YP250

2007
VP250
SERVICE MANUAL
5B2-F8197-E0
EAS20060
VP250 2007
SERVICE MANUAL
©2007 by MBK Industrie
First edition, February 2007
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
MBK Industrie
is expressly prohibited.
EAS20070
NOTICE
This manual was produced by MBK Industrie primarily for use by Yamaha dealers and their qualified
mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, any-
one 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 mainte-
nance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit
for use.
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:
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

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

CAUTION: age to 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
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
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 with a new one.
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
FEATURES...................................................................................................... 1-2
1
OUTLINE OF THE FI SYSTEM................................................................. 1-2
FI SYSTEM................................................................................................ 1-3
INSTRUMENT FUNCTIONS............................................................................ 1-4
IMPORTANT INFORMATION ......................................................................... 1-7

PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-7
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
CHECKING THE CONNECTIONS .................................................................. 1-9
SPECIAL TOOLS .......................................................................................... 1-10

IDENTIFICATION
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the frame.
EAS20150
MODEL LABEL
The model label “1” is affixed on the bottom of
the seat. This information will be needed to order
spare parts.
1-1
FEATURES
EAS20170
FEATURES
EAS5B21008
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 with the engine operating
conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter
the fuel through the use of jets have been provided with various auxiliary devices, so that an optimum
air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the
engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases increase,
it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To 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 resulted in a highly precise fuel supply, improved engine response,
better fuel economy, and reduced exhaust emissions.
1 2 3 4 5 6 7 8
16 15 14 13 12 1110 9
1. Air temperature sensor 13. Spark plug

2. Engine trouble warning light 14. Ignition coil
3. ECU (engine control unit) 15. Fuel pump
4. Lean angle sensor 16. Speed sensor
5. Fuel injector
6. Intake air pressure sensor
7. Throttle position sensor
8. ISC (idle speed control) unit
9. Intake air temperature sensor
10. Crankshaft position sensor
11. O2 sensor
12. Coolant temperature sensor
1-2
FEATURES
EAS5B21009
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 (36.3 psi) (2.50 kgf/cm²). 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. There-
fore, the longer the length of time the fuel injector is energized (injection duration), the greater the vol-
ume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized
(injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from the
throttle position sensor, coolant temperature sensor, lean angle sensor, crankshaft position sensor, in-
take air pressure sensor, intake air temperature sensor, speed sensor and O2 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.
7
8
2 C
6 9
3 10
A 5
4
1 11
17 12
B
16
15
14
13
1. Fuel pump 14. Intake air pressure sensor

2. Pressure regulator 15. Throttle body
3. Fuel injector 16. Intake air temperature sensor
4. Ignition coil 17. Air filter case
A. Fuel system
6. ECU (engine control unit)
B. Air system
C. Control system
9. Lean angle sensor
10. Speed sensor
11. O2 sensor
12. Catalytic converter
1-3
INSTRUMENT FUNCTIONS
EAS5B21014
INSTRUMENT FUNCTIONS "Mode"
Multi-function display
1 2
"Mode" "Mode"
4 3
"Mode"
1. Total
2. Trip 1
1 2 3 3. Trip 2
4. Trip/Fuel
1. “MODE” button
2. Multi-function display NOTE:
3. “SET” button • The Trip/fuel odometer is only activated if the
fuel level warning light comes on.
The multi-function display is equipped with the
• The Trip 2 odometer is automatically reset af-
following:
ter turning the key to “ ” and two hours have
• an odometer (which shows the total distance
passed.
traveled)
• two tripmeters (which show the distance trav- Pushing the “SET” button when in the tripmeter
eled since they were last set to zero, the time mode switches the display between the different
passed since the tripmeters were set to zero, tripmeter functions in the following order:
and the average speed traveled during this Trip 1 or Trip 2 → Time 1 or 2 → Average speed
time) 1 or 2 → Trip 1 or Trip 2
• a fuel reserve tripmeter (which shows the dis-
tance traveled since the fuel level warning light
came on) 1
• a clock "Set"
• an ambient temperature display
• an oil change indicator (which comes on when 2 "Set"
the engine oil should be changed) "Set"
NOTE:
3
• For the UK, the distance traveled is displayed
in miles and the temperature reading is dis-
played in °F. 1. Distance
• For other countries, the distance traveled is 2. Time
displayed in kilometers and the temperature 3. Average speed
reading is displayed in °C.
If the fuel level warning light comes on, the dis-
play will automatically change to the fuel reserve
Odometer and tripmeter modes tripmeter mode “Trip/fuel” and start counting the
Pushing the “MODE” button switches the display distance traveled from that point. In that case,
between the odometer mode “Total” and the trip- pushing the “MODE” button switches the display
meter modes “Trip” in the following order: between the various tripmeter and odometer
Total → Trip 1 → Trip 2 → Trip/fuel → Total modes in the following order:
Trip/Fuel → Trip 1 → Trip 2 → Total → Trip/fuel
1-4
Ambient temperature display
1
2
3
To reset a tripmeter, select it by pushing the

“MODE” button, and then push the “SET” button 1. Frost warning indicator “ ”
for at least one second. If you do not reset the 2. Minus item
fuel reserve tripmeter manually, it will reset itself 3. Temperature
automatically and the display will return to the
prior mode after refueling and traveling 5 km (3 This display shows the ambient temperature
mi). from -30 °C (-86 °F) to 50 °C (122 °F).
The frost warning indicator “ ” automatically
Clock mode comes on if the temperature is lower than 3 °C
To set the clock: (37.4 °F).
1. When the display is in the “Total” mode, push
the “SET” button for at least two seconds. Oil change indicator “OIL”
2. When the hour digits start flashing, push the
“SET” button to set the hours. 1
1. Oil change indicator “OIL”

The engine oil should be changed when this in-
3. Push the “MODE” button, and the minute dig- dicator comes on. The indicator stays on until it
its will start flashing. is reset. After changing the engine oil, reset the
4. Push the “SET” button to set the minutes. indicator as follows.
5. Push the “MODE” button and then release it 1. While holding the “MODE” and “SET” buttons
to start the clock. The display will return to the pushed, turn the key to “ ”.
“Total” mode. 2. Continue holding the “MODE” and “SET” but-
tons pushed for two to five seconds.
3. Release the buttons and the oil change indi-
cator will go off.
NOTE:
• The oil change indicator will come on at the ini-
tial 1000 km (600 mi) and every 3000 km (1800
mi) thereafter.
• If the engine oil is changed before the oil
change indicator comes on (i.e. before the pe-
riodic oil change interval has been reached),
the indicator must be reset after the oil change
for the next periodic oil change to be indicated
1-5
at the correct time. After resetting, the indicator

will come on for two seconds. If the indicator
does not come on, repeat the procedure.
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 surfac-
es, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
2. Use only the proper tools and cleaning equip- lips with grease.
ment.
Refer to “SPECIAL TOOLS” on page 1-10.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mat-
ed” through normal wear. Mated parts must
always be reused or replaced as an assem-
bly.
1. Oil
2. Lip
3. Spring
4. Grease
EAS20220
LOCK WASHERS/PLATES AND COTTER

PINS
4. During disassembly, clean all of the parts and After removal, replace all lock washers/plates
place them in trays in the order of disassem- “1” and cotter pins. After the bolt or nut has been
bly. This will speed up assembly and allow for tightened to specification, bend the lock tabs
the correct installation of all parts. along a flat of the bolt or nut.
5. Keep all parts away from any source of fire.
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 “1” and oil seals “2” so that the
manufacturer’s marks or numbers are visible.
When installing oil seals, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.
ECA13300
CAUTION:
Do not spin the bearing with compressed air
because this will damage the bearing 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
CHECKING THE CONNECTIONS Pocket tester

Check the leads, couplers, and connectors for 90890-03112
stains, rust, moisture, etc. Analog pocket tester
1. Disconnect: 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
(with the pocket tester)
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 numbers starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part numbers starting with “90890-”.
Reference
Tool name/Tool No. Illustration
pages
Pocket tester 1-9, 5-46, 8-67,
90890-03112 8-68, 8-69,
Analog pocket tester 8-73, 8-74,
YU-03112-C 8-75, 8-76,
8-77, 8-78,
8-79, 8-80,
8-81, 8-82
Tappet adjusting tool 3-4
90890-01311
Valve adjuster 3 mm & 4 mm
YM-08035-A
FI diagnostic tool 3-5, 8-34

90890-03182
Timing light 3-7

90890-03141
Inductive clamp timing light
YU-03141
Compression gauge 3-8

90890-03081
Engine compression tester
YU-33223
Steering nut wrench 3-19, 3-20,

90890-01403 4-51
Spanner wrench
YU-33975
1-10
SPECIAL TOOLS
Reference
pages
Damper rod holder 4-44, 4-46
90890-01294
Damping rod holder set
YM-01300
YM-01300
T-handle 4-44, 4-46

90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
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 (ø38) 4-46

90890-01372
Replacement 38 mm
YM-A5142-1
Slide hammer bolt 5-14

90890-01083
Slide hammer bolt 6 mm
YU-01083-1
1-11
SPECIAL TOOLS
Reference
pages
Weight 5-14
90890-01084
YU-01083-3
YU-01083-3
Valve spring compressor 5-18, 5-23

90890-04019
YM-04019
Valve spring compressor attachment 5-18, 5-23

90890-04108
Valve spring compressor adapter 22 mm
YM-04108
Valve guide remover (ø6) 5-19

90890-04064
Valve guide remover (6.0 mm)
YM-04064-A
Valve guide installer (ø6) 5-19

90890-04065
Valve guide installer (6.0 mm)
YM-04065-A
Valve guide reamer (ø6) 5-19

90890-04066
Valve guide reamer (6.0 mm)
YM-04066
1-12
SPECIAL TOOLS
Reference
pages
Piston pin puller set 5-25
90890-01304
Piston pin puller
YU-01304
YU-01304
Yamaha grease G 5-31

90793-40016
Rotor holding tool 5-33, 5-38

90890-01235
Universal magneto & rotor holder
YU-01235
Sheave holder 5-33, 5-37,

90890-01701 5-41, 5-42
Primary clutch holder
YS-01880-A
Locknut wrench 5-33, 5-37

90890-01348
YM-01348
Clutch spring holder 5-34, 5-37

90890-01337
1-13
SPECIAL TOOLS
Reference
pages
Clutch spring holder arm 5-34, 5-37
90890-01464
Oil seal guide (ø41) 5-36

90890-01396
Flywheel puller 5-41

90890-01362
Heavy duty puller
YU-33270-B
Yamaha bond No. 1215 5-43, 5-60, 6-9

90890-85505
(Three Bond No.1215®)
Crankcase separating tool 5-57

90890-01135
Crankcase separator
YU-01135-B
Crankshaft installer pot 5-59, 5-60

90890-01274
Installing pot
YU-90058
YU-90058/YU-90059
1-14
SPECIAL TOOLS
Reference
pages
Crankshaft installer bolt 5-59, 5-60
90890-01275
Bolt
YU-90060
Adapter (M14) 5-59

90890-01478
Adapter #6
YM-90066
Spacer (crankshaft installer) 5-59

90890-04081
Pot spacer
YM-91044
YM-91044
Adapter (M16) 5-60

90890-01280
Adapter #7
YM-90067
Spacer 5-60
90890-01288
Radiator cap tester 6-3

90890-01325
Radiator pressure tester
YU-24460-01
YU-24460-01
1-15
SPECIAL TOOLS
Reference
pages
Radiator cap tester adapter 6-3
90890-01352
Radiator pressure tester adapter
YU-33984
YU-33984
Mechanical seal installer 6-9

90890-04132
Water pump seal installer
YM-33221-A
Middle driven shaft bearing driver 6-9

90890-04058
Bearing driver 40 mm
YM-04058
Pressure gauge 7-6

90890-03153
YU-03153
Fuel pressure adapter 7-6

90890-03181
Ignition checker 8-75

90890-06754
Opama pet-4000 spark checker
YM-34487
1-16
SPECIAL TOOLS
1-17
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................ 2-2
CHASSIS SPECIFICATIONS ........................................................................ 2-10
ELECTRICAL SPECIFICATIONS ................................................................. 2-13
TIGHTENING TORQUES .............................................................................. 2-16

2
GENERAL TIGHTENING TORQUE SPECIFICATIONS......................... 2-16
ENGINE TIGHTENING TORQUES......................................................... 2-17
CHASSIS TIGHTENING TORQUES....................................................... 2-19
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-22

ENGINE................................................................................................... 2-22
CHASSIS................................................................................................. 2-24
COOLING SYSTEM DIAGRAMS .................................................................. 2-25
CABLE ROUTING ......................................................................................... 2-27

GENERAL SPECIFICATIONS
EAS20280
GENERAL SPECIFICATIONS
Model
Model 5B21 (Europe)
Dimensions
Overall length 2175 mm (85.6 in)
Overall width 785 mm (30.9 in)
Overall height 1460 mm (57.5 in)
Seat height 790 mm (31.1 in)
Wheelbase 1470 mm (57.9 in)
Ground clearance 165 mm (6.50 in)
Minimum turning radius 2400 mm (94.5 in)
Weight
With oil and fuel 173.0 kg (381 lb)
Maximum load 185 kg (408 lb)
2-1
ENGINE SPECIFICATIONS
EAS20290
Engine
Engine type Liquid cooled 4-stroke, SOHC
Displacement 249.8 cm³
Cylinder arrangement Forward-inclined single cylinder
Bore × stroke 69.0 × 66.8 mm (2.72 × 2.63 in)
Compression ratio 10.00 :1
Standard compression pressure (at sea level) 1400 kPa/500 r/min (199.1 psi/500 r/min) (14.0
kgf/cm²/500 r/min)
Minimum–maximum 1120–1570 kPa (159.3–223.3 psi) (11.2–15.7
kgf/cm²)
Starting system Electric starter
Fuel
Recommended fuel Regular unleaded gasoline only
Fuel tank capacity 10.5 L (2.77 US gal) (2.31 Imp.gal)
Fuel reserve amount 2.7 L (0.72 US gal) (0.60 Imp.gal)
Engine oil
Lubrication system Wet sump
Type SAE10W30, SAE10W40, SAE15W40,
SAE20W40 or SAE20W50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Engine oil quantity
Total amount 1.40 L (1.48 US qt) (1.23 Imp.qt)
Periodic oil change 1.20 L (1.27 US qt) (1.06 Imp.qt)
Final transmission oil

Type SAE10W30 type SE motor oil
Quantity 0.25 L (0.26 US qt) (0.22 Imp.qt)
Oil filter
Oil filter type Paper
Oil pump
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance Less than 0.15 mm (0.0059 in)
Limit 0.23 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing clearance 0.013–0.036 mm (0.0005–0.0014 in)
Limit 0.106 mm (0.0042 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.04–0.09 mm (0.0016–0.0035 in)
Limit 0.16 mm (0.0063 in)
Cooling system
Radiator capacity (including all routes) 1.02 L (1.08 US qt) (0.90 Imp.qt)
Coolant reservoir capacity (up to the maximum level
mark) 0.20 L (0.21 US qt) (0.18 Imp.qt)
Radiator cap opening pressure 110.0–140.0 kPa (16.0–20.3 psi) (1.10–1.40
kgf/cm²)
2-2
Thermostat
Model/manufacturer 4CH/NIPPON THERMOSTAT
Valve opening temperature 80.5–83.5 °C (176.9–182.3 °F)
Valve full open temperature 95 °C (203 °F)
Valve lift (full open) 3 mm (0.12 in)
Radiator core
Width 244.0 mm (9.61 in)
Height 128.0 mm (5.04 in)
Depth 23.0 mm (0.91 in)
Water pump
Water pump type Single suction centrifugal pump
Reduction ratio 37/22 × 25/37 (1.136)
Impeller shaft tilt limit 0.15 mm (0.0059 in)
Spark plug (s)

Manufacturer/model NGK/DPR8EA-9
Spark plug gap 0.8–0.9 mm (0.031–0.035 in)
Cylinder head
Volume 21.40–22.00 cm³ (1.31–1.34 cu.in)
Warpage limit 0.05 mm (0.0020 in)
Camshaft
Drive system Chain drive (left)
Camshaft lobe dimensions
Intake A 37.050–37.150 mm (1.4587–1.4626 in)
Limit 36.955 mm (1.4550 in)
Intake B 30.074–30.174 mm (1.1840–1.1880 in)
Limit 29.973 mm (1.1800 in)
Exhaust A 37.053–37.153 mm (1.4588–1.4627 in)
Limit 36.956 mm (1.4550 in)
Exhaust B 30.091–30.191 mm (1.1847–1.1886 in)
Limit 29.194 mm (1.1494 in)
2-3
Camshaft runout limit 0.030 mm (0.0012 in)
Timing chain
Model/number of links DID SC.A-0404A SV/104
Tensioning system Automatic
Rocker arm/rocker arm shaft

Rocker arm inside diameter 12.000–12.018 mm (0.4724–0.4731 in)
Limit 12.030 mm (0.4736 in)
Rocker arm shaft outside diameter 11.981–11.991 mm (0.4717–0.4721 in)
Limit 11.950 mm (0.4705 in)
Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.037 mm (0.0004–0.0015 in)
Limit 0.080 mm (0.0031 in)
Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.08–0.12 mm (0.0031–0.0047 in)
Exhaust 0.16–0.20 mm (0.0063–0.0079 in)
Valve dimensions
Valve head diameter A (intake) 33.90–34.10 mm (1.3346–1.3425 in)
Valve head diameter A (exhaust) 28.40–28.60 mm (1.1181–1.1260 in)
A
Valve face width B (intake) 3.394–3.960 mm (0.1336–0.1559 in)
Valve face width B (exhaust) 3.394–3.960 mm (0.1336–0.1559 in)
Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in)

Limit 1.6 mm (0.06 in)
Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)
Valve margin thickness D (intake) 0.80–1.20 mm (0.0315–0.0472 in)

Valve margin thickness D (exhaust) 0.80–1.20 mm (0.0315–0.0472 in)
2-4
Valve stem diameter (intake) 5.975–5.990 mm (0.2352–0.2358 in)

Limit 5.940 mm (0.2339 in)
Valve stem diameter (exhaust) 5.960–5.975 mm (0.2346–0.2352 in)
Limit 5.920 mm (0.2331 in)
Valve guide inside diameter (intake) 6.000–6.012 mm (0.2362–0.2367 in)
Limit 6.050 mm (0.2382 in)
Valve guide inside diameter (exhaust) 6.000–6.012 mm (0.2362–0.2367 in)
Limit 6.050 mm (0.2382 in)
Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in)
Limit 0.080 mm (0.0031 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)
Valve stem runout 0.010 mm (0.0004 in)
Cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in)

