE FRONT FORK LEGS .................................................. 4-45
ASSEMBLING THE FRONT FORK LEGS ............................................. 4-45
INSTALLING THE FRONT FORK LEGS ................................................ 4-48
STEERING HEAD ....................................................................................... 4-49
REMOVING THE LOWER BRACKET .................................................... 4-51
CHECKING THE STEERING HEAD ...................................................... 4-51
INSTALLING THE LOWER BRACKET................................................... 4-52
REAR SHOCK ABSORBER ASSEMBLY .................................................. 4-53
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY .................. 4-54
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY................... 4-54
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY................. 4-54
SWINGARM ................................................................................................ 4-55
REMOVING THE SWINGARM ............................................................... 4-56
CHECKING THE SWINGARM................................................................ 4-56
GENERAL CHASSIS
EAS21830
GENERAL CHASSIS
Removing the document box and side cover
6
3
5
8
7 7
2
5
Order Job/Parts to remove Q’ty Remarks

1 Document box 1
2 Rear cover 1
3 Left rear mat/right rear mat 1/1
4 Left side cover mole/right side cover mole 1/1
5 Left side cover/right side cover 1/1
6 Grab bar 1
Tail/brake light coupler/rear left turn signal cou-
7 2/1/1 Disconnect.
pler/rear right turn signal coupler
8 Tail/brake light assembly 1
For installation, reverse the removal proce-
dure.
4-1
GENERAL CHASSIS
Removing the trunk and footboard
4
3
6
7
2
7
8

Left side cover/right side cover
1 Trunk 1
2 Box light manual switch cover 1
3 Box light coupler 1 Disconnect.
4 Clip 1
Install the damper facing the rod side back-
5 Damper assembly 1
ward, the label side upward.
6 Seat 1
7 Left mat/right mat 1/1
8 Left footboard/right footboard 1/1
dure.
4-2
GENERAL CHASSIS
Removing the front cowling
2
10 3
16
4
9
8 6
1
7
12
15
14
11
12 13

Left footboard/right footboard
1 Upper cover 1
2 Windshield 1
3 Inner panel 1
4 Meter assembly 1
5 Leg shield mole 1
6 Meter assembly coupler 1 Disconnect.
7 Front left turn signal light 1
8 Front left turn signal coupler 1 Disconnect.
9 Front right turn signal light 1
10 Front right turn signal coupler 1 Disconnect.
11 Front mole 1
12 Front left side cowling/front right side cowling 1/1
13 Radiator cover 1
14 Front cowling 1
15 Headlight couplers 1 Disconnect.
16 Leg shield 1
dure.
4-3
GENERAL CHASSIS
Removing the air filter case
7
6
1 2
4
Left side cover/right side cover
1 Intake air temperature sensor 1 Disconnect.
2 Air filter case breather hose 1
3 Air induction system hose 1
4 Crankcase breather hose 1
5 Air induction system pipe 1
6 Air filter case clamp screw 1 Loosen.
7 Air filter case 1
dure.
4-4
FRONT WHEEL
EAS21870
FRONT WHEEL
Removing the front wheel and brake discs
1
6
4

Place the vehicle on a suitable stand so that
the front wheel is elevated.
1 Nut/washer 1/1
2 Front wheel axle 1
3 Front wheel assembly 1
4 Speed sensor 1
5 Spacer 1
6 Brake disc 1
dure.
4-5
FRONT WHEEL
Disassembling the front wheel
3
2
1

1 Oil seal 1
2 Bearing 2
3 Collar 1
For assembly, reverse the disassembly pro-
cedure.
4-6
FRONT WHEEL
EAS21900
REMOVING THE FRONT WHEEL

1. Stand the vehicle on a level surface. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EWA13120
WARNING EAS21920
CHECKING THE FRONT WHEEL

1. Check:
● Wheel axle
2. Elevate: Roll the wheel axle on a flat surface.

● Front wheel Bends → Replace.
NOTE:
Place the vehicle on a suitable stand so that the
front wheel is elevated.
3. Remove:
● Nut/washer
● Front wheel axle
● Front wheel
EAS21910
DISASSEMBLING THE FRONT WHEEL

1. Remove: EWA13460
● Oil seals WARNING

● Wheel bearings Do not attempt to straighten a bent wheel ax-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ le.
a. Clean the outside of the front wheel hub.
2. Check:
b. Remove the oil seals “1” with a flat-head
● Tire
screwdriver.
● Front wheel
NOTE:
Damage/wear → Replace.
To prevent damaging the wheel, place a rag “2”
Refer to “CHECKING THE TIRES” on page
between the screwdriver and the wheel surface.
3-22 and “CHECKING THE WHEELS” on
page 3-24.
3. Measure:
● Radial wheel runout “1”
● Lateral wheel runout “2”
Over the specified limits → Replace.
c. Remove the wheel bearings “3” with a gener-

al bearing puller.
Radial wheel runout limit

1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
4-7
FRONT WHEEL
4. Check: “4” or balls “5”. Contact should be made
● Wheel bearings only with the outer race “6”.
Front wheel turns roughly or is loose → Re- NOTE:
place the wheel bearings. Use a socket “7” that matches the diameter of
5. Replace: the wheel bearing outer race and oil seal.
● Wheel bearings
● Oil seals New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside of the front wheel hub.
b. Remove the oil seals “1” with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag “2”
between the screwdriver and the wheel surface.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21970
ADJUSTING THE FRONT WHEEL STATIC

BALANCE
NOTE:
● After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.
c. Remove the wheel bearings “3” with a gener- ● Adjust the front wheel static balance with the
al bearing puller. brake disc installed.
1. Remove:
● Balancing weight(s)
2. Find:
● Front wheel’s heavy spot
NOTE:
Place the front wheel on a suitable balancing
stand.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Spin the front wheel.
b. When the front wheel stops, put an “X1” mark
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ at the bottom of the wheel.
EAS21960
ASSEMBLING THE FRONT WHEEL

1. Install:
● Wheel bearings
● Oil seals New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
ECA14130
CAUTION:
c. Turn the front wheel 90° so that the “X1” mark
Do not contact the wheel bearing inner race
is positioned as shown.
4-8
FRONT WHEEL
d. Release the front wheel. c. If the heavy spot does not stay in that posi-
e. When the wheel stops, put an “X2” mark at tion, install a heavier weight.
the bottom of the wheel. d. Repeat steps (b) and (c) until the front wheel
is balanced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
● Front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the front wheel and make sure it stays
at each position shown.
f. Repeat steps (c) through (e) several times

until all the marks come to rest at the same
spot.
g. The spot where all the marks come to rest is
the front wheel’s heavy spot “X”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
● Front wheel static balance b. If the front wheel does not remain stationary
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ at all of the positions, rebalance it.
a. Install a balancing weight “1” onto the rim ex-
actly opposite the heavy spot “X”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1B702
INSTALLING THE FRONT WHEEL

1. Lubricate:
● Wheel bearing
● Oil seal lip
● Speed sensor
NOTE:
Start with the lightest weight.
2. Install:
b. Turn the front wheel 90° so that the heavy ● Spacer
spot is positioned as shown. ● Speed sensor
● Front wheel
NOTE:
● Make sure the speed sensor and the wheel
hub are installed with the two projections
meshed into the two slots respectively.
● Make sure the slot “a” in the speed sensor fits
over the stopper “b” on the outer tube.
4-9
FRONT WHEEL
3. Tighten:
Front wheel axle

70 Nm (7.0 m•kg 51 ft•lb)
T.
R.
EWA13500
WARNING
Make sure the brake hose is routed properly.
ECA14140
CAUTION:
Before tightening the wheel axle nut, push
down hard on the handlebar(s) several times
and check if the front fork rebounds smooth-
ly.
4-10
REAR WHEEL
EAS22020
REAR WHEEL
Removing the rear wheel
LS

Place the vehicle on the mainstand so that
the rear wheel is elevated.
Muffler Refer to “ENGINE REMOVAL” on page 5-1.
Swingarm Refer to “SWINGARM” on page 4-55.
1 Rear wheel 1
2 Rear brake disc 1
3 Rear fender 1
dure.
4-11
REAR WHEEL
EAS22090
CHECKING THE REAR WHEEL

1. Check:
● Wheel axle
● Rear wheel
Refer to “CHECKING THE FRONT WHEEL”

on page 4-7.
2. Check:
● Tire
● Rear wheel
Refer to “CHECKING THE TIRES” on page
3-22 and “CHECKING THE WHEELS” on
page 3-24.
3. Measure:
● Radial wheel runout
● Lateral wheel runout
Refer to “CHECKING THE FRONT WHEEL”

on page 4-7.
EAS22150
ADJUSTING THE REAR WHEEL STATIC

BALANCE
NOTE:
● After replacing the tire, wheel or both, the rear
wheel static balance should be adjusted.
● Adjust the rear wheel static balance with the
brake disc and rear wheel drive hub installed.
1. Adjust:
● Rear wheel static balance
Refer to “ADJUSTING THE FRONT WHEEL

STATIC BALANCE” on page 4-8.
4-12
FRONT BRAKE
EAS22210
FRONT BRAKE
Removing the front brake caliper
1 5
6
3
2

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-20.
1 Union bolt 1
2 Copper washer 2
3 Brake hose 1
4 Brake caliper bolt 2
5 Speed sensor lead holder 1
6 Front brake caliper 1
dure.
4-13
FRONT BRAKE
Disassembling the front brake caliper
2
7
3 9
11 10
8
6
1
5
4

2 Brake caliper bracket 1
3 Bleed screw 1
4 Brake pad 2
5 Brake pad shim 2
6 Brake pad spring 1
8 Brake caliper piston 2
9 Dust seal 2
10 Brake caliper piston seal 2
11 Brake caliper body 1
cedure.
*Apply silicon grease
4-14
FRONT BRAKE
Removing the front brake master cylinder
9 2
10
8
5 6
8
4
11

Drain.
1 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm
2 1
holder
3 Brake master cylinder reservoir diaphragm 1
4 Brake lever 1
5 Front brake light switch connector 2 Disconnect.
6 Union bolt 1
7 Brake hose 1
8 Copper washer 2
9 Brake master cylinder holder 1
10 Brake master cylinder 1
11 Front brake light switch 1
dure.
4-15
FRONT BRAKE
Disassembling the front brake master cylinder
2
1

1 Dust boot 1
2 Circlip 1
3 Master cylinder kit 1
4 Master cylinder body 1
cedure.
4-16
FRONT BRAKE
EAS22220
INTRODUCTION Brake disc deflection limit

EWA14100
0.15 mm (0.0059 in)
WARNING
Disc brake components rarely require disas- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
sembly. Therefore, always follow these pre- a. Place the vehicle on a suitable stand so that
ventive measures: the front wheel is elevated.
● Never disassemble brake components un- b. Before measuring the front brake disc deflec-
less absolutely necessary. tion, turn the handlebar to the left or right to
● If any connection on the hydraulic brake ensure that the front wheel is stationary.
system is disconnected, the entire brake c. Remove the brake caliper.
system must be disassembled, drained, d. Hold the dial gauge at a right angle against
cleaned, properly filled, and bled after re- the brake disc surface.
assembly. e. Measure the deflection 1.5 mm (0.06 in) be-
● Never use solvents on internal brake com- low the edge of the brake disc.
ponents.
● Use only clean or new brake fluid for
cleaning brake components. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

● Brake fluid may damage painted surfaces 3. Measure:
and plastic parts. Therefore, always clean ● Brake disc thickness
up any spilt brake fluid immediately. Measure the brake disc thickness at a few
● Avoid brake fluid coming into contact with different locations.
the eyes as it can cause serious injury. Out of specification → Replace.
● FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
● Flush with water for 15 minutes and get
immediate medical attention.
EAS22240
CHECKING THE FRONT BRAKE DISC

The following procedure applies to both brake
disc.
1. Check:
● Brake disc
Damage/galling → Replace. Brake disc thickness limit

4.5 mm (0.18 in)
2. Measure:
● Brake disc deflection
4. Adjust:
Out of specification → Correct the brake disc
deflection or replace the brake disc.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the front wheel.
Refer to “FRONT WHEEL” on page 4-5.
b. Remove the brake disc.
c. Rotate the brake disc by one bolt hole.
4-17
FRONT BRAKE
d. Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages and in a
crisscross pattern.
2. Remove:
● Brake pad “1”
● Brake pad spring “2”
● Brake pad shim “3”
Brake disc bolt

23 Nm (2.3 m•kg, 17 ft•lb)
T.
LOCTITE®
R.
2
e. Measure the brake disc deflection. 1
f. If out of specification, repeat the adjustment 3
steps until the brake disc deflection is within
specification.
g. If the brake disc deflection cannot be brought
within specification, replace the brake disc. 3. Measure:
h. Install the front wheel. ● Brake pad wear limit “a”
Refer to “FRONT WHEEL” on page 4-5. Out of specification → Replace the brake
pads as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Brake pad lining thickness (inner)
EAS22270 6.0 mm (0.24 in)
REPLACING THE FRONT BRAKE PADS Limit
The following procedure applies to both brake 0.8 mm (0.03 in)
caliper. Brake pad lining thickness (outer)
NOTE: 6.0 mm (0.24 in)
When replacing the brake pads, it is not neces- Limit
sary to disconnect the brake hose or disassem- 0.8 mm (0.03 in)
ble the brake caliper.
1. Loosen:
● Brake caliper bolt “1”
● Brake caliper “2”
● Brake pad spring
4. Install:
● Brake pad shim “1”
(onto the brake pads)
4-18
FRONT BRAKE
● Brake pad “2” 6. Check:
● Brake pad spring “3” ● Brake fluid level
NOTE: Below the minimum level mark “a” → Add the

Always install new brake pads, brake pad shims, recommended brake fluid to the proper level.
and a brake pad spring as a set. Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-18.
3
a
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
7. Check:
a. Connect a clear plastic hose “5” tightly to the
● Brake lever operation
bleed screw “4”. Put the other end of the
Soft or spongy feeling → Bleed the brake
hose into an open container.
system.
Refer to “BLEEDING THE HYDRAULIC
EAS22300
REMOVING THE FRONT BRAKE CALIPER

brake caliper.
NOTE:
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
b. Loosen the bleed screw and push the brake 1. Remove:
caliper pistons into the brake caliper with ● Union bolt “1”
your finger. ● Copper washers “2”
c. Tighten the bleed screw. ● Brake hose “3”
Bleed screw
6 Nm 0.6 m•kg, 4.3 ft•lb)
T.
R.
d. Install a new brake pad shim onto each new

brake pad.
e. Install new brake pads and a new brake pad
spring.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install: NOTE:
● Brake caliper Put the end of the brake hose into a container
● Brake caliper bolt and pump out the brake fluid carefully.
Brake caliper bolt

27 Nm (2.7 m•kg, 19 ft•lb)
T.
R.
4-19
FRONT BRAKE
EAS22340
DISASSEMBLING THE FRONT BRAKE Recommended brake component replacement

schedule
CALIPER
The following procedure applies to both of the Piston seals Every two years
brake caliper. Brake hoses Every four years
1. Remove:
Every year and whenever
● Brake caliper piston “1” Brake fluid
the brake is disassembled
● Dust seal “2”
● Brake caliper piston seals “3”

1. Check:
● Brake caliper pistons “1”
Rust/scratches/wear → Replace the brake

caliper pistons.
● Brake caliper cylinders “2”
Scratches/wear → Replace the brake caliper

assembly.
● Brake caliper body “3”
Cracks/damage → Replace the brake caliper

assembly.
● Brake fluid delivery passages
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ (brake caliper body)

a. Blow compressed air into the brake hose Obstruction → Blow out with compressed air.
joint opening “a” to force out the left side pis-
ton from the brake caliper.
EWA1B704
WARNING
EWA1B702 Whenever a brake caliper is disassembled,
WARNING replace the brake caliper piston seals and
● Cover the brake caliper pistons with a rag. dust seals.
Be careful not to get injured when the pis-
2. Check:
tons are expelled from the brake caliper.
● Brake caliper bracket “1”
● Never try to pry out the brake caliper pis-
tons.
b. Remove the dust seals, brake caliper piston
seals.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22390
CHECKING THE FRONT BRAKE CALIPER

Recommended brake component replacement
schedule
Brake pads If necessary
4-20
FRONT BRAKE
EAS22410
3. Install:
ASSEMBLING THE FRONT BRAKE CALIPER
● Copper washers “1” New
EWA1B705
WARNING ● Brake hose “2”
● Before installation, all internal brake com- ● Union bolt “3”
ponents should be cleaned and lubricated

2
with clean or new brake fluid.
● Never use solvents on internal brake com-
ponents as they will cause the piston seals 3
to swell and distort.
● Whenever a brake caliper is disassem-
1
bled, replace the brake caliper piston seals
1
and dust seals.
Recommended fluid
DOT 4 Brake hose union bolt
30 Nm (3.0 m•kg, 22 ft•lb)
1. Install:
T.
R.
● Brake caliper piston seal “1” New EWA13530
● Dust seal “2” New WARNING

● Brake caliper piston “3” Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CABLE
ROUTING” on page 2-27.
ECA14170
3 CAUTION:
3 When installing the brake hose onto the
brake caliper “1”, make sure the brake pipe
“a” touches the projection “b” on the brake
2 1 2 1
caliper.
EAS22440
INSTALLING THE FRONT BRAKE CALIPER

brake caliper.
1. Install:
● Brake caliper bracket
Brake caliper bracket bolt

35 Nm (3.5 m•kg 25 ft•lb)
T.
R.
4. Fill:
2. Install: ● Brake master cylinder reservoir
● Brake pad spring

● Brake pad
mended brake fluid)
● Brake caliper
● Brake caliper bolt

Recommended fluid
DOT 4
Brake caliper bolt
27 Nm (2.7 m•kg 19 ft•lb) EWA13090
WARNING
T.
R.
Refer to “REPLACING THE FRONT BRAKE ● Use only the designated brake fluid. Other
PADS” on page 4-18. brake fluids may cause the rubber seals to
4-21
FRONT BRAKE
deteriorate, causing leakage and poor 1. Disconnect:
brake performance. ● Brake switch coupler
● Refill with the same type of brake fluid that (from the brake switch)
is already in the system. Mixing brake flu- 2. Remove:
ids may result in a harmful chemical reac- ● Union bolt “1”
tion, leading to poor brake performance. ● Copper washers “2”
● When refilling, be careful that water does ● Brake hose “3”
not enter the brake fluid reservoir. Water NOTE:

will significantly lower the boiling point of To collect any remaining brake fluid, place a
the brake fluid and could cause vapor container under the master cylinder and the end
lock. of the brake hose.
ECA13540
CAUTION: 2
and plastic parts. Therefore, always clean up
5. Bleed:
● Brake system 1
Refer to “BLEEDING THE HYDRAULIC 3
6. Check:
EAS22500
CHECKING THE FRONT BRAKE MASTER
CYLINDER
recommended brake fluid to the proper level. 1. Check:
Refer to “CHECKING THE BRAKE FLUID ● Brake master cylinder “1”
LEVEL” on page 3-18. Damage/scratches/wear → Replace.
a
(brake master cylinder body)
Obstruction → Blow out with compressed air.
7. Check:

system. 2. Check:
Refer to “BLEEDING THE HYDRAULIC ● Brake master cylinder kit “1”
BRAKE SYSTEM” on page 3-20. Damage/scratches/wear → Replace.
EAS22490
REMOVING THE FRONT BRAKE MASTER

CYLINDER
NOTE:
Before removing the front brake master cylinder,
drain the brake fluid from the entire brake sys-
tem.
4-22
FRONT BRAKE
● Circlip “2” New
● Dust boot “3”
1
2
3. Check: 3
● Brake master cylinder reservoir cap “1”
Cracks/damage → Replace. EAS22530
● Brake master cylinder reservoir diaphragm

INSTALLING THE FRONT BRAKE MASTER
holder “2” CYLINDER
1. Install:
● Brake master cylinder “1”
“3”
● Master cylinder holder “2”
Brake master cylinder bracket bolt
10 Nm (1.0 m•kg, 7.2 ft•lb)
T.
1 R.
NOTE:
● Install the brake master cylinder holder with
2
the “R” mark.
3 ● Install the brake master cylinder holder with
the “UP” mark facing up.
● Align the end of the brake master cylinder
holder with the punch mark “a” on the handle-
4. Check: bar.
● Brake hose
● First, tighten the upper bolt, then the lower
Cracks/damage/wear → Replace. bolt.
EAS22520
ASSEMBLING THE FRONT BRAKE MASTER 1

CYLINDER
EWA13520
WARNING
● Before installation, all internal brake com-
a
ponents. 2
Recommended fluid 2. Install:

DOT 4 ● Copper washers New
● Brake hose
1. Install: ● Union bolt
● Master cylinder kit “1”
Cylinder cup installer

90890-01996
4-23
FRONT BRAKE
ing point of the brake fluid and could
Brake hose union bolt
cause vapor lock.
T. 30 Nm (3.0 m•kg, 22 ft•lb)
ECA13540
R.
EWA13530 CAUTION:
WARNING Brake fluid may damage painted surfaces
Proper brake hose routing is essential to in- and plastic parts. Therefore, always clean up
sure safe vehicle operation. Refer to “CABLE any spilt brake fluid immediately.
ROUTING” on page 2-27. 4. Bleed:
NOTE: ● Brake system
● When installing the brake hose onto the brake Refer to “BLEEDING THE HYDRAULIC
master cylinder, make sure the brake projec- BRAKE SYSTEM” on page 3-20.
tion “a” on the brake master cylinder touches 5. Check:
the pipe of the brake hose. ● Brake fluid level
● While holding the brake hose, tighten the Below the minimum level mark “a” → Add the
union bolt as shown. recommended brake fluid to the proper level.
● Turn the handlebar to the left and right to Refer to “CHECKING THE BRAKE FLUID
make sure the brake hose does not touch oth- LEVEL” on page 3-18.
er parts (e.g., wire harness, cables, leads).
Correct if necessary. a
6. Check:
a ● Brake lever operation

3. Fill:
system.
● Brake master cylinder reservoir
mended brake fluid)
Recommended fluid
DOT 4
EWA13540
WARNING
brake performance.
● When refilling, be careful that water does
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
4-24
REAR BRAKE
EAS22550
REAR BRAKE
Removing the rear brake caliper
5 8
7
6
10
14
11 12
1 3 4 13
13
12 14

Refer to “GENERAL CHASSIS” on page
Right side cover
4-1.
Drain.
1 Rear brake lock adjusting nut 1
2 Rear brake lock cable 1 Remove from the brake caliper.
3 Rear brake lock adjusting pin 1
4 Rear brake lock spring 1
5 Union bolt 1
6 Copper washer 2
7 Rear brake hose 1
8 Brake caliper bracket 1
10 Rear brake caliper 1
11 Brake pad 2
12 Brake pad shim cover 2
13 Brake pad shim 2
4-25
REAR BRAKE
Removing the rear brake caliper
5 8
7
6
10
14
11 12
1 3 4 13
13
12 14

dure.
4-26
REAR BRAKE
Disassembling the rear brake caliper
2
4

1 Brake caliper piston 1
2 Dust seal 1
3 Brake caliper piston seal 1
4 Bleed screw 1
5 Rear brake lock cable holder 1
6 Brake caliper body 1
cedure.
4-27
REAR BRAKE
Removing the rear brake master cylinder
1
9
2
3
10
8
6
5
8
7
4
11

Drain.
1 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm
2 1
holder
3 Brake master cylinder reservoir diaphragm 1
4 Brake lever 1
5 Rear brake light switch coupler 2 Disconnect.
6 Union bolt 1
7 Brake hose 1
8 Copper washer 2
9 Brake master cylinder holder 1
10 Brake master cylinder 1
11 Rear brake switch 1
dure.
4-28
REAR BRAKE
Disassembling the brake master cylinder
2
1

1 Dust boot 1
2 Circlip 1
3 Brake master cylinder kit 1
4 Brake master cylinder body 1
cedure.
4-29
REAR BRAKE
EAS22560
Refer to “CHECKING THE FRONT BRAKE
INTRODUCTION
EWA14100
DISC” on page 4-17.
WARNING
Brake disc thickness limit
Disc brake components rarely require disas- 4.5 mm (0.18 in)
sembly. Therefore, always follow these pre-
ventive measures: 5. Adjust:
● Never disassemble brake components un- ● Brake disc deflection
less absolutely necessary. Refer to “CHECKING THE FRONT BRAKE

● If any connection on the hydraulic brake DISC” on page 4-17.
system is disconnected, the entire brake
system must be disassembled, drained, Brake disc bolt
cleaned, properly filled, and bled after re- 23 Nm (2.3 m•kg, 17 ft•lb)
T.
LOCTITE®
R.
assembly.
6. Install:
ponents.
● Rear wheel
● Use only clean or new brake fluid for
Refer to “REAR WHEEL” on page 4-11.
cleaning brake components.
● Brake fluid may damage painted surfaces
EAS22580
REPLACING THE REAR BRAKE PADS

and plastic parts. Therefore, always clean
NOTE:
up any spilt brake fluid immediately.
When replacing the brake pads, it is not neces-
● Avoid brake fluid coming into contact with
sary to disconnect the brake hose or disassem-
the eyes as it can cause serious injury.
ble the brake caliper.
● FIRST AID FOR BRAKE FLUID ENTERING
THE EYES: 1. Remove:
● Flush with water for 15 minutes and get ● Left side cover
immediate medical attention. Refer to “GENERAL CHASSIS” on page 4-1.

● Muffler
EAS22570
Refer to “ENGINE REMOVAL” on page 5-1.
CHECKING THE REAR BRAKE DISC ● Brake caliper bracket
1. Remove:
● Brake caliper bolt “1”
● Rear wheel
● Rear brake caliper “2”
2. Check: 2
● Brake disc
Damage/galling → Replace.
3. Measure:
Out of specification → Correct the brake disc 1

deflection or replace the brake disc.
Refer to “CHECKING THE FRONT BRAKE
DISC” on page 4-17.
Brake disc deflection limit 2. Remove:

● Brake pad “1”
0.15 mm (0.0059 in)
● Brake pad shim cover
4. Measure: ● Brake pad shim
● Brake disc thickness ● Brake pad spring “2”
Measure the brake disc thickness at a few

different locations.
Out of specification → Replace.
4-30
REAR BRAKE
3. Measure: 5. Install:
● Brake pad wear limit “a” ● Brake caliper
Out of specification → Replace the brake ● Brake caliper bolt
pads as a set. (Apply the silicone grease)

Brake pad lining thickness (inner) Brake caliper bolt
7.3 mm (0.29 in) 27 Nm (2.7 m•kg 19 ft•lb)
T.
Limit
R.
0.8 mm (0.03 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Brake pad lining thickness (outer) a. Connect a clear plastic hose “1” tightly to the
7.3 mm (0.29 in) bleed screw “2”. Put the other end of the
Limit hose into an open container.
0.8 mm (0.03 in)
b. Loosen the brake caliper bleed screw, and

4. Install: then turn the brake caliper piston clockwise
● Brake caliper bracket until section “a” of the brake caliper piston is
● Brake pad spring“1” level with the surface of the brake caliper
● Brake pad shim body.
● Brake pad shim cover NOTE:
● Brake pad “2” Align the recesses “b” in the brake caliper piston
NOTE: with the brake caliper body as shown in the illus-
Always install new brake pads, brake pad shims, tration.
and a brake pad spring as a set.
4-31
REAR BRAKE
3 a
a
c. Tighten the bleed screw. 7. Check:

● Brake pedal operation
Bleed screw
6 Nm (0.6 m•kg, 4.3 ft•lb)
system.
T.
R.

d. Install the brake pad shims and brake pad
shim covers onto each new brake pads.
e. Install new brake pads and a new brake pad EAS22590
spring. REMOVING THE REAR BRAKE CALIPER

NOTE: NOTE:
Align the projection “c” on the piston side of the Before disassembling the brake caliper, drain
brake pad with the lower recess in the brake cal- the brake fluid from the entire brake system.
iper piston. 1. Remove:
● Rear brake lock cable
● Union bolt “1”
● Copper washers “2”
A ● Brake hose “3”
1 3
c
B
2
A. Upper
B. Lower
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ NOTE:
6. Check: Put the end of the brake hose into a container
and pump out the brake fluid carefully.
EAS22630
recommended brake fluid to the proper level. DISASSEMBLING THE REAR BRAKE
Refer to “CHECKING THE BRAKE FLUID CALIPER
LEVEL” on page 3-18. 1. Remove:
● Brake caliper piston “1”
● Dust seal “2”
● Brake caliper piston seal “3”
4-32
REAR BRAKE
(brake caliper body)
3
2 2
3
1 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Operate the rear brake lock lever “4” contin-
uously in the direction shown by the arrow
EWA1B706
until the piston comes out.
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston seal and
dust seal.
2. Check:
● Brake caliper bracket “1”
4
b. Remove the dust seal and brake caliper pis-

ton seal. 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22640
CHECKING THE REAR BRAKE CALIPER

EAS22660
Recommended brake component
replacement schedule
ASSEMBLING THE REAR BRAKE CALIPER
EWA1B707
Brake pads If necessary WARNING

Piston seals Every two years
Brake hoses Every four years
Every two years and ● Never use solvents on internal brake com-
Brake fluid whenever the brake is dis-
assembled
ponents as they will cause the piston seals
to swell and distort.
1. Check: ● Whenever a brake caliper is disassem-
bled, replace the brake caliper piston seal
Rust/scratches/wear → Replace the brake and dust seal.
caliper pistons.
● Brake caliper cylinder “2” Recommended fluid
Scratches/wear → Replace the brake caliper DOT 4
assembly.
● Brake caliper body “3” 1. Install:
Cracks/damage → Replace the brake caliper ● Brake caliper piston seal “1” New
assembly. ● Dust seal “2” New
4-33
REAR BRAKE
Brake caliper bracket

40 Nm (4.0 m•kg, 29 ft•lb)
T.
R.
30 Nm (3.0 m•kg, 22 ft•lb)
2 EWA13530
WARNING
1 Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CABLE
ROUTING” on page 2-27.
2. Install: ECA14170

CAUTION:
Turn the brake caliper piston clockwise until When installing the brake hose onto the
section “a” of the brake caliper piston is level brake caliper “1”, make sure the brake pipe
with the surface of the brake caliper body. “a” touches the projection “b” on the brake
NOTE: caliper.
Align the recesses “b” in the brake caliper piston
with the brake caliper body as shown in the illus-
tration. a
1
a
1 b
2. Remove:
b ● Brake caliper
3. Install:
EAS22670 ● Brake pad spring
INSTALLING THE REAR BRAKE CALIPER ● Brake pad
1. Install: ● Brake caliper
● Brake caliper bracket

● Brake caliper bolt
● Brake caliper “1”

Refer to “REPLACING THE REAR BRAKE
(temporarily) PADS” on page 4-30.
● Copper washers New

Brake caliper bolt
27 Nm (2.7 m•kg, 19 ft•lb)
T.
R.
1 2 4. Fill:
3

mended brake fluid)
Recommended fluid
DOT 4
EWA13090
WARNING
4-34
REAR BRAKE
deteriorate, causing leakage and poor EAS22700
REMOVING THE REAR BRAKE MASTER

brake performance.
CYLINDER
1. Remove:
● Copper washers “2”
not enter the brake fluid reservoir. Water 2
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
ECA13540
CAUTION:
1
and plastic parts. Therefore, always clean up 3
5. Bleed:
NOTE:
● Brake system
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
6. Check:
EAS22710
Below the minimum level mark “a” → Add the CHECKING THE REAR BRAKE MASTER
recommended brake fluid to the proper level. CYLINDER
Refer to “CHECKING THE BRAKE FLUID 1. Check:
LEVEL” on page 3-18. ● Brake master cylinder “1”
Damage/scratches/wear → Replace.
● Brake fluid delivery passages “2”
a
(brake master cylinder body)
7. Check:

system.
Refer to “BLEEDING THE HYDRAULIC 2. Check:
● Brake master cylinder kit “1”
8. Check: Damage/scratches/wear → Replace.
● Rear brake lock cable length
Refer to “ADJUSTING THE REAR BRAKE

LOCK LEVER CABLE” on page 3-19.
4-35
REAR BRAKE
Cylinder cup installer

90890-01996
3. Check: 1
● Brake master cylinder reservoir cap “1”
2
3
EAS1B703
holder “2” INSTALLING THE REAR BRAKE MASTER
Cracks/damage → Replace. CYLINDER
● Brake master cylinder reservoir diaphragm 1. Install:
“3” ● Brake master cylinder “1”
Cracks/damage → Replace. ● Brake master cylinder holder “2”
Brake master cylinder bracket bolt

10 Nm (1.0 m•kg, 7.2 ft•lb)
1
T.
R.
NOTE:
the “L” mark.
the “UP” mark facing up.
● Align the end of the brake master cylinder
4. Check: holder with the punch mark “a” on the handle-
● Brake hoses
bar.
Cracks/damage/wear → Replace. ● First, tighten the upper bolt, then the lower
bolt.
EAS22730
ASSEMBLING THE REAR BRAKE MASTER

1
CYLINDER
EWA13520
WARNING 2
● Never use solvents on internal brake com- a
ponents.
Recommended fluid 2. Install:

DOT 4 ● Copper washers New
● Brake hose
1. Install: ● Union bolt
● Master cylinder kit “1”
● Circlip “2” New
● Dust boot “3”
4-36
REAR BRAKE
ing point of the brake fluid and could
cause vapor lock.
T. 30 Nm (3.0 m•kg, 22 ft•lb)
ECA13540
R.
EWA13530 CAUTION:
WARNING Brake fluid may damage painted surfaces
Proper brake hose routing is essential to in- and plastic parts. Therefore, always clean up
sure safe vehicle operation. Refer to “CABLE any spilt brake fluid immediately.
ROUTING” on page 2-27. 4. Bleed:
NOTE: ● Brake system
● When installing the brake hose onto the brake Refer to “BLEEDING THE HYDRAULIC
master cylinder, make sure the brake projec- BRAKE SYSTEM” on page 3-20.
tion “a” on the brake master cylinder touches 5. Check:
the pipe of the brake hose. ● Brake fluid level
● While holding the brake hose, tighten the Below the minimum level mark “a” → Add the
union bolt as shown. recommended brake fluid to the proper level.
● Turn the handlebar to the left and right to Refer to “CHECKING THE BRAKE FLUID
make sure the brake hose does not touch oth- LEVEL” on page 3-18.
er parts (e.g., wire harness, cables, leads).
Correct if necessary. a
6. Check:

3. Fill:
system.
mended brake fluid)
Recommended fluid
DOT 4
EWA13540
WARNING
brake performance.
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
4-37
HANDLEBAR
EAS22840
HANDLEBAR
Removing the handlebar
9 14
2
3 13
12
6
8
5
15
10
16
1
17
11
4 18
19

1 Left rear view mirror 1
2 Right rear view mirror 1
3 Brake master cylinder bracket 1
4 Front brake master cylinder 1
5 Right grip end 1
6 Right handlebar switch 1
7 Throttle cable 2
8 Throttle grip 1
9 Brake master cylinder bracket 1
10 Rear brake master cylinder 1
11 Lock lever holder 1
12 Left handlebar switch 1
13 Left grip end 1
14 Handlebar grip 1
15 Handlebar upper holder 2
16 Handlebar 1
17 Steering upper cover 1
18 Steering center cover 1
19 Steering lower cover 1
4-38
HANDLEBAR
Removing the handlebar
9 14
2
3 13
12
6
8
5
15
10
16
1
17
11
4 18
19

dure.
4-39
HANDLEBAR
EAS22860
REMOVING THE HANDLEBARS
1. Stand the vehicle on a level surface. 2. Install:
EWA13120 ● Handlebar “1”
WARNING ● Upper handlebar holders “2”

no danger of it falling over. Upper handlebar holder bolt
23 Nm (2.3 m•kg, 19 ft•lb)
2. Remove:
T.
R.
● Right handlebar switch ECA1B701
● Throttle grip CAUTION:

3. Remove: First, tighten the bolts on the front side of the
● Handlebar grip “1” handlebar holder, and then on the rear side.
NOTE: NOTE:
Blow compressed air between the left handlebar ● The upper handlebar holders should be in-
and the handlebar grip, and gradually push the stalled with the punch marks “a” facing for-
grip off the handlebar. ward “A”.
● Align the match marks “b” on the handlebar
with the upper surface of the lower handlebar
holders.
EAS22880
CHECKING THE HANDLEBAR

1. Check:
● Handlebar “1”
Bends/cracks/damage → Replace.
EWA13690 1
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
2 b
3. Install:
● Handlebar grip
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of rubber adhesive onto the
left end of the handlebar.
EAS22930
b. Slide the handlebar grip over the left end of
INSTALLING THE HANDLEBAR
the handlebar.
EWA13120
c. Wipe off any excess rubber adhesive with a
WARNING
4-40
HANDLEBAR
clean rag.
EWA13700
b
WARNING
Do not touch the handlebar grip until the rub-
ber adhesive has fully dried.
a
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
● Brake master cylinder
Refer to “FRONT BRAKE” on page 4-13 and 8. Remove:

“REAR BRAKE” on page 4-25. ● Left grip end
5. Install: ● Right grip end
● Left handlebar switch
NOTE:
Grip end
Align the projection “a” of the left handlebar 26 Nm (2.6 m•kg 19 ft•lb)
T.
R.
switch with the hole “b” in the handlebar.
9. Adjust:
● Throttle cable free play
a Refer to “ADJUSTING THE THROTTLE CA-

b BLE FREE PLAY” on page 3-6.
Throttle cable free play

3.0–5.0 mm (0.12–0.20 in)
1
6. Install:
● Throttle grip
● Throttle cables “1”
(Apply the lithium-soap-based grease)
7. Install:
● Right handlebar switch
NOTE:
Align the projection “a” on the handlebar switch
with the hole “b” in the handlebar.
4-41
FRONT FORK
EAS22950
FRONT FORK
Removing the front fork legs
7
5
1
8
3

Front cowling
4-1.
Front wheel Refer to “FRONT WHEEL” on page 4-5.
1 Brake hose holder 1
2 Speed sensor lead holder 1
3 Front brake caliper 1
4 Front fender 1
5 Cap bolt 2
6 O-ring 2
7 Lower bracket pinch bolt 4 Loosen.
8 Fork leg (left/right) 1/1
dure.
4-42
FRONT FORK
Disassembling the front fork legs
1
2 10
9
11
3
4
12
15
13
14 6
5

1 Fork spring seat 1
2 Fork spring 1
3 Dust seal 1
4 Oil seal clip 1
5 Damper rod bolt 1
6 Copper washer 1
7 Damper rod 1
8 Rebound spring 1
9 Oil lock piece/bushing/spring 1/1/1
10 Inner tube 1
11 Inner tube bushing 1
12 Oil seal 1
13 Washer 1
14 Outer tube bushing 1
15 Outer tube 1
cedure.
4-43
FRONT FORK
EAS22960
REMOVING THE FRONT FORK LEGS

front fork legs.
EWA13120
WARNING
NOTE:
Place the vehicle on the mainstand so that the 3. Remove:
front wheel is elevated. ● Dust seal “1”
● Oil seal clip “2”

2. Remove:
● Cap bolt “1”
(with a flat-head screwdriver)
ECA14180
(Use the 17 mm hexagon wrench) CAUTION:
3. Loosen:
Do not scratch the inner tube.
● Lower bracket pinch bolt “2”
1
2
EWA13640 4. Remove:
WARNING ● Damper rod bolt “1”
Before loosening the upper and lower brack- NOTE:

et pinch bolts, support the front fork leg. While holding the damper rod with the damper
rod holder “2” and T-handle “3”, loosen the
4. Remove:
damper rod bolt.
● Front fork leg
EAS22980
T-handle
DISASSEMBLING THE FRONT FORK LEGS
90890-01326
front fork legs. YM-01326
1. Remove: Damper rod holder
● Fork spring seat
90890-01460
● Fork spring
2. Drain:
● Fork oil
NOTE:
Stroke the damper adjusting rod several times
while draining the fork oil.
4-44
FRONT FORK
5. Remove: Out of specification → Replace.
● Inner tube
Fork spring free length
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 278.2 mm (10.95 in)
a. Securely clamp the brake caliper bracket in a
Limit
vise with soft jaws. 272.6 mm (10.73 in)
b. Separate the inner tube from the outer tube
by pulling the inner tube forcefully but care-
fully.
ECA1B702
CAUTION:
Avoid bottoming the inner tube into the outer
tube during the above procedure, as the oil
flow stopper will be damaged.
3. Check:
● Damper rod “1”
Obstruction → Blow out all of the oil passag-
es with compressed air.
● Spring “2” /bushing “3”
● Oil lock piece “4”
Damage → Replace.
NOTE:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Do not lost the oil lock piece spring.
EAS23010
CHECKING THE FRONT FORK LEGS

front fork legs. 1
1. Check:
● Inner tube “1”
2
3
● Outer tube “2” 4
Bends/damage/scratches → Replace.
EWA13650
WARNING
Do not attempt to straighten a bent inner
EAS23020
tube as this may dangerously weaken it. ASSEMBLING THE FRONT FORK LEGS
front fork legs.
1 EWA13660
2 WARNING
● 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.
NOTE:
● When assembling the front fork leg, be sure to
2. Measure: replace the following parts:
● Spring free length “a” ● Inner tube bushing
4-45
FRONT FORK
● Outer tube bushing
● Oil seal
● O-ring (cap bolt)
● Copper washer
● Before assembling the front fork leg, make

sure all of the components are clean.
1. Install:
● Damper rod “1”
● Rebound spring “2”
ECA1B708
CAUTION:
4. Install:
● Outer tube bushing “1” New
Allow the damper rod assembly to slide
● Washer
slowly down the inner tube “3” until it pro-
(with the fork seal driver “2” and attachment
trudes from the bottom of the inner tube. Be
“3”)
careful not to damage the inner tube.
Fork seal driver weight
90890-01367
Replacement hammer
1 YM-A9409-7
3 Fork seal driver attachment (ø33)
90890-01368
Replacement 33 mm
YM-A9409-4
2
2. Lubricate:
● Inner tube’s outer surface
2
Recommended oil
3
Fork oil 10W or equivalent
3. Install:
● Copper washer New
1
● Damper rod bolt “1”
5. Install:
Damper rod assembly bolt ● Oil seal “1” New
18 Nm (1.8 m•kg, 13 ft•lb) (with the fork seal driver “2” and attachment
T.
LOCTITE®204 “3”)
R.
ECA14220
NOTE: CAUTION:
While holding the damper rod assembly with the Make sure the numbered side of the oil seal
damper rod holder “2” and T-handle “3”, tighten faces up.
the damper rod assembly bolt. NOTE:
● Before installing the oil seal, lubricate its lips
T-handle with lithium soap base grease.
90890-01326 ● Lubricate the outer surface of the inner tube
with fork oil.
YM-01326
● Before installing the oil seal, cover the top of
Damper rod holder
90890-01460 the front fork leg with a plastic bag “4” to pro-
tect the oil seal during installation.
4-46
FRONT FORK
8. Fill:
● Front fork leg

2 mended fork oil until level “a”)
3 Quantity
149.0 cm3 (5.04 US oz) (5.26
Imp.oz)
1 Recommended oil
Fork oil 10W or equivalent
6. Install:
Level
● Oil seal clip “1”
91.0 mm (3.58 in)
NOTE:
Adjust the oil seal clip so that it fits into the outer
tube’s groove.
NOTE:
● While filling the front fork leg, keep it upright.
7. Install: ● After filling, slowly pump the front fork leg up
● Dust seal “1” and down to distribute the fork oil.
(with the fork seal driver weight “2”)
9. Install:
Fork seal driver weight ● Fork spring “1”
90890-01367 ● Fork spring seat
Replacement hammer NOTE:

YM-A9409-7 Install the spring with the smaller pitch facing up-
ward.
4-47
FRONT FORK
2
1
EAS23060
INSTALLING THE FRONT FORK LEGS

front fork legs.
1. Install:
● Front fork leg
● O-ring New
● Cap bolt
NOTE:
● Before installing the cap bolt, lubricate its
O-ring with grease.
● Pull up the inner tube until it stops, then install
the cap bolt.
2. Tighten:
● Lower bracket pinch bolt “1”
NOTE:
Apply the fork oil 10W or equivalent to the lower
bracket pinch bolt (thread and flange).
After the tightening, blow the overflow oil by
compressed air.
Lower bracket pinch bolt

First (temporarily tighten)
T.
9 Nm (0.9 m•kg, 6.5 ft•lb)

R.
2nd (tighten)
23 Nm (2.3 m•kg, 19 ft•lb)
● Cap bolt “2”
Cap bolt
70 Nm (7.0 m•kg, 50 ft•lb)
T.
R.
4-48
STEERING HEAD
EAS23090
STEERING HEAD
Removing the lower bracket
2
3
5
4
6
7
8 12 LS
9 13 15
10 14
17 16
LS
18
11

Fork leg Refer to “FRONT FORK” on page 4-42.
Handlebar Refer to “HANDLEBAR” on page 4-38.
2 Steering stem nut 1
3 Washer 1
4 Handlebar lower holder 1
5 Woodruff key 1
6 Upper ring nut 1
7 Lock washer 1
8 Center ring nut 1
9 Rubber washer 1
10 Lower ring nut 1
11 Lower bracket 1
12 Bearing cover 1
13 Bearing races1 1
14 Upper bearing 1
15 Bearing races3 1
16 Lower bearing 1
17 Bearing races2 1
4-49
STEERING HEAD
Removing the lower bracket
2
3
5
4
6
7
8 12 LS
9 13 15
10 14
17 16
LS
18
11

18 Dust seal 1
dure.
4-50
STEERING HEAD
EAS23110
REMOVING THE LOWER BRACKET

EWA13120
WARNING
2. Remove:
● Handlebar lower holder “1”
● Woodruff key “2”
EWA13730
WARNING
1 Securely support the lower bracket so that
there is no danger of it falling.
EAS23120
CHECKING THE STEERING HEAD

2
1. Wash:
● Bearings
● Bearing races
3. Remove: Recommended cleaning solvent

● Upper ring nut “1” Kerosene
(Use the ring nut wrench)
● Lock washer “2” 2. Check:
● Center ring nut “3” ● Bearings “1”
● Rubber washer ● Bearing races “2”
Damage/pitting → Replace.
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
3. Replace:
● Bearings
● Bearing races
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
4. Remove: a. Remove the bearing races “1” from the steer-
● Lower ring nut “1” ing head pipe with a long rod “2” and ham-
(Use the ring nut wrench “2”) mer.
b. Remove the bearing “3” race from the lower
Ring nut wrench
bracket with a floor chisel “4” and hammer.
90890-01268
c. Install a new rubber seal and new bearing
Spanner wrench
YU-01268 races.
4-51
STEERING HEAD
NOTE:
Clean the area “a” of the lower bracket indicated
2
in the illustration and the inner surfaces of the
lower handlebar holder.
1 a
3 4
3. Install:
● Lower bracket
● Lower ring nut “1”
● Rubber washer
● Center ring nut “2”
● Lock washer “3”

ECA14270
CAUTION: ● Upper ring nut “4”
If the bearing race is not installed properly, Refer to “CHECKING AND ADJUSTING
the steering head pipe could be damaged. THE STEERING HEAD” on page 3-21.
NOTE:
● Always replace the bearings and bearing rac-
es as a set.
● Whenever the steering head is disassembled,
replace the rubber seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
4. Install:
● Lower bracket
● Woodruff key
(along with the steering stem) ● Handlebar lower holder
Lower handlebar holder nut
EAS23150
165 Nm (16.5 m•kg, 119 ft•lb)
INSTALLING THE LOWER BRACKET
T.
R.
1. Lubricate:
● Upper bearing
● Lower bearing
● Bearing races
2. Clean:
● All ring nuts
4-52
REAR SHOCK ABSORBER ASSEMBLY
EAS23160

Removing the rear shock absorber assembly

Document box
4-1.
Side cover
Tail/brake light assembly
Air filter case
1 Rear shock absorber assembly 2
dure.
4-53
EAS23220
REMOVING THE REAR SHOCK ABSORBER Rear shock absorber assembly up-
ASSEMBLY per nut
T.
1. Stand the vehicle on a level surface. 34 Nm (3.4 m•kg 26 ft•lb)
R.
EWA13120
Rear shock absorber assembly
WARNING lower bolt
Securely support the vehicle so that there is 29 Nm (2.9 m•kg 21 ft•lb)
NOTE:
Place the vehicle the mainstand so that the rear 1
wheel is elevated.
2
2. Remove:
● Muffler
Refer to “ENGINE REMOVAL” on page 5-1.

● Rear shock absorber assembly “1”.
EAS23240
CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY
1. Check:
● Rear shock absorber rod
Bends/damage → Replace the rear shock

absorber assembly.
● Rear shock absorber
Gas leaks/oil leaks → Replace the rear

shock absorber assembly.
● Spring
Damage/wear → Replace the rear shock ab-

sorber assembly.
● Bolts
Bends/damage/wear → Replace.
EAS23320
INSTALLING THE REAR SHOCK

ABSORBER ASSEMBLY
1. Remove:
● Rear shock absorber assembly upper nut“1”
● Rear shock absorber assembly lower bolt“2”
4-54
SWINGARM
EAS23330
SWINGARM
Removing the swingarm
3 4
2
7
10
9
8
6
1
5

Left side cover
4-1.
Refer to “REAR SHOCK ABSORBER
Rear shock absorber (right)
ASSEMBLY” on page 4-53.
1 Rear wheel axle nut 1
2 Rear brake caliper 1
4 Rear brake hose cover 1
5 Swingarm 1
6 Spacer 1
7 Collar 1
8 Oil seal 1
9 Bearing 1
10 Oil seal 1
dure.
4-55
SWINGARM
EAS23340
REMOVING THE SWINGARM

EWA13120
WARNING
Securely support the vehicle so that there is 2
no danger of it falling over. 3
NOTE: 1
Place the vehicle on the mainstand so that the
rear wheel is elevated. 4 3
2. Remove:
● Rear axle nut “1”

● Rear brake caliper
● Brake hose holder
● Rear shock absorber assembly lower bolt
(right) “2”
NOTE:
While removing the rear brake caliper, do not
apply the rear brake.
3. Remove:
● Swingarm
EAS23370
CHECKING THE SWINGARM

1. Check:
● Swingarm
2. Check:
● Spacers “1”
● Collar “2”
● Oil seals “3”
● Bearings “4”
● Bushing
● Dust seal
4-56
ENGINE
ENGINE REMOVAL .................................................................................... 5-1
INSTALLING THE ENGINE .................................................................... 5-4
CAMSHAFTS .............................................................................................. 5-5
REMOVING THE CAMSHAFTS ............................................................. 5-7
CHECKING THE CAMSHAFTS.............................................................. 5-8
CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET ......... 5-9
1
CHECKING THE TIMING CHAIN TENSIONERS................................... 5-9
INSTALLING THE CAMSHAFTS............................................................ 5-10
CYLINDER HEAD ....................................................................................... 5-13
REMOVING THE CYLINDER HEAD ...................................................... 5-14
2
CHECKING THE CYLINDER HEAD....................................................... 5-14
CHECKING THE TIMING CHAIN GUIDE............................................... 5-14
INSTALLING THE CYLINDER HEAD..................................................... 5-15
VALVES AND VALVE SPRINGS ............................................................... 5-16 3
REMOVING THE VALVES ..................................................................... 5-17
CHECKING THE VALVES AND VALVE GUIDES .................................. 5-18
CHECKING THE VALVE SEATS ........................................................... 5-19
CHECKING THE VALVE SPRINGS ....................................................... 5-21
CHECKING THE VALVE LIFTERS ........................................................ 5-21 4
INSTALLING THE VALVES .................................................................... 5-22
CYLINDER AND PISTON ........................................................................... 5-24
REMOVING THE PISTON ...................................................................... 5-25
CHECKING THE CYLINDER AND PISTON........................................... 5-25
CHECKING THE PISTON RINGS .......................................................... 5-26
5
CHECKING THE PISTON PIN ............................................................... 5-27
INSTALLING THE PISTON AND CYLINDER......................................... 5-27
V-BELT AUTOMATIC TRANSMISSION..................................................... 5-29
REMOVING THE PRIMARY SHEAVE ................................................... 5-32
6
REMOVING THE SECONDARY SHEAVE ............................................. 5-32
DISASSEMBLING THE SECONDARY SHEAVE ................................... 5-33
CHECKING THE CLUTCH HOUSING ................................................... 5-33
CHECKING THE CLUTCH SHOES........................................................ 5-33
CHECKING THE V-BELT ....................................................................... 5-33
7
CHECKING THE PRIMARY SHEAVE .................................................... 5-34
CHECKING THE PRIMARY SHEAVE WEIGHTS .................................. 5-34
CHECKING THE SLIDER ....................................................................... 5-34
CHECKING THE SECONDARY SHEAVE ............................................. 5-34
ASSEMBLING THE PRIMARY SHEAVE ............................................... 5-34
8
ASSEMBLING THE SECONDARY SHEAVE ......................................... 5-34
INSTALLING THE V-BELT ..................................................................... 5-35
PICKUP COIL ROTOR................................................................................ 5-37
REMOVING THE PICKUP COIL ROTOR .............................................. 5-40
9
CHECKING THE STARTER CLUTCH ................................................... 5-41
INSTALLING THE STARTER CLUTCH ................................................. 5-41
INSTALLING THE PICKUP COIL ROTOR ............................................. 5-42
OIL PUMP ................................................................................................... 5-43
CHECKING THE OIL PUMP................................................................... 5-44
CHECKING THE OIL PUMP DRIVE CHAIN .......................................... 5-44
ASSEMBLING THE OIL PUMP .............................................................. 5-44
INSTALLING THE OIL PUMP................................................................. 5-45
ELECTRIC STARTER................................................................................. 5-46
CHECKING THE STARTER MOTOR..................................................... 5-48
ASSEMBLING THE STARTER MOTOR ................................................ 5-49
INSTALLING THE STARTER MOTOR................................................... 5-49
CRANKCASE.............................................................................................. 5-50
DISASSEMBLING THE CRANKCASE ................................................... 5-52
CHECKING THE CRANKCASE ............................................................. 5-52
CHECKING THE TIMING CHAIN GUIDE............................................... 5-52
CHECKING THE OIL PUMP GEARS AND SHAFTS ............................. 5-52
CHECKING THE RELIEF VALVE........................................................... 5-52
CHECKING THE CIRCLIPS AND WASHERS ....................................... 5-53
ASSEMBLING THE CRANKCASE ......................................................... 5-53
CRANKSHAFT ASSEMBLY....................................................................... 5-54
REMOVING THE CRANKSHAFT JOURNAL BEARING ........................ 5-56
CHECKING THE CRANKSHAFT AND CONNECTING ROD................. 5-56
CHECKING THE BALANCER SHAFT.................................................... 5-58
CHECKING THE BEARINGS ................................................................. 5-58
INSTALLING THE CRANKSHAFT JOURNAL BEARING ...................... 5-58
INSTALLING THE CRANKSHAFT AND BALANCER SHAFT................ 5-59
TRANSMISSION ......................................................................................... 5-60
CHECKING THE TRANSMISSION ........................................................ 5-61
INSTALLING THE PRIMARY DRIVE GEAR .......................................... 5-61
ENGINE REMOVAL
EAS23710
ENGINE REMOVAL
Removing the exhaust pipe and muffler
2
3
1
4

First, disconnect the negative battery lead,
Battery negative lead
and then positive battery lead.
Battery positive lead
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-15.
Side cover/Document box
4-1.
Air filter case
Throttle body Refer to “THROTTLE BODY” on page 7-4.
Fuel injector
Refer to “ELECTRIC STARTER” on page
Starter motor
5-46.
Thermostat cover Refer to “THERMOSTAT” on page 6-4.
Thermostat
Loosen.
Rear wheel axle nut
Rear brake caliper Refer to “REAR BRAKE” on page 4-25.
1 Spark plug cap 1 Disconnect.
2 Coolant temperature sensor 1 Disconnect.
5-1
ENGINE REMOVAL
Removing the exhaust pipe and muffler
2
3
1
4

Crankshaft position sensor/stator assembly
3 1/1 Disconnect.
coupler
4 Coolant hose water pump-IN 1 Disconnect.
5 Muffler 1
6 Exhaust pipe 1
7 Gasket 1
dure.
5-2
ENGINE REMOVAL
Removing the engine
8
6
9 4
6
4
4
2 3
10 4
3
1
Place the vehicle on the mainstand.
1 Duct 1
Refer to “INSTALLING THE ENGINE” on
2 Rear shock absorber lower bolt 2
page 5-4.
3 Engine mounting bolt (front lower side) 2
4 Engine bracket bolt/nut (front upper side) 2/2
5 Engine bracket bolt 4
6 Engine mounting nut/bolt 1/1
7 Engine bracket (left) 1
8 Engine bracket (center) 1
9 Engine bracket (right) 1
10 Engine 1
dure.
5-3
ENGINE REMOVAL
EAS23720
4. Tighten:
INSTALLING THE ENGINE
● Engine bracket nut
1. Install:
● Engine mounting bolt
● Engine bracket (right) “1”
● Rear shock absober assembly lower bolt
● Engine bracket (center) “2”
● Engine bracket (left) “3” Engine bracket nut (front upper

● Engine mounting bolt/nut “4” side)
T.
● Engine bracket bolt “5” 45 Nm (4.5 m•kg 32 ft•lb)
R.
(Apply the LOCTITE®) Engine mounting nut (front lower
NOTE: side)
● Apply lithium-soap-based grease to the un- 45 Nm (4.5 m•kg 32 ft•lb)
threaded portion of the engine mounting bolt Rear shock absober assembly
shaft. lower bolt
29 Nm (2.9 m•kg 21 ft•lb)
● Do not fully tighten the bolts.
5 3 4
5
1
4 2
2. Tighten:
● Engine mounting nut
● Engine mounting bolt
Engine mounting nut

65 Nm (6.5 m•kg, 49 ft•lb)
T.
Engine mounting bolt

R.
56 Nm (5.6 m•kg, 40 ft•lb)

3. Install:
● Engine bracket bolt (front upper side)/nut
● Washer
● Engine mounting bolt (front lower side)
(Apply the LOCTITE®)

NOTE:
Do not fully tighten the bolts.
5-4
CAMSHAFTS
EAS23760
CAMSHAFTS
Removing the cylinder head cover
3 5
(9)
2
1

Trunk
4-1.
Throttle bodies/fuel injector Refer to “THROTTLE BODY” on page 7-4.
1 Spark plug cap 1
2 Spark plug 1
3 Cylinder head cover 1
4 Cylinder head cover gasket 1
5 Plug 2
dure.
5-5
CAMSHAFTS
Removing the camshafts
4 11 LS
9
1
4
5
M
(8) 6
12
8
10
M
E
7

1 Timing plug 1
2 V-belt case air filter cover 1
3 V-belt case air filter element 1
4 Camshaft sprocket bolt 4 Loosen.
5 Timing chain tensioner assembly 1
6 Gasket 1
7 Camshaft cap 1
8 Dowel pin 2
9 Intake camshaft 1
10 Exhaust camshaft 1
11 Intake camshaft sprocket 1
12 Exhaust camshaft sprocket 1
dure.
5-6
CAMSHAFTS
EAS23810
REMOVING THE CAMSHAFTS

1. Remove:
● Timing plug
● V-belt case air filter cover “1”

c
d
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Loosen.
● Camshaft sprocket bolt “1”
2. Align:
● “I” mark on the rotor
(with the mark on the crankcase cover)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise by
turning the primary sheave nut at the crank-
shaft.
1
b. When piston is at TDC on the compression
1
stroke, align the “I” mark “a” with the mark “b”
on the crankcase cover. 4. Loosen:
● Timing chain tensioner cap bolt “1”
5. Remove:
● Timing chain tensioner “2”
● Gasket
NOTE:
● TDC on the compression stroke can be found 2
when the camshaft lobes are turned away
from each other.
● In order to be sure that the piston is at TDC, 6. Remove:
the punch marks “c” on the intake camshaft ● Camshaft cap “1”
sprocket and the punch mark “d” on the ex- ● Dowel pins
haust camshaft sprocket must align with the ECA13720
cylinder head mating surface as shown in the CAUTION:

illustration. 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.
5-7
CAMSHAFTS
4
1
1
6
7
5
8
3
7. Remove: 2
● Intake camshaft “1”
● Exhaust camshaft “2”
NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire “3”.
3
1 3. Measure:
● Camshaft runout

2
Camshaft runout limit
0.03mm
EAS23850
CHECKING THE CAMSHAFTS

1. Check:
● Camshaft lobes
Blue discoloration/pitting/scratches → Re-

place the camshaft.
2. Measure:
● Camshaft lobe dimensions “A” and “B”
Out of specification → Replace the camshaft.