Cylinder head valve seat width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)
Valve spring
Inner spring
Free length (intake) 38.10 mm (1.50 in)
Limit 36.10 mm (1.42 in)
Free length (exhaust) 38.10 mm (1.50 in)
Limit 36.10 mm (1.42 in)
Installed length (intake) 30.10 mm (1.19 in)
Installed length (exhaust) 30.10 mm (1.19 in)
Spring rate K1 (intake) 10.29 N/mm (58.75 lb/in) (1.05 kgf/mm)
Spring rate K1 (exhaust) 10.29 N/mm (58.75 lb/in) (1.05 kgf/mm)
Installed compression spring force (intake) 76–88 N (17.20–19.85 lbf) (7.80–9.00 kgf)
Installed compression spring force (exhaust) 76–88 N (17.20–19.85 lbf) (7.80–9.00 kgf)
Spring tilt (intake) 2.5°/1.7 mm
2-5
Spring tilt (exhaust) 2.5°/1.7 mm
Winding direction (intake) Counterclockwise

Winding direction (exhaust) Counterclockwise
Outer spring
Free length (intake) 36.93 mm (1.45 in)
Limit 35.00 mm (1.38 in)
Free length (exhaust) 36.93 mm (1.45 in)
Limit 35.00 mm (1.38 in)
Installed length (intake) 31.60 mm (1.24 in)
Installed length (exhaust) 31.60 mm (1.24 in)
Installed compression spring force (intake) 115–133 N (25.85–29.90 lbf) (11.73–13.56 kgf)
Installed compression spring force (exhaust) 115–133 N (25.85–29.90 lbf) (11.73–13.56 kgf)
Spring tilt (intake) 2.5°/1.6 mm
Spring tilt (exhaust) 2.5°/1.6 mm
Winding direction (intake) Clockwise

Winding direction (exhaust) Clockwise
Cylinder
Bore 69.000–69.005 mm (2.7165–2.7167 in)
Wear limit 69.100 mm (2.7205 in)
Taper limit 0.030 mm (0.0012 in)
Out of round limit 0.030 mm (0.0012 in)
Warp limit 0.05 mm (0.0020 in)
Piston
Piston-to-cylinder clearance 0.020–0.040 mm (0.0008–0.0016 in)
Limit 0.15 mm (0.0059 in)
Diameter D 68.965–68.980 mm (2.7152–2.7157 in)
2-6
Height H 5.0 mm (0.20 in)
H
D
Offset 0.50 mm (0.0197 in)

Offset direction Intake side
Piston pin bore inside diameter 17.004–17.015 mm (0.6694–0.6699 in)
Limit 17.045 mm (0.6711 in)
Piston pin outside diameter 16.991–17.000 mm (0.6689–0.6693 in)
Limit 16.971 mm (0.6681 in)
Piston-pin-to-piston-pin-bore clearance 0.004–0.024 mm (0.0002–0.0009 in)
Limit 0.074 mm (0.0029 in)
Piston ring
Top ring
Ring type Barrel
Dimensions (B × T) 1.00 × 2.60 mm (0.04 × 0.10 in)
B
T
End gap (installed) 0.15–0.30 mm (0.0059–0.0118 in)

Limit 0.45 mm (0.0177 in)
Ring side clearance 0.040–0.080 mm (0.0016–0.0031 in)
Limit 0.120 mm (0.0047 in)
2nd ring
Ring type Taper
B
T

Limit 0.70 mm (0.0276 in)
Limit 0.120 mm (0.0047 in)
Oil ring
B
T

2-7
Crankshaft
Width A 59.75–59.80 mm (2.352–2.354 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)
Big end radial clearance E 0.010–0.025 mm (0.0004–0.0010 in)
Clutch
Clutch type Dry, centrifugal automatic
Automatic centrifugal clutch

Clutch shoe thickness 3.3 mm (0.13 in)
Wear limit 2.0 mm (0.08 in)
Clutch shoe spring free length 31.3 mm (1.23 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 20.0 mm (0.79 in)
Limit 19.5 mm (0.77 in)
Clutch-in revolution 2100–2700 r/min
Clutch-stall revolution 3650–4650 r/min
V-belt
V-belt width 23.0 mm (0.91 in)
Limit 21.0 mm (0.83 in)
Transmission
Transmission type V-belt automatic
Primary reduction system Helical gear
Primary reduction ratio 40/15 (2.666)
Secondary reduction system Helical gear
Secondary reduction ratio 42/14 (3.000)
Operation Centrifugal automatic type
Single speed automatic 2.210–0.760 :1
Decompression device
Device type Auto decomp
Air filter
Air filter element Oil-coated paper element
Fuel pump
Pump type Electrical
2-8
Model/manufacturer 5B2/BITRON
Output pressure 250.0 kPa (36.5 psi) (2.50 kgf/cm²)
Fuel injector
Model/quantity 1C04 00 / 1
Manufacturer AISAN
Throttle body
Type/quantity EFI / 1
Manufacturer AISAN
Throttle valve size 28
Fuel injection sensor

Crankshaft position sensor resistance 248–372 Ω at 20 °C (68 °F)
Intake air pressure sensor output voltage 3.75–4.25 V at 101 kPa (29.9 inHg) (759.4
mmHg)
Intake air temperature sensor resistance 2.21–2.69 kΩ at 20 °C (68 °F)
Coolant temperature sensor resistance 2.32–2.59 kΩ at 20 °C (68 °F)
310–326 Ω at 80 °C (176 °F)
Idling condition
Engine idling speed 1450–1650 r/min
Intake vacuum 29.3–36.0 kPa (8.7–10.6 inHg) (220–270
mmHg)
Throttle cable free play 3.0–5.0 mm (0.12–0.20 in)
2-9
CHASSIS SPECIFICATIONS
EAS20300
Chassis
Frame type Steel tube underbone
Caster angle 26.00°
Trail 96.0 mm (3.78 in)
Front wheel
Wheel type Cast wheel
Rim size 16M/C × MT3.00
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 0.25 mm (0.01 in)
Rear wheel
Wheel type Cast wheel
Rim size 15M/C × MT4.00
Rim material Aluminum
Wheel travel 105.0 mm (4.13 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 0.25 mm (0.01 in)
Front tire
Type Tubeless
Size 120/70–16 M/C 57P
Manufacturer/model PIRELLI/SPORT DEMON FRONT
Wear limit (front) 1.6 mm (0.06 in)
Rear tire
Type Tubeless
Size 140/70–15 M/C 69P
Manufacturer/model PIRELLI/SPORT DEMON
Wear limit (rear) 1.6 mm (0.06 in)
Tire air pressure (measured on cold tires)

Loading condition 0–90 kg (0–198 lb)
Front 170 kPa (25 psi) (1.70 kgf/cm²)
Rear 190 kPa (28 psi) (1.90 kgf/cm²)
Loading condition 90–185 kg (198–408 lb)
Front 180 kPa (26 psi) (1.80 kgf/cm²)
Rear 200 kPa (29 psi) (2.00 kgf/cm²)
Front brake
Type Single disc brake
Operation Right hand operation
Front disc brake
Disc outside diameter × thickness 270.0 × 5.0 mm (10.63 × 0.20 in)
Brake disc thickness limit 4.5 mm (0.18 in)
Brake disc deflection limit 0.20 mm (0.0079 in)
2-10
Brake pad lining thickness (inner) 6.5 mm (0.26 in)

Brake pad lining thickness (outer) 6.5 mm (0.26 in)
Master cylinder inside diameter 12.70 mm (0.50 in)
Caliper cylinder inside diameter 27.00 mm × 2 (1.06 in × 2)
Recommended fluid DOT 4
Rear brake
Type Single disc brake
Operation Left hand operation
Rear disc brake
Disc outside diameter × thickness 240.0 × 5.0 mm (9.45 × 0.20 in)
Brake disc thickness limit 4.5 mm (0.18 in)
Brake disc deflection limit 0.20 mm (0.0079 in)
Brake pad lining thickness (inner) 5.3 mm (0.21 in)
Brake pad lining thickness (outer) 5.3 mm (0.21 in)
Master cylinder inside diameter 11.0 mm (0.43 in)
Caliper cylinder inside diameter 22.22 mm × 2 (0.87 in × 2)
Recommended fluid DOT 4
Steering
Steering bearing type Ball and angular bearings
Center to lock angle (left) 43.0°
Center to lock angle (right) 43.0°
No./size of steel balls
(Upper) 19 pcs/0.190 in
(Lower) 18 pcs/0.230 in
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 306.0 mm (12.05 in)
Limit 300.0 mm (11.81 in)
Installed length 295.0 mm (11.61 in)
Spring rate K1 5.50 N/mm (31.41 lb/in) (0.56 kgf/mm)
Spring stroke K1 0.0–90.0 mm (0.00–3.54 in)
Inner tube outer diameter 37.0 mm (1.46 in)
Inner tube bending limit 0.2 mm (0.01 in)
Optional spring available No
Recommended oil Fork oil 10W or equivalent
Quantity 207.0 cm³ (7.00 US oz) (7.29 Imp.oz)
Level 93.0 mm (3.66 in)
Rear suspension
Type Unit swing
Spring/shock absorber type Coil spring/oil damper
Rear shock absorber assembly travel 105.0 mm (4.13 in)
2-11
Spring free length 263.0 mm (10.35 in)

Installed length 239.6 mm (9.43 in)
Optional spring available No
Spring preload adjusting positions
Minimum 1
Standard 2
Maximum 4
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)
2-12
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.) 10.0°/1550 r/min
Engine control unit

Model/manufacturer 5B200/MORIC
Ignition coil
Model/manufacturer 2JN/MORIC
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 2.16–2.64 Ω at 20 °C (68 °F)
Secondary coil resistance 8.64–12.96 Ω at 20 °C (68 °F)
Spark plug cap

Material Resin
Resistance 10.0 kΩ
AC magneto
Model/manufacturer F1C0/MORIC
Standard output 14.0 V, 235 W 5000 r/min
Stator coil resistance 0.32–0.48 Ω at 20 °C (68 °F)
Rectifier/regulator
Regulator type Semi conductor-short circuit
Model/manufacturer SH650D-11/SHINDENGEN
Regulated voltage (DC) 14.1–14.9 V
Rectifier capacity 25.0 A
Rectifier capacity (DC) 18.0 A
Withstand voltage 200.0 V
Battery
Model GTX9-BS
Voltage, capacity 12 V, 8.0 Ah
Manufacturer GS
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
Auxiliary light 12 V, 5.0 W × 2
Tail/brake light 12 V, 5.0 W/21.0 W × 2
Front turn signal light 12 V, 10.0 W × 2
Rear turn signal light 12 V, 10.0 W × 2
License plate light 12 V, 5.0 W × 1
2-13
Meter lighting LED
Indicator light
Turn signal indicator light LED × 2
High beam indicator light LED
Fuel level 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 at 20 °C (68 °F)
Brush overall length 10.0 mm (0.39 in)
Limit 4.00 mm (0.16 in)
Brush spring force 7.65–10.01 N (27.5–36.0 oz) (780–1020 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 MS5F-631/JIDECO
Amperage 180.0 A
Horn
Horn type Plane
Quantity 1 pc
Model/manufacturer YF-12/NIKKO
Maximum amperage 3.0 A
Coil resistance 1.15–1.25 Ω at 20 °C (68 °F)
Performance 105–113 dB/2m
Turn signal relay

Relay type Full transistor
Model/manufacturer FZ222SD/DENSO
Built-in, self-canceling device No
Turn signal blinking frequency 60.0–120.0 cycles/min
Wattage 10 W × 2.0 + 3.4 W
Fuel sender unit

Model/manufacturer 5B2/BITRON
Sender unit resistance (full) 0.0–7.0 Ω
Sender unit resistance (empty) 90.0–103.0 Ω
Starting circuit cut-off relay

Model/manufacturer ACA12115-M02/MATSUSHITA
Diode Yes
Headlight relay
Model/manufacturer ACM33211-M05/MATSUSHITA
2-14
Radiator fan
Model/manufacturer VA31-A100–46A/KTM
Fan motor relay

Model/manufacturer ACM33211M05/MATSUSHITA
Fuses
Main fuse 30.0 A
Headlight fuse 15.0 A
Signaling system fuse 15.0 A
Ignition fuse 10.0 A
Radiator fan fuse 5.0 A
ECU fuse 5.0 A
Backup fuse 5.0 A
Reserve fuse 30.0 A
Reserve fuse 15.0 A
Reserve fuse 10.0 A
Reserve fuse 5.0 A
2-15
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-
tern and progressive stages until the specified
tightening torque is reached. Unless otherwise
specified, tightening torque specifications re-
quire clean, dry threads. Components should be
at room temperature.
A. Distance between flats

B. Outside thread diameter
General tightening
A (nut) B (bolt) torques
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
2-16
TIGHTENING TORQUES
EAS20340
ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Oil check bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Exhaust pipe stud bolt M8 2 13 Nm (1.3 m·kg, 9.4 ft·lb)
Spark plug M12 1 18 Nm (1.8 m·kg, 13 ft·lb)
Camshaft sprocket cover bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Cylinder head nut M8 4 22 Nm (2.2 m·kg, 16 ft·lb)
Cylinder head bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Tappet cover bolt M6 5 10 Nm (1.0 m·kg, 7.2 ft·lb)
Valve adjusting screw locknut M6 2 14 Nm (1.4 m·kg, 10 ft·lb)
Camshaft retainer bolt M6 2 8 Nm (0.8 m·kg, 5.8 ft·lb)
Camshaft sprocket bolt M10 1 60 Nm (6.0 m·kg, 43 ft·lb)
Timing chain tensioner bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Timing chain tensioner cap bolt M8 1 8 Nm (0.8 m·kg, 5.8 ft·lb)
Timing chain guide bolt (intake
M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
side)
Water pump housing cover bolt M6 2 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)
Water pump outlet pipe M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Coolant temperature sensor M12 1 18 Nm (1.8 m·kg, 13 ft·lb)
Oil baffle plate bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb) LT
Oil pump assembly 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)
Fuel injector assembly bolt M6 1 12 Nm (1.2 m·kg, 8.7 ft·lb)
Intake air pressure sensor bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Intake manifold bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Fuel hose holder bolt M6 1 12 Nm (1.2 m·kg, 8.7 ft·lb)
Crankcase bolt M6 7 10 Nm (1.0 m·kg, 7.2 ft·lb)
Cylinder head stud bolt M8 4 13 Nm (1.3 m·kg, 9.4 ft·lb)
Engine oil drain bolt M12 1 20 Nm (2.0 m·kg, 14 ft·lb)
Final transmission oil drain bolt M8 1 22 Nm (2.2 m·kg, 16 ft·lb)
Transmission case cover bolt M8 6 16 Nm (1.6 m·kg, 11 ft·lb)
V-belt case cover screw M6 3 7 Nm (0.7 m·kg, 5.1 ft·lb)
V-belt case cover bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
V-belt case bolt M6 11 10 Nm (1.0 m·kg, 7.2 ft·lb)
Generator cover bolt M6 10 10 Nm (1.0 m·kg, 7.2 ft·lb)
Timing mark accessing plug M16 1 8 Nm (0.8 m·kg, 5.8 ft·lb)
Starter clutch bolt M8 3 30 Nm (3.0 m·kg, 22 ft·lb) LT
Generator rotor nut M16 1 80 Nm (8.0 m·kg, 58 ft·lb)
2-17
TIGHTENING TORQUES
Thread
size
Secondary sheave nut M14 1 60 Nm (6.0 m·kg, 43 ft·lb)
Primary fixed sheave nut M14 1 80 Nm (8.0 m·kg, 58 ft·lb)
Clutch carrier nut M36 1 90 Nm (9.0 m·kg, 65 ft·lb)
Secondary sheave bracket bolt M8 4 22 Nm (2.2 m·kg, 16 ft·lb) LT
Stator coil bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Crankshaft position sensor bolt M5 2 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
Starter motor bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Starter motor lead nut M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Starter motor cover bolt M5 2 5 Nm (0.5 m·kg, 3.6 ft·lb)
Air filter case bolt (to rear fender) M6 2 9 Nm (0.9 m·kg, 6.5 ft·lb)
Exhaust pipe nut M8 2 20 Nm (2.0 m·kg, 14 ft·lb)
Muffler mounting bolt M12 3 65 Nm (6.5 m·kg, 47 ft·lb)
Muffler joint bolt M8 1 14 Nm (1.4 m·kg, 10 ft·lb)
Exhaust pipe protector bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Muffler protector bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Silencer cap bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
O2 sensor M18 1 45 Nm (4.5 m·kg, 32 ft·lb)

Cylinder head tightening sequence:
Muffler tightening sequence:
2
3
2-18
TIGHTENING TORQUES
EAS20350
CHASSIS TIGHTENING TORQUES

Thread
size
Frame and engine bracket M12 2 59 Nm (5.9 m·kg, 43 ft·lb)
Frame and engine bracket rod M10 2 64 Nm (6.4 m·kg, 46 ft·lb)
Engine bracket, engine bracket
M10 1 32 Nm (3.2 m·kg, 23 ft·lb)
rod and engine
Rear shock absorber and swing-
M8 2 21 Nm (2.1 m·kg, 15 ft·lb)
arm
Rear shock absorber and frame M10 2 40 Nm (4.0 m·kg, 29 ft·lb)
See
Swingarm mounting bolt M10 2 59 Nm (5.9 m·kg, 43 ft·lb) “NOTE”.
LT
Rear brake hose holder and

M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
swingarm
Lower ring nut (initial tightening See
M25 1 38 Nm (3.8 m·kg, 27 ft·lb)
torque) “NOTE”.
Lower ring nut (final tightening See
M25 1 22 Nm (2.2 m·kg, 16 ft·lb)
torque) “NOTE”.
See
Upper ring nut M25 1 75 Nm (7.5 m·kg, 54 ft·lb)
“NOTE”.
Steering stem nut M20 1 120 Nm (12.0 m·kg, 85 ft·lb)
Windshield and windshield brack-
M6 4 4 Nm (0.4 m·kg, 2.9 ft·lb)
et
Windshield bracket and frame M6 4 13 Nm (1.3 m·kg, 9.4 ft·lb)
Rearview mirror M8 2 33 Nm (3.3 m·kg, 24 ft·lb)
Front brake master cylinder and
M6 2 9 Nm (0.9 m·kg, 6.5 ft·lb)
holder
Upper handlebar holder and low-
M8 4 23 Nm (2.3 m·kg, 17 ft·lb)
er handlebar holder
Grip end M6 2 6 Nm (0.6 m·kg, 4.3 ft·lb)
Front brake lever and front brake
M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
master cylinder
Rear brake lever and rear brake
M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
master cylinder
Rear brake master cylinder and
M6 2 9 Nm (0.9 m·kg, 6.5 ft·lb)
holder
Lower bracket pinch bolt M8 4 22 Nm (2.2 m·kg, 16 ft·lb)
Damper rod bolt M10 2 28 Nm (2.8 m·kg, 20 ft·lb)
Grab bar and frame M8 4 18 Nm (1.8 m·kg, 13 ft·lb)
Fuel tank bracket and frame M6 4 13 Nm (1.3 m·kg, 9.4 ft·lb) LT
Rear fender and swingarm M6 2 6 Nm (0.6 m·kg, 4.3 ft·lb)