Camshaft lobe dimension limit 4. Measure:
Intake A ● Camshaft-journal-to-camshaft-cap clearance
33.250–33.350 mm (1.3091–1.3130
Out of specification → Measure the camshaft
in)
journal diameter.
Intake B
24.950–25.050 mm (0.9823–0.9862 Camshaft-journal-to-cam-
in) shaft-cap clearance limit
Exhaust A 0.08mm
33.250–33.350 mm (1.3091–1.3130
in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Exhaust B a. Install the camshaft into the cylinder head
24.950–25.050 mm (0.9823–0.9862 (without the dowel pins and camshaft cap).
in) b. Position “a” strip of Plastigauge® “1” onto the
camshaft journal as shown.
5-8
CAMSHAFTS
c. Install the dowel pins and camshaft cap. EAS23870
CHECKING THE TIMING CHAIN AND

NOTE:
CAMSHAFT SPROCKET
● Tighten the camshaft cap bolts in the order of
1. Check:
the embossed numbers on the camshaft cap.
● Timing chain
● Do not turn the camshaft when measuring the
Damage/stiffness → Replace the timing
camshaft journal-to-camshaft cap clearance
chain and camshaft sprocket as a set.
with the Plastigauge®.
2. Check:
● Camshaft sprocket
Camshaft cap bolt
More than 1/4 tooth wear “a” → Replace the
10 Nm (1.0 m•kg, 7.2 ft•lb)
camshaft sprocket and the timing chain as a
T.
R.
d. Remove the camshaft cap and then measure set.

the width of the Plastigauge® “1”.
a. 1/4 tooth wear

b. Correct
1. Timing chain roller

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Camshaft sprocket
5. Measure: EAS23960
● Camshaft journal diameter “a” CHECKING THE TIMING CHAIN

Out of specification → Replace the camshaft. TENSIONERS
Within specification → Replace the cylinder The following procedure applies to both of the
head and the camshaft caps as a set. timing chain tensioners.
1. Check:
Camshaft journal diameter ● Timing chain tensioner
24.459–24.472mm Cracks/damage → Replace.
2. Check:
● One-way cam operation
Rough movement → Replace the timing

chain tensioner housing.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. While lightly pressing the timing chain
5-9
CAMSHAFTS
tensioner rod by hand, turn the tensioner rod 2. Install:
fully clockwise with a thin screwdriver “1”. ● Exhaust camshaft “1”
● Intake camshaft “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Make sure that the mark “a” on the pickup
coil rotor with the mark “b” on the crankcase
cover as shown. (T.D.C.)
b. Remove the screwdriver and slowly release

the timing chain tensioner rod.
c. Make sure that the timing chain tensioner rod
comes out of the timing chain tensioner
housing smoothly. If there is rough move-
ment, replace the timing chain tensioner. b. Install the timing chain “3” onto both cam-
shaft sprockets, and then install the cam-
shafts onto the cylinder head.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24000
INSTALLING THE CAMSHAFTS

1. Install: 3
2
● Exhaust camshaft sprocket “1”
● Intake camshaft sprocket “2”
(with the camshaft sprockets temporarily

tightened) 1
NOTE:
● Make sure that the punch marks “a” on the
camshaft sprockets are in the position shown NOTE:
in the illustration. The camshafts should be installed onto the cyl-
● Temporarily tighten the camshaft sprocket inder head so that the punch marks “c” on the in-
bolts. take camshaft sprocket and the punch marks “d”
● Install the bolt hole of the camshaft sprocket on the exhaust camshaft sprocket align with the
“E” side to the exhaust camshaft, the bolt hole cylinder head mating surface, as shown in the il-
of the camshaft sprocket “I” side to the intake lustration.
camshaft.
2 1
a a
ECA13740
CAUTION:
Do not turn the crankshaft when installing
5-10
CAMSHAFTS
the camshaft(s) to avoid damage or improp-
er valve timing.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
● Dowel pin
● Camshaft cap
● Camshaft cap bolt
NOTE:
● Lubricate the camshaft cap bolt threads with b. With the timing chain tensioner rod turned all
engine oil. the way into the timing chain tensioner hous-
● Finger tighten the camshaft cap bolts. ing (with the thin screwdriver still installed),
install the gasket and the timing chain
4. Tighten: tensioner “2” onto the cylinder block.
● Camshaft cap bolt
NOTE:
Camshaft cap bolt Always use a new gasket.
10 Nm (1.0 m•kg, 7.2 ft•lb)
T.
R.
3
NOTE:
Tighten the camshaft cap bolts in the order of
1
the embossed numbers on the camshaft cap.
3
2
5
8
3
2
c. Tighten the timing chain tensioner bolts “3” to

the specified torque.
4
● Timing chain tensioner cap bolt

6
Timing chain tensioner bolt

ECA1B709
10 Nm (1.0 m•kg, 7.2 ft•lb)
T.
R.
CAUTION:
The camshaft cap bolts must be tightened in d. Remove the screwdriver, make sure the tim-
several stages or damage to the cylinder ing chain tensioner rod releases, and then
head, camshaft caps, and camshafts will re- tighten the cap bolt to the specified torque.
● Cap bolt
sult.
5. Install: Timing chain tensioner cap bolt
● Timing chain tensioner
7 Nm (0.7 m•kg, 5.1 ft•lb)
T.
R.
NOTE:
Be sure the mark of the camshaft sprocket push- NOTE:
ing the timing chain before timing chain Return the timing chain tensioner rod moving
tensioner is assemble. the thin screwdriver lightly.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. While lightly pressing the timing chain ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
tensioner rod by hand, turn the tensioner rod 6. Tighten:
fully clockwise with a thin screwdriver “1”. ● Camshaft sprocket bolt “1”
5-11
CAMSHAFTS
Camshaft sprocket bolt

T.
R.
20 Nm (2.0 m•kg, 14 ft•lb)
1
1
7. Turn:
● Primary sheave nut
(several turns counterclockwise)

8. Check:
● TDC mark
Make sure the TDC mark is aligned with the

alignment mark.
● Camshaft punch mark
Make sure the punch mark on the camshaft

is aligned with the cylinder head mating sur-
face.
Out of alignment → Reinstall.
Refer to the installation steps above.
9. Measure:
● Valve clearance
Out of specification → Adjust.

Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-4.
5-12
CYLINDER HEAD
EAS24100
CYLINDER HEAD
Removing the cylinder head
3
2
4
8
1
5
E
E

Exhaust pipe Refer to “ENGINE REMOVAL” on page 5-1.
Drain.
page 3-15.
Thermostat Refer to “THERMOSTAT” on page 6-4.
Camshaft Refer to “CAMSHAFTS” on page 5-5.
1 Coolant temperature sensor 1
2 Throttle body joint 1
3 Intake manifold 1
4 Gasket 1
5 Cylinder head 1
6 Cylinder head gasket 1
7 Dowel pin 2
8 Timing chain dampers (exhaust side) 1
dure.
5-13
CYLINDER HEAD
EAS24120
REMOVING THE CYLINDER HEAD Warpage limit

1. Remove: 0.03 mm (0.0012 in)
● Cylinder head bolts
● Cylinder head nuts ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

NOTE: a. Place a straightedge “1” and a thickness
● Loosen the nuts in the proper sequence as gauge “2” across the cylinder head.
shown. b. Measure the warpage.
● Loosen each nut 1/2 of a turn at a time. After c. If the limit is exceeded, resurface the cylinder
all of the nuts are fully loosened, remove head as follows.
them. d. Place a 400–600 grit wet sandpaper on the
surface plate and resurface the cylinder head
using a figure-eight sanding pattern.
NOTE:
$ " To ensure an even surface, rotate the cylinder
head several times.
! #

EAS24160
CHECKING THE CYLINDER HEAD

1. Eliminate:
● Combustion chamber carbon deposits
(with a rounded scraper)

NOTE:
Do not use a sharp instrument to avoid damag-
1 2
ing or scratching:
● Spark plug bore threads
● Valve seats
e. After resurfacing, out of specification → Re-

place the cylinder head.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check: EAS24180
CHECKING THE TIMING CHAIN GUIDE

● Cylinder head
Damage/scratches → Replace.
camshaft sprockets and timing chain guide.
● Cylinder head water jacket
1. Check:
Mineral deposits/rust → Eliminate.
● Timing chain dampers (exhaust side)
3. Measure:
Damage/crack → Replace.
● Cylinder head warpage
Out of specification → Resurface the cylinder

head.
5-14
CYLINDER HEAD
EAS24240
INSTALLING THE CYLINDER HEAD

1. Install:
● Cylinder head gasket New
● Dowel pins
2. Install:
● Timing chain guide (exhaust side)
● Cylinder head
NOTE:
Pass the timing chain through the timing chain
cavity.
3. Tighten:
● Cylinder head nut “1”
● Cylinder head nut “2”
● Cylinder head bolt
Cylinder head nut (timing chain

side “1”)
T.
40 Nm (4.0 m•kg, 29 ft•lb)

R.
Cylinder head nut (V-belt side “2”)

52 Nm (5.2 m•kg, 37 ft•lb)
Cylinder head bolt
10 Nm (1.0 m•kg, 7.2 ft•lb)
NOTE:
● Lubricate the cylinder head nuts with engine
oil.
● Tighten the cylinder head nuts in the proper
tightening sequence as shown and torque
them in two stages. Refer to “TIGHTENING
TORQUES” on page 2-13.
!
#
1
2
"
$
5-15
VALVES AND VALVE SPRINGS
EAS24270

Removing the valves and valve springs
1
2
E 3 1
3 2
4
M 3
4
5
3 E
5
6
M 7 6 M
10
M
10
8
M
9

Cylinder head Refer to “CYLINDER HEAD” on page 5-13.
1 Valve lifter 4
2 Valve pad 4
3 Valve cotter 8
4 Upper spring seat 4
5 Valve spring 4
6 Valve stem seal 4
7 Lower spring seat 4
8 Exhaust valve 2
9 Intake valve 2
10 Valve guide 4
dure.
5-16
EAS24280
REMOVING THE VALVES

The following procedure applies to all of the ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
valves and related components. 3. Remove:
NOTE: ● Valve cotters “1”
Before removing the component parts of the cyl- NOTE:

inder head (e.g., valves, valve springs, valve Remove the valve cotters by compressing the
seats), make sure the valves properly seal. valve spring with the valve spring compressor
1. Remove: “2” and the valve spring compressor attachment
● Valve lifter “1”
“3”.
● Valve pad “2”
NOTE: Valve spring compressor

Make a note of the position of each valve lifter 90890-04019
YM-04019
and valve pad so that they can be reinstalled in
Valve spring compressor attach-
their original place.
ment
90890-04108
Valve spring compressor adapter
22 mm
YM-04108
2. Check:
● Valve sealing 1
Leakage at the valve seat → Check the valve
face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS” 4. Remove:
on page 5-19. ● Upper spring seat “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ● Valve spring “2”

a. Pour a clean solvent “a” into the intake and ● Valve stem seal “3”
exhaust ports. ● Lower spring seat “4”
b. Check that the valves properly seal. ● Valve “5”
NOTE: NOTE:
There should be no leakage at the valve seat Identify the position of each part very carefully
“1”. so that it can be reinstalled in its original place.
4 3
1 a
2
5
5-17
EAS24290
and to maintain the correct fit, heat the cylinder
CHECKING THE VALVES AND VALVE
head to 100°C (212°F) in an oven.
GUIDES
The following procedure applies to all of the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
valves and valve guides. a. Remove the valve guide with the valve guide
1. Measure: remover “1”.
● Valve-stem-to-valve-guide clearance
Out of specification → Replace the valve

guide.
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” -
Valve stem diameter “b”
Valve-stem-to-valve-guide clear-
ance
b. Install the new valve guide with the valve
ance (intake)
guide installer “2” and valve guide remover
0.010–0.037 mm (0.0004–0.0015
in) “1”.
Limit
0.080 mm (0.0032 in)
ance (exhaust)
0.025–0.052 mm (0.0010–0.0020
in)
Limit
0.100 mm (0.0039 in)
c. After installing the valve guide, bore the valve

guide with the valve guide reamer “3” to ob-
tain the proper valve-stem-to-valve-guide
clearance.
NOTE:
After replacing the valve guide, reface the valve
seat.
2. Replace:
● Valve guide
NOTE:
To ease valve guide removal and installation,
5-18
place the valve stem seal.
Valve guide remover (ø4.5)
90890-04116
Valve stem runout
Valve guide remover (4.5 mm)
0.01 mm
YM-04116
Valve guide installer (ø4.5)
90890-04117
Valve guide installer (4.5 mm)
YM-04117
Valve guide reamer (ø4.5)
90890-04118
Valve guide reamer (4.5 mm)
YM-04118
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24300
3. Eliminate: CHECKING THE VALVE SEATS
● Carbon deposits
(from the valve face and valve seat) valves and valve seats.
4. Check: 1. Eliminate:
● Valve face
● Carbon deposits
Pitting/wear → Grind the valve face. (from the valve face and valve seat)
● Valve stem end
2. Check:
Mushroom shape or diameter larger than the ● Valve seat
body of the valve stem → Replace the valve. Pitting/wear → Replace the cylinder head.
5. Measure: 3. Measure:
● Valve margin thickness “a”
● Valve seat width “a”
Out of specification → Replace the valve. Out of specification → Replace the cylinder
Valve margin thickness head.
(IN) Valve seat width limit
0.85–1.15 mm (0.0335–0.0453 in) 1.6 mm (0.0630 in)
(EX)
0.85–1.15 mm (0.0335–0.0453 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
6. Measure: a. Apply Mechanic’s blueing dye (Dykem) “b”
● Valve stem runout
onto the valve face.
Out of specification → Replace the valve.
NOTE:
● When installing a new valve, always replace
the valve guide.
● If the valve is removed or replaced, always re-
5-19
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all of
the lapping compound.
NOTE:
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth be-
tween your hands.
Valve lapper
90890-04101
b. Press the valve through the valve guide and Valve lapping tool
onto the valve seat to make a clear impres- YM-A8998
sion.
c. Measure the valve seat width.
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been re-
moved.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Lap:
● Valve face
e. Apply a fine lapping compound to the valve
● Valve seat
face and repeat the above steps.
NOTE: f. After every lapping procedure, be sure to
After replacing the cylinder head or replacing the clean off all of the lapping compound from
valve and valve guide, the valve seat and valve the valve face and valve seat.
face should be lapped. g. Apply Mechanic’s blueing dye (Dykem) “b”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ onto the valve face.
a. Apply a coarse lapping compound “a” to the
valve face.
ECA13790
CAUTION:
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
h. Press the valve through the valve guide and

onto the valve seat to make a clear impres-
sion.
i. Measure the valve seat width “a” again. If the
valve seat width is out of specification, reface
and lap the valve seat.
b. Apply molybdenum disulfide oil onto the

valve stem.
c. Install the valve into the cylinder head.
5-20
a. Installed length
Installed compression spring

force (intake)
279.40–321.40 N (62.81–72.25 lb)
(28.49–32.77 kgf)
Installed compression spring
force (exhaust)
279.40–321.40 N (62.81–72.25 lb)
(28.49–32.77 kgf)
3. Measure:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ● Valve spring tilt “a”

EAS24310
spring.
CHECKING THE VALVE SPRINGS
The following procedure applies to all of the Spring tilt limit
valve springs. Spring tilt (intake)
1. Measure: 2.5 °/1.9 mm
● Valve spring free length “a” Spring tilt (exhaust)
Out of specification → Replace the valve 2.5 °/1.9 mm
spring.
Valve spring free length

Limit (intake)
41.50 mm (1.63 in)
Limit (exhaust)
41.50 mm (1.63 in)
EAS24320
CHECKING THE VALVE LIFTERS

valve lifters.
1. Check:
● Valve lifter
Damage/scratches → Replace the valve lift-

2. Measure:
ers and cylinder head.
● Compressed valve spring force “1”

spring.
5-21
EAS24340
INSTALLING THE VALVES

The following procedure applies to all of the 5
2
valves and related components.
1. Deburr: 4
● Valve stem end
1
(with an oil stone)
2. Lubricate:
● Valve stem “1”
● Valve stem seal “2”
(with the recommended lubricant) a. Larger pitch

b. Smaller pitch
Molybdenum disulfide oil 4. Install:
● Valve cotters “1”
NOTE:
Install the valve cotters by compressing the
valve spring with the valve spring compressor
“2” and the valve spring compressor attachment
“3”.
Valve spring compressor

90890-04019
YM-04019
Valve spring compressor attach-
3. Install: ment
● Valve “1” 90890-04108
● Lower spring seat “2” Valve spring compressor adapter
● Valve stem seal “3” New 22 mm
● Valve spring “4”
YM-04108
● Upper spring seat “5”
(into the cylinder head)

NOTE: 2
Install the valve springs with the larger pitch “a”
3
facing up the smaller pitch facing “b” down.
5. To secure the valve cotters onto the valve
5-22
stem, lightly tap the valve tip with a soft-face
hammer.
ECA13800
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.
6. Lubricate:
● Valve pad
Molybdenum disulfide oil
● Valve lifter
Engine oil
7. Install:
● Valve pad “1”
● Valve lifter “2”
NOTE:
● Each valve lifter and valve pad must be rein-
stalled in its original position.
● Install the valve pads with the number side
facing valve lifter side.
● The valve lifter must move smoothly when ro-
tated with a finger.
2
1
5-23
CYLINDER AND PISTON
EAS24350
CYLINDER AND PISTON

Removing the cylinder and piston
6
8
9
7
6
E
E
5
LS
2
4
3
1

Cylinder head Refer to “CYLINDER HEAD” on page 5-13.
1 Water head pipe 1
2 O-ring 1
3 Cylinder 1
4 Cylinder gasket 1
5 Dowel pin 2
6 Piston pin clip 2
7 Piston pin 1
8 Piston 1
9 Piston ring set 1
dure.
5-24
CYLINDER AND PISTON
EAS24380 EAS24400
REMOVING THE PISTON CHECKING THE CYLINDER AND PISTON

1. Remove: 1. Check:
● Piston pin clips “1” ● Piston wall
● Piston pin “2” ● Cylinder wall
● Piston “3” Vertical scratches → Rebore or replace the

ECA13810
cylinder, and replace the piston and piston
CAUTION:
rings as a set.
Do not use a hammer to drive the piston pin 2. Measure:
out. ● Piston-to-cylinder clearance
NOTE: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
● Before removing the piston pin clip, cover the a. Measure cylinder bore “C” with the cylinder
crankcase opening with a clean rag to prevent bore gauge.
the piston pin clip from falling into the crank-
case.
● Before removing the piston pin, deburr the
piston pin clip’s groove and the piston’s pin
bore area. If both areas are deburred and the
piston pin is still difficult to remove.
2
NOTE:
Measure cylinder bore “C” by taking side-to-side
1
and front-to-back measurements of the cylinder.
Then, find the average of the measurements.
3 Bore “C”
Bore
2. Remove: 66.000–66.010 mm (2.5984–2.5988
● Top ring
in)
● 2nd ring
Taper limit “T”
● Oil ring Warp limit
NOTE: 0.05 mm (0.0020 in)
When removing a piston ring, open the end gap
with your fingers and lift the other side of the ring “C”= maximum of D1–D6
over the piston crown. “T”= (maximum of D1 or D2)—(maximum of
D5 or D6)
b. If out of specification, replace the cylinder,
and replace the piston and piston rings as a
set.
c. Measure piston skirt diameter “D” with the
micrometer.
5-25
CYLINDER AND PISTON
Piston ring side clearance

Top ring
Ring side clearance
0.030–0.065 mm (0.0012–0.0026
in)
Limit
0.100 mm (0.0039 in)
2nd ring
Ring side clearance
0.020–0.055 mm (0.0008–0.0022
a. 9 mm (0.35 in) from the bottom edge of the piston in)
Limit
Diameter D 0.100 mm (0.0039 in)
65.952–65.975 mm (2.5965–2.5974
in)
d. If out of specification, replace the piston and

piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” -
Piston skirt diameter “D”
2. Install:
Piston-to-cylinder clearance ● Piston ring
0.025–0.058 mm (0.0010–0.0023 (into the cylinder)
in)
NOTE:
Limit
Level the piston ring into the cylinder with the
0.15 mm (0.0059 in)
piston crown.
f. If out of specification, replace the cylinder,
and replace the piston and piston rings as a
set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24430
CHECKING THE PISTON RINGS

1. Measure:
● Piston ring side clearance
Out of specification → Replace the piston

a. 40 mm (1.57 in)
and piston rings as a set.
NOTE: 3. Measure:
● Piston ring end gap
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston Out of specification → Replace the piston
ring grooves and piston rings. ring.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings.
5-26
CYLINDER AND PISTON
Piston ring end gap

Top ring
End gap (installed)
0.15–0.25 mm (0.0059–0.0098 in)
Limit
0.40 mm (0.0157 in)
2nd ring
End gap (installed)
0.40–0.50 mm (0.0157–0.0197 in)
Limit
0.65 mm (0.0256 in) 4. Calculate:
Oil ring ● Piston-pin-to-piston-pin-bore clearance
End gap (installed) Out of specification → Replace the piston pin

0.10–0.35 mm (0.0039–0.0138 in) and piston as a set.
EAS24440 Piston-pin-to-piston-pin-bore clearance =
CHECKING THE PISTON PIN Piston pin bore diameter “b” -
1. Check: Piston pin outside diameter “a”
● Piston pin
Blue discoloration/grooves → Replace the Piston-pin-to-piston-pin-bore

piston pin and then check the lubrication sys- clearance
tem. 0.004–0.024mm
2. Measure: Limit
● Piston pin outside diameter “a” 0.070mm
Out of specification → Replace the piston
EAS24450
pin. INSTALLING THE PISTON AND CYLINDER
Piston pin outside diameter 1. Install:
● Top ring
15.991–16.000 mm (0.6296–0.6299
● 2nd ring
in)
Limit ● Upper oil ring rail
15.975 mm (0.6289 in) ● Lower oil ring rail
● Oil ring expander
NOTE:
Be sure to install the top ring and 2nd ring so that
the manufacturer’s marks or numbers face up.
3. Measure:
● Piston pin bore diameter “b”
Out of specification → Replace the piston.

Piston pin bore inside diameter 2. Install:
16.002–16.013 mm (0.6300–0.6304 ● Piston “1”
in) ● Piston pin “2”
Limit
● Piston pin clips “3” New
16.043 mm (0.6316 in)
5-27
CYLINDER AND PISTON
NOTE:
● Apply engine oil the piston pin. Cylinder bolt
10 Nm (1.0 m•kg, 7.2 ft•lb)
● Make sure the arrow mark “a” on the piston
T.
R.
points towards the exhaust side of the cylin-
NOTE:
der.
● While compressing the piston rings with one
● Before installing the piston pin clip, cover the hand, install the cylinder with the other hand.
crankcase opening with a clean rag to prevent
● Pass the timing chain and timing chain guide
the clip from falling into the crankcase. (exhaust side) through the timing chain cavity.
a
1
3. Install:
● Cylinder gasket New
● Dowel pins
4. Lubricate:
● Piston
● Piston rings
● Cylinder
(with the recommended lubricant)
Engine oil
5. Offset:
● Piston ring end gaps
a. Top ring
b. Upper oil ring rail
c. Oil ring expander
d. Lower oil ring rail
e. 2nd ring
f. 20mm
6. Install:
● Cylinder
5-28
V-BELT AUTOMATIC TRANSMISSION
EAS24610

Removing the V-belt case cover
(9)
6
(6)
5
4 1
3
(4)

Left side cover
4-1.
Air filter case
2 V-belt case air filter element 1
4 V-belt case cover gasket 1
5 V-belt case cover 1
6 V-belt case air duct 1 1
7 V-belt case air duct 2 1
dure.
5-29
Removing the primary sheave and secondary sheave
7
6
3
13 9
14 4
2 1 1
12 10
11
8

1 Primary sheave nut/collar 1/1
2 Primary fixed sheave 1
3 Secondary sheave nut 1
4 Collar 1
5 Clutch housing 1
6 Secondary sheave assembly 1
7 V-belt 1
8 Primary sliding sheave 1
9 Spacer 1
10 Cam 1
11 Primary sheave weight 8
12 Slider 4
13 Spacer 1
14 O-ring 1
For installation, reverse the disassembly
procedure.
*Apply Shell BT grease 3®

**Apply BEL-RAY assembly lube®
5-30
Disassembling the secondary sheave
9
5
4
3
10
6
9 1

1 Clutch carrier nut 1
2 Clutch carrier 1
3 Clutch shoe spring 3
4 Compression spring 1
5 Spring seat 1
6 Guide pin 4
7 Secondary sliding sheave 1
8 O-ring 2
9 Oil seal 2
10 Secondary fixed sheave 1
cedure.
*Apply BEL-RAY assembly lube®
5-31
EAS24620
2. Loosen:
REMOVING THE PRIMARY SHEAVE
● Clutch carrier nut “1”
1. Remove: ECA13860
● Primary sheave nut “1” CAUTION:

● Washer Do not remove the clutch carrier nut at this
● Primary fixed sheave “2” stage.
NOTE:
NOTE:
While holding the primary fixed sheave with the
While holding the clutch carrier with the rotor
rotor holding tool “3”, loosen the primary fixed
holding tool “2”, loosen the clutch carrier nut one
sheave nut.
full turn with the locknut wrench “3”.
Rotor holding tool
90890-01235 Rotor holding tool
Universal magneto & rotor holder 90890-01235
YU-01235 Universal magneto & rotor holder
YU-01235
Locknut wrench
90890-01348
YM-01348
3
2 1 3
EAS24630
REMOVING THE SECONDARY SHEAVE

1. Remove: 1
● Secondary sheave nut “1”
● Clutch housing “2”

3. Remove:
● Secondary sheave assembly “1”
NOTE:
● V-belt “2”
While holding the clutch housing with the
sheave holder “3”, loosen the secondary sheave NOTE:
nut. Remove the V-belt and secondary sheave as-
sembly from the primary sheave side.
Sheave holder
90890-01701
YS-01880-A
2 1
1
5-32
EAS24640
per.
DISASSEMBLING THE SECONDARY
NOTE:
SHEAVE
● After sanding the glazed areas, clean the
1. Remove:
clutch with a cloth.
● Do not apply the grease or oil on the clutch
NOTE:
shoes.
Install the sheave spring compressor “2” and
sheave fixed block “3” onto the secondary 2. Measure:
sheave as shown. Then, compress the spring, ● Clutch shoe thickness “a”
and remove the clutch carrier nut. Out of specification → Replace the clutch
shoes and springs as a set.
Sheave spring compressor
a a
90890-04134
YM-04134
Sheave fixed block
a a
90890-04135
Sheave fixed bracket
YM-04135
2 a a
Clutch shoe thickness

1 3.3 mm (0.13 in)
Wear limit
2.0 mm (0.08 in)
3
EAS24670
CHECKING THE V-BELT

EAS24650
1. Check:
CHECKING THE CLUTCH HOUSING ● V-belt “1”
1. Check: Cracks/damage/wear → Replace.

● Clutch housing Grease/oil → Clean the primary and second-
Damage/wear → Replace. ary sheave.
2. Measure: 2. Measure:
● Clutch housing inside diameter ● V-belt width “2”
Out of specification → Replace the clutch Out of specification → Replace.

housing.
V-belt width
Clutch housing inside diameter 30 mm (1.18 in)
145.0 mm (5.71 in) Limit
Limit 27 mm (1.06 in)
145.5 mm (5.73 in)
EAS24660
CHECKING THE CLUTCH SHOES 1

2
clutch shoes.
1. Check:
● Clutch shoe
Damage/wear → Replace the clutch shoes

and springs as a set.
Glazed areas → Sand with course sandpa-
5-33
EAS24680
fixed and sliding sheaves as a set.
CHECKING THE PRIMARY SHEAVE
3. Check:
1. Check:
● Guide pin “2”
● Primary sliding sheave
Damage/wear → Replace the secondary
● Primary fixed sheave
fixed and sliding sheaves as a set.
● Spacer
Cracks/damage/wear → Replace the prima-

ry sliding sheave and primary fixed sheave
as a set.
EAS24690
CHECKING THE PRIMARY SHEAVE

WEIGHTS
The following procedure applies to all of the pri-
mary sheave weights.
1. Check:
● Primary sheave weight EAS24720
Cracks/damage/wear → Replace. ASSEMBLING THE PRIMARY SHEAVE

2. Measure: 1. Clean:
● Primary sheave weight outside diameter ● Primary fixed sheave “1”
Out of specification → Replace. ● Primary sliding sheave “2”
● Spacer “3”
Primary sheave weight outside di- ● Primary sheave weights “4”

ameter ● Cam
25.0 mm (0.98 in)
Limit
24.5 mm (0.96 in)
2. Install:
● Primary sheave weights
● Spacer
EAS24700 NOTE:
CHECKING THE SLIDER Before installing the primary sheave weights, lu-
1. Check: bricate the inside and outside of each weight
● Slider
with BEL-RAY assembly lube®.
3. Install:
EAS24710
● Slider
CHECKING THE SECONDARY SHEAVE
● Cam
1. Check:
● Secondary fixed sheave EAS24730
● Secondary sliding sheave ASSEMBLING THE SECONDARY SHEAVE

Cracks/damage/wear → Replace the sec- 1. Lubricate:
● Secondary fixed sheave’s inner surface “1”
ondary fixed and sliding sheaves as a set.
● Secondary sliding sheave’s inner surface “2”
2. Check:
● Oil seals
● Torque cam groove “1”
● Bearing
Damage/wear → Replace the secondary
5-34
BEL-RAY assembly lube
3 1
5. Install:
● Spring seat
1
● Compression spring
2 ● Clutch carrier

2. Install:
NOTE:
● Secondary sliding sheave “1”
Attach the sheave spring compressor “2” and
NOTE:
sheave fixed block “3” onto the secondary
Install the secondary sliding sheave onto the
sheave as shown. Then, compress the spring,
secondary fixed sheave “2” with the oil seal
and tighten the clutch carrier nut.
guide “3”.
Sheave spring compressor
Oil seal guide (ø41)
90890-04134
90890-01396
YM-04134
Sheave fixed block
90890-04135
3 1 Sheave fixed bracket
2 YM-04135
3. Install:
● Guide pin “1” 3
4. Lubricate:
● Guide pin groove “2”
● Oil seal “3” New

EAS24740
INSTALLING THE V-BELT

1. Install:
Recommended lubricant ● V-belt “1”
BEL-RAY assembly lube ● Secondary sheave assembly “2”
ECA13870
CAUTION:
Do not allow grease to contact the V-belt,
secondary sheave assembly.
NOTE:
● Install the V-belt and secondary sheave as-
sembly onto the primary sheave side.
5-35
● Install the V-belt with the printed arrow mark sheave holder “3”.
on the V-belt facing in the direction shown in
the illustration. Sheave holder
90890-01701
YS-01880-A
1 2 2
2. Tighten:
● Clutch carrier nut “1” 3
Clutch carrier nut 4. Position:
90 Nm (9.0 m•kg, 65 ft•lb)
● V-belt
T.
R.
● Primary fixed sheave

NOTE:
● Collar
While holding the clutch carrier with the rotor
● Primary sheave nut
holding tool “2”, tighten the clutch carrier nut with
the locknut wrench “3”. Primary sheave nut
83 Nm (8.3 m•kg 60 ft•lb)
T.
Rotor holding tool

R.
90890-01235 NOTE:
Universal magneto & rotor holder ● Install the V-belt onto the primary sheave “1”
YU-01235 (when the pulley is at its widest position) and
Locknut wrench onto the secondary sheave assembly “2”
90890-01348 (when the pulley is at its narrowest position),
YM-01348 and make sure the V-belt is tight.
● While holding the primary fixed sheave with
the rotor holding tool, tighten the primary
2 sheave nut.
● After replacing the V-belt, and then reset the
V-belt replacement indicator. Refer to “FEA-
3 TURES” on page 1-2.
Rotor holding tool

1 90890-01235
Universal magneto & rotor holder
3. Install: YU-01235
● Clutch housing “1”
● Collar
● Secondary sheave nut “2”
Secondary sheave nut

60 Nm (6.0 m•kg 43 ft•lb)
T.
R.
NOTE:
Tighten the secondary sheave nut with the
5-36
PICKUP COIL ROTOR
EAS24520
PICKUP COIL ROTOR

Removing the pickup coil rotor
5
1 2
10
3
9
8
6
7
8
(11)

Remove the rear shock absorber assembly
lower bolts (left/right), and then place the
vehicle on the mainstand so that the rear
wheel is elevated.
Refer to “GENERAL CHASSIS” on
Right side cover
page 4-1.
Drain.
Engine oil Refer to “CHANGING THE ENGINE
OIL” on page 3-9.
Drain.
Coolant Refer to “CHANGING THE COOL-
ANT” on page 3-15.
Refer to “ENGINE REMOVAL” on page
Exhaust pipe
5-1.
1 Crankcase breather hose 1 Disconnect.
2 Hose (thermostat-IN) 1 Disconnect.
3 Hose (water pump-IN) 1 Disconnect.
4 Hose (heat exchanger-OUT) 1 Disconnect.
Crankshaft position sensor coupler/stator coil
5 1/1 Disconnect.
assembly
5-37
PICKUP COIL ROTOR
5
1 2
10
3
9
8
6
7
8
(11)

6 Right crankcase cover 1
7 Gasket 1
8 Dowel pin 2
Refer to “INSTALLING THE PICKUP
9 Stator coil assembly 1
COIL ROTOR” on page 5-42.
10 Crankshaft position sensor 1
dure.
5-38
PICKUP COIL ROTOR
6
5
3
2
(6)

Stator coil
1 Pickup coil rotor 1
2 Starter clutch 1
3 Woodruff key 1
4 Starter clutch gear 1
5 Shaft 1
6 Starter clutch idle gear 1
dure.
5-39
PICKUP COIL ROTOR
EAS24530
REMOVING THE PICKUP COIL ROTOR

1. Remove: 2 1
● Left rear shock absorber lower bolt
● Right rear shock absorber lower bolt “1”
Refer to “REAR SHOCK ABSORBER AS- 3

SEMBLY” on page 4-53. 4
1 4. Remove:
● Pickup coil rotor “1”
(with the starter clutch)

● Woodruff key
● Starter clutch gear
2
NOTE:
Remove the rear shock absorber assembly low-
er bolts (left/right), and then place the vehicle on
the mainstand so that the rear wheel is elevated. 1
2. Remove:
● Right crankcase cover bolt
● Right crankcase cover
NOTE:
ECA13880
Loosen each bolt 1/4 of a turn at a time, in stag-
CAUTION:
es and in a crisscross pattern.
To protect the end of the crankshaft, place
After all of the bolts are fully loosened, remove
an appropriate sized socket between the fly-
them.
wheel puller set’s center bolt and the crank-
3. Remove: shaft.
● Pickup coil rotor nut “1”
NOTE:
● Washer
● Install the flywheel puller bolts to the threaded
● Starter clutch bolt “2”
holes of the starter clutch.
NOTE:
● Make sure the flywheel puller “2” is centered
● While holding the generator rotor “3” with the
over the pickup coil rotor.
sheave holder “4”, loosen the generator rotor
nut and all starter clutch bolts.
● Do not allow the sheave holder to touch the 2
projection on the generator rotor.
● Remove every other starter clutch bolt (3 bolts
only) to install the flywheel puller. 1
Sheave holder
90890-01701
YS-01880-A
5-40
PICKUP COIL ROTOR
starter clutch “2” and hold the starter clutch.
Flywheel puller
b. When turning the starter clutch gear clock-
90890-01362
wise “A”, the starter clutch and the starter
Heavy duty puller
YU-33270-B clutch gear should engage, otherwise the
Flywheel puller attachment starter clutch is faulty and must be replaced.
90890-04089 c. When turning the starter clutch gear counter-
Crankshaft protector clockwise “B”, it should turn freely, otherwise
YM-33282 the starter clutch is faulty and must be re-
placed.
5. Remove:
● Starter clutch bolt
● Starter clutch
EAS24570
CHECKING THE STARTER CLUTCH

1. Check:
● Starter clutch rollers “1”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24600
INSTALLING THE STARTER CLUTCH

1. Install:
● Starter clutch
Starter clutch bolt

2. Check:
30 Nm (3.0 m•kg, 22 ft•lb)
● Starter clutch idle gear
T.
R.
● Starter clutch gear

NOTE:
Burrs/chips/roughness/wear → Replace the ● While holding the pickup coil rotor “2” with the
defective part(s). sheave holder “3”, tighten the starter clutch
3. Check: bolt.
● Starter clutch gear’s contacting surfaces
● Do not allow the sheave holder to touch the
Damage/pitting/wear → Replace the starter projection on the rotor.
clutch gear.
Sheave holder
90890-01701
YS-01880-A
4. Check:
● Starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch gear “1” onto the
5-41
PICKUP COIL ROTOR
EAS24540
INSTALLING THE PICKUP COIL ROTOR

1. Install: 1
● Starter clutch gear “1”
● Woodruff key“2”
● Pickup coil rotor
● Washer
3
● Pickup coil rotor nut
2
1
3. Apply:
● Sealant
2 (onto the crankshaft position sensor lead

grommet)
Yamaha bond No. 1215

(Three Bond No. 1215®)
90890-85505
NOTE:
● Clean the tapered portion of the crankshaft
and the pickup coil rotor hub.
● When installing the pickup coil rotor, make
sure the woodruff key is properly seated in the
keyway of the crankshaft.
2. Tighten:
● Pickup coil rotor nut “1”
Pickup coil rotor nut

130 Nm (13.0 m•kg, 94 ft•lb)
4. Install:
T.
R.
● Pickup coil rotor cover

NOTE:
● While holding the pickup coil rotor “2” with the ● Right crankcase cover bolts
rotor holding tool “3”, tighten the pickup coil ro-

Right crankcase cover bolt
tor bolt. 10 Nm (1.0 m•kg 7.2 ft•lb)
● Do not allow the sheave holder to touch the
T.
R.
projection on the generator rotor. NOTE:

● Align the projection “b” on the impeller shaft
Sheave holder with the slit “a” on the balancer shaft.
90890-01701 ● Tighten the pickup coil rotor cover bolts in
Primary clutch holder stages and in a crisscross pattern.
YS-01880-A
a b
5-42
OIL PUMP
EAS24910
OIL PUMP
Removing the oil pump
4
5

Refer to “PICKUP COIL ROTOR” on page
Pickup coil rotor
5-37.
1 Oil pump assembly 1
2 Oil pump gasket 1
3 Oil pump driven sprocket 1
4 Oil pump drive chain 1
5 Oil pump drive sprocket 1
dure.
5-43
OIL PUMP
EAS24960
CHECKING THE OIL PUMP

1. Check:
● Oil pump drive gear
● Oil pump driven gear
● Oil pump housing
● Oil pump housing cover
Cracks/damage/wear → Replace the defec-

tive part(s).
2. Measure:
● Inner-rotor-to-outer-rotor-tip clearance “a”
● Outer-rotor-to-oil-pump-housing clearance
“b”
● Oil-pump-housing-to-inner-rotor-and-out-
er-rotor clearance “c”

Out of specification → Replace the oil pump.
Inner-rotor-to-outer-rotor-tip clear-
ance
0.100–0.340 mm (0.0039–0.0134
in) 1. Inner rotor
Limit 2. Outer rotor
0.40 mm (0.0157 in) 3. Oil pump housing
Outer-rotor-to-oil-pump-housing 3. Check:
clearance ● Oil pump operation
0.013–0.036 mm (0.0005–0.0014 Rough movement → Repeat steps (1) and
in)
(2) or replace the defective part(s).
Limit
0.150 mm (0.0059 in) EAS25620
Oil-pump-housing-to-in- CHECKING THE OIL PUMP DRIVE CHAIN

ner-and-outer-rotor clearance 1. Check:
0.04–0.09 mm (0.0016–0.0035 in) ● Oil pump drive chain
Limit Damage/stiffness → Replace the oil pump

0.15 mm (0.0059 in) drive chain, oil pump drive sprocket and oil
pump shaft as a set.
2. Check:
● Oil pump drive sprocket
Cracks/damage/wear → Replace the oil

pump drive sprocket and the oil pump drive
chain as a set.
EAS25000
ASSEMBLING THE OIL PUMP

1. Lubricate:
● Inner rotor
● Outer rotor
● Oil pump shaft

Engine oil
2. Install:
● Oil pump shaft “1”
5-44
OIL PUMP
(to the oil pump cover “2”)
● Pin “3”
● Inner rotor “4”
● Outer rotor “5”
● Oil pump housing “6”
● Screw
NOTE:
When installing the inner rotor, align the pin “3”
in the oil pump shaft with the groove in the inner
rotor “4”.
3. Check:
● Oil pump operation
Refer to “CHECKING THE OIL PUMP” on

page 5-44.
EAS25020
INSTALLING THE OIL PUMP

1. Install:
● Oil pump gasket New
● Oil pump
Oil pump bolt

7 Nm (0.7 m•kg, 5.1 ft•lb)
T.
R.
ECA13890
CAUTION:
After tightening the bolts, make sure the oil
pump turns smoothly.
NOTE:
Align the projection “a” on the oil pump shaft with
the groove in the oil pump driven gear shaft “b”.
5-45
ELECTRIC STARTER
EAS24780
ELECTRIC STARTER
Removing the starter motor

Battery negative lead Disconnect.
Refer to “REPLACING THE AIR FILTER
Air filter case
ELEMENT” on page 3-12.
Throttle bodies Refer to “THROTTLE BODY” on page 7-4.
1 Starting motor lead 1 “THROTTLE BODY” on page 7-4.
2 Starter motor assembly 1
dure.
5-46
ELECTRIC STARTER
Disassembling the starter motor
10
5
8 9
7
6 3
4
1

1 Front bracket 1
2 O-ring 1
3 Washer set 1
4 Lock washer 1
5 Rear bracket 1
6 O-ring 1
7 Washer set 1
8 Brush holder assembly 1
9 Armature coil 1
10 Stator assembly 1
cedure.
5-47
ELECTRIC STARTER
EAS24790
motor.
CHECKING THE STARTER MOTOR
1. Check:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the armature assembly resistances
● Commutator
with the digital circuit tester.
Dirt → Clean with 600 grit sandpaper.
2. Measure: Digital circuit tester
● Commutator diameter “a” 90890-03174
Out of specification → Replace the starter Model 88 Multimeter with tachome-
motor. ter
YU-A1927
Commutator diameter
28.0 mm (1.10 in)
Armature coil
Limit
Commutator resistance “1”
27.0 mm (1.06 in)
0.0012–0.0022 Ω at 20°C (68°F)
(reference)
Insulation resistance “2”
Above 1 MΩ at 20°C (68°F) (refer-
ence)
b.
2
1
3. Measure:
● Mica undercut “a”
1
Out of specification → Scrape the mica to the 2
proper measurement with a hacksaw blade
that has been grounded to fit the commuta- If any resistance is out of specification, re-
tor. place the starter motor.
Mica undercut (depth)
0.70 mm (0.03 in) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
NOTE:
● Brush length “a”
The mica of the commutator must be undercut to
Out of specification → Replace the brushes
ensure proper operation of the commutator.
as a set.
Limit
4.00 mm (0.16 in)
Brush overall length
12.0 mm (0.47 in)
4. Measure:
● Armature assembly resistances (commuta-
tor and insulation)

Out of specification → Replace the starter
5-48
ELECTRIC STARTER
6. Measure: EAS24810
● Brush spring force

INSTALLING THE STARTER MOTOR
Out of specification → Replace the brush 1. Install:
● Starter motor
holder.
● Starter motor bolts
Brush spring force

7.65–10.01 N (27.54–36.03 oz) Starter motor bolt
(780–1021 gf) 12 Nm (1.2 m•kg, 8.6 ft•lb)
T.
R.
2. Connect:
● Starter motor lead
7. Check:
● Bearing (front bracket)
● Oil seal (front bracket)
Damage/wear → Replace the defective

part(s).
EAS24800
ASSEMBLING THE STARTER MOTOR

1. Install:
● Stator assembly “1”
● Front bracket “2”
● Rear bracket “3”
NOTE:
Align the match marks “a” on the starter motor
yoke with the match marks “b” on the front and
rear brackets.
5-49
CRANKCASE
EAS25540
CRANKCASE
Separating the crankcase
7
2
3
10
1
4
5
6
9
E 8
(3)
(7)
E
11
12

Engine Refer to “ENGINE REMOVAL” on page 5-1.
Refer to “CYLINDER AND PISTON” on
Cylinder/piston
page 5-24.
Refer to “V-BELT AUTOMATIC TRANSMIS-
V-belt automatic transmission
SION” on page 5-29.
Oil pump Refer to “OIL PUMP” on page 5-43.
Transmission Refer to “TRANSMISSION” on page 5-60.
1 Timing chain 1
2 Timing chain guide (intake side) 1
3 Right crankcase 1
4 Dowel pin 1
5 O-ring 1
6 Dowel pin 2
7 Left crankcase 1
8 Relief valve assembly 1
9 Oil pump drive gear 1
10 Oil pump drive gear shaft 1
11 Oil pump driven gear 1
12 Oil pump driven gear shaft 1
5-50
CRANKCASE
Separating the crankcase
7
2
3
10
1
4
5
6
9
E 8
(3)
(7)
E
11
12

dure.
5-51
CRANKCASE
EAS25560 EAS23950
DISASSEMBLING THE CRANKCASE CHECKING THE TIMING CHAIN GUIDE

1. Remove: The following procedure applies to all of the
● Crankcase bolts camshaft sprockets and timing chain guides.
1. Check:
● Timing chain
Damage/stiffness → Replace the timing

chain, crankshaft and camshaft sprockets as
a set.
NOTE:
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.
2. Remove:
2. Check:
● Right crankcase
● Timing chain guide
ECA13900
CAUTION: Damage/wear → Replace the defective

Tap on one side of the crankcase with a part(s).
soft-face hammer. Tap only on reinforced EAS1B705
portions of the crankcase, not on the crank- CHECKING THE OIL PUMP GEARS AND
case mating surfaces. Work slowly and care- SHAFTS
fully and make sure the crankcase halves 1. Check:
separate evenly. ● Oil pump drive gear
● Oil pump driven gear
● Oil pump drive gear shaft
● Oil pump driven gear shaft
● Timing chain
Cracks/damage/wear → Replace the defec-

tive part(s).
EAS1B706
CHECKING THE RELIEF VALVE

1. Check:
● Relief valve body “1”
EAS1B704 ● Relief valve“2”
CHECKING THE CRANKCASE ● Spring “3”
1. Thoroughly wash the crankcase halves in a Damage/wear → Replace the defective

mild solvent. part(s).
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:
● Crankcase
● Oil delivery passages
5-52
CRANKCASE
Bolt “1” M8×100mm

30 Nm (3.0 m•kg 22 ft•lb)
T.
3
R.
16 Nm (1.6 m•kg 12 ft•lb)
2 Bolt “3” M8×80mm
16 Nm (1.6 m•kg 12 ft•lb)
1 16 Nm (1.6 m•kg 12 ft•lb)
10 Nm (1.0 m•kg 7.2 ft•lb)
EAS1B708
CHECKING THE CIRCLIPS AND WASHERS

1. Check: 2 3 5
● Circlips
Bends/damage/looseness → Replace.
● Washers
Bends/damage → Replace. 4
1
EAS25700
ASSEMBLING THE CRANKCASE

1. Thoroughly clean all the gasket mating sur- 5
5
faces and crankcase mating surfaces.
2. Apply:
● Sealant
(onto the crankcase mating surfaces)

Yamaha bond No. 1215
(Three Bond No.1215®)
90890-85505
NOTE:
Do not allow any sealant to come into contact
with the oil gallery.
3. Install:
● Crankcase bolts
NOTE:
Tighten the crankcase bolts in stages and in a
crisscross pattern.
5-53
CRANKSHAFT ASSEMBLY
EAS25970
CRANKSHAFT ASSEMBLY
Removing the crankshaft assembly
2 E

Separate.
Crankcase
Refer to “CRANKCASE” on page 5-50.
1 Crankshaft assembly 1
2 Balancer shaft assembly 1
dure.
5-54
CRANKSHAFT ASSEMBLY
Removing the crankcase bearing
E
2
1
E

1 Crankshaft journal bearing 2
2 Bearing 2
3 Oil seal 1
dure.
5-55
CRANKSHAFT ASSEMBLY
EAS26050
REMOVING THE CRANKSHAFT JOURNAL

BEARING
1. Remove:
● Crankshaft main journal bearings “1”
NOTE:
Remove the main journal bearing by the bearing
installer “2”.
Plane bearing installer

90890-04146
2. Check:
● Crankshaft journal surfaces
Scratches/wear → Replace the crankshaft.

3. Measure:
2 ● Big end side clearance
1 Out of specification → Replace the crank-

shaft assembly.
Big end side clearance D

0.350–0.850 mm (0.0138–0.0335
in)
4. Measure:
● Crankshaft-journal-to-crankshaft-jour-
nal-bearing oil clearance

2 Out of specification → Replace the crank-
shaft journal bearings as a set.
Crankshaft-journal-to-crank-
shaft-journal- bearing oil clearance
1 0.030–0.077 mm (0.0012–0.0030
in)
NOTE:
Identify the position of each crankshaft main
journal bearing so that it can be reinstalled in its ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
original place. a. Clean the surface of the journal and the jour-
nal bearing.
EAS26060
b. Check the bearing surface. If the bearing sur-
CHECKING THE CRANKSHAFT AND face is worn or scratched, replace the bear-
CONNECTING ROD
ings as a set.
1. Measure:
NOTE:
● Crankshaft runout limit
If either the left or right journal bearing is worn or
Out of specification → Replace the crank-
scratched, replace both bearings as a set.
shaft, bearing or both.
NOTE: c. Measure the crankshaft journal outside di-
Turn the crankshaft slowly. ameter “a” in two places. If it is out of specifi-
cation, replace the crankshaft.
Crankshaft runout limit
0.030 mm (0.0012 in)
5-56
CRANKSHAFT ASSEMBLY
A
1
d. Measure the journal bearing inside diameter

B
“b” in two places.
1
b
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Select the crankshaft journal bearings from
NOTE: the following table according to the number
When calculating the journal oil clearance, use stamped on the inside of the crankcase.
the larger of the two values from the crankshaft
BEARING COLOR CODE
journal and use the smaller of the two values
from the journal bearing. 0 white
e. If the journal bearing inside diameter is 1 blue

“35.064” and the crankshaft journal outside 2 black
diameter is “35.014”, then the journal oil 3 brown
clearance is: 4 green
Journal oil clearance:
Journal bearing inside diameter-
Crankshaft journal outside diameter ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
=35.064 – 35.014 = 0.050mm 6. Measure:
● Crankshaft width
Out of specification → Replace the crank-

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ shaft.
5. Select:
● Crankshaft journal bearings Crankshaft width
NOTE: 63.95 – 64.00 mm (2.518 – 2.520 in)
The numbers “1” on the crankcase are used to
determine the replacement crankshaft journal
bearing size.
A: Left crankcase
B: Right crankcase
5-57
CRANKSHAFT ASSEMBLY
7. Check: EAS1B707
● Crankshaft sprocket“1”
CHECKING THE BEARINGS
Damage/wear → Replace the crankshaft. 1. Check:
● Bearing
● Balancer drive gear “2”
Damage/wear → Replace the crankshaft. Clean and lubricate the bearings, then rotate
the inner race with your finger.
2 Rough movement → Replace.
EAS25630
INSTALLING THE CRANKSHAFT JOURNAL

BEARING
1. Attach:
● Crankshaft journal bearings “1”
1
NOTE:
Attach the crankshaft journal bearing to the in-
staller “2”.
8. Check:
● Crankshaft journal Plane bearing installer
Damage/wear → Replace the crankshaft. 90890-04146
● Crankshaft journal oil passage
A B
a
EAS26130
CHECKING THE BALANCER SHAFT

1. Check: a
● Balancer shaft
b
Scratches/wear → Replace the balancer
shaft b
A. Left crankcase
B. Right crankcase
5-58
CRANKSHAFT ASSEMBLY
2. Install:
● Crankshaft journal bearings
NOTE:
● Install each crankshaft journal bearing from
the inside of the crankcase with the notch “a”
aligned with groove “b” on the crankcase jour-
nal as shown.
● To install the crankshaft journal bearings,
press each bearing into the left crankcase “3”
and right crankcase “4” as shown in the illus-
tration. (length “c” = 1.9-2.7mm)
c c 3
4
EAS26220
INSTALLING THE CRANKSHAFT AND

BALANCER SHAFT
1. Install:
● Crankshaft assembly
● Balancer shaft assembly
NOTE:
Align the punch mark “a” in the crankshaft gear
with the punch mark “b” in the balancer shaft
gear.
b a
5-59
TRANSMISSION
EAS26240
TRANSMISSION
Removing the transmission
12 8
11
7
10
6
9
5
4
3
1
(7)

Rear wheel Refer to “REAR WHEEL” on page 4-11.
Drain.
Transmission oil Refer to “CHANGING THE TRANSMISSION
OIL” on page 3-11.
Refer to “V-BELT AUTOMATIC TRANSMIS-
Secondary sheave assembly
SION” on page 5-29.
1 Transmission gear case cover 1
2 Gasket 1
3 Dowel pin 2
4 Primary drive gear 1
5 Washer 1
6 Washer 1
7 1st wheel gear 1
8 Drive axle 1
9 Main axle 1
10 Washer 1
11 Primary driven gear 1
12 Washer 1
dure.
5-60
TRANSMISSION
EAS26300
CHECKING THE TRANSMISSION

1. Check:
● Transmission gears
Blue discoloration/pitting/wear → Replace

the defective gear(s).
● Transmission gear dogs
Cracks/damage/rounded edges → Replace

the defective gear(s).
2. Check:
● Transmission gear engagement
Incorrect → Replace.
EAS26340
INSTALLING THE PRIMARY DRIVE GEAR

1. Install:
● Main axle assembly
● Drive axle assembly
● Circlip New
● Washer
2. Install:
● Primary drive gear oil seal “1”
NOTE:
Press the primary drive gear oil seal into the
transmission case cover as shown in the illustra-
tion.
a
1
a. 1.5–2.0mm (0.059–0.079 in)
5-61
TRANSMISSION
5-62
COOLING SYSTEM
RADIATOR.................................................................................................. 6-1
CHECKING THE RADIATOR ................................................................. 6-2
INSTALLING THE RADIATOR ............................................................... 6-2
THERMOSTAT............................................................................................ 6-4
CHECKING THE THERMOSTAT ........................................................... 6-5
INSTALLING THE THERMOSTAT ......................................................... 6-5
1
WATER PUMP ............................................................................................ 6-6
CHECKING THE WATER PUMP ........................................................... 6-7
ASSEMBLING THE WATER PUMP ....................................................... 6-7 2
9
RADIATOR
EAS26380
RADIATOR
Removing the radiator
4
5
7
3
8
9

Radiator cover/front cowling
4-1.
Drain.
page 3-15.
1 Coolant reservoir 1
2 Coolant reservoir hose 1
3 Coolant reservoir tank overflow hose 1
4 Radiator filler hose 1
5 Radiator hose (IN) 1 Disconnect.
6 Radiator hose (OUT) 1 Disconnect.
7 Radiator fan motor coupler 1 Disconnect.
8 Radiator 1
9 Radiator fan 1
dure.
6-1
RADIATOR
EAS26390
CHECKING THE RADIATOR

1. Check:
● Radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the radi-
ator.
Damage → Repair or replace.
NOTE:
Straighten any flattened fins with a thin,
flat-head screwdriver. b. Apply the specified pressure for ten seconds
and make sure there is no drop in pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
● Radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” on page 8-25.
EAS26400
2. Check: INSTALLING THE RADIATOR

● Radiator hoses (IN/OUT)
1. Fill:
● Cooling system
● Radiator filler hose

Cracks/damage → Replace. mended coolant)
3. Measure: Refer to “CHANGING THE COOLANT” on
● Radiator cap opening pressure
page 3-15.
Below the specified pressure → Replace the 2. Check:
● Cooling system
radiator cap.
Leaks → Repair or replace any faulty part.
Radiator cap opening pressure ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
110.0–140.0 kPa (16.0–20.3 psi) a. Attach the radiator cap tester “1” to the radi-
(1.10–1.40 kgf/cm2) ator.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Radiator cap tester
a. Install the radiator cap tester “1” and radiator 90890-01325
cap tester adapter “2” to the radiator cap “3”. Radiator pressure tester
YU-24460-01
Radiator cap tester
90890-01325
Radiator pressure tester
YU-24460-01
Radiator cap tester adapter
90890-01352
Radiator pressure tester adapter
YU-33984
b. Apply 100 kPa (14.22 psi) (1.0 kg/cm2) of
6-2
RADIATOR
pressure.
c. Measure the indicated pressure with the
gauge.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Measure:
Below the specified pressure → Replace the

radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-2.
6-3
THERMOSTAT
EAS26440
THERMOSTAT
Removing the thermostat

Trunk
4-1.
Rubber sheet
Drain.
page 3-15.
1 Hose (thermostat-OUT) 1 Disconnect.
2 Bleed hose 1 Disconnect.
3 Hose (thermostat-IN) 1 Disconnect.
4 Thermostat cover 1
5 Thermostat 1
dure.
6-4
THERMOSTAT
EAS26450
CHECKING THE THERMOSTAT

1. Check: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
● Thermostat “1” 2. Check:
Does not open at 70.5–73.5°C (159–164°F) ● Thermostat housing cover
→ Replace. Cracks/damage → Replace.