Rear footrest and frame M6 2 13 Nm (1.3 m·kg, 9.4 ft·lb)
Luggage hook and storage com-
M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
partment
2-19
TIGHTENING TORQUES
Thread
size
Rear fender and air filter case M6 2 9 Nm (0.9 m·kg, 6.5 ft·lb)
Front wheel axle M14 1 59 Nm (5.9 m·kg, 43 ft·lb)
Front wheel axle pinch bolt M6 1 9 Nm (0.9 m·kg, 6.5 ft·lb)
See
Rear wheel axle nut M14 1 135 Nm (13.5 m·kg, 98 ft·lb)
“NOTE”.
Front brake caliper and outer
M8 2 23 Nm (2.3 m·kg, 17 ft·lb) LT
tube
Rear brake caliper and swingarm M10 3 40 Nm (4.0 m·kg, 29 ft·lb) LT
Front brake disc and wheel hub M8 6 23 Nm (2.3 m·kg, 17 ft·lb) LT
Rear brake disc and wheel hub M8 4 23 Nm (2.3 m·kg, 17 ft·lb) LT
Brake hose union bolt M10 4 23 Nm (2.3 m·kg, 17 ft·lb)

Starter relay lead and starter re-
M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
lay
Ignition coil and frame M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Front brake pad retaining pin (on
M8 1 18 Nm (1.8 m·kg, 13 ft·lb)
brake caliper)
Front brake pad retaining pin cap
M8 1 3 Nm (0.3 m·kg, 2.2 ft·lb)
(on brake caliper)
Front brake caliper bleed screw M8 1 6 Nm (0.6 m·kg, 4.3 ft·lb)
Front brake pad retaining pin (on
M8 1 13 Nm (1.3 m·kg, 9.4 ft·lb)
caliper bracket)
Rear brake caliper bleed screw M7 1 6 Nm (0.6 m·kg, 4.3 ft·lb)
Rear brake caliper retaining bolt M10 2 27 Nm (2.7 m·kg, 19 ft·lb)
NOTE:
Lower ring nut
1. Tighten the lower ring nut 38 Nm (3.8 m·kg, 27 ft·lb) with a torque wrench and the steering nut
wrench, and then loosen the nut 1/4 turn.
2. Tighten the lower ring nut 22 Nm (2.2 m·kg, 16 ft·lb) with a torque wrench and the steering nut
wrench.
3. Install the rubber washer and the center ring nut.
4. Finger tighten the center ring nut, align the slots of both ring nuts, and then install the lock washer.
5. Hold the lower and center ring nuts, and then tighten the upper ring nut 75 Nm (7.5 m·kg, 54 ft·lb)
with a torque wrench and the steering nut wrench.
NOTE:
Swingarm mounting bolt
1. Temporarily install the rear wheel axle nut “1”.
2. Temporarily install the swingarm mounting bolt (upper side) “2”, then the swingarm mounting bolt
(lower side) “3”.
3. Tighten the rear wheel axle nut to 135 Nm (13.5 m·kg, 98 ft·lb).
4. Tighten the swingarm mounting bolt (upper side), then the swingarm mounting bolt (lower side) to
59 Nm (5.9 m·kg, 43 ft·lb).
2-20
TIGHTENING TORQUES
Swingarm tightening sequence:
2 1
1
3
2-21
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20360

EAS20370
ENGINE
Lubrication point Lubricant
Oil seal lips LS
Bearings E
O-rings LS
Cylinder head nut mounting surface E
Crankshaft pin E
Connecting rod big end thrust surface E
Rotary filter inner surface E
Oil pump drive gear inner surface E
Timing chain sprocket inner surface E
Piston pin E
Piston, ring grooves, and piston rings E
Cylinder inner surface E
Camshaft lobes M
Valve stems (intake and exhaust) M
Valve stem ends (intake and exhaust) M
Valve stem seals M
Rocker arm shafts E
Rocker arm inner surface M
Oil pump assembly shaft E
Oil pump assembly gasket LS
Oil pump rotors (inner and outer) E
Engine mounting bolt collars LS
Starter clutch idle gear thrust surfaces E
Starter clutch idle gear shaft E
Starter clutch gear thrust surfaces E
Starter clutch gear inner surface E
Main axle thrust surfaces G
Main and drive axle serration G
O-ring and collar (clutch housing) B
Primary sheave weights Shell BT grease 3®

BEL-RAY assembly
Secondary sheave
lube®
BEL-RAY assembly
Oil seal (secondary sliding sheave)
lube®
2-22

BEL-RAY assembly
Secondary sheave guide pins
lube®
Yamaha bond No.
Crankcase mating surfaces 1215 (Three bond
No.1215®)
Yamaha bond No.
Crankshaft position sensor/stator assembly lead grommet 1215 (Three bond
No.1215®)
2-23
EAS20380
CHASSIS
Front wheel axle LS
Speed sensor oil seal lip LS
Front wheel oil seal lip LS
Drive axle LS
Brake lever pivoting point and metal-to-metal moving parts LS
Front brake pad retaining pins LS
Rear brake caliper retaining bolts LS
Throttle grip (tube guide) inner surface and throttle cables LS
Steering bearings (upper and lower) LS
Steering bearing races (inner and outer) LS
Swingarm oil seal lips LS
Centerstand and sidestand spring hook metal-to-metal moving parts LS
Centerstand shaft pivoting point and metal-to-metal moving parts LS
Centerstand stopper pivoting point LS
Sidestand pivoting point and metal-to-metal moving parts LS
2-24
COOLING SYSTEM DIAGRAMS
EAS20420
A
3 4
2
3
1
4
A
2-25
1. Coolant reservoir
2. Coolant reservoir breather hose
3. Coolant reservoir hose
4. Radiator cap
5. Radiator filler hose
6. Radiator inlet hose
7. Radiator outlet hose
8. Radiator
2-26
CABLE ROUTING
EAS20430
CABLE ROUTING
A A 7
1
2
3
B 4 6
5
A-A
2 3 9
6
8
5
2-27
CABLE ROUTING
1. Throttle cable (accelerator cable)

2. Throttle cable (decelerator cable)
3. Front brake hose
4. Air temperature sensor lead
5. Wire harness
6. Rear brake hose
7. Meter assembly coupler
8. Front brake light switch lead
9. Rear brake light switch lead
A. Position the front brake light switch lead, rear brake
light switch lead, handlebar switch coupler, start
switch coupler, wire harness, and air temperature
sensor coupler behind the handlebar.
B. Route the air temperature sensor lead through the
lower handlebar holder.
2-28
CABLE ROUTING
10
8
9 11 4
A
B-B
8
4
C 12
C
C-C
12
A 1
8 4
6 5
2-29
CABLE ROUTING
1. Front brake hose

2. Main switch lead
3. Speed sensor lead
4. Rear brake hose
5. Radiator fan motor lead
6. Sidestand switch lead
7. ECU connector
8. Wire harness
11. Seat lock cable
12. Rectifier/regulator lead
A. Fasten the wire harness to the frame with a plastic
locking tie, making sure to fasten the wire harness
at the white tape.
2-30
CABLE ROUTING
A-A B
1
2 A 3 4 5
A
A
B A
7 6 B
8
2-31
CABLE ROUTING
1. Wire harness
2. Ground lead
3. Positive battery lead
4. Ignition coil
5. Negative battery lead
6. Spark plug cap
7. O2 sensor lead
8. Rear brake hose
9. License plate light lead
A. Install the grommet that is on the wire harness on
the storage box.
B. Make sure that the ignition coil installation bolt
holes are parallel to the frame.
2-32
CABLE ROUTING
8 7
5 5
7
8 C 2 3 4 7 8
5 5
7 7
8 8 D
A-A B-B C-C D-D
G G
9 5
E
F 13
12 10
4 1
11
E F
5
A F
4
2
7 8 A A
A
3 1
2
G-G B
7 8
B
6
D
C
C D
D
D A
9
B E
2-33
CABLE ROUTING

2. Front brake hose
3. Rear brake hose
4. Wire harness
5. Seat lock cable
6. ECU coupler
9. Sidestand switch lead
10. Front left turn signal light coupler
11. Rectifier/regulator lead
12. Front right turn signal light coupler
13. Main switch lead
A. Face the end of each plastic locking tie downward.
B. Face the end of the plastic locking tie inward.
C. Fasten the front brake hose and rear brake hose
with a plastic locking tie. After fastening the brake
hoses, turn the handlebar 45° to the left and right
and check that the hoses are not pulled and that
they do not touch the frame.
D. Fasten the wire harness to the frame with a plastic
locking tie, making sure to fasten the wire harness
at the white tape.
E. Route the rear brake hose between the wire
harness and the front brake hose.
F. 60–80 mm (2.36–3.15 in)
2-34
CABLE ROUTING
4 5 6
C 4 4
7 16 16
B
8
15 15
B C
9 B-B C-C
D D
10
6
10
9
11
C
D-D
14 13 12
A-A 1
A A
B 3 2 A
2-35
CABLE ROUTING
1. Seat lock cable

4. Wire harness
5. Coolant temperature sensor lead
6. Crankshaft position sensor/stator assembly lead
7. Intake air pressure sensor coupler
8. ISC (idle speed control) unit coupler
9. Starter motor lead
10. Ground lead
11. Intake air temperature sensor lead
12. Air filter case to throttle body hose
13. Crankcase breather hose
14. Fuel injector lead
15. Rear brake hose
16. Ignition coil lead
A. Connect the throttle cables to the throttle cable
pulley, making sure that the decelerator cable is
routed above the accelerator cable.
B. Face the end of the plastic locking tie downward.
C. Fasten the crankshaft position sensor/stator
assembly lead, ground lead, and starter motor lead
with the holder on the engine bracket, making sure
to align the white mark on each lead with the
holder.
2-36
CABLE ROUTING
3
2
4
1
5
A
18
13
17
6
16
C 7
15
B
14
B
B
8
A
A
17 18
16
13 9
13
10
12
11
D
B-B
2-37
CABLE ROUTING
1. Front left turn signal light lead

3. Front brake hose
4. Headlight assembly lead
5. Front right turn signal light lead
6. Rear brake hose
7. Wire harness
8. Fuel pump lead
10. Ground lead
12. Lean angle sensor lead
13. Fuel hose
14. ECU coupler
15. Fuel sender lead
16. Seat lock cable
A. Route the throttle cables between the steering
head pipe and the storage compartment.
B. 5–15 mm (0.20–0.59 in)
C. Connect the fuel hose, and then rotate it in the
direction of the arrow shown in the illustration so
that the hose does not touch the frame, plastic
locking tie, or seat lock cable.
D. Route the fuel hose so that it does not touch the
plastic locking tie.
2-38
CABLE ROUTING
3 4
17
6
2 7
A A
1
8
16
A
15
9
10
11
12
14 13
2-39
CABLE ROUTING
1. Seat lock cable

2. Lean angle sensor lead
4. Ground lead
5. Wire harness
7. Starter relay lead
8. Rear brake hose
9. Turn signal relay
10. Starting circuit cut-off relay
11. Radiator fan motor relay
12. License plate light lead
13. Right tail/brake light assembly coupler
14. Left tail/brake light assembly coupler
15. Headlight relay
16. Fuse box
17. O2 sensor lead
A. Fasten the wire harness to the frame with a plastic
locking tie, making sure to pass the plastic locking
tie through the frame.
2-40
CABLE ROUTING
2-41
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE ............................................................................ 3-1

INTRODUCTION ....................................................................................... 3-1
PERIODIC MAINTENANCE AND LUBRICATION CHART....................... 3-1
ENGINE ........................................................................................................... 3-3

ADJUSTING THE VALVE CLEARANCE .................................................. 3-3
ADJUSTING THE EXHAUST GAS VOLUME ........................................... 3-5
ADJUSTING THE THROTTLE CABLE FREE PLAY ................................ 3-5
CHECKING THE SPARK PLUG ............................................................... 3-6
CHECKING THE IGNITION TIMING......................................................... 3-7
MEASURING THE COMPRESSION PRESSURE.................................... 3-8
CHECKING THE ENGINE OIL LEVEL...................................................... 3-9
CHANGING THE ENGINE OIL ................................................................. 3-9
CHANGING THE FINAL TRANSMISSION OIL....................................... 3-11
REPLACING THE AIR FILTER ELEMENT ............................................. 3-11 3
CLEANING THE V-BELT CASE AIR FILTER ELEMENT ....................... 3-12
CHECKING THE THROTTLE BODY JOINT........................................... 3-12
CHECKING THE FUEL HOSE ................................................................ 3-12
CHECKING THE BREATHER HOSES ................................................... 3-12
CHECKING THE EXHAUST SYSTEM.................................................... 3-13
CHECKING THE COOLANT LEVEL....................................................... 3-13
CHECKING THE COOLING SYSTEM .................................................... 3-14
CHANGING THE COOLANT................................................................... 3-14
CHASSIS ....................................................................................................... 3-17

CHECKING THE BRAKE FLUID LEVEL................................................. 3-17
CHECKING THE FRONT BRAKE PADS ................................................ 3-17
CHECKING THE REAR BRAKE PADS .................................................. 3-17
CHECKING THE FRONT BRAKE HOSE................................................ 3-18
CHECKING THE REAR BRAKE HOSE .................................................. 3-18
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-18
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-19
CHECKING THE FRONT FORK ............................................................. 3-20
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES .............. 3-20
CHECKING THE TIRES.......................................................................... 3-21
CHECKING THE WHEELS ..................................................................... 3-22
CHECKING AND LUBRICATING THE CABLES .................................... 3-23
LUBRICATING THE LEVERS ................................................................. 3-23
LUBRICATING THE SIDESTAND........................................................... 3-23
LUBRICATING THE CENTERSTAND .................................................... 3-23
ELECTRICAL SYSTEM................................................................................. 3-24

CHECKING AND CHARGING THE BATTERY....................................... 3-24
CHECKING THE FUSES ........................................................................ 3-24
REPLACING A HEADLIGHT BULB ........................................................ 3-24
ADJUSTING THE HEADLIGHT BEAM ................................................... 3-25
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.
EAU17707
PERIODIC MAINTENANCE AND LUBRICATION CHART

NOTE:
• The annual checks must be performed every year, except if a kilometer-based maintenance is
performed instead.
• From 50000 km, repeat the maintenance intervals starting from 10000 km.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
ODOMETER READING (× 1000 km) ANNU-

NO. ITEM CHECK OR MAINTENANCE JOB AL
1 10 20 30 40 CHECK
1 * Fuel line • Check fuel hoses for cracks or damage. √ √ √ √ √
• Check condition.
• Clean and regap. √ √
2 Spark plug
• Replace. √ √
• Check valve clearance.
3 * Valves • Adjust. √ √
4 Air filter element • Replace. √ √
V-belt case air filter
5 element • Clean. √ √ √ √
• Check operation, fluid level and vehicle for fluid √ √ √ √ √ √
6 * Front brake leakage.
• Replace brake pads. Whenever worn to the limit
• Check operation, fluid level and vehicle for fluid √ √ √ √ √ √
7 * Rear brake leakage.
• Replace brake pads. Whenever worn to the limit
• Check for cracks or damage. √ √ √ √ √
8 * Brake hoses
• Replace. Every 4 years
9 * Wheels • Check runout and for damage. √ √ √ √
• Check tread depth and for damage.
• Replace if necessary.
10 * Tires • Check air pressure. √ √ √ √ √
• Correct if necessary.
11 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √
• Check bearing play and steering for roughness. √ √ √ √ √
12 * Steering bearings
• Lubricate with lithium-soap-based grease. Every 20000 km
• Make sure that all nuts, bolts and screws are prop-
13 * Chassis fasteners erly tightened. √ √ √ √ √
14 Sidestand, center- • Check operation. √ √ √ √ √

stand • Lubricate.
15 * Sidestand switch • Check operation. √ √ √ √ √ √
16 * Front fork • Check operation and for oil leakage. √ √ √ √
Shock absorber as- • Check operation and shock absorbers for oil leak-
17 * semblies age. √ √ √ √
18 * Fuel injection • Check engine idle speed. √ √ √ √ √ √
When the oil change indicator light
• Change. √ comes on (every 3000 km)
19 Engine oil
• Check oil level and vehicle for oil leakage. Every 3000 km √
20 * Engine oil strainer • Clean. √
• Check coolant level and vehicle for coolant leakage. √ √ √ √ √
21 * Cooling system
• Change. Every 3 years
3-1
ODOMETER READING (× 1000 km) ANNU-

NO. ITEM CHECK OR MAINTENANCE JOB AL
1 10 20 30 40 CHECK
Final transmission • Check vehicle for oil leakage. √ √ √
22 oil • Change. √ √ √
23 * V-belt • Replace. Every 20000 km
Front and rear brake
24 * switches • Check operation. √ √ √ √ √ √
Moving parts and ca-
25 bles • Lubricate. √ √ √ √ √
Throttle grip hous- • Check operation and free play.