EAS26480
INSTALLING THE THERMOSTAT

1. Install:
● Thermostat“1”
● Thermostat cover
Thermostat cover bolt

10 Nm (1.0 m•kg 7.2 ft•lb)
T.
R.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Suspend the thermostat “1” in a container “2” 1
filled with water.
b. Slowly heat the water.
c. Place a thermometer “3” in the water.
d. While stirring the water “4”, observe the ther-
mostat and thermometer’s indicated temper-
ature.
2. Fill:
● Cooling system

mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-15.
3. Check:
● Cooling system
Leaks → Repair or replace any faulty part.

4. Measure:
Below the specified pressure → Replace the

radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-2.
A. Fully closed
B. Fully open
NOTE:
If the accuracy of the thermostat is in doubt, re-
place it. A faulty thermostat could cause serious
overheating or overcooling.
6-5
WATER PUMP
EAS26500
WATER PUMP
Removing the water pump
3
9
4
5
13
1
12
11
10
8
7

Refer to “PICKUP COIL ROTOR” on page
Right crankcase cover
5-37.
1 Heat exchanger pipe 1
2 O-ring 2
3 Hose (water pump-OUT) 1
4 Heat exchanger cover 1
5 Gasket 1
6 Pickup coil rotor inner bracket 1
7 Water pump cover 1
8 O-ring 1
9 Circlip 1
10 Impeller shaft 1
11 Water pump seal 1
12 Circlip 1
13 Bearing 1
dure.
6-6
WATER PUMP
EAS26530
CHECKING THE WATER PUMP Middle driven shaft bearing driver

1. Check: 90890-04058
● Water pump cover Bearing driver 40 mm
● Impeller shaft YM-04058
Cracks/damage/wear → Replace. Mechanical seal installer
2. Check: 90890-04145
● Hose (water pump-IN)
● Hose (water pump-OUT)

A
Cracks/damage → Replace. 4
3. Check: 3
● Heat exchanger “1”
Cracks/damage → Replace. 1
1 2
A. Push down.
2. Apply the lithium-soap-based grease to the
water pump seal lip.
4. Check:
● Heat exchanger cover “1”
5. Check:
● Hose (heat exchanger-OUT)
EAS26560
ASSEMBLING THE WATER PUMP

1. Install:
● Bearing New
● Circlip New
● Oil pump seal “1” New
(to the right crankcase cover “2”)

NOTE:
Install the water pump seal with the mechanical
seal installer “3” and middle driven shaft bearing
driver “4”
6-7
FUEL SYSTEM
FUEL TANK ................................................................................................ 7-1
REMOVING THE FUEL TANK ............................................................... 7-2
REMOVING THE FUEL PUMP............................................................... 7-2
INSTALLING THE FUEL PUMP ............................................................. 7-2
INSTALLING THE FUEL HOSE ............................................................. 7-2
THROTTLE BODY ...................................................................................... 7-4 1
CHECKING THE FUEL INJECTOR........................................................ 7-5
CHECKING THE THROTTLE BODY...................................................... 7-5
CHECKING THE PRESSURE REGULATOR OPERATION .................. 7-5
ADJUSTING THE THROTTLE POSITION SENSOR ............................. 7-6
AIR INDUCTION SYSTEM.......................................................................... 7-7
2
CHECKING THE AIR INDUCTION SYSTEM ......................................... 7-10
9
FUEL TANK
EAS26620
FUEL TANK
Removing the fuel tank
6 3
2
7
(6)
13
10 12
11
5 9
1

Radiator Refer to “RADIATOR” on page 6-1.
1 Inner fender 1
2 Canister 1
Hose (rollover valve to canister)/hose (canister
3 1/1
to throttle body)
4 Plate (left) 1
5 Radiator pipe assembly 1
6 Fuel pump coupler 1 Disconnect.
7 Fuel hose connector cover/fuel hose 1/1
8 Front under bracket 1
9 Rollover valve 1
10 Rollover valve bracket 1
11 Clamp 1
12 Fuel tank 1
13 Fuel pump 1
dure.
7-1
FUEL TANK
EAS26630 EAS26700
REMOVING THE FUEL TANK INSTALLING THE FUEL PUMP

1. Extract the fuel in the fuel tank through the 1. Install:
fuel tank cap with a pump. ● Fuel pump
2. Remove: ● Fuel pump gasket New
● Fuel pump coupler ● Fuel pump bolts
● Fuel hose connector cover “1”

Fuel pump bolts
● Fuel hose “2”
ECA1B704
4 Nm (0.4 m•kg, 2.9 ft•lb)
T.
R.
CAUTION:
● Be sure to disconnect the fuel hose by NOTE:
hand. Do not forcefully disconnect the ● Do not damage the installation surfaces of the
hose with tools. fuel tank when installing the fuel pump.
● Although the fuel has been removed from ● Always use a new fuel pump gasket.
the fuel tank, be careful when removing ● Align the projection “a” on the fuel pump with
the fuel hose, since there may be fuel re- the alignment mark “b” on the fuel tank.
maining in it. ● Tighten the fuel pump bolts in the proper tight-
● Do not disconnect the fuel hose from the ening sequence as shown and torque them in
fuel hose connector. Disconnect the con- two stages.
nector from the fuel pump.
a
b 2
2 1 4
A
5
6
3
1
A. Forward
NOTE: EAS1B712
Before removing the hoses, place a few rags in INSTALLING THE FUEL HOSE
the area under where it will be removed. 1. Install:
● Fuel hose
3. Remove: ● Fuel hose connector cover
● Fuel tank ECA1B705
NOTE: CAUTION:
Be careful that the fuel doesn't leak. Be sure to connect the fuel hose securely
and install the fuel hose connector cover in
EAS26640
the correct position, otherwise the fuel hose
REMOVING THE FUEL PUMP
will not be properly installed.
1. Remove:
● Fuel pump NOTE:
ECA14720 Install the fuel hose connector securely onto the
CAUTION: fuel tank until a distinct “click” is heard, and then
● Do not drop the fuel pump or give it a make sure that it does not come loose. After in-
strong shock. stalling the fuel hose connector cover “1” to the
● Do not touch the base section of the fuel fuel hose “2”, make sure that it is installed se-
sender. curely.
7-2
FUEL TANK
2 1
7-3
THROTTLE BODY
EAS26970
THROTTLE BODY
Removing the throttle body
3 9
14
1
10
13
8
11
12
4
7 7

Refer to “REPLACING THE AIR FILTER
Air filter case
ELEMENT” on page 3-12.
1 ISC (idle speed control) valve coupler 1 Disconnect.
2 Throttle position sensor coupler 1 Disconnect.
3 Intake air pressure sensor 1
4 Throttle body clamp screw 1 Loosen.
5 Bracket 1
6 Throttle cable 2 Disconnect.
Hose (air filter case to throttle body)/hose (can-
7 1/1 Disconnect.
ister to throttle body hose)
8 Throttle bodies 1
9 Vacuum chamber cover 1
10 Piston valve spring 1
11 Piston valve
12 Throttle position sensor 1
13 Fuel injector coupler 1 Disconnect.
14 Fuel injector 1
dure.
7-4
THROTTLE BODY
EAS26980
4. Check:
CHECKING THE FUEL INJECTOR
● Piston valve movement
1. Check:
Insert the piston valve into the throttle body
● Fuel injector
and move it up and down.
Damage → Replace.
Tightness → Replace the piston valve.
EAS26990
EAS27010
CHECKING THE THROTTLE BODY
CHECKING THE PRESSURE REGULATOR
1. Check:
OPERATION
● Throttle body
1. Check:
Cracks/damage → Replace the throttle bod-
● Pressure regulator operation
ies as a set.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2. Check:
a. Remove the trunk.
● Piston valve “1”
Damage/scratches/wear → Replace.
b. Remove the fuel hose connector cover “1”
● Piston valve diaphragm “2”
and disconnect the fuel hose “2” from the fuel
Cracks/tears → Replace.
pump.
ECA1B704
CAUTION:
2 ● Be sure to disconnect the fuel hose by

hand. Do not forcefully disconnect the
hose with tools.
● Although the fuel has been removed from
1 the fuel tank, be careful when removing
the fuel hose, since there may be fuel re-
maining in it.
● Do not disconnect the fuel hose from the
3. Check: fuel hose connector. Disconnect the con-
● Vacuum chamber cover “1”
nector from the fuel pump.
● Piston valve spring “2”
2 1
NOTE:
Before removing the hoses, place a few rags in
7-5
THROTTLE BODY
the area under where it will be removed.
c. Connect the adapter “3” onto the fuel tank
and the pressure gauge “4” onto the adaptor.
Pressure gauge
90890-03153
YU-03153
Fuel pressure adapter
90890-03181
3 4
d. Start the engine.

e. Measure the fuel pressure.
Fuel pressure
246–254 kPa (35.0–36.1 psi)
(2.46–2.54 kg/cm2)
f. Out of specification → Replace the fuel

pump.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS27030
ADJUSTING THE THROTTLE POSITION

SENSOR
1. Check:
● Throttle position sensor
Refer to “CHECKING THE THROTTLE PO-

SITION SENSOR” on page 8-76.
7-6
AIR INDUCTION SYSTEM
EAS27040
7-7
1. Air induction system hose (air filter case
to air cut-off valve)
2. Air cut-off valve
3. Air induction system hose (air cut-off
valve to muffler)
4. Air induction system pipe
5. Air filter case cover
7-8
Removing the air cut-off valve assembly and hoses

Air induction system hose (air filter case to air
1 1 Disconnect.
cut-off valve)
Air induction system hose (air cut-off valve to
2 1 Disconnect.
muffler)
3 Air cut-off valve 1
dure.
7-9
EAS27060
CHECKING THE AIR INDUCTION SYSTEM

Air induction system
The air induction system burns unburned ex-
haust gases by injecting fresh air (secondary air)
into the exhaust port, reducing the emission of
hydrocarbons. When there is negative pressure
at the exhaust port, the reed valve opens, allow-
ing secondary air to flow into the exhaust port.
The required temperature for burning the un-
burned exhaust gases is approximately 600 to
700°C.
Air cut-off valve
The air cut-off valve prevents air backflow from
the exhaust port of the cylinder head to the air fil-
ter.
A B
A. From the air filter

B. To the muffler
1. Check:
● Air induction system hose
Loose connections → Connect properly.

● Pipes
2. Check:
● Reed valve
● Reed valve stopper
● Reed valve seat
Cracks/damage → Replace the reed valve.

3. Check:
● Air cut-off valve
7-10
7-11
ELECTRICAL SYSTEM
IGNITION SYSTEM ..................................................................................... 8-1
CIRCUIT DIAGRAM................................................................................ 8-1
TROUBLESHOOTING ............................................................................ 8-3
ELECTRIC STARTING SYSTEM................................................................ 8-5
CIRCUIT DIAGRAM................................................................................ 8-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ....................... 8-7
1
CHARGING SYSTEM ................................................................................. 8-11
CIRCUIT DIAGRAM................................................................................ 8-11
2
LIGHTING SYSTEM.................................................................................... 8-15
CIRCUIT DIAGRAM................................................................................ 8-15
SIGNALING SYSTEM ................................................................................. 8-19
3
CIRCUIT DIAGRAM................................................................................ 8-19
COOLING SYSTEM .................................................................................... 8-25 4
CIRCUIT DIAGRAM................................................................................ 8-25
FUEL INJECTION SYSTEM ....................................................................... 8-29
CIRCUIT DIAGRAM................................................................................ 8-29 5
ECU SELF-DIAGNOSTIC FUNCTION ................................................... 8-31
FAIL-SAFE ACTIONS (SUBSTITUTE CHARACTERISTICS
OPERATION CONTROL) ...................................................................... 8-32
TROUBLESHOOTING METHOD ........................................................... 8-34
DIAGNOSTIC MONITORING MODE ..................................................... 8-34
TROUBLESHOOTING DETAILS ............................................................ 8-40
6
ELECTRICAL COMPONENTS ................................................................... 8-59
CHECKING THE SWITCHES ................................................................. 8-61
CHECKING THE BULBS AND BULB SOCKETS ................................... 8-64
CHECKING THE FUSES ........................................................................ 8-65
7
CHECKING AND CHARGING THE BATTERY ...................................... 8-66
CHECKING THE RELAYS...................................................................... 8-69
CHECKING THE SPARK PLUG CAP .................................................... 8-70
CHECKING THE IGNITION COIL .......................................................... 8-71
CHECKING THE CRANKSHAFT POSITION SENSOR ......................... 8-72
8
CHECKING THE LEAN ANGLE SENSOR ............................................. 8-72
CHECKING THE STATOR COIL ............................................................ 8-73
CHECKING THE RECTIFIER/REGULATOR ......................................... 8-73
CHECKING THE HORN ......................................................................... 8-74
CHECKING THE SPEED SENSOR ....................................................... 8-74
9
CHECKING THE RADIATOR FAN MOTOR........................................... 8-75
CHECKING THE COOLANT TEMPERATURE SENSOR ...................... 8-75
CHECKING THE THROTTLE POSITION SENSOR .............................. 8-76
CHECKING THE INTAKE AIR PRESSURE SENSOR ........................... 8-77
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ................... 8-77
CHECKING THE V-BELT REPLACEMENT INDICATOR
RESET COUPLER................................................................................. 8-77
EAS27100
EAS27090
10A 10A
R/G R R R
O Gy Sb R L Y/R Y/G P/W

W/R
O/B P Lg W R/W B/R Br/W R/L
W/L
G/B W/B B/L L/G G/L W/R Y G/R R
W/L W/R R W R/G G/Y B B/W Y/L L/B W/L
R/B
W W L B/L Y/L O O
CIRCUIT DIAGRAM
W W R W/R
IGNITION SYSTEM
W W 30A W/L
R
B R L
R R
W W W W W W W W W Y/L Y/L B Y Y P B P
B
L/W L/B B/L L L B L L Lg B Lg
(BLACK) R
R R P/W P/W B P/W P/W Gy B Gy
(BLACK)
B/L G/R B G/R G/R Sb B Sb
Lg Sb
B/L P/W L
R B P Gy
R/G G/W G/R B/L
L/B R/B
L/B B/L
OFF B B B (GREEN)
L/W
ON B Br/W Br/W B Br/W Br/W R/G
B
Br/W B/L R/L
B L/B
B L/Y G/W
Br/L R R Br/L L/W (BLACK) (BLACK)
L/G R/B G/Y
L/G L/Y L/Y L/B B/L
A B/L B B/L B/L L Y O/B R/L
(RED) (RED) B
L/G R
L/W L/Y
G/Y Y/G O/B B O/B R/L B R/L
Br/L L/G
L/Y Y/G
L B/L
W/B
10A B/R
G/B
10A L Y/G B/L
B/R B/R
Br/L R/W
R/W G B
R/G
R/B L/G R/L B
G/W
G/Y
L/Y
L/B R/W
OFF OFF
L/B RUN ON Y/L
A B B L/B W W
L/B (BLUE) L
B/L
L/B Br G/W R/W R/W L/W Br B
8-1
B/W B
G/Y L/B R/B R/B B G/Y B L/Y
W R
(BLUE)
L/B Br G/Y B
15A
Br/L R/Y L W
B B/
L
10A
R Br/R
Br
10A
Br/L Br Br G/B
Br/R C C
10A L Br G/B
R/G Br/L Br
Br/R R/W G/Y
Br R/W
R/Y Br Br
R/Y Br
Br
Br Br R/G
R/Y L
B B Br/W
L/B Br P
Br G/B
(BLACK) Br
R/Y W/B
B
P L G/Y
L/B L G/B
W/B Br/W
L
L
OFF Br L
B B ON L L
L L
L/B P Br/W Br G/Y (RED) (RED)
(BLACK) (BLACK)
L
B
L
HI OFF R
LO ON NR
N L L
NL L L
L
G/Y G Y B P P B Y G L/Y (BLUE) (BLUE)
Br Ch Dg Br/W L/B L/B Br/W Dg Ch B/Y
L
R/W G
R/G Y/L Gy Y Dg Ch
L
G B Ch Dg
L L
L B
(BLUE) (BLUE)
B
B Gy
B
IGNITION SYSTEM
IGNITION SYSTEM
1. Main switch
2. Pickup coil
7. Ignition fuse
8. Main fuse
9. Battery
14. Engine stop switch
17. Starting circuit cut-off relay
18. Sidestand switch
24. ECU
25. Ignition coil
8-2
IGNITION SYSTEM
EAS27130
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
NOTE:
● Before troubleshooting, remove the following part(s):
1. Document box
2. Left side cover
3. Left footboard
4. Trunk
5. Front cowling
1. Check the fuses.

(Main and ignition)
NG→ Replace the fuse(s).
Refer to “CHECKING THE FUSES”
on page 8-65.
OK↓
2. Check the battery.
● Clean the battery terminals.
Refer to “CHECKING AND CHARG- NG→
● Recharge or replace the battery.
ING THE BATTERY” on page 8-66.
OK↓
3. Check the spark plug.
Refer to “CHECKING THE SPARK NG→ Re-gap or replace the spark plug.
PLUG” on page 3-7.
OK↓
4. Check the spark plug cap.
Refer to “CHECKING THE SPARK NG→ Replace the spark plug cap.
PLUG CAP” on page 8-70.
OK↓
5. Check the ignition coil.
Refer to “CHECKING THE IGNI- NG→ Replace the ignition coil.
TION COIL” on page 8-71.
OK↓
6. Check the crankshaft position sensor.
Refer to “CHECKING THE CRANK-
NG→ Replace the crankshaft position sensor.
SHAFT POSITION SENSOR” on
page 8-72.
OK↓
7. Check the stator coil.
Refer to “CHECKING THE STATOR NG→ Replace the stator assembly.
COIL” on page 8-73.
OK↓
8. Check the main switch.
Refer to “CHECKING THE NG→ Replace the main switch.
SWITCHES” on page 8-61.
OK↓
9. Check the engine stop switch.
Refer to “CHECKING THE NG→ Replace the right handlebar switch.
8-3
IGNITION SYSTEM
OK↓
10.Check the sidestand switch.
Refer to “CHECKING THE NG→ Replace the sidestand switch.
OK↓
11.Check the starting circuit cut-off relay.
Refer to “CHECKING THE RELAYS” NG→ Replace the starting circuit cut-off relay.
on page 8-69.
OK↓
12.Check the lean angle sensor.
Refer to “CHECKING THE NG→ Replace the lean angle sensor.
OK↓
13.Check the entire ignition system’s wir-
ing. Properly connect or repair the ignition system’s
NG→
Refer to “CIRCUIT DIAGRAM” on wiring
page 8-1.
OK↓
Replace the ECU.
8-4
EAS27170
EAS27160
10A 10A
R/G R R R

W/R
W/L
G/B W/B B/L L/G G/L W/R Y G/R
W W L B/L Y/L
W W R W/R
W W 30A W/L
R
B R L
CIRCUIT DIAGRAM
R R
W W W W W W W W W Y/L Y/L B Y Y
B
L/W L/B B/L L L B L L
(BLACK) R
R R P/W P/W B P/W P/W
(BLACK)
B/L G/R B G/R G/R
B/L P/W L
R B
L/G R/G R/G G/W G/R B/L
L/B R/B
L/B B/L
OFF B B B (GREEN)
R L/G
L/W
ON B Br/W Br/W B Br/W Br/W
B
Br/W B/L
B L/B
B L/Y G/W
Br/L R R Br/L L/W
L/G R/B G/Y
L/G L/Y L/Y L/B B/L
A B/L B B/L B/L
(RED) (RED) B
R
ELECTRIC STARTING SYSTEM
L/G L/W L/Y

Br/L G/Y Y/G
L/G
L/Y Y/G
L B/L
W/B
10A B/R
10A L Y/G B/L

B/R B/R
Br/L R/W
R/W
R/G
R/B G/W L/G
G/Y
L/Y
L/B R/W
OFF OFF
L/B RUN ON Y/L
A B B L/B
L/B (BLUE)
8-5
L/B
(BLUE)
L/B Br G/Y
B B/W 15A
Br/L R/Y
B
10A
R Br/R
Br
10A
Br/L Br
Br/R
10A L
R/G Br/L Br
Br/R R/W G/Y
Br R/W
R/Y
R/Y Br
R/G Br Br R/G
R/Y
B B Br/W
L/B Br P
(BLACK) Br
R/Y W/B
B
P L G/Y
L/B
W/B Br/W
B
L
L/B P Br/W Br G/Y
(BLACK)
HI OFF R
LO ON NR
N
NL
L
G/Y G Y B P P B Y G L/Y
R/W G
R/G Y/L Gy Y Dg Ch
G B Ch Dg
1. Main switch
7. Ignition fuse
8. Main fuse
9. Battery
10. Starter motor
11. Starter relay
12. Diode
15. Start switch
16. Front brake light switch
40. Rear brake light switch
65. Signal fuse
8-6
EAS27180
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the
starter motor can only operate if at least one of the following conditions is met:
● The brake lever is pulled to the handlebar (the brake switch is closed) and the sidestand is up (the
sidestand switch is closed).

The starting circuit cut-off relay prevents the starter motor from operating when neither of these condi-
tions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the
starter motor. When at least one of the above conditions has been met the starting circuit cut-off relay
is closed and the engine can be started by pressing the start switch.
8-7
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
7. Sidestand switch
8. Signal fuse
11. Start switch
12. Starter relay
13. Starter motor
8-8
EAS27190
TROUBLESHOOTING
The starter motor fails to turn.
NOTE:
1. Trunk
2. Footboard
3. Front cowling
1. Check the fuses.

(Main and ignition)
on page 8-65.
OK↓
OK↓
3. Check the starter motor.
Refer to “CHECKING THE NG→ Repair or replace the starter motor.
STARTER MOTOR” on page 5-48.
OK↓
4. Check the starting circuit cut-off relay.
Refer to “CHECKING THE RELAYS” NG→ Replace the starting circuit cut-off relay.
on page 8-69.
OK↓
5. Check the starter relay.
Refer to “CHECKING THE RELAYS” NG→ Replace the starter relay.
on page 8-69.
OK↓
OK↓
7. Check the engine stop switch.
OK↓
8. Check the sidestand switch.
Refer to “CHECKING THE NG→ Replace the sidestand switch.
OK↓
9. Check the front brake light switch.
Refer to “CHECKING THE NG→ Replace the front brake light switch.
OK↓
8-9
10.Check the start switch.
OK↓
11.Check the entire starting system’s
wiring. Properly connect or repair the starting system’s
NG→
Refer to “CIRCUIT DIAGRAM” on wiring
page 8-5.
OK↓
The starting system circuit is OK.
8-10
EAS27210
EAS27200
10A 10A
R/G R R R
W/R
CIRCUIT DIAGRAM
W/L
CHARGING SYSTEM
W/L W/R R W
W W
W W R
W W 30A
R
B R R R
W W W W W W W W W
B
R L/W L/B
(BLACK) R R
(BLACK)
R B
L/G R/G R/G
L/B
OFF B L/B
R L/G B B
L/W
ON B
B
8-11
B L/B
B
Br/L R R Br/L L/W
L/G
L/G L/Y L/Y L/B
A
(RED) (RED) B
L/G R
L/W
Br/L L/G
L/Y
10A
10A
Br/L R/W
R/W
R/G
R/B G/W
L/B OFF OFF

L/B RUN ON
A
L/B
L/B B
L/B Br G/W R/W R/W L/W Br
G/Y L/B R/B R/B B G/Y
L/B Br G/Y
B B/W 15A
CHARGING SYSTEM
CHARGING SYSTEM
3. Stator coil
8. Main fuse
9. Battery
8-12
CHARGING SYSTEM
EAS27220
TROUBLESHOOTING
The battery is not being charged.
NOTE:
1. Trunk
2. Left footboard
3. Front cowling
4. Leg shield
1. Check the fuse.

(Main)
NG→ Replace the fuse.
on page 8-65.
OK↓
OK↓
3. Check the stator coil.
Refer to “CHECKING THE STATOR NG→ Replace the stator assembly.
COIL” on page 8-73.
OK↓
4. Check the rectifier/regulator.
Refer to “CHECKING THE RECTI- NG→ Replace the rectifier/regulator.
FIER/REGULATOR” on page 8-73.
OK↓
5. Check the entire charging system’s
wiring. Properly connect or repair the charging sys-
NG→
Refer to “CIRCUIT DIAGRAM” on tem’s wiring.
page 8-11.
OK↓
This circuit is OK.
8-13
CHARGING SYSTEM
8-14
EAS27250
EAS27240
10A 10A
R/G R R R

W/R
W/L
R/B
W W L B/L Y/L O O
W W R W/R
30A R
W W R W/L R/B
B R L
R R
W W W W W W W W W Y/L Y/L B Y Y P B P R
B
(BLACK) R R/L
(BLACK) R/B R/G
Lg Sb
B/L P/W L
R B P Gy
L/G R/G
CIRCUIT DIAGRAM
R/G G/W G/R B/L

L/B R/B
L/B B/L
OFF B B B (GREEN) R/G
R L/G
LIGHTING SYSTEM
L/W R/L
B
Br/W B/L R/L
B L/B
B L/Y G/W
L/G R/B G/Y
L/G L/Y L/Y L/B B/L
(RED) (RED) B
L/G R
L/W L/Y
Br/L G/Y Y/G O/B B O/B R/L B R/L
L/G
L/Y Y/G
L B/L R/L G
W/B
10A B/R
G/B
10A L Y/G B/L
B/R B/R
Br/L R/W
R/W G B
R/G
R/B L/G R/L B
G/W
G/Y B B
L/Y
L/B R/W
OFF OFF
L/B RUN ON Y/L
A B B L/B W W
L/B (BLUE) L
L/B B B/L
B/W B
W R
(BLUE)
L/B Br G/Y B
B B/W 15A
Br/L R/Y L W
B B/
L
10A
R Br/R
Br
10A
Br/L Br Br G/B
Br/R C C
10A L Br G/B
R/G Br/L Br
Br/R R/W G/Y
Br R/W
R/Y Br Br
R/Y Br
Br
R/G Br Br R/G
8-15
R/Y L
B B Br/W
L/B Br P
Br G/B
(BLACK) Br
R/Y W/B
B
P L G/Y
L/B L G/B
W/B Br/W
L
L
OFF Br L
A
B B ON L L
L L
(BLACK) (BLACK)
L
B
L L/G L/B L/B L/G
HI OFF R (GRAY)
(GRAY)
LO ON NR
N L L
NL L L
L
WIRE HARNESS SUB-WIRE HARNESS
L
R/W G
R/G Y/L Gy Y Dg Ch
L
G B Ch Dg B
L L
L B
Gy Y/L R/L O/B P
P O/B R/L Y
(BLUE) (BLUE)
Sb Gy Lg G/R G/R Lg Gy Sb
Br/W L B/L P/W P/W B/L L Br/W
B
Gy B B Gy
B
B B
WIRE HARNESS ENGNE SUB-LEAD WIRE
C
Y G Br Ch Br Dg Ch Dg Br Br G/Y
Gy G R/W R/G
Y Dg Y/L Ch B
G/B G/B
G Y B Ch Br B Dg Br Ch B Dg B Br
Br
B (BROWN) (GREEN) (BROWN) (GREEN)
B B
B B B B
Br Ch B Br Dg B
B B Ch B Dg
Y G (BROWN) (GREEN)
(BROWN) (GREEN) L Y
B WIRE HARNESS SUB-WIRE HARNESS
Br B B
B B
B Br G/Y Br
B
LIGHTING SYSTEM
LIGHTING SYSTEM
1. Main switch
5. Backup fuse
8. Main fuse
9. Battery
43. Dimmer switch
46. Tail/brake light
47. License light
51. Front left turn signal light
52. Headlight
56. High beam indicator light
59. Meter light
60. Multi-function display
63. Headlight fuse
66. Taillight fuse
69. Box light switch
70. Box light
71. Box light manual switch
8-16
LIGHTING SYSTEM
EAS27260
TROUBLESHOOTING
Any of the following fail to light: headlight, high beam indicator light, taillight, box light, license light or
meter light.
NOTE:
1. Trunk
2. Side cover
3. Footboard
4. Front cowling
1. Check the each bulbs and bulb sock-

ets condition.
Refer to “CHECKING THE BULBS NG→ Replace the bulb(s) and bulb socket(s).
AND BULB SOCKETS” on page
8-64.
OK↓
2. Check the fuses.
(Main, headlight and taillight)
on page 8-65.
OK↓
OK↓
OK↓
5. Check the dimmer switch.
The dimmer switch is faulty. Replace the left
Refer to “CHECKING THE NG→
handlebar switch.
OK↓
6. Check the headlight relay.
Refer to “CHECKING THE RELAYS” NG→ Replace the headlight relay.
on page 8-69.
OK↓
7. Check the box light switch.
Refer to “CHECKING THE NG→ Replace the box light switch.
OK↓
8. Check the box light manual switch.
Refer to “CHECKING THE NG→ Replace the box light manual switch.
OK↓
8-17
LIGHTING SYSTEM
9. Check the entire lighting system’s wir-
ing. Properly connect or repair the lighting system’s
NG→
Refer to “CIRCUIT DIAGRAM” on wiring.
page 8-15.
OK↓
This circuit is OK.
8-18
EAS27280
EAS27270
10A 10A
R/G R R R

W/R
W/L
R/B
W W L B/L Y/L O O
W W R W/R
30A R
W W R W/L R/B
B R L
R R
B
(BLACK) R R/L
(BLACK) R/B R/G
Lg Sb
B/L P/W L
R B P Gy
L/G R/G R/G
CIRCUIT DIAGRAM
G/W G/R B/L

L/B R/B
L/B B/L
R L/G
L/W R/L
B
Br/W B/L R/L
B L/B
SIGNALING SYSTEM
B L/Y G/W
L/G R/B G/Y
L/G L/Y L/Y L/B B/L
(RED) (RED) B
L/G R
L/W L/Y
Br/L L/G
L/Y Y/G
L B/L R/L G
W/B
10A B/R
G/B
10A L Y/G B/L
B/R B/R
Br/L R/W
R/W G B
R/G
R/B L/G R/L B
G/W
G/Y B B
L/Y
L/B R/W
OFF OFF
L/B RUN ON Y/L
A B B L/B W W
L/B (BLUE) L
L/B B B/L
B/W B
W R
(BLUE)
L/B Br G/Y B
B B/W 15A
Br/L R/Y L W
B B/
L
10A
R Br/R
Br
10A
Br/L Br Br G/B
Br/R C C
10A L Br G/B
R/G Br/L Br
Br/R R/W G/Y
Br R/W
R/Y Br Br
R/Y Br
Br
R/G Br Br R/G
8-19
R/Y L
B B Br/W
L/B Br P
Br G/B
(BLACK) Br
R/Y W/B
B
P L G/Y
L/B L G/B
W/B Br/W
L
L
OFF Br L
A
B B ON L L
L L
(BLACK) (BLACK)
L
B
L L/G L/B L/B L/G
HI OFF R (GRAY)
(GRAY)
LO ON NR
N L L
NL L L
L
L
R/W G
R/G Y/L Gy Y Dg Ch
L
G B Ch Dg B
L L
Gy L B
P O/B R/L Y Y/L R/L O/B P
(BLUE) (BLUE)
B
Gy B B Gy
B
B B
C
Gy G R/W R/G
Y Dg Y/L Ch B
G/B G/B
Br
B B
B B B B
Br Ch B Br Dg B
B B Ch B Dg
Y G (BROWN) (GREEN)
(BROWN) (GREEN) L Y
Br B B
B B
B Br G/Y Br
B
SIGNALING SYSTEM
SIGNALING SYSTEM
1. Main switch
5. Backup fuse
8. Main fuse
9. Battery
24. ECU
30. Speed sensor
37. Turn signal relay
38. Horn
41. Turn switch
42. Horn switch
48. Rear right turn signal light
49. Rear left turn signal light
51. Front left turn signal light
54. Left turn signal indicator light
55. Right turn signal indicator light
62. V-belt replacement indicator reset coupler
65. Signal fuse
66. Taillight fuse
8-20
SIGNALING SYSTEM
EAS27290
TROUBLESHOOTING
● Any of the following fail to light: brake light, turn signal light or an indicator light.
● The horn fails to sound.
● Defective speed meter.
● The V-belt replacement indicator fails to come on.
NOTE:
1. Side cover
2. Footboard
3. Front cowling
1. Check the fuses.