26 * • Adjust the throttle cable free play if necessary. √ √ √ √ √
ing and cable • Lubricate the throttle grip housing and cable.
27 * Lights, signals and • Check operation. √ √ √ √ √ √
switches • Adjust headlight beam.
EAU18670
NOTE:
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-2
ENGINE
EAS20470
ENGINE
EAS20520
ADJUSTING THE VALVE CLEARANCE

The following procedure applies to all of the
valves.
NOTE:
• Valve clearance adjustment should be made 1
on a cold engine, at room temperature.
• When the valve clearance is to be measured or
adjusted, the piston must be at the top dead 5. Measure:
center (TDC) on the compression stroke. • Valve clearance
Out of specification → Adjust.
1. Remove:
• Storage box Valve clearance (cold)
• Left footrest board Intake
Refer to “GENERAL CHASSIS” on page 4-1. 0.08–0.12 mm (0.0031–0.0047 in)
2. Remove: Exhaust
• V-belt case air filter cover “1” 0.16–0.20 mm (0.0063–0.0079 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the primary sheave nut on the left side
of the crankshaft counterclockwise to turn the
crankshaft.
3. Remove:
• Spark plug
• Tappet covers “1”
• Camshaft sprocket cover “2”
b. When the piston is at TDC on the compres-
sion stroke, align the “I” mark “a” on the cam-
1 shaft sprocket with the alignment mark “b” on
the cylinder head.
2
b
1
a
4. Remove:
• Timing mark accessing plug “1”
c. Align the TDC mark “c” on the generator rotor

with the stationary pointer “d” on the genera-
tor cover.
3-3
ENGINE
Tappet adjusting tool

90890-01311
Valve adjuster 3 mm & 4 mm
YM-08035-A
d. Measure the valve clearance with a thickness

a
gauge “1”.
Out of specification → Adjust. 3 4
• Hold the adjusting screw to prevent it from

moving and tighten the locknut to specifica-
tion.
1 Locknut (valve clearance adjust-

ing screw)
T.
R.
14 Nm (1.4 m·kg, 10 ft·lb)
d. Measure the valve clearance again.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ e. If the valve clearance is still out of specifica-
6. Adjust: tion, repeat all of the valve clearance adjust-
• Valve clearance ment steps until the specified clearance is
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ obtained.
a. Loosen the locknut “1”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. Insert a thickness gauge “2” between the end
of the adjusting screw and the valve tip. 7. Install:
• Timing mark accessing plug
1 (along with the O-ring New )
• Camshaft sprocket cover
(along with the O-ring New )
• Tappet covers
(along with the O-rings New )
2 Timing mark accessing plug
8 Nm (0.8 m·kg, 5.8 ft·lb)
T.
R.
Camshaft sprocket cover

c. Turn the adjusting screw “3” in direction “a” or 10 Nm (1.0 m·kg, 7.2 ft·lb)
Tappet cover
“b” with the tappet adjusting tool “4” until the
10 Nm (1.0 m·kg, 7.2 ft·lb)
specified valve clearance is obtained.
8. Install:
Direction “a”
• Left footrest board
Valve clearance is increased.
Direction “b” • Storage box
Valve clearance is decreased. Refer to “GENERAL CHASSIS” on page 4-1.
3-4
ENGINE
EAS20600
6. Press the “UP” button to select the CO adjust-
ADJUSTING THE EXHAUST GAS VOLUME
ment mode “CO” or the diagnostic mode “DI-
NOTE: AG”.
Be sure to set the CO density level to standard, 7. After selecting “CO”, press the “MODE” but-
and then adjust the exhaust gas volume. ton.
1. Remove: 8. Check that “C1” appears on the LCD of the FI
• Battery cover diagnostic tool, and then press the “MODE”
Refer to “GENERAL CHASSIS” on page 4-1. button.
2. Set the main switch to “OFF”. 9. Start the engine.
ECA5B21011
3. Remove: CAUTION:
• Self-diagnosis signal coupler cap
Perform the adjustment after the battery has
4. Connect:
been sufficiently charged.
• FI diagnostic tool “1”
FI diagnostic tool
90890-03182
FI Diagnostic Tool
1 1550rpm
C1 : -10
10.Change the CO adjustment volume by press-

ing the “UP” and “DOWN” buttons.
NOTE:
5. While pressing the “MODE” button “1”, set The CO adjustment volume and engine idling
the main switch to “ON”. speed appears on the LCD of the FI diagnostic
tool.
NOTE:
• To decrease the CO adjustment volume, press
• “DIAG” appears on the LCD “2” of the FI diag- the “DOWN” button.
nostic tool. • To increase the CO adjustment volume, press
• “POWER” LED (Green) “3” comes on. the “UP” button.
11.Release the “DOWN” and “UP” buttons to ex-
3 ecute the selection.
FI Diagnostic Tool 12.Set the main switch to “OFF” to cancel the
2 mode.
DIAG 13.Disconnect:
• FI diagnostic tool
14.Install:
1 • Self-diagnosis signal coupler cap
15.Install:
• Battery cover
Refer to “GENERAL CHASSIS” on page 4-1.
EAS20640
ADJUSTING THE THROTTLE CABLE FREE

PLAY
1. Check:
• Throttle cable free play “a”
3-5
ENGINE
NOTE:
Throttle cable free play
3.0–5.0 mm (0.12–0.20 in) If the specified throttle cable free play cannot be
obtained on the throttle body end of the cable,
use the adjusting nut on the handlebar end.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Handlebar end
a a. Slide back the rubber cover “1”.
b. Loosen the locknut “2”.
c. Turn the adjusting nut “3” in direction “a” or “b”
until the specified throttle cable free play is
obtained.
2. Remove:
Direction “a”
• Left center panel
Throttle cable free play is increased.
• Meter assembly Direction “b”
Refer to “GENERAL CHASSIS” on page 4-1. Throttle cable free play is decreased.
3. Adjust:
• Throttle cable free play
1 3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 2
Throttle body end b
a. Loosen the locknut “1” on the decelerator ca-
ble.
b. Turn the adjusting nut “2” in direction “a” or “b” a
to take up any slack on the decelerator cable.
c. Loosen the locknut “3” on the accelerator ca-
ble.
d. Turn the adjusting nut “4” in direction “a” or “b”
until the specified throttle cable free play is d. Tighten the locknut.
obtained. e. Slide the rubber cover to its original position.
EWA12910
Direction “a” WARNING

Throttle cable free play is increased. After adjusting the throttle cable free play,
Direction “b” start the engine and turn the handlebar to the
Throttle cable free play is decreased. right and to the left to ensure that this does
not cause the engine idling speed to change.
e. Tighten the locknuts “1”, “3”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• Meter assembly
2 1 • Left center panel
a Refer to “GENERAL CHASSIS” on page 4-1.
EAS20690
b CHECKING THE SPARK PLUG
a
1. Remove:
b • Right center panel
4 3
• Right footrest board
2. Disconnect:
• Spark plug cap
3. Remove:
• Spark plug
3-6
ENGINE
ECA13330
• Right center panel
CAUTION: Refer to “GENERAL CHASSIS” on page 4-1.
Before removing the spark plug, blow away
EAS20700
any dirt accumulated in the spark plug well
CHECKING THE IGNITION TIMING
with compressed air to prevent it from falling
NOTE:
into the cylinder.
Prior to checking the ignition timing, check the
4. Check: wiring connections of the entire ignition system.
• Spark plug type Make sure that all connections are tight and free
Incorrect → Change. of corrosion.
Manufacturer/model 1. Stand the vehicle on a level surface.
NGK/DPR8EA-9 NOTE:
5. Check: Place the vehicle on a suitable stand.

• Electrode “1” 2. Remove:
Damage/wear → Replace the spark plug. • Right center panel
• Insulator “2” • Right footrest board
Abnormal color → Replace the spark plug. Refer to “GENERAL CHASSIS” on page 4-1.
Normal color is medium-to-light tan. 3. Remove:
6. Clean: • Timing mark accessing plug “1”
• Spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
• Spark plug gap “a”
(with a wire thickness gauge)
Out of specification → Regap.
Spark plug gap

0.8–0.9 mm (0.031–0.035 in) 1
4. Connect:
• Timing light “1”
(onto the spark plug lead)
• Digital tachometer
(onto the spark plug lead)
Timing light
90890-03141
Inductive clamp timing light
YU-03141
8. Install:
• Spark plug
Spark plug
18 Nm (1.8 m·kg, 13 ft·lb)
T.
R.
NOTE:
Before installing the spark plug, clean the spark
plug and gasket surface.
9. Connect:
1
• Spark plug cap
10.Install:
5. Check:
• Ignition timing
3-7
ENGINE
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 2. Measure:
a. Start the engine, warm it up for several min- • Valve clearance
utes, and then let it run at the specified en- Out of specification → Adjust.
gine idling speed. Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-3.
Engine idling speed
3. Start the engine, warm it up for several min-
1450–1650 r/min
utes, and then turn it off.
b. Check that the stationary pointer “a” on the 4. Disconnect:
generator cover is within the firing range “b” • Spark plug cap
on the generator rotor. 5. Remove:
Incorrect firing range → Check the ignition • Spark plug
ECA5B21012
system. CAUTION:
NOTE:
Before removing the spark plug, use com-
The ignition timing is not adjustable. pressed air to blow away any dirt accumulat-
ed in the spark plug well to prevent it from
falling into the cylinder.
6. Install:
• Compression gauge “1”
Compression gauge
90890-03081
Engine compression tester
YU-33223
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1
6. Disconnect:
• Digital tachometer
• Timing light
7. Install:
• Timing mark accessing plug
(along with the O-ring New )
Timing mark accessing plug

8 Nm (0.8 m·kg, 5.8 ft·lb) 7. Measure:
T.
R.
• Compression pressure
8. Install:
Out of specification → Refer to steps (c) and
(d).
Refer to “GENERAL CHASSIS” on page 4-1. Standard compression pressure
EAS20710
(at sea level)
MEASURING THE COMPRESSION 1400 kPa/500 r/min (199.1
PRESSURE psi/500 r/min) (14.0 kgf/cm²/500
r/min)
NOTE:
Minimum–maximum
Insufficient compression pressure will result in a 1120–1570 kPa (159.3–223.3 psi)
loss of performance. (11.2–15.7 kgf/cm²)
1. Remove:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Right center panel a. Set the main switch to “ON”.
• Right footrest board b. With the throttle wide open, crank the engine
Refer to “GENERAL CHASSIS” on page 4-1. until the reading on the compression gauge
stabilizes.
3-8
ENGINE
EWA5B21004
4. Check:
WARNING • Engine oil level
To prevent sparking, ground the spark plug The engine oil level should be between the
lead before cranking the engine. minimum level mark “a” and maximum level
c. If the compression pressure is above the mark “b”.
maximum specification, check the cylinder Below the minimum level mark → Add the
head, valve surfaces and piston crown for recommended engine oil to the proper level.
carbon deposits. NOTE:
Carbon deposits → Eliminate. • Before checking the engine oil level, wait a few
d. If the compression pressure is below the min- minutes until the oil has settled.
imum specification, pour a teaspoonful of en- • Do not screw the dipstick in when inspecting
gine oil into the spark plug bore and measure the oil level.
again.
Refer to the following table. Type
Compression pressure (with oil applied into SAE10W30, SAE10W40,
the cylinder) SAE15W40, SAE20W40 or
Reading Diagnosis SAE20W50
Recommended engine oil grade
Higher than without Piston ring(s) wear or API service SG type or higher,
oil damage → Repair. JASO standard MA
Piston, valves, cylin- ECA5B21021
der head gasket or CAUTION:
Same as without oil piston ring(s) possi-
bly defective → Re- Do not allow foreign materials to enter the
pair. crankcase.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1
8. Install:
• Spark plug
Spark plug b
18 Nm (1.8 m·kg, 13 ft·lb) 1
T.
R.
a
9. Connect:
• Spark plug cap
10.Install:
• Right footrest board 5. Start the engine, warm it up for several min-
• Right center panel utes, and then turn it off.
Refer to “GENERAL CHASSIS” on page 4-1. 6. Check the engine oil level again.
EAS20740 NOTE:
CHECKING THE ENGINE OIL LEVEL Before checking the engine oil level, wait a few
1. Stand the vehicle on a level surface. minutes until the oil has settled.
NOTE:
7. Install:
• Place the vehicle on a suitable stand.
• Dipstick
• Make sure the vehicle is upright.
EAS20780
2. Start the engine, warm it up for several min- CHANGING THE ENGINE OIL
utes, and then turn it off. 1. Remove:
3. Remove: • Right center panel
• Dipstick “1” • Right footrest board
3-9
ENGINE
2. Start the engine, warm it up for several min- 9. Fill:

utes, and then turn it off. • Crankcase
3. Place a container under the engine oil drain (with the specified amount of the recom-
bolt. mended engine oil)
4. Remove:
• Engine oil filler cap Engine oil quantity
• Engine oil drain bolt “1” Total amount
(along with the gasket) 1.40 L (1.48 US qt) (1.23 Imp.qt)
Periodic oil change
1.20 L (1.27 US qt) (1.06 Imp.qt)
10.Install:
• Engine oil filler cap
1 11.Start the engine, warm it up for several min-
12.Check:
• Engine
(for engine oil leaks)
13.Check:
5. Drain: • Engine oil level
• Engine oil Refer to “CHECKING THE ENGINE OIL
(completely from the crankcase) LEVEL” on page 3-9.
6. If the oil strainer is also to be cleaned, per- 14.Check:
form the following procedure. • Engine oil pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the oil strainer cover “1” and oil a. Slightly loosen the oil check bolt “1”.
strainer “2”.
b. Install a new O-ring “3”.
1
2
1 3
1 b. Start the engine and keep it idling until engine
oil starts to seep from the oil check bolt. If no
c. Install the oil strainer cover. engine oil comes out after one minute, turn
the engine off so that it will not seize.
Oil strainer cover c. Check the engine oil passages and the oil
32 Nm (3.2 m·kg, 23 ft·lb) pump for damage or leakage. Refer to “OIL
T.
R.
PUMP” on page 5-48.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ d. Start the engine after solving the problem(s)
7. Check: and check the engine oil pressure again.
• Engine oil drain bolt gasket e. Tighten the oil check bolt to specification.
Damage → Replace.
8. Install: Oil check bolt
• Engine oil drain bolt 7 Nm (0.7 m·kg, 5.1 ft·lb)
T.
R.
(along with the gasket)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Engine oil drain bolt 15.Install:
20 Nm (2.0 m·kg, 14 ft·lb) • Right footrest board
T.
R.
3-10
ENGINE

Refer to “GENERAL CHASSIS” on page 4-1. Final transmission oil
Type
EAS20830 SAE10W30 type SE motor oil
CHANGING THE FINAL TRANSMISSION OIL Quantity
1. Stand the vehicle on a level surface. 0.25 L (0.26 US qt) (0.22 Imp.qt)
NOTE:
• Place the vehicle on a suitable stand. 8. Install:
• Make sure that the vehicle is upright. • Oil filler cap
• O-ring
2. Start the engine, warm it up for several min- 9. Start the engine, warm it up for several min-
utes, and then turn it off. utes, turn it off, and then check for oil leak-
3. Place a container under the transmission. age.
4. Remove:
EAS20960
• Oil filler cap “1”
REPLACING THE AIR FILTER ELEMENT
• O-ring “2”
NOTE:
Check hoses are located on the bottom of the air
1 filter case. If dust or water or both collects in a
1 hose, remove the clamp from the hose, and then
2 remove the plug to drain the hose.
1. Remove:
• Air filter case cover “1”
• Air filter element
• Air filter case cover seal
5. Remove:
• Final transmission oil drain bolt “1”
Completely drain the final transmission oil. 1
2. Check:
• Air filter element
Damage → Replace.
NOTE:
6. Install: • Replace the air filter element every 40000 km
• Final transmission oil drain bolt of operation.
• The air filter needs more frequent service if you
Final transmission oil drain bolt are riding in unusually wet or dusty areas.
22 Nm (2.2 m·kg, 16 ft·lb)
T.
R.
3. Install:
7. Fill: • Air filter case cover seal
• Final transmission oil • Air filter element
(specified amount of the recommended final • Air filter case cover
ECA5B21013
transmission oil)
CAUTION:
Never operate the engine without the air filter
element installed. Unfiltered air will cause
rapid wear of engine parts and may damage
the engine. Operating the engine without the
3-11
ENGINE
air filter element will also affect the throttle EAS21020
CHECKING THE THROTTLE BODY JOINT

body tuning, leading to poor engine perfor-
1. Remove:
mance and possible overheating.
• Storage box
NOTE: Refer to “GENERAL CHASSIS” on page 4-1.
When installing the air filter element into the air 2. Check:
filter case cover, make sure that the sealing sur- • Throttle body joint “1”
faces are aligned to prevent any air leaks. Cracks/damage → Replace.
EAS20980
CLEANING THE V-BELT CASE AIR FILTER

ELEMENT
1. Remove:
• V-belt case air filter cover “1”
• V-belt case air filter element
• V-belt case air filter cover seal
1
3. Install:
• Storage box
EAS21030
CHECKING THE FUEL HOSE

1. Remove:
1 • Center panels
• Fuel tank cover
2. Clean: Refer to “GENERAL CHASSIS” on page 4-1.
• V-belt case air filter element “1” 2. Check:
Blow compressed air onto the outer surface • Fuel hose “1”
of the V-belt case air filter element. Cracks/damage → Replace the fuel injector
1 assembly.
3. Check:
• V-belt case air filter element
Damage → Replace.
ECA13440 3. Install:
CAUTION: • Fuel tank cover
Since the V-belt case air filter element is a • Center panels
dry type, do not let grease or water contact it. Refer to “GENERAL CHASSIS” on page 4-1.
4. Install: EAS21070
• V-belt case air filter cover seal CHECKING THE BREATHER HOSES
• V-belt case air filter element 1. Remove:
• V-belt case air filter cover • Storage box
3-12
ENGINE
2. Check:
• Crankcase breather hose “1” Exhaust pipe nut
• Transmission case breather hose “2” 20 Nm (2.0 m·kg, 14 ft·lb)
T.
R.
Cracks/damage → Replace. Muffler joint bolt
14 Nm (1.4 m·kg, 10 ft·lb)
ECA5B21014
Muffler mounting bolt
CAUTION: 65 Nm (6.5 m·kg, 47 ft·lb)
O2 sensor
Make sure the crankcase breather hose and
45 Nm (4.5 m·kg, 32 ft·lb)
transmission case breather hose are routed
correctly.
3
1
3
2
4. Install:
3. Install: • Right footrest board
• Storage box • Right center panel
Refer to “GENERAL CHASSIS” on page 4-1. Refer to “GENERAL CHASSIS” on page 4-1.
EAS21080 EAS21110
CHECKING THE EXHAUST SYSTEM CHECKING THE COOLANT LEVEL
1. Remove: 1. Stand the vehicle on a level surface.
• Right center panel NOTE:
2. Check:
• Exhaust pipe “1” 2. Check:
• Muffler “2” • Coolant level
Cracks/damage → Replace. The coolant level should be between the
• Gaskets “3” maximum level mark “a” and minimum level
Exhaust gas leaks → Replace. mark “b”.
3. Check: Below the minimum level mark → Add the
• Tightening torque recommended coolant to the proper level.
3-13
ENGINE
ECA5B21022
CAUTION:
• Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is 4
used instead of coolant, check, and if nec- 2
essary, correct the antifreeze concentra-
tion of the coolant. 1 5
• Use only distilled water. However, if dis- 3
tilled water is not available, soft water may
be used.
7
6
a
b
3. Start the engine, warm it up for several min- 3. Install:

utes, and then turn it off. • Storage box
4. Check: • Footrest board
• Coolant level Refer to “GENERAL CHASSIS” on page 4-1.
NOTE:
EAS21130
Before checking the coolant level, wait a few CHANGING THE COOLANT
minutes until it settles. 1. Remove:
• Front cowling
EAS21120
CHECKING THE COOLING SYSTEM Refer to “GENERAL CHASSIS” on page 4-1.