(Main, ignition, signaling and tail-
light) NG→ Replace the fuse(s).
on page 8-65.
OK↓
OK↓
OK↓
4. Check the entire signaling system’s
wiring. Properly connect or repair the signaling sys-
NG→
page 8-19.
OK↓
This circuit is OK.
Check the signaling system
The horn fails to sound.
1. Check the horn switch.
Refer to “CHECKING THE NG→ Replace the left handlebar switch.
OK↓
2. Check the horn.
Refer to “CHECKING THE HORN” NG→ Replace the horn.
on page 8-74.
OK↓
NG→
page 8-19.
OK↓
This circuit is OK.
8-21
SIGNALING SYSTEM
The tail/brake light fails to come on.
1. Check the tail/brake light bulb and
socket.
Refer to “CHECKING THE BULBS NG→ Replace the tail/brake light bulb, socket or both.
8-64.
OK↓
2. Check the brake light switch.
Refer to “CHECKING THE NG→ Replace the brake light switch.
OK↓
NG→
page 8-19.
OK↓
Replace the tail/brake light assembly.
The turn signal light, turn signal indicator light or both fail to blink.
1. Check the turn signal indicator light
bulb and socket.
Replace the turn signal indicator light bulb,
Refer to “CHECKING THE BULBS NG→
socket or both.
8-64.
OK↓
2. Check the turn signal switch.
Refer to “CHECKING THE NG→ Replace the left handlebar switch.
OK↓
3. Check the turn signal relay.
The turn signal relay is faulty and must be
Refer to “CHECKING THE RELAYS” NG→
replaced.
on page 8-69.
OK↓
NG→
page 8-19.
OK↓
This circuit is OK.
8-22
SIGNALING SYSTEM
The V-belt replacement indicator fails to come on.
1. Check the V-belt replacement indica-
tor reset coupler.
Replace the V-belt replacement indicator reset
Refer to “CHECKING THE V-BELT NG→
coupler.
REPLACEMENT INDICATOR
RESET COUPLER” on page 8-77.
OK↓
NG→
page 8-19.
OK↓
Replace the meter assembly.
The speedometer fails to operate.

1. Check the speed sensor.
Refer to “CHECKING THE SPEED NG→ Replace the speed sensor.
SENSOR” on page 8-74.
OK↓
NG→
page 8-19.
OK↓
Replace the meter assembly.
8-23
SIGNALING SYSTEM
8-24
10A 10A
EAS27310
EAS27300
R/G R R R

W/R
W/L
W/R R W R/G G/Y B B/W Y/L L/B W/L
R/B
W W L B/L Y/L O O
W W R W/R
30A R
W W R W/L R/B
B R L
R R
W W W W W W W Y/L Y/L B Y Y P B P R
B
(BLACK) R R/L
(BLACK) R/B R/G
Lg Sb
B/L P/W L
R B P Gy
CIRCUIT DIAGRAM
G/W G/R B/L

L/B R/B
L/B B/L
B (GREEN) R/G
COOLING SYSTEM
OFF B B
L/W R/L
B
Br/W B/L R/L
B L/B
B L/Y G/W
R/B G/Y B/L
L/G L/Y L/Y L/B
B/L B B/L B/L L Y O/B R/L
(RED) (RED) B
R
L/W L/Y
Br/L G/Y Y/G O/B B O/B R/L B R/L
L/G
L/Y Y/G
L B/L R/L G
W/B
10A B/R
G/B
10A L Y/G B/L
B/R B/R
Br/L R/W
R/W G B
R/G
R/B L/G R/L B
G/W
G/Y B B
L/Y
R/W
OFF OFF
RUN ON Y/L
B B L/B W W
(BLUE) L
B/L
Br G/W R/W R/W L/W Br B
B/W B
W R
(BLUE)
L/B Br G/Y B
15A
Br/L R/Y L W
B/
L
10A
R Br/R
Br
10A
Br/L Br Br G/B
Br/R C C
10A L Br G/B
Br/L Br
Br/R R/W G/Y
8-25
Br R/W
R/Y Br Br
R/Y Br
Br
R/G
R/Y L
B Br/W
L/B Br P
Br G/B
(BLACK) Br
R/Y W/B
B
P L G/Y
L/B L G/B
W/B Br/W
L
L
OFF Br L
A
B B ON L L
L L
(BLACK) (BLACK)
L
B
L L/G L/B L/B L/G
HI OFF R (GRAY)
(GRAY)
LO ON NR
N L L
NL L L
L
L
R/W G
R/G Y/L Gy Y Dg Ch
L
G B Ch Dg B
L L
L B
P O/B R/L Y Y/L R/L O/B P
(BLUE) (BLUE)
B
B
C
Gy G R/W R/G
Y Dg Y/L Ch B
G/B G/B
Br
B B
B B B B
Br Ch B Br Dg B
B B Ch B Dg
Y G (BROWN) (GREEN)
(BROWN) (GREEN) L Y
Br B B
B B
B Br G/Y Br
B
COOLING SYSTEM
COOLING SYSTEM
1. Main switch
7. Ignition fuse
8. Main fuse
9. Battery
23. Coolant temperature sensor
24. ECU
35. Radiator fan motor relay
36. Radiator fan motor
64. Radiator fan motor fuse
8-26
COOLING SYSTEM
EAS27320
TROUBLESHOOTING
● The radiator fan motor fails to turn.
● The coolant temperature meter (meter assembly) fails to indicate.
NOTE:
1. Trunk
2. Footboard
3. Radiator cover
4. Drain the coolant.
1. Check the fuses.

(Main, ignition and radiator fan
motor) NG→ Replace the fuse(s).
on page 8-65.
OK↓
OK↓
OK↓
4. Check the radiator fan motor.
The radiator fan motor is faulty and must be
Refer to “CHECKING THE RADIA- NG→
replaced.
TOR FAN MOTOR” on page 8-75.
OK↓
5. Check the radiator fan motor relay.
Refer to “CHECKING THE RELAYS” NG→ Replace the radiator fan motor relay.
on page 8-69.
OK↓
6. Check the coolant temperature sen-
sor.
Refer to “CHECKING THE COOL- NG→ Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR” on
page 8-75.
OK↓
7. Check the entire cooling system’s wir-
ing. Properly connect or repair the cooling system’s
NG→
Refer to “CIRCUIT DIAGRAM” on wiring.
page 8-25.
OK↓
This circuit is OK.
8-27
COOLING SYSTEM
8-28
EAS27340
EAS27330
10A 10A
R/G R R R

W/R
W/L
R/B
W W L B/L Y/L O O
W W R W/R
30A R
W W R W/L R/B
B R L
R R
B
(BLACK) R R/L
(BLACK) R/B R/G
Lg Sb
B/L P/W L
R B P Gy
L/G R/G R/G G/W
CIRCUIT DIAGRAM
G/R B/L
L/B R/B
L/B B/L R/G
OFF B B B (GREEN)
R L/G
L/W R/L
B
Br/W B/L R/L
B L/B
B L/Y G/W
L/G R/B G/Y
L/G L/Y L/Y L/B B/L
(RED) (RED) B
L/G R
L/W L/Y
Br/L L/G G/Y Y/G O/B B O/B R/L B R/L
L/Y Y/G
L B/L R/L G
W/B
10A B/R
G/B
L Y/G B/L
FUEL INJECTION SYSTEM
10A B/R B/R

Br/L R/W
R/W G B
R/G
R/B L/G R/L B
G/W
G/Y
L/Y B B
L/B R/W
OFF OFF
L/B RUN ON Y/L
A B B L/B W W
L/B (BLUE) L
L/B B B/L
B/W B
W R
(BLUE)
L/B Br G/Y B
B B/W 15A
Br/L R/Y L W
B B/
L
10A
R Br/R
Br
10A
Br/L Br Br G/B
Br/R C C
10A L Br G/B
R/G Br/L Br
Br/R R/W G/Y
Br R/W
R/Y Br Br
R/Y Br
Br
R/G Br Br R/G
8-29
R/Y L
B B Br/W
L/B Br P
Br G/B
(BLACK) Br
R/Y W/B
B
P L G/Y
L/B L G/B
W/B Br/W
L
L
OFF Br L
A
B B ON L L
L L
(BLACK) (BLACK)
L
B
L L/G L/B L/B L/G
HI OFF R (GRAY)
(GRAY)
LO ON NR
N L L
NL L L
L
L
R/W G
R/G Y/L Gy Y Dg Ch
L
G B Ch Dg B
L L
L B
Gy Y/L R/L O/B P
P O/B R/L Y
(BLUE) (BLUE)
B
Gy B B Gy
B
B B
C
Gy G R/W R/G
Y Dg Y/L Ch B
G/B G/B
Br
B B
B B B B
Br Ch B Br Dg B
B B Ch B Dg
Y G (BROWN) (GREEN)
(BROWN) (GREEN) L Y
Br B B
B B
B Br G/Y Br
B
1. Main switch
2. Crankshaft position sensor
6. Fuel injection system fuse
7. Ignition fuse
8. Main fuse
9. Battery
19. Throttle position sensor
20. Intake air pressure sensor
21. Intake air temperature sensor
22. Lean angle sensor
24. ECU
25. Ignition coil
26. ISC (idle speed control) valve
28. Fuel injector
29. Fuel pump
30. Speed sensor
57. Engine warning light
8-30
EAS27350
ECU SELF-DIAGNOSTIC FUNCTION

The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is
operating normally. If this function detects a malfunction in the system, it immediately operates the en-
gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider
that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is
stored in the memory of the ECU.
● To inform the rider that the fuel injection system is not functioning, the engine trouble warning light
flashes when the start switch is being pushed to start the engine.
● If a malfunction is detected in the system by the self-diagnostic function, the ECU provides an appro-
priate substitute characteristic operation, and alerts the rider of the detected malfunction by illuminat-
ing the engine trouble warning light.
● After the engine has been stopped, the lowest fault code number appears on the clock LCD. Once
a fault code has been displayed, it remains stored in the memory of the ECU until it is deleted.
Engine trouble warning light indication and FI system operation
Warning light
ECU operation FI operation Vehicle operation
indication
Warning provided when
Flashing* Operation stopped Cannot be operated
unable to start engine
Operated with substi-
tute characteristics in Can or cannot be oper-
Remains on Malfunction detected accordance with the ated depending on the
description of the mal- fault code
function
* The warning light flashes when any one of the conditions listed below is present and the start switch is pushed:
Fuel injector
12: Crankshaft position sensor 39:
(Open or short circuit)
Sidestand switch Lean angle sensor
19: 41:
(Open circuit wireharness to ECU) (Open or short circuit)
Lean angle sensor ECU internal malfunction
30: 50:
(Latch up detected) (Memory check error)
Ignition coil
33:
(Faulty ignition)
Checking for a defective engine trouble warning light bulb
The engine trouble warning light comes on for 1.4 seconds after the main switch has been turned to
“ON” and when the start switch is being pushed. If the warning light does not come on under these con-
ditions, the warning light bulb may be defective.
Main switch Main switch

OFF ON
Engine trouble Light Light ON for Light

warning light OFF 1.4 seconds OFF
Initialize
8-31
EAS27390
FAIL-SAFE ACTIONS (SUBSTITUTE CHARACTERISTICS OPERATION CONTROL)

If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi-
nates the engine trouble warning light and provides the engine with alternate operating instructions that
are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue to operate or stop operating, depending on the conditions.
The ECU takes fail-safe actions in two ways: one in which the sensor output is set to a prescribed value,
and the other in which the ECU directly operates an actuator. Details on the fail-safe actions are given
in the table below.
Self-Diagnostic Function
Fault Able / Able /
code Item Symptom unable unable
No. to start to drive
Crankshaft position sen- No normal signals are received from the
12 Unable Unable
sor crankshaft position sensor.
Intake air pressure sen-
Intake air pressure sensor-open or short cir-
13 sor Able Able
cuit detected.
(open or short circuit)
Intake air pressure sensor-pipe system mal-
14 sor Able Able
function (clogged or detached hose).
(pipe system)
Throttle position sensor Throttle position sensor-open or short circuit
15 Able Able
(open or short circuit) detected.
Throttle position sensor
16 Stuck throttle position sensor detected. Able Able
(lock)
Sidestand switch
Open circuit is detected in the input line from
19 (open circuit wire har- Unable Unable
the sidestand switch to the ECU.
ness to ECU)
Coolant temperature Coolant temperature sensor-open or short cir-
21 Able Able
sensor cuit detected.
Intake air temperature Intake air temperature sensor-open or short
22 Able Able
sensor circuit detected.
Lean angle sensor
30 The vehicle has overturned. Unable Unable
(latch up detected)
Ignition coil Malfunction detected in the primary wire of the
33 Unable Unable
(faulty ignition) ignition coil.
ISC (Idle speed control) Engine speed is high when the engine is
37 Able Able
valve idling.
39 Fuel injector Fuel injector-open or short circuit detected. Unable Unable
Lean angle sensor Lean angle sensor-open or short circuit
41 Unable Unable
(open or short circuit) detected.
No normal signals are received from the
42 Speed sensor Able Able
speed sensor.
8-32
Fault Able / Able /
Fuel system voltage Supply power to the fuel injector and fuel
43 Able Able
(monitor voltage) pump is not normal.
Error in writing the Error is detected while reading or writing on
44 amount of CO adjust- EEPROM (throttle valve fully closed notifica- Able Able
ment on EEPROM tion value).
Vehicle system power
Power supply to the FI system relay is not nor-
46 supply Able Able
mal.
(Monitor voltage)
ECU internal malfunc- Faulty ECU memory. (When this malfunction
50 tion is detected in the ECU, the fault code number Unable Unable
(memory check error) might not appear on the meter.)
ISC (idle speed control) ISC (idle speed control) valve-open or short
61 Able Able
valve circuit detected.
Relay is not turned ON even if the crank signal
is input while the start switch is turned ON.
— Start unable warning When the start switch is turned ON while an Unable Unable
error is detected with the fault code of No.12,
19, 30, 33, 39, 41 or 50.
Communication error with the meter
Fault Able / Able /
ECU internal malfunc-
Er-1 tion No signals are received from the ECU. Unable Unable
(output signal error)
No signals are received from the ECU within
Er-2 tion Unable Unable
the specified duration.
Data from the ECU cannot be received cor-
rectly.
Non-registered data has been received from
the meter.
(input signal error)
8-33
EAS27400
TROUBLESHOOTING METHOD 01: Throttle position sensor (throttle angle)

The engine operation is not normal and the 30: Ignition coil
engine trouble warning light comes on. 36: Fuel injector
1. Check: If malfunction the sensors or actuators, repair
● Fault code number
or replace it.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ If not malfunction the sensors and actuators,
a. Check the fault code number displayed on check and repair the engine inner parts.
the meter.
EAS27440
b. Identify the system with the malfunction. Re-
DIAGNOSTIC MONITORING MODE
fer to “Self-Diagnostic Function table”. Setting the diagnostic monitoring mode
c. Identify the probable cause of malfunction. 1. Turn the main switch to “OFF” and set the en-
Refer to “Diagnostic monitoring code table”. gine stop switch to “ ”.
2. Disconnect the wire harness coupler from
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ the fuel pump.
2. Checking and repair the probable case of 3. Simultaneously press and hold the “SE-
malfunction. LECT” and “RESET” buttons, turn the main
switch to “ON”, and continue to press the but-
Fault code No. YES Fault code No. NO tons for 8 seconds or more.
Check and repair. Check and repair.
Refer to “TROUBLE- Refer to “FAIL-SAFE
SHOOTING DETAILS” ACTIONS (SUBSTI-
on page 8-40. TUTE CHARACTER-
Monitor the operation ISTICS OPERATION
of the sensors and CONTROL)” on page
actuators in the diag- 8-32.
nostic mode. Refer to
“Sensor operation
table”.
3. Perform ECU reinstatement action. NOTE:
Refer to “Reinstatement method” of table in ● All displays on the meter disappear except the
“TROUBLESHOOTING DETAILS”. clock and tripmeter displays.
4. Turn the main switch to “OFF” and back to ● “dIAG” appears on the clock LCD.
“ON”, then check the fault code number is not
4. After selecting “dIAG”, simultaneously press
displayed.
the “SELECT” and “RESET” buttons for 2
NOTE:
seconds or more to execute the selection.
If other fault code displayed, repeat steps (1) to
5. Select the diagnostic monitoring code num-
(4) until all fault code number is not displayed.
ber that applies to the item that was verified
5. The Malfunction history is stored even if the with the fault code number by pressing the
main switch is turned OFF. The malfunction “SELECT” and “RESET” buttons.
history must be erased in the diagnostic NOTE:
mode. Refer to “Sensor operation table (Di- The diagnostic monitoring code number ap-
agnostic code No.62)”. pears on the clock LCD (01–70).
The engine operation is not normal but the ● To decrease the selected diagnostic monitor-
engine trouble warning light does not come ing code number, press the “RESET” button.
on. Press the “RESET” button for 1 second or
1. Check the operation of following sensors and longer to automatically decrease the diagnos-
actuators in the Diagnostic mode. Refer to tic monitoring code numbers.
“Sensor operation table”. ● To increase the selected diagnostic monitor-
8-34
ing code number, press the “SELECT” button. The data representing the operating condi-
Press the “SELECT” button for 1 second or tions of the sensor appears on the trip LCD.
longer to automatically increase the diagnos- ● Actuator operation
tic monitoring code numbers. Set the engine stop switch to “ON” to operate
the actuator.
NOTE:
If the engine stop switch is set to “ ”, set it to
“ ”, and then set it to “ ” again.
7. Turn the main switch to “OFF” to cancel the
diagnostic monitoring mode.
NOTE:
To perform a reliable diagnosis, make sure to
70 01
turn “OFF” the power supply before every check
01 70
and then start right from the beginning.
6. Verify the operation of the sensor or actuator.
● Sensor operation
Diagnostic monitoring code table

Fault Diagnostic
code Symptom Probable cause of malfunction monitoring
No. code No.
● Open or short circuit in wire harness.
No normal signals are ● Defective crankshaft position sensor.
12 received from the crank- ● Malfunction in pickup rotor. —
shaft position sensor. ● Malfunction in ECU.
● Improperly installed sensor.
● Open or short circuit in wire sub lead.
13 sor-open or short circuit 03
● Defective intake air pressure sensor.
detected.
● Malfunction in ECU.
Intake air pressure sen- ● Intake air pressure sensor hose is
14 sor-pipe system malfunction detached, clogged, kinked, or pinched. 03
(clogged or detached hose). ● Malfunction in ECU.
Throttle position sen- ● Defective throttle position sensor.
15 sor-open or short circuit ● Malfunction in ECU. 01
detected. ● Improperly installed throttle position sen-
sor.
Stuck throttle position sen- ● Stuck throttle position sensor.
16 01
sor detected. ● Malfunction in ECU.
Open circuit is detected in ● Open or short circuit in wire harness.
19 the input line from the ● Malfunction in ECU. 20
sidestand switch to the ECU.
Coolant temperature sen- ● Defective coolant temperature sensor.
detected. ● Improperly installed coolant temperature
sensor.
8-35
Fault Diagnostic
No. code No.
Intake air temperature sen- ● Defective intake temperature sensor.
detected. ● Improperly installed intake air tempera-
ture sensor.
● Overturned.
30 The vehicle has overturned. 08
Malfunction detected in the ● Malfunction in ignition coil.
33 primary wire of the ignition ● Malfunction in ECU. 30
coil. ● Malfunction in a component of ignition
cut-off circuit system.
● Defective speed sensor.
● Malfunction in throttle body.
Engine speed is high when ● Malfunction in throttle cables.
37 54
the engine is idling. ● ISC (idle speed control) valve is stuck
fully open.
Fuel injector-open or short
39 ● Defective fuel injector. 36
circuit detected.
Lean angle sensor-open or
41 ● Defective lean angle sensor. 08
short circuit detected.
● Open or short circuit in wiring harness.
No normal signals are ● Defective speed sensor.
42 received from the speed ● Malfunction in vehicle speed sensor 07
sensor. detected unit.
Supply power to the fuel ● Open circuit in wire harness.
43 injector and fuel pump is not ● Malfunction in ECU. 09
normal.
Error is detected while read- ● Malfunction in ECU. (throttle valve fully
ing or writing on EEPROM closed notification value are not properly
44 60
(throttle valve fully closed written on or read from the internal mem-
notification value). ory.)
Power supply to the FI sys- ● Malfunction in charging system.
46 —
tem relay is not normal.
Faulty ECU memory. (When ● Malfunction in ECU. (The program and
this malfunction is detected data are not properly written on or read
50 in the ECU, the fault code from the internal memory.) —
number might not appear on
the meter.)
8-36
Fault Diagnostic
No. code No.
ISC (idle speed control) ● Open or short circuit in wiring harness.

61 valve-open or short circuit ● Defective ISC (idle speed control) valve. 54
detected. ● Malfunction in ECU.
● Open or short circuit in communication
No signals are received from line.
Er-1 —
the ECU. ● Malfunction in meter unit.
No signals are received from
line.
Er-2 the ECU within the specified —
● Malfunction in meter unit.
duration.
Data from the ECU cannot line.
Er-3 —
be received correctly. ● Malfunction in meter unit.
Non-registered data has
line.
Er-4 been received from the —
● Malfunction in meter unit.
meter.
Sensor operation table
Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to
“DIAGNOSTIC MONITORING MODE”.
Diagnostic
monitoring Item Meter display Checking method
code No.
01 Throttle angle
● Fully closed position (8–22) Check with throttle fully
closed.
● Fully opened position (92–106) Check with throttle fully
open.
03 Pressure difference Displays the pressure differ- Turn “ ” the engine stop
(atmospheric pres- ence. switch, then operate the
sure-intake air pressure) throttle while pressing the
start switch. (If the display
value changes, the perfor-
mance is OK.)
05 Intake air temperature Displays the intake air temper- Compare the actually mea-
ature. sured intake air temperature
with the meter display value.
(*1)
8-37
Diagnostic
code No.
06 Coolant temperature Displays the coolant tempera- Compare the actually mea-
ture. sured coolant temperature
with the meter display value.
(*1)
07 Vehicle speed pulse 0–999 Check that the number
changes (integrating) when
the front wheels are rotated.
08 Lean angle sensor Remove the lean angle sen-
sor and incline it more than
● Upright 0.4–1.4 V
65 degrees.
● Overturned 3.7–4.4 V
09 Fuel system voltage Compare with the actually
(battery voltage) Approximately 12.0 measured battery voltage. (If
the battery voltage is lower,
perform recharging.)
20 Sidestand switch Turn ON/OFF the Sidestand
switch.
● Stand retracted ON
● Stand extended OFF
60 EEPROM fault code display —
● No fault 0
● Fault detected 04 (Throttle valve fully closed
notification value is detected.)
● (If both cylinders are
defective, the display alter-
nates every two seconds.)
61 Malfunction history code dis- —
play
● No history 0
● History exists 12–61 (Fault detection code)
● (If code numbers more
than one are detected, the
display alternates every two
seconds to show all the
detected code numbers.
When all code numbers are
shown, the display repeats
the same process.)
8-38
Diagnostic
code No.
62 Malfunction history code

erasure
● No history 0 —
● History exists 0–19 (Memory numbers of the Erases only the history
fault detection) codes when the engine stop
switch is turned from “ ” to
“ ”. If the engine stop
switch is “ ”, turn it “ ”
once, and then turn it back
“ ”.
70 Control number 00–255 —
*1 If it is not possible to check the intake temperature, use the ambient temperature as reference (use
the compared values for reference).
Actuator operation table
Diagnostic
monitoring Item Actuation Checking method
code No.
The engine stop switch is

turned from “ ” to “ ”. Actu- The engine stop switch is
ates the ignition coil for five turned from “ ” to “ ”.
30 Ignition coil
times every second. Check the spark five times.
Illuminates the engine trouble Connect an ignition checker.
warning light.
ates the injector for five times turned from “ ” to “ ”.
36 Injector
every second. Check the operating sound
Illuminates the engine trouble of the injector five times.
warning light.
turned from “ ” to “ ”. Actu-
ates the fuel injection system
relay for five times every sec- The engine stop switch is
ond.
turned from “ ” to “ ”.
Illuminates the engine trouble
50 Fuel injection system relay Check the operating sound
warning light.
of the fuel injection system
(The engine trouble warning
relay five times.
light is OFF when the relay is
ON, and the engine trouble
warning light is ON when the
relay is OFF).
8-39
Diagnostic
monitoring Item Actuation Checking method
code No.

ates the radiator fan motor
relay for five cycles every
51 Radiator fan motor relay Check the operating sound
five-second. (ON 2 seconds,
of the Radiator fan motor
OFF 3 seconds)
relay five times.
Illuminates the engine trouble
warning light.
ates the headlight relay for five turned from “ ” to “ ”.
52 Headlight relay times every five-second. (ON Check the operating sound
2 seconds, OFF 3 seconds) of the headlight relay five
Illuminates the engine trouble times.
warning light.
When the ISC (idle speed
The ISC (idle speed control) control) valve fully closes,
ISC (idle speed control) valve unit vibrates when the and then it opens until it is at
54
valve ISC (idle speed control) valve the standby opening position
operates. when the engine is started.
This operation takes approx-
imately 12 seconds until it is
completed.
Actuates the grip warmer relay
for one time. The engine stop switch is
Illuminates the engine trouble turned from “ ” to “ ”.
57 Grip warmer relay warning light. Check the operating sound
(the light is OFF when the of the grip warmer relay one
relay is OFF, and the light is time.
ON when the relay is ON).
EAS27480
TROUBLESHOOTING DETAILS
This section describes the measures per fault code number displayed on the meter. Carry out check
and maintenance on items or components that could be a cause of malfunction in accordance with the
order.
When the check and maintenance of malfunctioned part is completed, restore the meter display ac-
cording to the “Reinstatement method”.
Fault code No.:
Fault code number displayed on the meter when the engine failed to work normally. Refer to “DIAG-
NOSTIC MONITORING MODE” on page 8-34.
Diagnostic monitoring code No.:
Code number to be used when the diagnostic monitoring mode is operated. Refer to “DIAGNOSTIC
MONITORING MODE” on page 8-34.
8-40
No normal signals are received from the crankshaft position

Fault code No. 12 Symptom
sensor.
Diagnostic
—
monitoring code No.
Item/components and probable Reinstatement

Order Check or maintenance job
cause method
1 Installed condition of crankshaft posi- Check the installed area for loose- Cranking the
tion sensor ness or pinching. engine.
2 Connected state of connector ● Check the coupler for any pins
● Crankshaft position sensor coupler that may have pulled out.
● Main wire harness ECU coupler ● Check the locking condition of
the coupler.
● If there is a malfunction, repair
it and connect it securely.
3 Open or short circuit in wire harness. ● Repair or replace if there is an
open or short circuit.
● Between sensor coupler and
ECU coupler.
(White/Blue–White/Blue)
(White/Red–White/Red)
4 Defective crankshaft position sensor. ● Replace if defective.
Refer to “CHECKING THE
CRANKSHAFT POSITION SEN-
SOR” on page 8-72.
8-41
Fault code No. 13 Symptom Intake air pressure sensor-open or short circuit detected.
Diagnostic
03 Intake air pressure sensor
monitoring code No.

cause method
1 Connected state of connector ● Check the coupler for any pins Turning the
● Intake air pressure sensor coupler that may have pulled out. main switch ON.
● Sub-wire harness coupler the coupler.
2 Open or short circuit in wire harness ● Repair or replace if there is an
and/or sub lead. open or short circuit.
● Between intake air pressure
sensor coupler and ECU coupler
(Black/Blue–Black/Blue)
(Pink/White–Pink/White)
(Blue–Blue)
3 Defective intake air pressure sensor ● Execute the diagnostic moni-
toring mode. (Code No.03)
● Replace if defective.
Refer to “CHECKING THE IN-
TAKE AIR PRESSURE SENSOR”
on page 8-77.
8-42
Intake air pressure sensor-hose system malfunction

(clogged or detached hose).
Diagnostic
03 Intake air pressure sensor
monitoring code No.

cause method
1 Intake air pressure sensor hose Repair or replace the sensor hose. Starting the
detached, clogged, kinked, or pinched. engine and
operating it at
2 Intake air pressure sensor malfunction Check and repair the connection.
idle.
at intermediate electrical potential.
● Intake air pressure sensor coupler that may have pulled out.
the coupler.
4 Defective intake air pressure sensor ● Execute the diagnostic moni-
TAKE AIR PRESSURE SENSOR”
on page 8-77.
8-43
Fault code No. 15 Symptom Throttle position sensor-open or short circuit detected.
Diagnostic
01 Throttle position sensor
monitoring code No.

cause method
1 Installed condition of throttle position ● Check the installed area for Turning the
sensor. looseness or pinching. main switch ON.
● Check that is installed in the
specified position.
● Throttle position sensor coupler that may have pulled out.
● Sub-wire harness coupler the coupler.
● Between throttle position sen-
sor coupler and ECU coupler
(Yellow–Yellow/Blue)
(Blue–Blue)
4 Throttle position sensor lead wire open ● Check for open circuit and
circuit output voltage check. replace the throttle position sen-
sor.
(Black/Blue–Yellow/Blue)
Open circuit Output voltage
item
Ground wire 5V
open circuit
Output wire 0V
open circuit
Power supply 0V
wire open circuit
5 Defective throttle position sensor. ● Execute the diagnostic moni-
THROTTLE POSITION SEN-
8-44
Fault code No. 16 Symptom Stuck throttle position sensor detected.
Diagnostic
01 Throttle position sensor
monitoring code No.

cause method
1 Installed condition of throttle position ● Check the installed area for Reinstated by
sensor. looseness or pinching. starting the
● Check that is installed in the engine, operat-
specified position. ing it at idle, and
then racing it.
2 Defective throttle position sensor. ● Execute the diagnostic moni-
THROTTLE POSITION SEN-
Open circuit is detected in the input line from the sidestand

switch to the ECU.
Diagnostic
20 Sidestand switch
monitoring code No.

cause method
1 Connected state of connector ● Execute the diagnostic moni- Reinstated by
● Main wire harness ECU coupler toring mode. (Code No.20) reconnecting
● (Blue/Yellow connector) ● Check the coupler for any pins the wiring and
that may have pulled out. retracting the
● Check the locking condition of sidestand.
the coupler.
● Between ECU and sidestand
switch
(Blue/Yellow–Blue/Green)
3 Defective sidestand switch. ● Replace if defective.
8-45
Fault code No. 21 Symptom Coolant temperature sensor-open or short circuit detected.
Diagnostic
06 Coolant temperature sensor
monitoring code No.

cause method
1 Installed condition of coolant tempera- Check the installed area for loose- Turning the
ture sensor. ness or pinching. main switch ON.
● Coolant temperature sensor cou- that may have pulled out.
pler ● Check the locking condition of
● Main wire harness ECU coupler the coupler.
● Sub-wire harness coupler ● If there is a malfunction, repair
● Between coolant temperature
sensor coupler and ECU coupler.
(Green/Red–Green/Red)
4 Defective coolant temperature sensor. ● Execute the diagnostic moni-
Refer to “CHECKING THE COOL-
ANT TEMPERATURE SENSOR”
on page 8-75.
8-46
Intake air temperature sensor-open or short circuit

detected.
Diagnostic
05 Intake air temperature sensor
monitoring code No.

cause method
1 Installed condition of intake air tempera- Check the installed area for loose- Turning the
ture sensor. ness or pinching. main switch ON.
● Intake air temperature sensor cou- that may have pulled out.
pler ● Check the locking condition of
● Between intake air tempera-
ture sensor coupler and ECU
coupler.
(Brown/White–Brown/White)
4 Defective intake air temperature sensor. ● Execute the diagnostic moni-
TAKE AIR TEMPERATURE SEN-
8-47
Fault code No. 30 Symptom The vehicle has overturned.
Diagnostic
08 Lean angle sensor
monitoring code No.

cause method
1 The vehicle has overturned. Raise the vehicle upright. Turning the
main switch ON
2 Installed condition of the lean angle Check the installed area for loose-
(however, the
sensor ness or pinching.
engine cannot
3 Connected state of connector Check the coupler for any pins that be restarted
Lean angle sensor coupler may have pulled out. unless the main
Main wire harness ECU coupler Check the locking condition of the switch is first
coupler. turned OFF).
If there is a malfunction, repair it
and connect it securely.
4 Defective lean angle sensor. Execute the diagnostic monitoring
mode. (Code No.08)
Replace if defective.
Refer to “CHECKING THE LEAN
ANGLE SENSOR” on page 8-72.
8-48
Fault code No. 33 Symptom Malfunction detected in the primary wire of the ignition coil.
Diagnostic
30 Ignition coil
monitoring code No.

cause method
1 Connected state of connector ● Check the coupler for any pins Starting the
● Ignition coil primary side coupler that may have pulled out. engine and
(Orange) ● Check the locking condition of operating it at
● Main wire harness ECU coupler the coupler. idle.
2 Open or short circuit in wire harness or ● Repair or replace if there is an
sub lead. open or short circuit.
● Between ignition coil coupler
and ECU coupler/main wire har-
ness.
(Orange–Orange)
3 Defective ignition coil ● Execute the diagnostic moni-
● Test the primary and second-
ary coils for continuity.
Refer to “CHECKING THE IGNI-
TION COIL” on page 8-71.
8-49
Fault code No. 37 Symptom Engine speed is high when the engine is idling.
Diagnostic
54 ISC (Idle speed control) valve
monitoring code No.

cause method
1 Incorrect speed sensor signal ● Check the speed sensor. Starting the
● Check the speed sensor leads. engine and
● Check the speed sensor cou- operating it at
pler. idle.
2 Throttle valve does not fully close ● Check the throttle body.
Refer to “THROTTLE BODY” on
page 7-4.
● Check the throttle cables.
Refer to “ADJUSTING THE
THROTTLE CABLE FREE PLAY”
on page 3-6.
3 ISC (idle speed control) valve stuck fully The ISC (idle speed control) valve
open is stuck fully open if it does not
operate when the main switch is
set to OFF. (Touch the ISC (idle
speed control) valve unit with your
hand and check if it is vibrating to
confirm if the ISC (idle speed con-
trol) valve is operating.) Do not
remove the ISC valve.
4 ISC (idle speed control) valve not mov- ● Execute the diagnostic moni-
ing correctly toring mode. (Code No.54)
● After the ISC (idle speed con-
trol) valve is fully closed, it opens
until it is at the standby opening
position when the engine is
started. This operation takes
approximately 12 seconds until it
is completed.
● Start the engine. If the error
recurs, replace the throttle body
assembly.
8-50
Fault code No. 39 Symptom Fuel injector-open or short circuit detected.
Diagnostic
36 Fuel injector
monitoring code No.

cause method
● Fuel injector coupler (Orange/ that may have pulled out. engine.
Black) ● Check the locking condition of
2 Open or short circuit in wire harness or ● Repair or replace if there is an
sub lead. open or short circuit.
● Between fuel injector coupler
and ECU coupler/main harness
(Orange/Black–Orange/Black)
3 Defective fuel injector ● Execute the diagnostic moni-
Fault code No. 41 Symptom Lean angle sensor-open or short circuit detected.
Diagnostic
08 Lean angle sensor
monitoring code No.

cause method
● Lean angle sensor coupler that may have pulled out. main switch ON.
the coupler.
2 Open or short circuit in wire harness. ● Repair or replace if there is an
open or short circuit.
● Between switch coupler and
ECU coupler.
(Yellow/Green–Yellow/Green)
(Blue–Blue)
3 Defective lean angle sensor ● Execute the diagnostic moni-
Refer to “CHECKING THE LEAN
ANGLE SENSOR” on page 8-72.
8-51
Fault code No. 42 Symptom No normal signals are received from the speed sensor.
Diagnostic
07 Speed sensor
monitoring code No.

cause method
● Speed sensor coupler that may have pulled out. engine, and
● Main wire harness ECU coupler ● Check the locking condition of inputting the
the coupler. vehicle speed
● If there is a malfunction, repair signals by oper-
it and connect it securely. ating the vehi-
cle at a 20 to 30
2 Open or short circuit in speed sensor ● Repair or replace if there is an km/h.
lead. open or short circuit.
ECU coupler.
(Blue–Blue)
(White–White)
3 Defective speed sensor ● Execute the diagnostic moni-
SPEED SENSOR” on page 8-74.
8-52
Supply power to the fuel injector and fuel pump is not

normal.
Diagnostic
09 Fuel system voltage
monitoring code No.

cause method
● Fuel injection system relay coupler that may have pulled out. engine and
● Fuel pump coupler ● Check the locking condition of operating it at
● Fuel injector coupler the coupler. idle.
● ECU coupler ● If there is a malfunction, repair
2 Malfunction in ECU Fuel injection system relay is on.
3 Open or short circuit in the wire har- ● Repair or replace if there is an
ness. open or short circuit.
● Between battery and ECU cou-
pler
(Red–Red)
4 Malfunction or open circuit in fuel injec- ● Execute the diagnostic moni-
tion system relay toring mode. (Code No. 09)
Refer to “CHECKING THE RE-
LAYS” on page 8-69.
● If there is no malfunction with
the fuel injection system relay,
replace the ECU.
Error is detected while reading or writing on EEPROM

(throttle valve fully closed notification value).
Diagnostic
60 EEPROM improper cylinder indication
monitoring code No.

cause method
1 Malfunction in ECU Execute the diagnostic monitoring Turning the
mode. (Code No. 60) main switch ON.
Meter Maintenance job
display
03 Replace the ECU.
04 ● Turn the main switch
to ON, and turn the
throttle grip to full open
and then to full close
position.
Replace ECU if defec-
tive.
8-53
Fault code No. 46 Symptom Power supply to the FI system relay is not normal.
Diagnostic
—
monitoring code No.

cause method
● ECU coupler that may have pulled out. engine and
● Check the locking condition of operating it at
the coupler. idle.
2 Faulty battery. ● Replace or charge the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 8-66.
3 Open or short circuit in the wire har- Repair or replace if there is an
ness. open or short circuit.
● Between battery and main
switch
(Red–Red)
● Between main switch and fuse
(ignition)
(Brown/Blue–Brown/Blue)
● Between fuse (ignition) and
engine stop switch
(Red/White–Red/White)
● Between engine stop switch
and fuel injection system relay
(Red/Black–Red/Black)
● Between fuel injection system
relay and ECU
(Red/Green–Red/Green)
Faulty ECU memory. (When this malfunction is detected in

Fault code No. 50 Symptom the ECU, the fault code number might not appear on the
meter.)
Diagnostic
—
monitoring code No.

cause method
1 Malfunction in ECU Replace the ECU. Turning the
main switch ON
8-54
ISC (idle speed control) valve-open or short circuit

detected.
Diagnostic
54 ISC (idle speed control) valve
monitoring code No.

cause method
● ISC (idle speed control) valve cou- that may have pulled out. main switch to
pler ● Check the locking condition of ON.
● Main wiring harness ECU coupler the coupler. The ISC (idle
● Sub-wire harness coupler ● If there is a malfunction, repair speed control)
it and connect it securely. valve fully
closes, and then
2 Open or short circuit in the wire har- ● Repair or replace if there is an it opens until it is
ness. open or short circuit. at the standby
● Between ISC (idle speed con- opening posi-
trol) valve and ECU coupler/main tion when the
harness engine is
(Pink–Pink) started.
(Light green–Light green)
(Gray–Gray)
(Sky blue–Sky blue)
3 Detective ISC (idle speed control) valve ● Execute the diagnostic moni-
Refer to “THROTTLE BODY” on
page 7-4.
8-55
Fault code No. Er-1 Symptom No signals are received from the ECU.
Diagnostic
—
monitoring code No.

cause method
1 Connected state of connector ● Check the coupler for any pins Reinstated if
● Main wire harness ECU coupler that may have pulled out. normal signal is
● Sub-wire harness coupler ● Check the locking condition of received from
the coupler. the ECU when
● If there is a malfunction, repair the main switch
it and connect it securely. is turn to ON.

and/or sub lead open or short circuit.
ECU coupler
(Yellow/Blue–Yellow/Blue)
3 Malfunction in meter unit Replace the meter unit.
4 Malfunction in ECU Replace the ECU.
No signals are received from the ECU within the specified

Fault code No. Er-2 Symptom
duration.
Diagnostic
—
monitoring code No.

cause method

and/or sub lead open or short circuit.
ECU coupler
8-56
Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly.
Diagnostic
—
monitoring code No.

cause method

ECU coupler
Fault code No. Er-4 Symptom Non-registered data has been received from the meter.
Diagnostic
—
monitoring code No.

cause method

ECU coupler
8-57
8-58
ELECTRICAL COMPONENTS
EAS27970
! " #
'

&
'
&

%
"
$
# !
8-59
3. Turn signal relay
4. Headlight relay
5. Fuel injection system relay
6. Main switch
10. Stator coil assembly
12. Ignition coil
13. Radiator fan
15. Horn
16. Battery
17. Fuse box
18. ECU
19. Starter relay
20. Main fuse
21. Wireharness
8-60
EAS27980
CHECKING THE SWITCHES
14 15 16 1 Ch L L
R R L R
B L Y B
W B W OFF
OFF OFF
ON
RUN ON
R Br/L R L/G
69
R/W L/W Br L/Y L/B
R/B B G/Y Ch G/Y (RED)
71
B B/W
43 42 41 18
Y
L
G P B Ch
Ch
Dg 40 Br G/Y B B
B W (BLUE)
HI OFF R
LO ON NR
N
NL
P B Y G L/Y L
L/B Br/W Dg Ch B/Y
8-61
1. Main switch
15. Start switch
41. Turn signal switch
42. Horn switch
43. Dimmer switch
69. Box light switch
8-62
Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the
wiring connections and if necessary, replace the switch.
ECA14370
CAUTION:
Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from
the opposite end of the coupler, taking care not to loosen or damage the leads.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NOTE:
● Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range.
● When checking for continuity, switch back and forth between the switch positions a few times.
The terminal connections for switches (e.g., main switch, engine stop switch) are shown in an illustra-
tion similar to the one on the left.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in the
top row in the switch illustration.
NOTE:
“ ” indicates a continuity of electricity between switch terminals (i.e., a closed circuit at the re-
spective switch position).
The example illustration on the left shows that:
There is continuity between black and black/white when the switch is set to “OFF”.
There is continuity between red and brown when the switch is set to “ON”.
*H 4 >
*H 4
8-63
EAS27990
1. Remove:
CHECKING THE BULBS AND BULB
● Bulb
SOCKETS EWA13320
Check each bulb and bulb socket for damage or WARNING
wear, proper connections, and also for continu- Since the headlight bulb gets extremely hot,
ity between the terminals. keep flammable products and your hands
Damage/wear → Repair or replace the bulb, away from the bulb until it has cooled down.
bulb socket or both. ECA14380
Improperly connected → Properly connect. CAUTION:
No continuity → Repair or replace the bulb, bulb ● Be sure to hold the socket firmly when re-
socket or both. moving the bulb. Never pull the lead, oth-
Types of bulbs erwise it may be pulled out of the terminal
The bulbs used on this vehicle are shown in the in the coupler.
illustration on the left. ● Avoid touching the glass part of the head-
● Bulbs “a” and “b” are used for the headlights
light bulb to keep it free from oil, otherwise
and usually use a bulb holder that must be de- the transparency of the glass, the life of
tached before removing the bulb. The majority the bulb, and the luminous flux will be ad-
of these types of bulbs can be removed from versely affected. If the headlight bulb gets
their respective socket by turning them coun- soiled, thoroughly it with a cloth moist-
terclockwise. ened with alcohol or lacquer thinner.
● Bulbs “c” is used for turn signal and tail/brake
lights and can be removed from the socket by 2. Check:

● Bulb (for continuity)
pushing and turning the bulb counterclock-
wise. (with the pocket tester)
● Bulbs “d” and “e” are used for meter and indi-
No continuity → Replace.
cator lights and can be removed from their re- Pocket tester
spective socket by carefully pulling them out. 90890-03112
a b YU-03112-C
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to terminal
“1” and the negative tester probe to terminal
“2”, and check the continuity.
b. Connect the positive tester probe to terminal
“1” and the negative tester probe to terminal
“3”, and check the continuity.
c c. If either of the readings indicate no continuity,
d e replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the condition of the bulbs

bulbs.
8-64
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and
check the continuity.
NOTE:
Set the pocket tester selector to “Ω × 1”.
Pocket tester
90890-03112
YU-03112-C
Checking the condition of the bulb sockets
The following procedure applies to all of the bulb b. If the pocket tester indicates “∞”, replace the
sockets. fuse.
1. Check:
● Bulb socket (for continuity)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
(with the pocket tester)
No continuity → Replace. 3. Replace:
● Blown fuse
Pocket tester ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

90890-03112 a. Set the main switch to “OFF”.
Analog pocket tester b. Install a new fuse of the correct amperage
YU-03112-C rating.
NOTE: c. Set on the switches to verify if the electrical
Check each bulb socket for continuity in the circuit is operational.
same manner as described in the bulb section; d. If the fuse immediately blows again, check
however, note the following. the electrical circuit.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Fuses
Amperage
Q’ty
a. Install a good bulb into the bulb socket. rating
b. Connect the pocket tester probes to the re- Main 30A 1
spective leads of the bulb socket.
c. Check the bulb socket for continuity. If any of Headlight 15A 1
the readings indicate no continuity, replace Signal 10A 1
the bulb socket. Ignition 10A 1
Radiator fan 10A 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
DC terminal 10A 1
EAS28000
Taillight 10A 1
CHECKING THE FUSES
The following procedure applies to all of the fus- Fuel injection system 10A 1
es. Backup 10A 1
ECA13680
CAUTION: Reserve 30A 1

To avoid a short circuit, always set the main Reserve 15A 1
switch to “OFF” when checking or replacing
Reserve 10A 1
a fuse.
EWA13310
1. Remove: WARNING
● Upper cover
Never use a fuse with an amperage rating
Refer to “GENERAL CHASSIS” on page 4-1. other than that specified. Improvising or us-
2. Check: ing a fuse with the wrong amperage rating
● Fuse
may cause extensive damage to the electri-
8-65
cal system, cause the lighting and ignition ies. The MF battery should be charged as
systems to malfunction and could possibly explained in the charging method illustra-
cause a fire. tions. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charg-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ing the battery.
4. Install: NOTE:
● Upper cover
Since MF batteries are sealed, it is not possible
Refer to “GENERAL CHASSIS” on page 4-1. to check the charge state of the battery by mea-
EAS28030 suring the specific gravity of the electrolyte.
CHECKING AND CHARGING THE BATTERY Therefore, the charge of the battery has to be
EWA13290
WARNING checked by measuring the voltage at the battery

terminals.
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of poi- 1. Remove:
sonous and highly caustic sulfuric acid. ● Upper cover
Therefore, always follow these preventive Refer to “GENERAL CHASSIS” on page 4-1.
measures: 2. Disconnect:
● Wear protective eye gear when handling or ● Battery leads (negative lead “1”, positive lead
working near batteries. “2”)

● Charge batteries in a well-ventilated area. (from the battery terminals)
● Keep batteries away from fire, sparks or ● Plate “3”
open flames (e.g., welding equipment, ● Collar “4”
lighted cigarettes). ECA13640
CAUTION:
● DO NOT SMOKE when charging or han-
dling batteries. First, disconnect the negative battery lead
● KEEP BATTERIES AND ELECTROLYTE
“1”, and then positive battery lead “2”.
OUT OF REACH OF CHILDREN.
● Avoid bodily contact with electrolyte as it
2 3 4
can cause severe burns or permanent eye 1
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
● Skin — Wash with water.
● Eyes — Flush with water for 15 minutes

and get immediate medical attention.
INTERNAL
● Drink large quantities of water or milk fol- 3. Remove:
● Battery
lowed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical at- 4. Check:
● Battery charge
tention.
ECA13660
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CAUTION: a. Connect a pocket tester to the battery termi-
● This is a sealed battery. Never remove the nals.
sealing caps because the balance be- ● Positive tester probe →
tween cells will not be maintained and bat- positive battery terminal
tery performance will deteriorate. ● Negative tester probe →
● Charging time, charging amperage and negative battery terminal
charging voltage for an MF battery are dif-
ferent from those of conventional batter-
8-66
5. Charge:
Digital circuit tester
● Battery
90890-03174 EWA13300
Model 88 Multimeter with tachome- WARNING
ter Do not quick charge a battery.
YU-A1927
ECA13670
NOTE: CAUTION:
● The charge state of an MF battery can be ● Never remove the MF battery sealing caps.
checked by measuring its open-circuit voltage ● Do not use a high-rate battery charger
(i.e., the voltage when the positive battery ter- since it forces a high-amperage current
minal is disconnected). into the battery quickly and can cause bat-
● No charging is necessary when the open-cir- tery overheating and battery plate dam-
cuit voltage equals or exceeds 12.8 V. age.
● If it is impossible to regulate the charging
b. Check the charge of the battery, as shown in
current on the battery charger, be careful
the charts and the following example.
not to overcharge the battery.
Example ● When charging a battery, be sure to re-
Open-circuit voltage = 12.0 V move it from the vehicle. (If charging has
Charging time = 6.5 hours to be done with the battery mounted on the
Charge of the battery = 20–30%
vehicle, disconnect the negative battery
lead from the battery terminal.)
● To reduce the chance of sparks, do not
plug in the battery charger until the battery
A charger leads are connected to the bat-
tery.
● Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
Hour
B ● Make sure the battery charger lead clips
are in full contact with the battery terminal
A. Open-circuit voltage and that they are not shorted. A corroded
B. Charging time battery charger lead clip may generate
heat in the contact area and a weak clip
C spring may cause sparks.
● If the battery becomes hot to the touch at
any time during the charging process, dis-
A connect the battery charger and let the
battery cool before reconnecting it. Hot
batteries can explode!
● As shown in the following illustration, the
open-circuit voltage of an MF battery sta-
B bilizes about 30 minutes after charging
A. Open-circuit voltage has been completed. Therefore, wait 30
B. Charge of the battery minutes after charging is completed be-
C. Temperature 20°C (68°F) fore measuring the open-circuit voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-67
a lapse of 5 hours. If there is any change in
Charge C the amperage, readjust the voltage to obtain
the standard charging current.
g. Measure the battery open-circuit voltage af-
A ter leaving the battery unused for more than
30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
B (minutes) Under 12.0 V --- Replace the battery.
A. Open-circuit voltage
B. Checking the open-circuit voltage ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
C. Temperature 20°C (68°F) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Charging method using a constant voltage
Charging method using a variable-current charger
(voltage) charger a. Measure the open-circuit voltage prior to
a. Measure the open-circuit voltage prior to charging.
charging. NOTE:
NOTE: Voltage should be measured 30 minutes after
Voltage should be measured 30 minutes after the machine is stopped.
the machine is stopped. b. Connect a charger and AMP meter to the
b. Connect a charged and AMP meter to the battery and start charging.
battery and start charging. c. Make sure that the current is higher than the
NOTE: standard charging current written on the bat-
Set the charging voltage at 16–17 V.If the setting tery.
is lower, charging will be insufficient. If too high, NOTE:
the battery will be over-charged. If the current is lower than the standard charging
current written on the battery, This type of bat-
c. Make sure that the current is higher than the
tery charger cannot charge the MF battery. A
standard charging current written on the bat-
variable voltage charger is recommended.
tery.
NOTE: d. Charge the battery until the battery’s charg-
If the current is lower than the standard charging ing voltage is 15 V.
current written on the battery, set the charging NOTE:
voltage adjust dial at 20–24 V and monitor the Set the charging time at 20 hours (maximum).
amperage for 3–5 minutes to check the battery. e. Measure the battery open-circuit voltage af-
ter leaving the battery unused for more than
● Reach the standard charging current
30 minutes.
Battery is good.
● Does not reach the standard charging cur- 12.8 V or more --- Charging is complete.
rent 12.7 V or less --- Recharging is required.
Replace the battery. Under 12.0 V --- Replace the battery.
d. Adjust the voltage so that the current is at the

standard charging level. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
e. Set the time according to the charging time
6. Install:
suitable for the open-circuit voltage.
● Battery
Refer to “Battery condition checking steps”.
● Plate
f. If charging requires more than 5 hours, it is
● Collar
advisable to check the charging current after
8-68
7. Connect:
● Battery leads (positive lead “1”, negative lead !
“2”) "
(to the battery terminals)
ECA13630
CAUTION:
First, connect the positive battery lead “1”, W/B R/Y
and then the negative battery lead “2”. L/B
R/Y
1 2 1. Positive battery terminal

2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
Relay operation
Continuity/No continuity
(between “3” to “4”)
8. Check:
● Battery terminals
Starting circuit cut-off relay
Dirt → Clean with a wire brush.
!
9. Lubricate:
● Battery terminals
"
Dielectric grease L/Y G/W
R/B G/Y
10.Install:
● Upper cover
Refer to “GENERAL CHASSIS” on page 4-1. 1. Positive battery terminal

EAS28040
CHECKING THE RELAYS 3. Positive tester probe
Check each switch for continuity with the pocket 4. Negative tester probe
tester. If the continuity reading is incorrect, re-
place the relay. Result
Continuity → OK
Pocket tester No continuity → Replace.
90890-03112
Analog pocket tester Starter relay
YU-03112-C
1. Disconnect the relay from the wire harness.
2. Connect the pocket tester (Ω × 1) and battery
(12 V) to the relay terminal as shown.
Check the relay operation.
1. Positive battery terminal
8-69
2. Negative battery terminal Turn signal relay
Result
Continuity → OK B
No continuity → Replace. Br/W
Br
Headlight relay

!
" 1. Positive battery terminal
Result
W/B R/Y Relay operate → OK
L/B Relay do not operate → Replace.
R/Y
EAS28060
1. Positive battery terminal CHECKING THE SPARK PLUG CAP

1. Check:
● Spark plug cap resistance
4. Negative tester probe Out of specification → Replace.
Resistance
Result 10.0 kΩ
Continuity → OK
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the spark plug cap from the spark
Radiator fan motor relay
plug lead.
! b. Connect the pocket tester (Ω × 1k) to the
spark plug cap as shown.
"
Pocket tester
90890-03112
L/Y R/W YU-03112-C
L
Br/R
1. Positive battery terminal

Result
Continuity → OK
c. Measure the spark plug cap resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-70
EAS28090
CHECKING THE IGNITION COIL Pocket tester

1. Check: 90890-03112
● Primary coil resistance Analog pocket tester
Out of specification → Replace. YU-03112-C
Primary coil resistance ● Negative tester probe

2.16–2.64 Ω Red/Black “1”
● Positive tester probe
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ High tension code “2”
a. Disconnect the ignition coil connectors from
the ignition coil terminals.
b. Connect the pocket tester (Ω × 1) to the igni-
tion coil as shown.
Pocket tester
90890-03112
YU-03112-C

Orange “1” c. Measure the secondary coil resistance.
● Negative tester probe
Red/Black “2”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
● Ignition spark gap

Minimum ignition spark gap
6.0 mm (0.24 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the spark
plug.
c. Measure the primary coil resistance. b. Connect the ignition checker/dynamic spark
tester “1” as shown.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Ignition checker
2. Check: 90890-06754
● Secondary coil resistance Opama pet-4000 spark checker
Out of specification → Replace. YM-34487
Secondary coil resistance

8.64–12.96 kΩ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the igni-
tion coil.
b. Connect the pocket tester (Ω × 1k) to the ig-
nition coil as shown.
8-71
1. Ignition checker/Opama pet-4000 spark
checker
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Spark plug cap
EAS28130
c. Set the main switch to “ON”.
CHECKING THE LEAN ANGLE SENSOR
d. Measure the ignition spark gap “a”.
1. Remove:
e. Crank the engine by pushing the starter
● Lean angle sensor
switch and gradually increase the spark gap
(from the bracket.)
until a misfire occurs.
2. Check:
● Lean angle sensor out put voltage
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Out of specification → Replace.