1. Remove: 2. Disconnect:
• Footrest board • Coolant reservoir hose “1”
• Storage box
2. Check:
• Radiator “1” 1
• Radiator inlet hose “2”
• Radiator outlet hose “3”
• Radiator filler hose “4”
• Coolant reservoir hose “5”
• Thermostat cover “6”
• Thermostat inlet hose “7”
Cracks/damage → Replace. 3. Drain:
Refer to “RADIATOR” on page 6-1 and • Coolant
“THERMOSTAT” on page 6-4. (from the coolant reservoir)
4. Remove:
• Radiator cap “1”
EWA5B21008
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
3-14
ENGINE
be blown out, which could cause serious in-

jury. When the engine has cooled, open the Recommended antifreeze
radiator cap as follows: High-quality ethylene glycol anti-
Place a thick rag or a towel over the radiator freeze containing corrosion in-
hibitors for aluminum engines
cap and slowly turn the radiator cap counter-
Mixing ratio
clockwise toward the detent to allow any re- 1:1 (antifreeze:water)
sidual pressure to escape. When the hissing Radiator capacity (including all
sound has stopped, press down on the radi- routes)
ator cap and turn it counterclockwise to re- 1.02 L (1.08 US qt) (0.90 Imp.qt)
move it. Coolant reservoir capacity (up
to the maximum level mark)
0.20 L (0.21 US qt) (0.18 Imp.qt)
1
NOTE:
The specified amount of coolant is a standard
amount. Fill the cooling system with coolant until
coolant comes out of the air bleed bolt hole “1”.
5. Remove:
• Coolant drain bolt (water pump) “1”
(along with the copper washer) 1
Handling notes for coolant

Coolant is potentially harmful and should be
handled with special care.
EWA13040
1 WARNING
• If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
6. Drain:
tor.
• Coolant
• If coolant splashes on your clothes, quickly
(from the engine and radiator)
wash it away with water and then with soap
7. Install:
and water.
• Coolant drain bolt (water pump)
• If coolant is swallowed, induce vomiting
(along with the copper washer New ) and get immediate medical attention.
ECA5B21023
Coolant drain bolt (water pump)
CAUTION:
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
• Adding water instead of coolant lowers the

8. Connect: antifreeze content of the coolant. If water is
• Coolant reservoir hose used instead of coolant, check, and if nec-
9. Fill: essary, correct the antifreeze concentra-
• Cooling system tion of the coolant.
(with the specified amount of the recom- • Use only distilled water. However, if dis-
mended coolant) tilled water is not available, soft water may
be used.
3-15
ENGINE
• If coolant comes into contact with painted

surfaces, immediately wash them with wa-
ter.
• Do not mix different types of antifreeze.
10.Install:
• Radiator cap
11.Fill:
• Coolant reservoir
(with the recommended coolant to the maxi-
mum level mark “a”)
12.Install:
• Coolant reservoir cap
13.Start the engine, warm it up for several min-
14.Check:
• Coolant level
Refer to “CHECKING THE COOLANT LEV-
EL” on page 3-13.
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant has settled.
15.Install:
• Front cowling
3-16
CHASSIS
EAS21140
• Refill with the same type of brake fluid that
CHASSIS is already in the system. Mixing brake fluids
EAS21240
may result in a harmful chemical reaction,
CHECKING THE BRAKE FLUID LEVEL leading to poor brake performance.
1. Stand the vehicle on a level surface. • When refilling, be careful that water does
NOTE: not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
ECA13540
2. Check: CAUTION:
• Brake fluid level Brake fluid may damage painted surfaces
Below the minimum level mark “a” → Add the and plastic parts. Therefore, always clean up
recommended brake fluid to the proper level. any spilt brake fluid immediately.
Front brake NOTE:
Recommended fluid In order to ensure a correct reading of the brake
DOT 4
fluid level, make sure the top of the brake fluid
Rear brake
Recommended fluid reservoir is horizontal.
DOT 4
EAS21250
CHECKING THE FRONT BRAKE PADS

A The following procedure applies to all of the
brake pads.
1. Operate the brake.
MIN
a 2. Check:
• Front brake pad
Wear indicator grooves “a” have almost dis-
appeared → Replace the brake pads as a
set.
Refer to “FRONT BRAKE” on page 4-14.
a
MIN
a
MIN
EAS21260
CHECKING THE REAR BRAKE PADS

A. Front brake The following procedure applies to all of the
B. Rear brake brake pads.
EWA13090 1. Operate the brake.
WARNING 2. Check:
• Use only the designated brake fluid. Other • Rear brake pad
brake fluids may cause the rubber seals to Wear indicator groove “a” has almost disap-
deteriorate, causing leakage and poor peared → Replace the brake pads as a set.
brake performance. Refer to “REAR BRAKE” on page 4-26.
3-17
CHASSIS
3. Hold the vehicle upright and apply the rear

brake several times.
4. Check:
• Brake hose
Brake fluid leakage → Replace the damaged
hose.
Refer to “REAR BRAKE” on page 4-26.
EAS21350
BLEEDING THE HYDRAULIC BRAKE

SYSTEM
EAS21270 EWA5B21005
CHECKING THE FRONT BRAKE HOSE WARNING

1. Check: Bleed the hydraulic brake system whenever:
• Brake hose “1” • The system is disassembled.
Cracks/damage/wear → Replace. • A brake hose is loosened, disconnected or
replaced.
• The brake fluid level is very low.
• The brake operation is faulty.
1 NOTE:
• Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir to overflow.
• When bleeding the hydraulic brake system,
make sure there is always enough brake fluid
before applying the brake. Ignoring this pre-
caution could allow air to enter the hydraulic
2. Hold the vehicle upright and apply the front
brake system, considerably lengthening the
brake several times.
bleeding procedure.
3. Check:
• If bleeding is difficult, it may be necessary to let
• Brake hose
the brake fluid settle for a few hours. Repeat
Brake fluid leakage → Replace the damaged
the bleeding procedure when the tiny bubbles
hose.
in the hose have disappeared.
Refer to “FRONT BRAKE” on page 4-14.
1. Bleed:
EAS21290
CHECKING THE REAR BRAKE HOSE • Hydraulic brake system

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1. Check:
a. Fill the brake master cylinder reservoir to the
• Brake hose “1”
proper level with the recommended brake flu-
Cracks/damage/wear → Replace.
id.
2. Check:
b. Install the brake master cylinder reservoir di-
• Brake hose holder “2”
aphragm.
Loose connection → Connect.
c. Connect a clear plastic hose “1” tightly to the
bleed screw “2”.
A
2
1
2
3-18
CHASSIS
NOTE:
B
Place the vehicle on a suitable stand so that the
1 front wheel is elevated.
2
2. Check:
• Steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness → Adjust the steering
head.
3. Remove:
A. Front brake caliper • Lower handlebar holder
B. Rear brake caliper Refer to “STEERING HEAD” on page 4-49.
4. Adjust:
d. Place the other end of the hose into a con-
• Steering head
tainer.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
e. Slowly apply the brake several times. a. Remove the upper ring nut “1”, the lock wash-
f. Fully pull the brake lever and hold it in posi- er “2”, the center ring nut “3” and the rubber
tion. washer.
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release the pres-
sure and cause the brake lever to contact the
throttle grip.
h. Tighten the bleed screw, and then release
the brake lever.
i. Repeat steps (e) to (h) until all of the air bub-
bles have disappeared from the brake fluid in
the plastic hose.
j. Tighten the bleed screw to specification. b. Loosen the lower ring nut “4”, and then tight-
en it to specification with the steering nut
Brake caliper bleed screw wrench “5”.
6 Nm (0.6 m·kg, 4.3 ft·lb)
T.
R.
Lower ring nut (initial tightening

k. Fill the brake master cylinder reservoir to the torque)
T.
R.
proper level with the recommended brake flu- 38 Nm (3.8 m·kg, 27 ft·lb)
id.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-17. Steering nut wrench
EWA13110 90890-01403
WARNING Spanner wrench
YU-33975
After bleeding the hydraulic brake system,
check the brake operation.
NOTE:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Be sure to install all the ring nuts with the broad
EAS21510 side of the inner tapered section facing down.
CHECKING AND ADJUSTING THE • Set a torque wrench at a right angle to the
STEERING HEAD steering nut wrench.
1. Stand the vehicle on a level surface.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
3-19
CHASSIS
i. Hold the lower and center ring nuts with a

steering nut wrench and tighten the upper
ring nut with another steering nut wrench.
Steering nut wrench

90890-01403
Spanner wrench
YU-33975
Upper ring nut

c. Loosen the lower ring nut “4” 1/4 of a turn, 75 Nm (7.5 m·kg, 54 ft·lb)
T.
R.
and then tighten it to specification with a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
steering nut wrench.
EWA13140 5. Install:
WARNING • Lower handlebar holder
Do not overtighten the lower ring nut. Refer to “STEERING HEAD” on page 4-49.
EAS21530
Lower ring nut (final tightening CHECKING THE FRONT FORK

torque) 1. Stand the vehicle on a level surface.
T.
R.
22 Nm (2.2 m·kg, 16 ft·lb) EWA13120
WARNING
d. Check the steering head for looseness or Securely support the vehicle so that there is
binding by turning the front fork all the way in no danger of it falling over.
both directions. If any binding is felt, remove
2. Check:
the lower bracket and check the upper and
• Inner tubes
lower bearings.
Damage/scratches → Replace.
Refer to “STEERING HEAD” on page 4-49.
• Oil seals
e. Install the rubber washer.
Oil leakage → Replace.
f. Install the center ring nut.
3. Hold the vehicle upright and apply the front
g. Finger tighten the center ring nut, and then
brake.
align the slots of both ring nuts. If necessary,
4. Check:
hold the lower ring nut and tighten the center
• Front fork operation
ring nut until their slots are aligned.
Push down hard on the handlebar several
NOTE: times and check if the front fork rebounds
Align the slots, by turning the center ring nut in smoothly.
the tightening direction. Rough movement → Repair.
h. Install the lock washer “2”. Refer to “FRONT FORK” on page 4-41.
NOTE:
Make sure the lock washer tabs “a” sit correctly
in the ring nut slots “b”.
EAS21630
ADJUSTING THE REAR SHOCK ABSORBER

ASSEMBLIES
The following procedure applies to both of the
rear shock absorber assemblies.
3-20
CHASSIS
EWA5B21007
1. Check:
WARNING • Tire pressure
• Securely support the vehicle so that there Out of specification → Regulate.
is no danger of it falling over.
• Always adjust both rear shock absorber as-
semblies evenly. Uneven adjustment can
result in poor handling and loss of stability.
Spring preload
ECA13590
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
EWA13180
1. Adjust: WARNING
• Spring preload • The tire pressure should only be checked
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting ring “1” in direction “a” or and regulated when the tire temperature
“b”. equals the ambient air temperature.
Align the desired position on the adjusting • The tire pressure and the suspension must
ring with the stopper “2”. be adjusted according to the total weight
(including cargo, rider, passenger and ac-
Direction “a” cessories) and the anticipated riding
Spring preload is increased (suspen- speed.
sion is harder). • Operation of an overloaded vehicle could
Direction “b” cause tire damage, an accident or an injury.
Spring preload is decreased (suspen- NEVER OVERLOAD THE VEHICLE.
sion is softer).
Tire air pressure (measured on
cold tires)
Spring preload adjusting positions Loading condition
Minimum 0–90 kg (0–198 lb)
1 Front
Standard 170 kPa (25 psi) (1.70 kgf/cm²)
2 Rear
Maximum 190 kPa (28 psi) (1.90 kgf/cm²)
4 Loading condition
90–185 kg (198–408 lb)
Front
180 kPa (26 psi) (1.80 kgf/cm²)
Rear
2
1 200 kPa (29 psi) (2.00 kgf/cm²)
b 4
3
Maximum load
185 kg (408 lb)
2 * Total weight of rider, passenger, cargo
a
1 and accessories
EWA13190
WARNING
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ It is dangerous to ride with a worn-out tire.
EAS21650 When the tire tread reaches the wear limit, re-
CHECKING THE TIRES place the tire immediately.
tires. 2. Check:
• Tire surfaces
Damage/wear → Replace the tire.
3-21
CHASSIS
EWA5B21012
Wear limit (front) WARNING

1.6 mm (0.06 in) After extensive tests, the tires listed below
Wear limit (rear) have been approved by MBK Industrie for
1.6 mm (0.06 in) this model. The front and rear tires should al-
ways be by the same manufacturer and of
the same design. No guarantee concerning
handling characteristics can be given if a tire
combination other than one approved by
MBK Industrie is used on this vehicle.
Front tire
Size
120/70–16 M/C 57P
Manufacturer/model
PIRELLI/SPORT DEMON FRONT
1. Tire tread depth
2. Side wall
3. Wear indicator Rear tire
Size
EWA14080
140/70–15 M/C 69P
WARNING
Manufacturer/model
• Do not use a tubeless tire on a wheel de- PIRELLI/SPORT DEMON
signed only for tube tires to avoid tire fail-
ure and personal injury from sudden EWA13210
deflation. WARNING
• When using a tube tire, be sure to install the New tires have a relatively low grip on the
correct tube. road surface until they have been slightly
• Always replace a new tube tire and a new worn. Therefore, approximately 100 km
tube as a set. should be traveled at normal speed before
• To avoid pinching the tube, make sure the any high-speed riding is done.
wheel rim band and tube are centered in the
NOTE:
wheel groove.
• Patching a punctured tube is not recom- For tires with a direction of rotation mark “1”:
mended. If it is absolutely necessary to do Install the tire with the mark pointing in the direc-
so, use great care and replace the tube as tion of wheel rotation.
soon as possible with a good quality re-
placement.
EAS21670
CHECKING THE WHEELS

A. Tire
wheels.
B. Wheel
1. Check:
Tube wheel Tube tire only • Wheel
Damage/out-of-round → Replace.
Tubeless wheel Tube or tubeless tire
3-22
CHASSIS
EWA13260 EAS21730
WARNING LUBRICATING THE CENTERSTAND

Never attempt to make any repairs to the Lubricate the pivoting point and metal-to-metal
wheel. moving parts of the centerstand.
NOTE: Recommended lubricant

After a tire or wheel has been changed or re- Lithium-soap-based grease
placed, always balance the wheel.
EAS21690
CHECKING AND LUBRICATING THE

CABLES
The following procedure applies to all of the in-
ner and outer cables.
EWA5B21010
WARNING
A damaged outer cable may cause the cable
to corrode and interfere with its movement.
Replace damaged outer cable and inner ca-
bles as soon as possible.
1. Check:
• Outer cable
Damage → Replace.
2. Check:
• Cable operation
Rough movement → Lubricate.
Recommended lubricant
Engine oil or a suitable cable lu-
bricant
NOTE:
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubricating device.
EAS21700
LUBRICATING THE LEVERS

Lubricate the pivoting points and metal-to-metal
moving parts of the levers.
Lithium-soap-based grease
EAS21720
LUBRICATING THE SIDESTAND

Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.
3-23
ELECTRICAL SYSTEM
EAS21750
5. Install:
ELECTRICAL SYSTEM
• Headlight bulb New
EAS21760 Secure the new headlight bulb with the head-
CHECKING AND CHARGING THE BATTERY light bulb holder.
Refer to “ELECTRICAL COMPONENTS” on ECA13690
page 8-63. CAUTION:
EAS21770
Avoid touching the glass part of the head-
CHECKING THE FUSES light bulb to keep it free from oil, otherwise
Refer to “ELECTRICAL COMPONENTS” on the transparency of the glass, the life of the
page 8-63. bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
EAS21780
thoroughly clean it with a cloth moistened
REPLACING A HEADLIGHT BULB
with alcohol or lacquer thinner.
To replace a high beam headlight bulb 6. Install:
1. Remove: • Headlight bulb holder
• Front cowling (with the headlight bulb)
Refer to “GENERAL CHASSIS” on page 4-1. 7. Install:
2. Remove: • Headlight bulb cover
• Headlight bulb cover “1” 8. Install:
• Front cowling
To replace a low beam headlight bulb

1. Remove:
• Front cowling
1 Refer to “GENERAL CHASSIS” on page 4-1.
2. Remove:
• Headlight bulb cover “1”
3. Remove:
• Headlight bulb holder “1”
(with the headlight bulb)
3. Disconnect:
1 • Headlight coupler “1”
4. Detach:
• Headlight bulb holder “2”
5. Remove:
4. Remove: • Headlight bulb “3”
• Headlight bulb EWA13320
EWA13320
WARNING
WARNING
Since the headlight bulb gets extremely hot,
Since the headlight bulb gets extremely hot, keep flammable products and your hands
keep flammable products and your hands away from the bulb until it has cooled down.
away from the bulb until it has cooled down.
3-24
ELECTRICAL SYSTEM
2 3
b b
a
a
1
1 1
6. Install: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Headlight bulb New
ECA13690
CAUTION:
Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
7. Attach:
• Headlight bulb holder
8. Connect:
• Headlight coupler
9. Install:
• Headlight bulb cover
10.Install:
• Front cowling
EAS21800
ADJUSTING THE HEADLIGHT BEAM

1. Adjust:
• Headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw “1” in direction “a” or
“b”.
Direction “a”
Headlight beam is raised.
Direction “b”
Headlight beam is lowered.
3-25
CHASSIS
GENERAL CHASSIS....................................................................................... 4-1
FRONT WHEEL............................................................................................... 4-6

REMOVING THE FRONT WHEEL............................................................ 4-8
DISASSEMBLING THE FRONT WHEEL.................................................. 4-8
CHECKING THE FRONT WHEEL ............................................................ 4-8
ASSEMBLING THE FRONT WHEEL........................................................ 4-9
ADJUSTING THE FRONT WHEEL STATIC BALANCE ........................... 4-9
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC).................. 4-10
REAR WHEEL ............................................................................................... 4-12

REMOVING THE REAR WHEEL ............................................................ 4-13
CHECKING THE REAR WHEEL............................................................. 4-13
ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-13
INSTALLING THE REAR WHEEL (REAR BRAKE DISC) ...................... 4-13
FRONT BRAKE ............................................................................................. 4-14

INTRODUCTION ..................................................................................... 4-19
CHECKING THE FRONT BRAKE DISC ................................................. 4-19
REPLACING THE FRONT BRAKE PADS .............................................. 4-20
4
REMOVING THE FRONT BRAKE CALIPER.......................................... 4-21
DISASSEMBLING THE FRONT BRAKE CALIPER ................................ 4-21
CHECKING THE FRONT BRAKE CALIPER .......................................... 4-21
ASSEMBLING THE FRONT BRAKE CALIPER ...................................... 4-22
INSTALLING THE FRONT BRAKE CALIPER ........................................ 4-22
REMOVING THE FRONT BRAKE MASTER CYLINDER ....................... 4-23
CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 4-23
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-24
INSTALLING THE FRONT BRAKE MASTER CYLINDER...................... 4-24
REAR BRAKE ............................................................................................... 4-26

INTRODUCTION ..................................................................................... 4-31
CHECKING THE REAR BRAKE DISC.................................................... 4-31
REPLACING THE REAR BRAKE PADS................................................. 4-31
REMOVING THE REAR BRAKE CALIPER ............................................ 4-32
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........................................... 4-33
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-34
CHECKING THE REAR BRAKE MASTER CYLINDER .......................... 4-35
ASSEMBLING THE REAR BRAKE MASTER CYLINDER...................... 4-35
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-35
HANDLEBAR ................................................................................................ 4-37
REMOVING THE HANDLEBAR.............................................................. 4-39
CHECKING THE HANDLEBAR .............................................................. 4-39
INSTALLING THE HANDLEBAR ............................................................ 4-39
FRONT FORK................................................................................................ 4-41

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 STEERING HEAD ..................................................... 4-51
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM................... 4-53

REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES ............... 4-54
REMOVING THE SWINGARM................................................................ 4-54
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-54
CHECKING THE SWINGARM ................................................................ 4-54
INSTALLING THE SWINGARM .............................................................. 4-54
GENERAL CHASSIS
EAS21830
GENERAL CHASSIS
Removing the seat and rear panels
18 Nm (1.8 m • kg, 13 ft • Ib)
T.
R.
6 7 (4)
12
10 8
(4)
11
10
1
9
5
3 12
2
11
Order Job/Parts to remove Q’ty Remarks

1 Battery cover 1
2 Negative battery lead 1 Disconnect.
3 Positive battery lead 1 Disconnect.
4 Battery 1
5 Seat bracket 1
6 Seat 1
7 Grab bar 1
8 Rear cover 1
9 Tail/brake light assembly coupler 2 Disconnect.
10 Tail/brake light assembly 2
11 Center panel 2
12 Rear panel 2
For installation, reverse the removal proce-
dure.
4-1
GENERAL CHASSIS
Removing the storage box
7 8 9
10 6
13 11 (8) 15
12
4
14 1
3
(9)

1 License plate light coupler 1 Disconnect.
2 Mudguard 1
3 Fuel tank cover 1
4 Footrest board cover 2
5 Under cover 1
6 Seat rail 1
7 Turn signal relay 1
8 Starting circuit cut-off relay 1
9 Radiator fan motor relay 1
10 Headlight relay 1
11 Fuse box 1
12 Lean angle sensor 1
13 Starter relay 1
14 Seat lock cable 1 Disconnect.
15 Storage box 1
dure.
4-2
GENERAL CHASSIS
Removing the meter assembly
3
4 Nm (0.4 m kg, 2.9 ft Ib)
• • 33 Nm (3.3 m • kg, 24 ft • Ib)
T.
R.
T.
R.
1
3
4
8
(4) 2 5
9
6
4
7
(4)
(9)
13 Nm (1.3 m • kg, 9.4 ft • Ib) 10
T.
R.

1 Windshield 1
2 Windshield bracket 2
3 Rearview mirror 2
4 Brake master cylinder cover 2
5 Start switch coupler 1 Disconnect.
6 Handlebar switch coupler 1 Disconnect.
7 Meter assembly coupler 1 Disconnect.
8 Start switch 1
9 Handlebar switch 1
10 Meter assembly 1
dure.
4-3
GENERAL CHASSIS
Removing the storage compartment
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
(10)
6
3
5 7
4 2
(4)
5 6

1 Radiator cover 1
2 Headlight assembly coupler 1 Disconnect.
3 Front turn signal light coupler 2 Disconnect.
4 Front cowling 1
5 Front panel 2
6 Footrest board 2
7 Storage compartment 1
dure.
4-4
GENERAL CHASSIS
Removing the air filter case assembly
New (6)
(3)
2
9 Nm (0.9 m • kg, 6.5 ft • Ib)

T.
R.

Refer to “GENERAL CHASSIS” on page
Storage box 4-1.
1 Air filter case cover 1
2 Air filter element 1
3 Intake air temperature sensor coupler 1 Disconnect.
4 Intake air temperature sensor 1
5 Crankcase breather hose 1 Disconnect.
6 Air filter case to throttle body hose 1 Disconnect.
7 Air filter case 1
dure.
4-5
FRONT WHEEL
EAS21870
FRONT WHEEL
Removing the front wheel and brake disc
9 Nm (0.9 m • kg, 6.5 ft • Ib)
T.
R.
59 Nm (5.9 m • kg, 43 ft • Ib)
T.
R.
LS
5
6
LS
(6)
3
4
LT
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.

1 Front wheel axle pinch bolt 1 Loosen.
2 Front wheel axle 1
3 Front wheel 1
4 Speed sensor 1
5 Collar 1
6 Front brake disc 1
dure.
4-6
FRONT WHEEL
Disassembling the front wheel
New
LS
1
2
3

1 Oil seal 1
2 Wheel bearing 2
3 Spacer 1
For assembly, reverse the disassembly pro-
cedure.
4-7
FRONT WHEEL
EAS21890 EAS21920
REMOVING THE FRONT WHEEL CHECKING THE FRONT WHEEL

1. Stand the vehicle on a level surface. 1. Check:
EWA13120
• Wheel axle
WARNING Roll the wheel axle on a flat surface.
Securely support the vehicle so that there is Bends → Replace.
no danger of it falling over. EWA13460
WARNING
NOTE:
Do not attempt to straighten a bent wheel ax-
Place the vehicle on a suitable stand so that the le.
front wheel is elevated.
2. Remove:
• Front wheel
NOTE:
Do not apply the front brake lever when remov-
ing the front wheel.
EAS21910
DISASSEMBLING THE FRONT WHEEL

1. Remove:
• Oil seal 2. Check:
• Wheel bearings • Tire
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Front wheel
a. Clean the outside of the front wheel hub. Damage/wear → Replace.
b. Remove the oil seal “1” with a flat-head Refer to “CHECKING THE TIRES” on page
screwdriver. 3-21 and “CHECKING THE WHEELS” on
NOTE: page 3-22.
To prevent damaging the wheel, place a rag “2” 3. Measure:
between the screwdriver and the wheel surface. • Radial wheel runout “1”
• Lateral wheel runout “2”
Over the specified limits → Replace.
Radial wheel runout limit

1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
c. Remove the wheel bearings “3” with a gener-

al bearing puller.
4. Check:
• Wheel bearings
Front wheel turns roughly or is loose → Re-
place the wheel bearings.
• Oil seal
Damage/wear → Replace.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-8
FRONT WHEEL
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 New
• Oil seal New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the new wheel bearings and oil seal in
the reverse order of disassembly.
ECA5B21001
c. Turn the front wheel 90° so that the “X1” mark
CAUTION: is positioned as shown.
Do not apply pressure to the wheel bearing d. Release the front wheel.
inner race “1” or balls “2”. Pressure should e. When the wheel stops, put an “X2” mark at
only be applied to the outer race “3”. the bottom of the wheel.
NOTE:
Use a socket “4” that matches the diameter of
the wheel bearing outer race and oil seal.
f. Repeat steps (d) through (f) several times un-

til 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:
EAS21970
• Front wheel static balance
ADJUSTING THE FRONT WHEEL STATIC ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
BALANCE a. Install a balancing weight “1” onto the rim ex-
NOTE: actly opposite the heavy spot “X”.
• After replacing the tire, wheel or both, the front NOTE:
wheel static balance should be adjusted. Start with the lightest weight.
• Adjust the front wheel static balance with the
brake disc installed.
1. Remove:
• Balancing weight(s)
2. Find:
• Front wheel’s heavy spot
4-9
FRONT WHEEL
Front brake disc bolt

23 Nm (2.3 m·kg, 17 ft·lb)
T.
R.
LOCTITE®
NOTE:
• Be sure to install the front brake disc with the
arrow mark “a” on the disc facing out.
• Tighten the brake disc bolts in stages and in a
crisscross pattern.
b. Turn the front wheel 90° so that the heavy
spot is positioned as shown. a
c. If the heavy spot does not stay in that posi-

tion, install a heavier weight.
d. Repeat steps (b) and (c) until the front wheel
is balanced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the front wheel and make sure it stays at
2. Check:
each position shown.
• Front brake disc
Refer to “CHECKING THE FRONT BRAKE
DISC” on page 4-19.
3. Lubricate:
• Oil seal lips
• Speed sensor
4. Install:
b. If the front wheel does not remain stationary • Collar
at all of the positions, rebalance it. • Speed sensor
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Front wheel
EAS21990 NOTE:
INSTALLING THE FRONT WHEEL (FRONT • Make sure that the speed sensor and the
BRAKE DISC) wheel hub are installed with the projection “a”
1. Install: of the wheel hub inserted in a slot “b” of the
• Front brake disc speed sensor.
• When installing the speed sensor, make sure
that the projection on the wheel hub does not
damage the lip of the speed sensor oil seal.
4-10
FRONT WHEEL
• Make sure that the projections “c” in the speed

sensor fits over the stopper “d” on the outer
tube.
b
a
c d
5. Tighten:
• Wheel axle
• Wheel axle pinch bolts
Wheel axle
59 Nm (5.9 m·kg, 43 ft·lb)
T.
R.
Wheel axle pinch bolt

9 Nm (0.9 m·kg, 6.5 ft·lb)
EWA5B21001
WARNING
Make sure the brake hose is routed properly.
ECA5B21002
CAUTION:
Before tightening the wheel axle, push down
hard on the handlebar several times and
check if the front fork rebounds smoothly.
4-11
REAR WHEEL
EAS22020
REAR WHEEL
Removing the rear wheel and brake disc
9 Nm (0.9 m • kg, 6.5 ft • Ib)

1
T.
R.
LS
5
LT
(4)
3
2 23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.

Muffler Refer to “ENGINE REMOVAL” on page 5-1.
Refer to “REAR SHOCK ABSORBER AS-
Swingarm SEMBLIES AND SWINGARM” on page
4-53.
1 Air filter case mounting bolt 2
2 Rear fender 1
3 Rear wheel 1
4 Washer 1
5 Rear brake disc 1
dure.
4-12
REAR WHEEL
EAS28760
REMOVING THE REAR WHEEL NOTE:

1. Stand the vehicle on a level surface. • Be sure to install the rear brake disc with the ar-
EWA13120 row mark “a” on the disc facing out.
WARNING • Tighten the brake disc bolts in stages and in a
Securely support the vehicle so that there is crisscross pattern.
NOTE: a
Place the vehicle on the centerstand so that the
rear wheel is elevated. Also, place a suitable
stand under the engine.
EAS22090
CHECKING THE REAR WHEEL

1. Check:
• Tire
• Rear wheel
Refer to “CHECKING THE TIRES” on page
3-21 and “CHECKING THE WHEELS” on
page 3-22.
2. Measure:
• Radial wheel runout
• Lateral wheel runout
Refer to “CHECKING THE FRONT WHEEL”
on page 4-8.
2. Check:
Radial wheel runout limit • Rear brake disc
1.0 mm (0.04 in)
Refer to “CHECKING THE REAR BRAKE
Lateral wheel runout limit
0.5 mm (0.02 in) DISC” on page 4-31.
3. Install:
EAS22150
• Rear fender
ADJUSTING THE REAR WHEEL STATIC • Air filter case mounting bolts
BALANCE
Air filter case mounting bolt
NOTE:
9 Nm (0.9 m·kg, 6.5 ft·lb)
T.
R.
• After replacing the tire, wheel or both, the rear

wheel static balance should be adjusted. NOTE:
• Adjust the rear wheel static balance with the Place the rear fender between the air filter case
brake disc installed. and the crankcase, and then install the air filter
1. Adjust: case mounting bolts.
• Rear wheel static balance
Refer to “ADJUSTING THE FRONT WHEEL
STATIC BALANCE” on page 4-9.
EAS28770
INSTALLING THE REAR WHEEL (REAR

BRAKE DISC)
1. Install:
• Rear brake disc
Rear brake disc bolt

23 Nm (2.3 m·kg, 17 ft·lb)
T.
R.
LOCTITE®
4-13
FRONT BRAKE
EAS22210
FRONT BRAKE
Removing the front brake pads
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.
R.
LT
LT
LT 7
23 Nm (2.3 m • kg, 17 ft • Ib) 2
T.
R.
5
4
3
3 Nm (0.3 m • kg, 2.2 ft • Ib)

5
T.
R.
6 18 Nm (1.8 m • kg, 13 ft • Ib)

T.
R.

1 Front brake caliper bolt 2
2 Front brake caliper 1
3 Brake pad pin cap 1
4 Brake pad pin 1
5 Front brake pad 2
6 Brake pad spring 1
7 Brake pad support 1
dure.
4-14
FRONT BRAKE
Removing the front brake master cylinder
1
9 Nm (0.9 m • kg, 6.5 ft • Ib)
T.
R.
2
LS 3
10
11
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
New 7
6 5
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.

Meter assembly 4-1.
Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-18.
1 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm hold-
2 1
er
3 Brake master cylinder reservoir diaphragm 1
4 Front brake lever 1
5 Front brake light switch connector 2 Disconnect.
6 Brake hose union bolt 1
7 Copper washer 2
8 Front brake hose 1
9 Front brake master cylinder holder 1
10 Front brake master cylinder 1
11 Front brake light switch 1
dure.
4-15
FRONT BRAKE
Disassembling the front brake master cylinder
1 New
LS

1 Brake master cylinder kit 1
2 Brake master cylinder body 1
cedure.
4-16
FRONT BRAKE
Removing the front brake caliper
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.
R.
5
3
2 New
LT
23 Nm (2.3 m • kg, 17 ft • Ib)

T.
R.
LT
LT
23 Nm (2.3 m • kg, 17 ft • Ib)

T.
R.

Drain.
2 Copper washer 2
3 Front brake hose 1
4 Front brake caliper bolt 2
dure.
4-17
FRONT BRAKE
Disassembling the front brake caliper
8 New
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.
R.
7
LS 9
LT
LS New 8
13 Nm (1.3 m • kg, 9.4 ft • Ib)
10
T.
R.
5 2
4 1
3
18 Nm (1.8 m • kg, 13 ft • Ib)
T.
R.
3 Nm (0.3 m • kg, 2.2 ft • Ib)

T.
R.

1 Brake pad pin cap 1
2 Brake pad pin 1
3 Front brake pad 2
4 Brake pad spring 1
6 Brake caliper bracket 1
7 Brake caliper piston 2
8 Brake caliper piston seal 4
9 Bleed screw 1
10 Brake caliper body 1
cedure.
4-18
FRONT BRAKE
EAS22220
INTRODUCTION
EWA5B21011
WARNING
Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
ventive measures:
• Never disassemble brake components un-
less absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained, ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
cleaned, properly filled, and bled after reas- 4. Measure:
sembly. • Brake disc thickness
• Never use solvents on internal brake com- Measure the brake disc thickness at a few dif-
ponents. ferent locations.
• Use only clean or new brake fluid for clean- Out of specification → Replace.
ing brake components.
• Brake fluid may damage painted surfaces Brake disc thickness limit
and plastic parts. Therefore, always clean 4.5 mm (0.18 in)
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
• FIRST AID FOR BRAKE FLUID GETTING
INTO THE EYES:
• Flush with water for 15 minutes and get im-
mediate medical attention.
EAS22230
CHECKING THE FRONT BRAKE DISC

1. Remove:
• Front wheel 5. Adjust:
Refer to “FRONT WHEEL” on page 4-6. • Brake disc deflection
2. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Brake disc a. Remove the brake disc.
Damage/galling → Replace. b. Rotate the brake disc by one bolt hole.
3. Measure: c. Install the brake disc.
• Brake disc deflection
Out of specification → Correct the brake disc Front brake disc bolt
23 Nm (2.3 m·kg, 17 ft·lb)
T.
deflection or replace the brake disc.