EAS28120 a a
CHECKING THE CRANKSHAFT POSITION ON ON
SENSOR
1. Disconnect:
● Crankshaft position sensor coupler
(from the wire harness)

2. Check:
● Crankshaft position sensor resistance
Out of specification → Replace the crank- b

shaft position sensor.
Lean angle sensor out put voltage
Crankshaft position sensor resis-
Less than 35° “a”: 0.4–1.4 V
tance
More than 35° “b”: 3.7–4.4 V
248–372Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the lean angle sensor coupler to the
a. Connect the pocket tester (Ω × 100) to the
wireharness.
crankshaft position sensor coupler as shown.
b. Connect the pocket tester (20 V DC) to the
Pocket tester lean angle sensor coupler as shown.
90890-03112
Analog pocket tester Pocket tester
YU-03112-C 90890-03112
YU-03112-C
Red “1”
● Negative tester probe ● Positive tester probe
White “2” Blue “1”
Yellow/Green “2”
L
Y/G B/R
4 9
B/L
b. Measure the crankshaft position sensor re-

sistance.
8-72
c. When turn the lean angle sensor.
d. Measure the lean angle sensor out put volt-
age.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ !
EAS28150
CHECKING THE STATOR COIL 999

1. Disconnect:

● Stator coil coupler
(from the wire harness) b. Measure the stator coil resistance.

2. Check:
● Stator coil resistance
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Out of specification → Replace the stator
coil. EAS28170
CHECKING THE RECTIFIER/REGULATOR

Stator coil resistance 1. Check:
0.19–0.27 ΩW-W ● Rectifier/regulator input voltage
Out of specification → Correct the stator coil

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ condition.
a. Connect the pocket tester (Ω × 1) to the sta- Refer to “CHECKING THE STATOR COIL”
tor coil coupler as shown. on page 8-73.
Pocket tester Rectifier/regulator input voltage
90890-03112 about 14 V at 5000 r/min
YU-03112-C
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the engine tachometer to the ignition coil
of cylinder.
White “1”
b. Connect the pocket tester (20 V DC) to the
rectifier/regulator coupler as shown.
White “2”
Digital circuit tester
● Positive tester probe 90890-03174
White “1” Model 88 Multimeter with tachome-
● Negative tester probe ter
White “3” YU-A1927
Digital tachometer
● Positive tester probe 90890-06760
White “2”
● Negative tester probe ● Positive tester probe
White “3” Positive battery terminal “1”
Negative battery terminal “2”
8-73
the horn coupler.
1 2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
● Operation of the horn
The horn fails to sound → check the step (3).

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the horn coupler at the horn.
b. Connect a jumper lead “1” to the brown ter-
c. Start the engine and let it run at approximate- minal in the horn coupler and the horn termi-
ly 5000 r/min. nal.
d. Measure the rectifier/regulator input voltage.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
*H
EAS28180
CHECKING THE HORN

1. Check: 2
● Horn voltage
Out of specification → Properly connect or

repair the signaling system’s wiring.
c. Set the main switch to “ON”.
Horn voltage
d. Check that the horn does sound.
12V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. Connect the pocket tester (20V DC) to the
EAS28240
horn terminal. CHECKING THE SPEED SENSOR
Pocket tester 1. Check:
● Speed sensor output voltage
90890-03112
Analog pocket tester Out of specification → Replace.
YU-03112-C
Output voltage reading cycle
0 V–5 V–0 V–5V–0 V
● Positive tester prove
Brown “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (20 V DC) to the
Ground
speed sensor coupler (wire harness side) as
shown.
Pocket tester
90890-03112
*H
YU-03112-C
2 ● Positive tester probe

White “1”
Black/Blue “2”
b. Set the main switch to “ON”.
c. Measure the voltage (DC 12 V) of brown at
8-74
EAS28260
CHECKING THE COOLANT TEMPERATURE

SENSOR
1. Remove:
● Coolant temperature sensor
L W W R
B
Refer to “THERMOSTAT” on page 6-4.
L B EWA14130
WARNING
● Handle the coolant temperature sensor
with special care.
● Never subject the coolant temperature
b. Set the main switch to “ON”. sensor to strong shocks. If the coolant
c. Elevate the rear wheel and slowly rotate it. temperature sensor is dropped, replace it.
d. Measure the voltage (5 V) of White and
Black/Blue. With each full rotation of the rear 2. Check:
● Coolant temperature sensor resistance
wheel, the voltage reading should cycle from
0 V to 5 V to 5 V to 0 V. Out of specification → Replace.
Resistance at 80°C
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 310.0–326.0 Ω
Resistance at 100°C
EAS28250 183.6 Ω
CHECKING THE RADIATOR FAN MOTOR
1. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
● Radiator fan motor a. Connect the pocket tester (Ω × 100) to the
Faulty/rough movement → Replace. coolant temperature sensor “1” as shown.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Pocket tester
a. Disconnect the radiator fan motor coupler 90890-03112
from the wire harness. Analog pocket tester
b. Connect the battery (12 V) as shown. YU-03112-C
Blue “1” ● Positive tester probe
● Negative tester probe Green/Red “1”
Black “2” ● Negative tester probe
Black/Blue “2”
B
L

c. Measure the radiator fan motor movement.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-75
Y/L B/L L
!
b. Measure the throttle position sensor voltage.
Out of specification → Replace the throttle
position sensor.
Throttle position sensor voltage

5 V (Blue-Black/Blue)
c. Connect the digital circuit tester to the throttle

position sensor as shown.
b. Immerse the coolant temperature sensor in a ● Tester positive lead →

container filled with water “2”. Yellow/Blue “1”
NOTE: ● Tester negative lead →
Make sure the coolant temperature sensor ter- Black/Blue “2”
minals do not get wet.
c. Place a thermometer “3” in the water.
d. Check the coolant temperature sensor for Y/L B/L L
continuity at the temperatures indicated in
the table.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28300 !
CHECKING THE THROTTLE POSITION
SENSOR d. While slowly opening the throttle, check that
1. Check: the throttle position sensor voltage is in-
● Throttle position sensor creased.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ The resistance does not change or it chang-
a. Connect the digital circuit tester to the throttle es abruptly → Replace the throttle position
position sensor as shown. sensor.
Out of specification (closed position) → Re-
Digital circuit tester place the throttle position sensor.
90890-03174
Model 88 Multimeter with tachome- Throttle position sensor voltage
ter (closed position)
YU-A1927 0.4–0.9 V (Yellow/Blue-Black/
Blue)
● Tester positive lead →
Blue “1”
● Tester negative lead → ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Black/Blue “2”
8-76
EAS28410
sensor to strong shocks. If the intake air
CHECKING THE INTAKE AIR PRESSURE
temperature sensor is dropped, replace it.
SENSOR
1. Check: 2. Check:
● Intake air pressure sensor output voltage ● Intake air temperature sensor resistance
Out of specification → Replace. Out of specification → Replace.
Intake air pressure sensor output Intake air temperature sensor re-
voltage sistance
3.4–3.8V 2.2 – 2.7kΩ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (20V DC) to the in- a. Connect the pocket tester (Ω × 1k) to the in-
take air pressure sensor coupler (wire har- take air temperature sensor terminal as
ness side) as shown. shown.
Pocket tester Pocket tester

90890-03112 90890-03112
Analog pocket tester Analog pocket tester
YU-03112-C YU-03112-C
● Positive tester probe ● Positive tester probe

Pink/White “1” Brown/White “1”
● Negative tester probe ● Negative tester probe
Black/Blue “2” Black/Blue “2”
Br/W B/L
L P/W B/L
b. Set the main switch to “ON”. b. Measure the intake air temperature sensor
c. Measure the intake air pressure sensor out- resistance.
put voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install:
● Intake air temperature sensor
EAS28420
CHECKING THE INTAKE AIR EAS1B709
TEMPERATURE SENSOR CHECKING THE V-BELT REPLACEMENT

1. Remove: INDICATOR RESET COUPLER
● Intake air temperature sensor 1. Check:
(from the air filter case) ● V-belt replacement indicator reset coupler for
EWA14110
continuity
WARNING No continuity → Replace
● Handle the intake air temperature sensor ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
with special care. a. Connect the pocket tester (Ω × 1) to the
● Never subject the intake air temperature V-belt replacement indicator reset coupler as
8-77
shown.
Pocket tester
90890-03112
YU-03112-C
● Positive tester probe 1 Gy G R/W R/G

Y Dg Y/L Ch B
Gray “1” 2
Black “2”
b. Set the main switch to “ON”.
c. Measure the voltage of gray “1” and black “2”
at the meter assembly coupler.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
/O *
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
● V-belt replacement indicator reset coupler
voltage
V-belt replacement indicator reset
coupler voltage
12V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (20V DC) to the
meter assembly coupler (wire harness side)
as shown.
Pocket tester
90890-03112
YU-03112-C

Gray “1”
Black “2”
8-78
8-79
TROUBLESHOOTING
TROUBLESHOOTING ................................................................................ 9-1
GENERAL INFORMATION..................................................................... 9-1
STARTING FAILURE/HARD STARTING ............................................... 9-1
INCORRECT ENGINE IDLING SPEED.................................................. 9-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ........................ 9-2
FAULTY CLUTCH................................................................................... 9-2
OVERHEATING ...................................................................................... 9-2
1
OVERCOOLING ..................................................................................... 9-3
POOR BRAKING PERFORMANCE ....................................................... 9-3
FAULTY FRONT FORK LEGS ............................................................... 9-3
UNSTABLE HANDLING ......................................................................... 9-3
FAULTY LIGHTING OR SIGNALING SYSTEM ..................................... 9-3
2
9
TROUBLESHOOTING
EAS28450
●Deteriorated or contaminated fuel
TROUBLESHOOTING ● Sucked-in air
EAS28460 ● Clogged emulsion tube
GENERAL INFORMATION Electrical system

NOTE: 1. Battery
The following guide for troubleshooting does not ● Discharged battery
cover all the possible causes of trouble. It should ● Faulty battery
be helpful, however, as a guide to basic trouble- 2. Fuse(s)
shooting. Refer to the relative procedure in this ● Blown, damaged or incorrect fuse
manual for checks, adjustments, and replace- ● Improperly installed fuse
ment of parts. 3. Spark plug
● Incorrect spark plug gap
EAS28480
● Incorrect spark plug heat range
STARTING FAILURE/HARD STARTING
Engine ● Fouled spark plug
1. Cylinder and cylinder head ● Worn or damaged electrode
● Loose spark plug ● Worn or damaged insulator
● Loose cylinder head or cylinder ● Faulty spark plug cap
● Damaged cylinder head gasket 4. Ignition coil

● Damaged cylinder gasket ● Cracked or broken ignition coil body
● Worn or damaged cylinder ● Broken or shorted primary or secondary coils
● Incorrect valve clearance ● Faulty spark plug lead
● Improperly sealed valve 5. Ignition system

● Incorrect valve-to-valve-seat contact ● Faulty ignitor unit
● Incorrect valve timing ● Faulty pickup coil
● Faulty valve spring ● Broken generator rotor woodruff key
● Seized valve 6. Switches and wiring

2. Piston and piston ring ● Faulty main switch
● Improperly installed piston ring ● Faulty engine stop switch
● Damaged, worn or fatigued piston ring ● Broken or shorted wiring
● Seized piston ring ● Faulty front, rear or both brake light switches
● Seized or damaged piston ● Faulty start switch
3. Air filter ● Faulty sidestand switch
● Improperly installed air filter ● Improperly grounded circuit
● Clogged air filter element ● Loose connections
4. Crankcase and crankshaft 7. Starting system

● Improperly assembled crankcase ● Faulty starter motor
● Seized crankshaft ● Faulty starter relay
Fuel system ● Faulty starting circuit cut-off relay
1. Fuel tank ● Faulty starter clutch
● Empty fuel tank

EAS28500
● Clogged fuel tank cap breather hole INCORRECT ENGINE IDLING SPEED
● Deteriorated or contaminated fuel Engine
● Clogged or damaged fuel hose 1. Cylinder and cylinder head
2. Fuel pump ● Incorrect valve clearance
● Faulty fuel pump ● Damaged valve train components
● Faulty fuel pump relay 2. Air filter

● Damaged vacuum hose ● Clogged air filter element
● Improperly routed hose Fuel system

3. Throttle body 1. Throttle body
9-1
TROUBLESHOOTING
●Improperly adjusted engine idling speed (de- 3. Primary sliding sheave
tective ISC motor) ● Seized primary sliding sheave
● Improper throttle cable free play Poor starting performance

Electrical system 1. V-belt
1. Battery ● V-belt slips
● Discharged battery ● Oil or grease on the V-belt
● Faulty battery 2. Primary sliding sheave

2. Spark plug ● Faulty operation
● Incorrect spark plug gap ● Worn pin groove
● Incorrect spark plug heat range ● Worn pin
● Fouled spark plug 3. Clutch shoe(s)

● Worn or damaged electrode ● Bent, damaged or worn clutch shoe
● Worn or damaged insulator Poor speed performance

● Faulty spark plug cap 1. V-belt
3. Ignition coil ● Oil or grease on the V-belt
● Faulty spark plug lead 2. Primary pulley weight(s)

4. Ignition system ● Faulty operation
● Faulty ignitor unit ● Worn primary pulley weight
● Faulty pickup coil 3. Primary fixed sheave

● Worn primary fixed sheave
EAS28510
POOR MEDIUM-AND-HIGH-SPEED 4. Primary sliding sheave

PERFORMANCE ● Worn primary sliding sheave
Refer to “STARTING FAILURE/HARD START- 5. Secondary fixed sheave

ING” on page 9-1. ● Worn secondary fixed sheave
Engine 6. Secondary sliding sheave

1. Air filter ● Worn secondary sliding sheave
● Clogged air filter element

EAS28600
Fuel system OVERHEATING
1. Throttle body Engine
● Faulty diaphragm 1. Clogged coolant passages
2. Fuel pump ● Cylinder head and piston
● Faulty fuel pump ● Heavy carbon buildup
EAS28580
2. Engine oil
FAULTY CLUTCH ● Incorrect oil level
Engine operates but scooter will not move ● Incorrect oil viscosity
1. V-belt ● Inferior oil quality
● Bent, damaged or worn V-belt Cooling system

● Slipping V-belt 1. Coolant
2. Primary pulley cam and primary pulley slider ● Low coolant level
● Damaged or worn primary pulley cam 2. Radiator

● Damaged or worn primary pulley slider ● Damaged or leaking radiator
3. Clutch spring(s) ● Faulty radiator cap
● Damaged clutch spring ● Bent or damaged radiator fin
4. Transmission gear(s) 3. Water pump

● Damaged transmission gear ● Damaged or faulty water pump
Clutch slips ● Thermostat
1. Clutch shoe spring(s) ● Thermostat stays closed
● Damaged, loose or worn clutch shoe spring ● Oil cooler
2. Clutch shoe(s) ● Clogged or damaged oil cooler
● Damaged or worn clutch shoe ● Hose(s) and pipe(s)
9-2
TROUBLESHOOTING
Damaged hose
● ● Bent or damaged outer tube
● Improperly connected hose ● Damaged fork spring
● Damaged pipe ● Worn or damaged outer tube bushing
● Improperly connected pipe ● Bent or damaged damper rod
Fuel system ● Incorrect oil viscosity
1. Throttle body ● Incorrect oil level
● Damaged or loose throttle body joint
EAS28670
2. Air filter UNSTABLE HANDLING
● Clogged air filter element 1. Handlebar
Chassis ● Bent or improperly installed handlebar
1. Brake(s) 2. Steering head components

● Dragging brake
● Improperly installed upper bracket
Electrical system ● Improperly installed lower bracket

1. Spark plug (improperly tightened ring nut)
● Incorrect spark plug gap
● Bent steering stem
● Incorrect spark plug heat range

● Damaged ball bearing or bearing race
2. Ignition system 3. Front fork leg(s)
● Faulty ignitor unit
● Uneven oil levels (both front fork legs)
EAS28610 ● Unevenly tensioned fork spring (both front
OVERCOOLING fork legs)

Cooling system ● Broken fork spring
1. Thermostat ● Bent or damaged inner tube
● Thermostat stays open

● Bent or damaged outer tube
EAS28620 4. Swingarm
POOR BRAKING PERFORMANCE ● Worn bearing or bushing
● Worn brake pad ● Bent or damaged swingarm
● Worn brake disc 5. Rear shock absorber assembly(-ies)

● Air in hydraulic brake system ● Faulty rear shock absorber spring
● Leaking brake fluid ● Leaking oil or gas
● Faulty brake caliper kit 6. Tire(s)

● Faulty brake caliper seal ● Uneven tire pressures (front and rear)
● Loose union bolt ● Incorrect tire pressure
● Damaged brake hose ● Uneven tire wear
● Oil or grease on the brake disc 7. Wheel(s)

● Oil or grease on the brake pad ● Incorrect wheel balance
● Incorrect brake fluid level ● Deformed cast wheel
EAS28660 ● Damaged wheel bearing
FAULTY FRONT FORK LEGS ● Bent or loose wheel axle
Leaking oil ● Excessive wheel runout
● Bent, damaged or rusty inner tube 8. Frame

● Cracked or damaged outer tube ● Bent frame
● Improperly installed oil seal ● Damaged steering head pipe
● Damaged oil seal lip ● Improperly installed bearing race
● Incorrect oil level (high)

EAS28710
● Loose damper rod assembly bolt
FAULTY LIGHTING OR SIGNALING SYSTEM
● Damaged damper rod assembly bolt copper
Headlight does not come on
washer ● Wrong headlight bulb
● Cracked or damaged cap bolt O-ring ● Too many electrical accessories
Malfunction ● Hard charging
● Bent or damaged inner tube
9-3
TROUBLESHOOTING
● Incorrect connection ● Faulty wire harness
● Improperly grounded circuit
● Poor contacts (main or light switch)
● Burnt-out headlight bulb

Headlight bulb burnt out
● Wrong headlight bulb
● Faulty battery
● Faulty rectifier/regulator
● Faulty main switch
● Faulty light switch
● Headlight bulb life expired

Tail/brake light does not come on
● Wrong tail/brake light bulb
● Too many electrical accessories
● Incorrect connection
● Burnt-out tail/brake light bulb
Tail/brake light bulb burnt out

● Wrong tail/brake light bulb
● Faulty battery
● Incorrectly adjusted rear brake light switch
● Tail/brake light bulb life expired

Turn signal does not come on
● Faulty turn signal switch
● Faulty turn signal relay
● Burnt-out turn signal bulb
● Incorrect connection
● Damaged or faulty wire harness
● Faulty battery
● Blown, damaged or incorrect fuse

Turn signal blinks slowly

● Faulty turn signal switch
● Incorrect turn signal bulb
Turn signal remains lit


Turn signal blinks quickly
● Incorrect turn signal bulb

Horn does not sound
● Improperly adjusted horn
● Damaged or faulty horn
● Faulty horn switch
● Faulty battery
● Blown, damaged or incorrect fuse
9-4
CP250V WIRING DIAGRAM
EAS28740
48. Rear right turn signal light Br/L Brown/Blue
WIRING DIAGRAM 49. Rear left turn signal light Br/R Brown/Red
CP250V WIRING DIAGRAM 50. Front right turn signal light Br/W Brown/White
1. Main switch 51. Front left turn signal light
G/B Green/Black
2. Crankshaft position sensor 52. Headlight
3. Stator coil G/R Green/Red
53. Meter assembly
4. Rectifier/regulator 54. Left turn signal indicator G/W Green/White
5. Backup fuse light G/Y Green/Yellow
6. Fuel injection system fuse 55. Right turn signal indicator Gy/G Gray/Green
7. Ignition fuse light Gy/R Gray/Red
8. Main fuse 56. High beam indicator light L/B Blue/Black
9. Battery 57. Engine trouble warning light L/R Blue/Red
10. Starter motor 58. Coolant temperature indica- L/W Blue/White
11. Starter relay tor light
L/Y Blue/Yellow
12. Diode 59. Meter light
13. Right handlebar switch 60. Multi-function display O/B Orange/Black
14. Engine stop switch 61. Oil level warning indicator P/W Pink/White
15. Start switch reset switch R/B Red/Black
16. Front brake light switch 62. V-belt replacement indica- R/G Red/Green
17. Starting circuit cut-off relay tor reset coupler R/L Red/Blue
18. Sidestand switch 63. Headlight fuse R/W Red/White
19. Throttle position sensor 64. Radiator fan fuse R/Y Red/Yellow
20. Intake air pressure sensor 65. Signal fuse
Sb/W Sky blue/White
21. Intake air temperature sen- 66. Taillight fuse
sor W/B White/Black
67. Option connector
22. Lean angle sensor 68. DC terminal fuse W/R White/Red
23. Coolant temperature sensor 69. Box light switch W/Y White/Yellow
24. ECU (electronic control 70. Box light Y/B Yellow/Black
unit) 71. Box light manual switch Y/G Yellow/Green
25. Ignition coil EAS28750 Y/L Yellow/Blue
26. ISC (idle speed control) COLOR CODE Y/R Yellow/Red
valve
B Black
27. Fuel injection system relay
28. Fuel injector Br Brown
29. Fuel pump Ch Chocolate
30. Speed sensor Dg Dark green
31. Grip warmer relay G Green
32. Grip warmer switch Gy Gray
33. Grip warmer (left) L Blue
34. Grip warmer (right) O Orange
P Pink
36. Radiator fan motor
37. Turn signal relay R Red
38. Horn Sb Sky blue
39. Headlight relay W White
40. Rear brake light switch Y Yellow
41. Turn signal switch B/G Black/Green
42. Horn switch B/L Black/Blue
43. Dimmer switch B/R Black/Red
44. Left handlebar switch
B/W Black/White
B/Y Black/Yellow
46. Taillight
47. License light Br/G Brown/Green
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
PRINTED IN U.S.A.
10A 10A
R/G R R R

W/R
W/L
R/B
W W L B/L Y/L O O
W W R W/R
30A R
W W R W/L R/B
B R L
R R
B
(BLACK) R R/L
(BLACK) R/B R/G
Lg Sb
B/L P/W L
R B P Gy
L/G R/G R/G G/W G/R B/L
L/B R/B
L/B B/L
R L/G
L/W R/L
B
Br/W B/L R/L
B L/B
B L/Y G/W
L/G R/B G/Y
L/G L/Y L/Y L/B B/L
(RED) (RED) B
L/G R
L/W L/Y
Br/L L/G
L/Y Y/G
L B/L R/L G
W/B
10A B/R
G/B
10A L Y/G B/L
B/R B/R
Br/L R/W
R/W G B
R/G
R/B L/G R/L B
G/W
G/Y B B
L/Y
L/B R/W
OFF OFF
L/B RUN ON Y/L
A B B L/B W W
L/B (BLUE) L
L/B B B/L
B/W B
W R
(BLUE)
L/B Br G/Y B
B B/W 15A
Br/L R/Y L W
B B/
L
10A
R Br/R
Br
10A
Br/L Br Br G/B
Br/R C C
10A L Br G/B
R/G Br/L Br
Br/R R/W G/Y
Br
R/W Br Br
R/Y
R/Y Br
Br
R/G Br Br R/G
R/Y L
B B Br/W
L/B Br P
Br G/B
(BLACK) Br
R/Y W/B
B
P L G/Y
L G/B
L/B
W/B Br/W
L
L
OFF Br L
A
B B ON L L
L L
(BLACK) (BLACK)
L
B
L L/G L/B L/B L/G
HI OFF R (GRAY)
(GRAY)
LO ON NR
N L L
NL L L
L
Dg Br/W L/B WIRE HARNESS SUB-WIRE HARNESS
Br Ch L/B Br/W Dg Ch B/Y
L
R/W G
R/G Y/L Gy Y Dg Ch
L
G B Ch Dg B
L L
L B
Gy Y/L R/L O/B P
P O/B R/L Y
(BLUE) (BLUE)
B
Gy B B Gy
B
B B
C
Gy G R/W R/G
Y Dg Y/L Ch B
G/B G/B
Br
B B
B B B B
Br Ch B Br Dg B
B B Ch B Dg
Y G (BROWN) (GREEN)
(BROWN) (GREEN) L Y
Br B B
B B
B Br G/Y Br
B
10A 10A
30A
(BLACK)
(BLACK)
(GREEN)
(BLACK) (BLACK)
(RED) (RED)
10A
10A
(BLUE)
(BLUE)
15A
10A
10A
10A
(BLACK)
(RED) (RED)
(BLACK) (BLACK)
(GRAY) (GRAY)

(BLUE) (BLUE)
(BLUE) (BLUE)
(BROWN) (GREEN) (BROWN) (GREEN)

(BROWN) (GREEN) (BROWN) (GREEN)
COLOR CODE
Black Dark green Orange White Black/White Blue/White Green/Black Green/Yellow Red/Blue White/Black Yellow/Green
Blue Green Pink Yellow Blue/Black Blue/Yellow Green/Blue Orange/Black Red/Green White/Blue
Brown Gray Red Black/Blue Blue/Green Brown/Blue Green/Red Pink/White Red/White White/Red
Chocolate Light green Sky blue Black/Red Blue/Red Brown/White Green/White Red/Black Red/Yellow Yellow/Blue

Yamaha CP 250 V &#39;06 - Service Manual

Transféré par

Informations du document

Description originale:

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Yamaha CP 250 V &#39;06 - Service Manual

Transféré par

Droits d'auteur :

Formats disponibles

CP250V

IMPORTANT MANUAL INFORMATION

Failure to follow WARNING instructions could result in severe injury or death to

A CAUTION indicates special precautions that must be taken to avoid damage to

NOTE: A NOTE provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL

bly step “4”.

parts, notes in jobs, etc “6”.

SPECIAL TOOLS........................................................................................ 1-10

VEHICLE IDENTIFICATION NUMBER

ENGINE SERIAL NUMBER

OUTLINE OF THE FI SYSTEM

1. Fuel pump 11. Air filter case

PREPARATION FOR REMOVAL AND

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS

Loose connection → Connect properly.

Ring nut wrench 3-22, 4-51

Radiator cap tester 6-2

Radiator cap tester adapter 6-2

T-handle 4-44, 4-46

Locknut wrench 5-32, 5-36

Flywheel puller 5-41

Flywheel puller attachment 5-41

Fork seal driver weight 4-46, 4-47

Fork seal driver attachment (ø33) 4-46

Oil seal guide (ø41) 5-35

Sheave holder 5-32, 5-36,

Cylinder cup installer 4-23, 4-36

Thickness gauge 3-4

Compression gauge 3-8

Pocket tester 1-9, 8-63, 8-64,

Digital circuit tester 5-48, 8-73, 8-76

Valve spring compressor 5-17, 5-22

Valve spring compressor attachment 5-17, 5-22

Middle driven shaft bearing driver 6-7

Mechanical seal installer 6-7

Valve lapper 3-5, 5-20

Valve guide remover (ø4.5) 5-19

Valve guide installer (ø4.5) 5-19

Sheave spring compressor 5-33, 5-35

Sheave fixed block 5-33, 5-35

Plane bearing installer 5-56, 5-58

Ignition checker 8-71

Digital tachometer 3-6, 8-73

Yamaha bond No. 1215 5-42, 5-53

ENGINE SPECIFICATIONS........................................................................ 2-2

CHASSIS SPECIFICATIONS...................................................................... 2-8

ELECTRICAL SPECIFICATIONS............................................................... 2-10

CABLE ROUTING....................................................................................... 2-27

Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in)

Valve stem diameter (intake) 4.475–4.490 mm (0.1762–0.1768 in)

Winding direction (intake) Clockwise

Offset 0.50 mm (0.0197 in)

End gap (installed) 0.15–0.25 mm (0.0059–0.0098 in)

End gap (installed) 0.40–0.50 mm (0.0157–0.0197 in)

End gap (installed) 0.10–0.35 mm (0.0039–0.0138 in)

Big end radial clearance E 0.010–0.022 mm (0.0004–0.0009 in)

GENERAL TIGHTENING TORQUE

ENGINE TIGHTENING TORQUES

Protector plate bolt M6 4 7 Nm (0.7 m•kg, 5.1 ft• lb) LT

Exhaust pipe (nut) M8 2 20 Nm (2.0 m•kg, 14 ft• lb)

Yamaha CP 250 V '06 - Service Manual

Yamaha CP 250 V '06 - Service Manual