R.
LOCTITE®
Brake disc deflection limit
0.20 mm (0.0079 in) NOTE:
Tighten the brake disc bolts in stages and in a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ crisscross pattern.
a. Place the vehicle on a suitable stand so that
the front wheel is elevated.
b. Before measuring the front brake disc deflec-
tion, turn the handlebar to the left or right to
ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 1.5 mm (0.06 in) be-
low the edge of the brake disc.
4-19
FRONT BRAKE
2. Install:
• Brake pad support New
• Brake pad spring New
• Brake pads New
NOTE:
Always install new brake pads, new brake pad
spring, and new brake pad support as a set.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose “1” tightly to the
d. Measure the brake disc deflection.
bleed screw “2”. Put the other end of the hose
e. If out of specification, repeat the adjustment
into an open container.
steps until the brake disc deflection is within
b. Loosen the bleed screw and push the brake
specification.
caliper pistons into the brake caliper with your
f. If the brake disc deflection cannot be brought
finger.
within specification, replace the brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1
2
6. Install:
• Front wheel
Refer to “FRONT WHEEL” on page 4-6.
EAS22270
REPLACING THE FRONT BRAKE PADS

NOTE:
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem-
ble the brake caliper. c. Tighten the bleed screw.
1. Measure: Bleed screw

• Brake pad wear limit “a” 6 Nm (0.6 m·kg, 4.3 ft·lb)
T.
R.
Out of specification → Replace the brake

pads as a set. d. Install new brake pad support, new brake pad
spring and new brake pads.
Brake pad lining thickness (in- NOTE:
ner) The arrow mark “a” on the brake pad support
6.5 mm (0.26 in)
must point in the direction shown in the illustra-
Limit
1.5 mm (0.06 in) tion.
Brake pad lining thickness (out-
er)
6.5 mm (0.26 in) a
Limit
1.5 mm (0.06 in)
a ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Brake pad pin
• Brake pad pin cap
• Front brake caliper
• Front brake caliper bolts
4-20
FRONT BRAKE
EAS22320
Front brake caliper bolt DISASSEMBLING THE FRONT BRAKE

23 Nm (2.3 m·kg, 17 ft·lb) CALIPER
T.
R.
LOCTITE® 1. Remove:
• Brake caliper pistons “1”
4. Check: • Brake caliper piston seals “2”
• Brake fluid level
Below the minimum level mark “a” → Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID 2
LEVEL” on page 3-17.
MIN
a 1
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose joint
opening “a” to force out the pistons from the
brake caliper.
EWA13550
5. Check: WARNING
• Brake lever operation • Cover the brake caliper piston with a rag.
Soft or spongy feeling → Bleed the brake sys- Be careful not to get injured when the pis-
tem. ton is expelled from the brake caliper.
Refer to “BLEEDING THE HYDRAULIC • Never try to pry out the brake caliper pis-
BRAKE SYSTEM” on page 3-18. ton.
EAS22290
REMOVING THE FRONT BRAKE CALIPER a

NOTE:
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
• Brake hose union bolt “1”
• Copper washers “2”
• Front brake hose “3”
NOTE:
Put the end of the brake hose into a container b. Remove the brake caliper piston seals.
and pump out the brake fluid carefully. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22380
CHECKING THE FRONT BRAKE CALIPER

Recommended brake component replace-
3 ment schedule
Brake pads If necessary
1
Piston seals Every two years
Brake hose Every four years
2 Every two years and
Brake fluid whenever the brake
is disassembled
4-21
FRONT BRAKE
1. Check: • Brake hose union bolt “4”

• Brake caliper pistons “1”
Rust/scratches/wear → Replace the brake Front brake hose union bolt
caliper pistons. 23 Nm (2.3 m·kg, 17 ft·lb)
T.
R.
• Brake caliper cylinders “2” EWA13530
Scratches/wear → Replace the brake caliper WARNING

assembly. Proper brake hose routing is essential to in-
• Brake caliper body “3” sure safe vehicle operation. Refer to “CABLE
Cracks/damage → Replace the brake caliper ROUTING” on page 2-27.
assembly.
ECA14170
• Brake fluid delivery passages
CAUTION:
(brake caliper body)
Obstruction → Blow out with compressed air. When installing the brake hose onto the
EWA13600 brake caliper “1”, make sure the brake pipe
WARNING “a” touches the projection “b” on the brake
Whenever a brake caliper is disassembled, caliper.
replace the piston seals.
a
3
b
2
3 1 4
2 New
1
2. Remove:
2. Check:
• Brake caliper
• Brake caliper bracket
3. Install:
Cracks/damage → Replace.
• Brake pad support
EAS22400 • Brake pad spring
ASSEMBLING THE FRONT BRAKE CALIPER • Brake pads
EWA13620
• Brake pad pin
WARNING
• Brake pad pin cap
• Before installation, all internal brake com- • Brake caliper
ponents should be cleaned and lubricated
with clean or new brake fluid. Brake pad pin
• Never use solvents on internal brake com- 18 Nm (1.8 m·kg, 13 ft·lb)
T.
R.
ponents as they will cause the piston seals Brake pad pin cap
to swell and distort. 3 Nm (0.3 m·kg, 2.2 ft·lb)
• Whenever a brake caliper is disassembled, Front brake caliper bolt
replace the brake caliper piston seals. 23 Nm (2.3 m·kg, 17 ft·lb)
LOCTITE®
Recommended fluid Refer to “REPLACING THE FRONT BRAKE
DOT 4 PADS” on page 4-20.
4. Fill:
EAS22420
INSTALLING THE FRONT BRAKE CALIPER • Brake master cylinder reservoir

1. Install: (with the specified amount of the recom-
• Brake caliper “1” mended brake fluid)
(temporarily)
Recommended fluid
• Copper washers “2” New DOT 4
• Front brake hose “3”
4-22
FRONT BRAKE
EWA13090 EAS22490
WARNING REMOVING THE FRONT BRAKE MASTER

• Use only the designated brake fluid. Other CYLINDER
brake fluids may cause the rubber seals to NOTE:
deteriorate, causing leakage and poor Before removing the front brake master cylinder,
brake performance. drain the brake fluid from the entire brake sys-
• Refill with the same type of brake fluid that tem.
is already in the system. Mixing brake fluids
1. Remove:
• Union bolt “1”
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of NOTE:
the brake fluid and could cause vapor lock. To collect any remaining brake fluid, place a
ECA13540
container under the master cylinder and the end
CAUTION: of the brake hose.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
5. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
6. Check: 2
• Brake fluid level 1
Below the minimum level mark “a” → Add the 3
recommended brake fluid to the proper level. EAS22500
Refer to “CHECKING THE BRAKE FLUID CHECKING THE FRONT BRAKE MASTER
LEVEL” on page 3-17. CYLINDER
1. Check:
• Brake master cylinder
Damage/scratches/wear → Replace.
MIN
a • Brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed air.
2. Check:
• Brake master cylinder kit
3. Check:
7. Check: • Brake master cylinder reservoir cap
• Brake lever operation • Brake master cylinder reservoir diaphragm
Soft or spongy feeling → Bleed the brake sys- holder
tem. Cracks/damage → Replace.
Refer to “BLEEDING THE HYDRAULIC • Brake master cylinder reservoir diaphragm
BRAKE SYSTEM” on page 3-18. Cracks/damage → Replace.
4. Check:
• Brake hose
4-23
FRONT BRAKE
EAS22520 ECA14160
ASSEMBLING THE FRONT BRAKE MASTER CAUTION:

CYLINDER When installing the brake hose onto the
EWA13520
WARNING brake master cylinder, make sure the brake

pipe touches the projection “a” as shown.
• Before installation, all internal brake com-
ponents should be cleaned and lubricated NOTE:
with clean or new brake fluid. Turn the handlebar to the left and right to make
• Never use solvents on internal brake com- sure the brake hose does not touch other parts
ponents. (e.g., wire harness, cables, leads). Correct if
necessary.
Recommended fluid
DOT 4
EAS22530
INSTALLING THE FRONT BRAKE MASTER

CYLINDER
1. Install: a
• Brake master cylinder “1”
• Brake master cylinder holder
1 New
Brake master cylinder holder bolt 2 3
9 Nm (0.9 m·kg, 6.5 ft·lb)
T.
3. Fill:
R.
NOTE: • Brake master cylinder reservoir

(with the specified amount of the recom-
• Align the projection “a” on the brake master cyl-
mended brake fluid)
inder with the hole “b” in the handlebar.
• First, tighten the front bolt, then the rear bolt. Recommended fluid
DOT 4
1 b EWA13540
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
a is already in the system. Mixing brake fluids
2. Install: leading to poor brake performance.
• Copper washers “1” New • When refilling, be careful that water does
• Brake hose “2” not enter the brake master cylinder reser-
• Brake hose union bolt “3” voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
Brake hose union bolt vapor lock.
23 Nm (2.3 m·kg, 17 ft·lb) ECA13540
T.
R.
CAUTION:
EWA13530
WARNING Brake fluid may damage painted surfaces

Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CABLE
ROUTING” on page 2-27.
4-24
FRONT BRAKE
4. Bleed:
• Brake system
5. Check:
MIN
a
6. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
tem.
4-25
REAR BRAKE
EAS22550
REAR BRAKE
Removing the rear brake pads
3 6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.
R.
5
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
4
5 2
4
LS
27 Nm (2.7 m • kg, 19 ft • Ib)
T.
R.
LS
1

1 Rear brake caliper retaining bolt 2
2 Rear brake caliper 1
3 Rear brake pad 2
4 Brake pad shim 4
dure.
4-26
REAR BRAKE
Removing the rear brake master cylinder
9 Nm (0.9 m • kg, 6.5 ft • Ib)
T.
R.
1
9
2
10 5
New 7
LS
4
8 11
New 7
6 10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)

T.
R.

Meter assembly 4-1.
Drain.
1 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm hold-
2 1
er
3 Brake master cylinder reservoir diaphragm 1
4 Rear brake lever 1
5 Rear brake light switch connector 2 Disconnect.
7 Copper washer 2
8 Rear brake hose 1
9 Rear brake master cylinder holder 1
10 Rear brake master cylinder 1
11 Rear brake light switch 1
dure.
4-27
REAR BRAKE
Disassembling the rear brake master cylinder
1 New
LS

1 Brake master cylinder kit 1
2 Brake master cylinder body 1
cedure.
4-28
REAR BRAKE
Removing the rear brake caliper
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
6 Nm (0.6 m • kg, 4.3 ft • Ib)

1 3
T.
R.
New 2
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
5
R.
LT
LT
4
LT 40 Nm (4.0 m • kg, 29 ft • Ib)
4
T.
R.

Drain.
2 Copper washer 2
3 Rear brake hose 1
4 Rear brake caliper bolt 3
dure.
4-29
REAR BRAKE
Disassembling the rear brake caliper
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.
R.
8
9
LS
6
1 7 New
7 New
1
27 Nm (2.7 m • kg, 19 ft • Ib) 4

T.
R.
3 5

1 Rear brake caliper retaining bolt 2
2 Brake caliper bracket 1
3 Rear brake pad 2
4 Brake pad shim 4
6 Brake caliper piston 2
7 Brake caliper piston seal 4
8 Bleed screw 1
9 Brake caliper body 1
cedure.
4-30
REAR BRAKE
EAS22560
INTRODUCTION Brake disc thickness limit

EWA5B21011
4.5 mm (0.18 in)
WARNING
Disc brake components rarely require disas- 5. Adjust:
sembly. Therefore, always follow these pre- • Brake disc deflection
ventive measures: Refer to “CHECKING THE FRONT BRAKE
• Never disassemble brake components un- DISC” on page 4-19.
less absolutely necessary.
• If any connection on the hydraulic brake Rear brake disc bolt
system is disconnected, the entire brake 23 Nm (2.3 m·kg, 17 ft·lb)
T.
R.
system must be disassembled, drained, LOCTITE®
cleaned, properly filled, and bled after reas-
sembly. 6. Install:
• Never use solvents on internal brake com- • Rear wheel
ponents. Refer to “REAR WHEEL” on page 4-12.
• Use only clean or new brake fluid for clean- EAS22580
ing brake components. REPLACING THE REAR BRAKE PADS

• Brake fluid may damage painted surfaces NOTE:
and plastic parts. Therefore, always clean When replacing the brake pads, it is not neces-
up any spilt brake fluid immediately. sary to disconnect the brake hose or disassem-
• Avoid brake fluid coming into contact with ble the brake caliper.
the eyes as it can cause serious injury.
• FIRST AID FOR BRAKE FLUID GETTING 1. Measure:
INTO THE EYES: • Brake pad wear limit “a”
• Flush with water for 15 minutes and get im- Out of specification → Replace the brake
mediate medical attention. pads as a set.
Brake pad lining thickness (in-

EAS22570
CHECKING THE REAR BRAKE DISC ner)

5.3 mm (0.21 in)
1. Remove:
Limit
• Rear wheel 0.8 mm (0.03 in)
Refer to “REAR WHEEL” on page 4-12. Brake pad lining thickness (out-
2. Check: er)
• Brake disc 5.3 mm (0.21 in)
Damage/galling → Replace. Limit
3. Measure: 0.8 mm (0.03 in)
• Brake disc deflection
Out of specification → Correct the brake disc
deflection or replace the brake disc.
Refer to “CHECKING THE FRONT BRAKE
DISC” on page 4-19.
Brake disc deflection limit

0.20 mm (0.0079 in)
4. Measure:
• Brake disc thickness
Measure the brake disc thickness at a few dif- 2. Install:
ferent locations.
Out of specification → Replace. • Brake pad supports New
Refer to “CHECKING THE FRONT BRAKE • Brake pad shims New
DISC” on page 4-19. (onto the brake pads)
• Brake pads New
4-31
REAR BRAKE
NOTE: 5. Check:
Always install new brake pads, brake pad shims, • Brake lever operation
and brake pad supports as a set. Soft or spongy feeling → Bleed the brake sys-
tem.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Refer to “BLEEDING THE HYDRAULIC
a. Connect a clear plastic hose “1” tightly to the
bleed screw “2”. Put the other end of the hose
into an open container. EAS22590
b. Loosen the bleed screw and push the brake REMOVING THE REAR BRAKE CALIPER
caliper pistons into the brake caliper with your NOTE:
finger. Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
2 • Rear brake hose “3”
1
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
c. Tighten the bleed screw. 1
Bleed screw 3
6 Nm (0.6 m·kg, 4.3 ft·lb)
T.
R.
d. Install new brake pad shims onto each new

2
brake pad.
e. Install new brake pad supports and new
brake pads.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22610
3. Install:
DISASSEMBLING THE REAR BRAKE
• Rear brake caliper
CALIPER
• Rear brake caliper retaining bolts
1. Remove:
Rear brake caliper retaining bolt • Brake caliper pistons “1”
27 Nm (2.7 m·kg, 19 ft·lb) • Brake caliper piston seals “2”
T.
R.
4. Check:
MIN
a ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
MIN
a. Blow compressed air into the brake hose joint
opening “a” to force out the pistons from the
brake caliper.
4-32
REAR BRAKE
EWA13550
WARNING
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.
2. Check:
• Brake caliper bracket
EAS22650
ASSEMBLING THE REAR BRAKE CALIPER

EWA13620
WARNING
b. Remove the brake caliper piston seals. • Before installation, all internal brake com-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ponents should be cleaned and lubricated
EAS22640
with clean or new brake fluid.
CHECKING THE REAR BRAKE CALIPER • Never use solvents on internal brake com-
ponents as they will cause the piston seals
Recommended brake component replace-
to swell and distort.
ment schedule
• Whenever a brake caliper is disassembled,
Brake pads If necessary replace the brake caliper piston seals.
Piston seals Every two years
Brake hose Every four years Recommended fluid
DOT 4
Every two years and
Brake fluid whenever the brake EAS22670
is disassembled INSTALLING THE REAR BRAKE CALIPER
1. Install:
1. Check: • Brake caliper “1”
• Brake caliper pistons “1” (temporarily)
Rust/scratches/wear → Replace the brake
caliper pistons. • Copper washers “2” New
• Brake caliper cylinders “2” • Rear brake hose “3”
Scratches/wear → Replace the brake caliper • Brake hose union bolt “4”
assembly.
Rear brake hose union bolt
• Brake caliper body “3” 23 Nm (2.3 m·kg, 17 ft·lb)
Cracks/damage → Replace the brake caliper
T.
R.
assembly.
• Brake fluid delivery passages 4
(brake caliper body)
Obstruction → Blow out with compressed air. 3
EWA13610
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals. New 2
4-33
REAR BRAKE
EWA13530
WARNING is already in the system. Mixing brake fluids
Proper brake hose routing is essential to in- may result in a harmful chemical reaction,
sure safe vehicle operation. Refer to “CABLE leading to poor brake performance.
ROUTING” on page 2-27. • When refilling, be careful that water does
ECA14170 not enter the brake fluid reservoir. Water
CAUTION: will significantly lower the boiling point of
When installing the brake hose onto the the brake fluid and could cause vapor lock.
brake caliper “1”, make sure the brake pipe ECA13540
“a” touches the projection “b” on the brake CAUTION:

caliper. Brake fluid may damage painted surfaces
a 5. Bleed:
• Brake system
6. Check:
1 • Brake fluid level
b recommended brake fluid to the proper level.
2. Remove: Refer to “CHECKING THE BRAKE FLUID
• Brake caliper LEVEL” on page 3-17.
3. Install:
• Brake pad supports
• Brake pad shims
MIN
• Brake pads a
• Brake caliper MIN
• Brake hose holder
Rear brake caliper bolt

40 Nm (4.0 m·kg, 29 ft·lb)
T.
R.
LOCTITE®
Rear brake caliper retaining bolt
27 Nm (2.7 m·kg, 19 ft·lb) 7. Check:
Brake hose holder bolt • Brake lever operation
10 Nm (1.0 m·kg, 7.2 ft·lb) Soft or spongy feeling → Bleed the brake sys-
tem.
Refer to “REPLACING THE REAR BRAKE Refer to “BLEEDING THE HYDRAULIC
PADS” on page 4-31. BRAKE SYSTEM” on page 3-18.
4. Fill:
EAS22700
• Brake master cylinder reservoir REMOVING THE REAR BRAKE MASTER
(with the specified amount of the recom- CYLINDER
mended brake fluid)
NOTE:
Recommended fluid Before removing the rear brake master cylinder,
DOT 4 drain the brake fluid from the entire brake sys-
tem.
EWA13090
WARNING 1. Remove:
• Use only the designated brake fluid. Other • Union bolt “1”
brake fluids may cause the rubber seals to • Copper washers “2”
deteriorate, causing leakage and poor • Brake hose “3”
brake performance.
4-34
REAR BRAKE
EAS22750
NOTE: INSTALLING THE REAR BRAKE MASTER
To collect any remaining brake fluid, place a CYLINDER
container under the master cylinder and the end 1. Install:
of the brake hose. • Brake master cylinder “1”
• Brake master cylinder holder
Brake master cylinder holder bolt

9 Nm (0.9 m·kg, 6.5 ft·lb)
T.
3
R.
NOTE:
2 inder with the hole “b” in the handlebar.
• First, tighten the front bolt, then the rear bolt.
1
EAS22710
b
CHECKING THE REAR BRAKE MASTER 1
CYLINDER
1. Check:
• Brake master cylinder
Damage/scratches/wear → Replace. a
• Brake fluid delivery passages
(brake master cylinder body)
2. Check: 2. Install:
• Brake master cylinder kit
• Copper washers “1” New
3. Check:
• Brake master cylinder reservoir cap
• Brake master cylinder reservoir diaphragm Brake hose union bolt
holder 23 Nm (2.3 m·kg, 17 ft·lb)
T.
R.
• Brake master cylinder reservoir diaphragm EWA13530
Cracks/damage → Replace. WARNING

4. Check: Proper brake hose routing is essential to in-
• Brake hose sure safe vehicle operation. Refer to “CABLE
Cracks/damage/wear → Replace. ROUTING” on page 2-27.
ECA14160
EAS22730
CAUTION:
ASSEMBLING THE REAR BRAKE MASTER
CYLINDER When installing the brake hose onto the
EWA13520 brake master cylinder, make sure the brake
WARNING pipe touches the projection “a” as shown.
• Before installation, all internal brake com-
NOTE:
ponents should be cleaned and lubricated
with clean or new brake fluid. Turn the handlebar to the left and right to make
• Never use solvents on internal brake com- sure the brake hose does not touch other parts
ponents. (e.g., wire harness, cables, leads). Correct if
necessary.
Recommended fluid
DOT 4
4-35
REAR BRAKE
2
MIN
a a
MIN
New 1
3
3. Fill:
6. Check:
• Brake master cylinder reservoir
• Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
mended brake fluid)
tem.
Recommended fluid Refer to “BLEEDING THE HYDRAULIC
DOT 4 BRAKE SYSTEM” on page 3-18.
EWA13090
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
is already in the system. Mixing brake fluids
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
ECA13540
CAUTION:
Brake fluid may damage painted surfaces
4. Bleed:
• Brake system
5. Check:
4-36
HANDLEBAR
EAS22840
HANDLEBAR
Removing the handlebar
9 Nm (0.9 m • kg, 6.5 ft • Ib)
T.
R.
3
9 Nm (0.9 m • kg, 6.5 ft • Ib)
T.
R.
9
6
10 2 LS
13
7 1
6
8 5
LS
6 Nm (0.6 m • kg, 4.3 ft • Ib)

11
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
12 R.
14
6 Nm (0.6 m • kg, 4.3 ft • Ib)

T.
R.

Meter assembly 4-1.
1 Grip end 2
2 Front brake light switch connector 2 Disconnect.
3 Front brake master cylinder holder 1
4 Front brake master cylinder 1
5 Throttle cable housing 2
6 Throttle cable 2 Disconnect.
7 Throttle grip 1
8 Rear brake light switch connector 2 Disconnect.
9 Rear brake master cylinder holder 1
10 Rear brake master cylinder 1
11 Handlebar grip 1
12 Upper handlebar holder 2
13 Handlebar 1
4-37
HANDLEBAR
Removing the handlebar

9 Nm (0.9 m • kg, 6.5 ft • Ib)
T.
R.
3
9 Nm (0.9 m • kg, 6.5 ft • Ib)
T.
R.
9
6
10 2 LS
13
7 1
6
8 5
LS
6 Nm (0.6 m • kg, 4.3 ft • Ib)

11
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
12
R.
1
14
6 Nm (0.6 m • kg, 4.3 ft • Ib)

T.
R.

14 Handlebar cover 1
dure.
4-38
HANDLEBAR
EAS22860
REMOVING THE HANDLEBAR NOTE:

1. Stand the vehicle on a level surface. The upper handlebar holders should be installed
EWA13120 with the arrow marks “a” facing forward “A”.
WARNING
2. Remove:
• Handlebar grip “1”
NOTE:
Blow compressed air between the left handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
3. Install:
• Handlebar grip
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of a rubber adhesive to the
left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
EWA13700
WARNING
EAS22880
CHECKING THE HANDLEBAR Do not touch the handlebar grip until the rub-
1. Check: ber adhesive has fully dried.
• Handlebar
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Bends/cracks/damage → Replace.
EWA13690 4. Install:
WARNING • Rear brake master cylinder “1”
Do not attempt to straighten a bent handle- • Rear brake master cylinder holder
bar as this may dangerously weaken it.
9 Nm (0.9 m·kg, 6.5 ft·lb)
T.
R.
EAS22920
INSTALLING THE HANDLEBAR

1. Stand the vehicle on a level surface. NOTE:
EWA13120 • Align the projection “a” on the brake master cyl-
WARNING inder with the hole “b” in the handlebar.
Securely support the vehicle so that there is • First, tighten the front bolt, then the rear bolt.
2. Install: b
• Handlebar
• Upper handlebar holders 1
Upper handlebar holder bolt

23 Nm (2.3 m·kg, 17 ft·lb)
T.
R.
a
ECA5B21024
CAUTION:
First, tighten the front bolt on each handle-
bar holder, then the rear bolt. 5. Install:
• Throttle grip “1”
• Throttle cables “2”
4-39
HANDLEBAR
• Throttle cable housing “3”

NOTE:
• Lubricate the inside of the throttle grip with a
thin coat of lithium-soap-based grease and in-
stall it onto the handlebar.
• Align the projection “a” on the throttle cable
housing with the hole “b” in the handlebar.
• Be sure to slide the throttle cable rubber cover
to its original position.
3
a 2
1
b 3
6. Install:
• Front brake master cylinder “1”
• Front brake master cylinder holder

9 Nm (0.9 m·kg, 6.5 ft·lb)
T.
R.
NOTE:
inder with the hole “b” in the handlebar.
• First, tighten the front bolt, then the rear bolt.
1 b
7. Adjust:
• Throttle cable free play
Refer to “ADJUSTING THE THROTTLE CA-
BLE FREE PLAY” on page 3-5.
Throttle cable free play

3.0–5.0 mm (0.12–0.20 in)
4-40
FRONT FORK
EAS22950
FRONT FORK
Removing the front fork legs
4 New
22 Nm (2.2 m • kg, 16 ft • Ib)
T.
R.
5
5
6
1
3 LT
LT
(4) LT
23 Nm (2.3 m • kg, 17 ft • Ib)

T.
R.

Front cowling 4-1.
Front wheel Refer to “FRONT WHEEL” on page 4-6.
2 Lower front fender 1
3 Upper front fender 1
4 Clip 1
5 Lower bracket pinch bolt 2 Loosen.
6 Front fork leg 1
dure.
4-41
FRONT FORK
Disassembling the front fork legs
1
2 New
3
6 New
4 New 11
7 New
14 New
15
5
16 New
12
10
17
13
New
28 Nm (2.8 m • kg, 20 ft • Ib)

8
T.
R.

The following procedure applies to both of
the front fork legs.
1 Rubber cap 1
2 Clip 1
3 Front fork cap 1
4 O-ring 1
5 Fork spring 1
6 Dust seal 1
7 Oil seal clip 1
8 Damper rod bolt 1
9 Copper washer 1
10 Damper rod 1
11 Rebound spring 1
12 Inner tube 1
13 Oil flow stopper 1
14 Oil seal 1
15 Washer 1
16 Outer tube bushing 1
4-42
FRONT FORK
Disassembling the front fork legs
1
2 New
3
6 New
4 New 11
7 New
14 New
15
5
16 New
12
10
17
13
New
28 Nm (2.8 m • kg, 20 ft • Ib)

8
T.
R.

17 Outer tube 1
cedure.
4-43
FRONT FORK
EAS22960
REMOVING THE FRONT FORK LEGS NOTE:

The following procedure applies to both of the Stroke the inner tube several times while drain-
front fork legs. ing the fork oil.
EWA13120
WARNING
2. Loosen:
• Lower bracket pinch bolts “1”
EWA5B21002
WARNING
Before loosening the lower bracket pinch
bolts, support the front fork leg. 3. Remove:
• Dust seal “1”
• Oil seal clip “2”
(with a flat-head screwdriver)
ECA14180
CAUTION:
Do not scratch the inner tube.
1
1
EAS22980
DISASSEMBLING THE FRONT FORK LEGS 2

front fork legs.
1. Remove:
• Rubber cap
• Clip “1” 4. Remove:
• Front fork cap “2” • Damper rod bolt “1”
(with O-ring) • Damper rod
• Fork spring • Rebound spring
NOTE: NOTE:
Push the front fork cap in the direction of the ar- While holding the damper rod with the damper
row shown in the illustration to remove the clip. rod holder “2” and T-handle “3”, loosen the
damper rod bolt.
1 1 Damper rod holder

90890-01294
2 Damping rod holder set
YM-01300
T-handle
90890-01326
YM-01326
2. Drain:
• Fork oil
4-44
FRONT FORK
EAS23030
ASSEMBLING THE FRONT FORK LEGS

front fork legs.
EWA13660
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.
EAS23010 NOTE:
CHECKING THE FRONT FORK LEGS • When assembling the front fork leg, be sure to
The following procedure applies to both of the replace the following parts:
front fork legs. – Outer tube bushing
1. Check: – Oil seal
• Inner tube – Dust seal
• Outer tube – Clip
Bends/damage/scratches → Replace. • Before assembling the front fork leg, make
EWA13650
sure all of the components are clean.
WARNING
Do not attempt to straighten a bent inner 1. Install:
tube as this may dangerously weaken it. • Damper rod “1”
• Rebound spring “2”
2. Measure: ECA5B21004
• Spring free length “a” CAUTION:

Out of specification → Replace. Allow the damper rod to slide slowly down
the inner tube “3” until it protrudes from the
Fork spring free length
306.0 mm (12.05 in) bottom of the inner tube. Be careful not to
Limit damage the inner tube.
300.0 mm (11.81 in) NOTE:
Install the spring with the smaller pitch “a” facing
up “A”.
2 1
3
3. Check:
• Damper rod
Obstruction → Blow out all of the oil passag-
es with compressed air.
• Oil flow stopper
Damage → Replace.
ECA5B21003
CAUTION:
When disassembling and assembling the
front fork leg, do not allow any foreign mate-
rial to enter the front fork.
4-45
FRONT FORK
2. Lubricate:
• Inner tube’s outer surface
Recommended oil
Fork oil 10W or equivalent
3. Tighten:
• Damper rod bolt “1”
Damper rod bolt

28 Nm (2.8 m·kg, 20 ft·lb)
T.
R.
5. Install:
NOTE: • Oil seal “1” New
While holding the damper rod with the damper (with the fork seal driver weight “2” and fork
rod holder “2” and T-handle “3”, tighten the seal driver attachment “3”)
damper rod bolt.
Fork seal driver weight
90890-01367
Damper rod holder Replacement hammer
90890-01294 YM-A9409-7
Damping rod holder set Fork seal driver attachment (ø38)
YM-01300 90890-01372
T-handle Replacement 38 mm
90890-01326 YM-A5142-1
YM-01326 ECA14220
CAUTION:
Make sure the numbered side of the oil seal
faces up.
NOTE:
• Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.
• Lubricate the outer surface of the inner tube
with fork oil.
• Before installing the oil seal, cover the top of
the front fork leg with a plastic bag to protect
4. Install: the oil seal during installation.
• Outer tube bushing “1” New
• Washer “2”
(with the fork seal driver weight “3” and fork
seal driver attachment “4”)

90890-01367
Replacement hammer
YM-A9409-7
Fork seal driver attachment (ø38)
90890-01372
Replacement 38 mm
YM-A5142-1
4-46
FRONT FORK
Recommended oil
Fork oil 10W or equivalent
Quantity
207.0 cm³ (7.00 US oz) (7.29
Imp.oz)
ECA14230
CAUTION:
• Be sure to use the recommended fork oil.
Other oils may have an adverse effect on
front fork performance.
6. Install:
• When disassembling and assembling the
• Oil seal clip “1”
front fork leg, do not allow any foreign ma-
NOTE: terial to enter the front fork.
Adjust the oil seal clip so that it fits into the outer
tube’s groove. 9. After filling the front fork leg, slowly stroke the
inner tube “1” up and down (at least ten
times) to distribute the fork oil.
NOTE:
Be sure to stroke the inner tube slowly because
the fork oil may spurt out.
7. Install:
• Dust seal “1” New
(with the fork seal driver weight “2”)

90890-01367 10.Before measuring the fork oil level, wait ten
Replacement hammer minutes until the oil has settled and the air
YM-A9409-7 bubbles have dispersed.
NOTE:
Be sure to bleed the front fork leg of any residual
air.
11.Measure:
• Front fork leg oil level “a”
(from the top of the inner tube, with the inner
tube fully compressed and without the fork
spring)
Out of specification → Correct.
8. Fill: Level
• Front fork leg 93.0 mm (3.66 in)
mended fork oil)
4-47
FRONT FORK
Lower bracket pinch bolt

22 Nm (2.2 m·kg, 16 ft·lb)
T.
R.
12.Install:
• Fork spring “1”
NOTE:
Install the spring with the smaller pitch “a” facing
up.
a
1
13.Install:
• O-ring New
(to front fork cap)
• Front fork cap
• Clip New
NOTE:
• Before installing the front fork cap, lubricate its
O-ring with grease.
• Insert the front fork cap into the inner tube, and
then install the clip, making sure that the cap is
securely held in place with the clip.
EAS23050
INSTALLING THE FRONT FORK LEGS

front fork legs.
1. Install:
• Front fork leg “1”
EWA13680
WARNING
Make sure the brake hoses are routed prop-
erly.
NOTE:
Pull up the inner tube until it stops, and then
tighten the lower bracket pinch bolts.
4-48
STEERING HEAD
EAS23090
STEERING HEAD
Removing the lower bracket
120 Nm (12.0 m • kg, 85 ft • lb) 2 1

T.
R.
3
75 Nm (7.5 m • kg, 54 ft • lb)
T.
R.
LS
17
1st 38 Nm (3.8 m • kg, 27 ft • lb) 14
5
T.
2nd 22 Nm (2.2 m • kg, 16 ft • lb)

R.
6 15
7 16
8
LS 9
11
10 4
12
13
18

Front cowling 4-1.
Handlebar cover Refer to “HANDLEBAR” on page 4-37.
Front fork legs Refer to “FRONT FORK” on page 4-41.
1 Air temperature sensor 1
2 Steering stem nut 1
3 Lower handlebar holder 1
4 Woodruff key 1
5 Upper ring nut 1
6 Lock washer 1
7 Center ring nut 1
8 Rubber washer 1
9 Lower ring nut 1
10 Lower bracket 1
11 Upper bearing cover 1
12 Upper bearing inner race 1
4-49
STEERING HEAD
Removing the lower bracket
120 Nm (12.0 m • kg, 85 ft • lb) 2 1

T.
R.
3
75 Nm (7.5 m • kg, 54 ft • lb)
T.
R.
LS
17
1st 38 Nm (3.8 m • kg, 27 ft • lb) 14
5
T.
2nd 22 Nm (2.2 m • kg, 16 ft • lb)

R.
6 15
7 16
8
LS 9
11
10 4
12
13
18

13 Upper bearing 1
14 Lower bearing 1
15 Lower bearing inner race 1
16 Dust seal 1
17 Lower bearing outer race 1
18 Upper bearing outer race 1
dure.
4-50
STEERING HEAD
EAS23110
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
REMOVING THE LOWER BRACKET a. Remove the bearing races from the steering
1. Stand the vehicle on a level surface. head pipe “1” with a long rod “2” and hammer.
EWA13120
b. Remove the bearing race from the lower
WARNING
bracket “3” with a floor chisel “4” and ham-
Securely support the vehicle so that there is mer.
no danger of it falling over. c. Install new bearing races.
ECA14270
2. Remove:
CAUTION:
• Upper ring nut “1”
• Lock washer If the bearing race is not installed properly,
• Center ring nut the steering head pipe could be damaged.
• Rubber washer NOTE:
• Lower ring nut “2”
Always replace the bearings and bearing races
• Lower bracket
EWA13730 as a set.
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
NOTE:
Remove the upper ring nut and lower ring nut
with the steering nut wrench “3”.
Steering nut wrench

90890-01403
Spanner wrench
YU-33975
2 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Lower handlebar holder
EAS23120
CHECKING THE STEERING HEAD • Lower bracket

1. Wash: (along with the steering stem)
• Bearings Bends/cracks/damage → Replace.
• Bearing races EAS23150
INSTALLING THE STEERING HEAD

Recommended cleaning solvent 1. Lubricate:
Kerosene • Upper bearing
• Lower bearing
2. Check:
• Bearing races
• Bearings
• Bearing races Recommended lubricant
Damage/pitting → Replace. Lithium-soap-based grease
3. Replace:
• Bearings 2. Install:
• Bearing races • Lower ring nut “1”
4-51
STEERING HEAD
• Rubber washer
• Center ring nut “2”
• Lock washer “3”
• Upper ring nut “4”
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-19.
3. Install:
• Woodruff key “1”
• Lower handlebar holder “2”
• Steering stem nut
Steering stem nut

120 Nm (12.0 m·kg, 85 ft·lb)
T.
R.
NOTE:
Align the woodruff key with the groove “a” in the
lower handlebar holder.
2
1
4-52
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM
EAS23160

Removing the rear shock absorber assemblies and swingarm
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
2
3
LT
4
7
New 8 LT
LS
4
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R.
5 11
10
New 9
LS 6 1
135 Nm (13.5 m • kg, 98 ft • lb)
T.
R.
40 Nm (4.0 m • kg, 29 ft • Ib)

T.
R.
21 Nm (2.1 m • kg, 15 ft • Ib)

59 Nm (5.9 m • kg, 43 ft • Ib)
T.
R.
T.
R.

1 Rear wheel axle nut 1
2 Brake hose holder 1
4 Rear shock absorber assembly 2
5 Swingarm 1
6 Spacer 1
7 Collar 1
8 Oil seal 1
9 Oil seal 1
10 Circlip 1
11 Bearing 1
dure.
4-53
EAS23220
• Rear shock absorber
REMOVING THE REAR SHOCK ABSORBER
Oil leaks → Replace the rear shock absorber
ASSEMBLIES
assembly.
EWA13120
• Spring
WARNING Damage/wear → Replace the rear shock ab-
Securely support the vehicle so that there is sorber assembly.
no danger of it falling over. • Bushings
NOTE: • Bolts
Place the vehicle on the centerstand so that the Bends/damage/wear → Replace.
rear wheel is elevated. EAS23370
CHECKING THE SWINGARM

EAS23340
1. Check:
REMOVING THE SWINGARM • Swingarm
1. Stand the vehicle on a level surface. Bends/cracks/damage → Replace.
EWA13120
WARNING 2. Check:
• Spacer
• Collar
• Oil seals
NOTE: • Bearing
Place the vehicle on the centerstand so that the Damage/wear → Replace.
rear wheel is elevated. EAS28780
2. Remove: INSTALLING THE SWINGARM

• Rear wheel axle nut “1” 1. Lubricate:
• Brake hose holder “2” • Bearing
• Rear brake caliper “3” • Spacer
• Rear shock absorber assembly lower bolt “4” • Collar
• Oil seal lips
NOTE:
Do not squeeze the brake lever when removing Recommended lubricant
the brake caliper. Lithium-soap-based grease
2. Install:
• Swingarm “1”
2 • Rear wheel axle nut “2”
3
(temporarily tighten)
• Swingarm mounting bolt (upper side) “3”
4 • Swingarm mounting bolt (lower side) “4”
3. Tighten:
1
• Rear wheel axle nut “2”
3. Remove: • Swingarm mounting bolt (upper side) “3”
• Swingarm • Swingarm mounting bolt (lower side) “4”
EAS23240
Rear wheel axle nut
CHECKING THE REAR SHOCK ABSORBER 135 Nm (13.5 m·kg, 98 ft·lb)
T.
ASSEMBLY
R.
Swingarm mounting bolt (upper

1. Check: side)
• Rear shock absorber rod 59 Nm (5.9 m·kg, 43 ft·lb)
Bends/damage → Replace the rear shock Swingarm mounting bolt (lower
absorber assembly. side)
59 Nm (5.9 m·kg, 43 ft·lb)
4-54
2 1
4. Install:
• Brake hose holder bolt “1”
• Rear fender mounting bolt “2”
Rear fender mounting bolt

6 Nm (0.6 m·kg, 4.3 ft·lb)
T.
R.
1
2
5. Tighten:
• Brake hose holder bolt
Brake hose holder bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
4-55
ENGINE
ENGINE REMOVAL ........................................................................................ 5-1

INSTALLING THE ENGINE....................................................................... 5-5
CYLINDER HEAD............................................................................................ 5-7

REMOVING THE CYLINDER HEAD......................................................... 5-9
CHECKING THE CYLINDER HEAD ......................................................... 5-9
CHECKING THE CAMSHAFT SPROCKET............................................ 5-10
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-10
INSTALLING THE CYLINDER HEAD ..................................................... 5-10
INSTALLING THE INTAKE MANIFOLD.................................................. 5-12
CAMSHAFT ................................................................................................... 5-13

REMOVING THE ROCKER ARMS AND CAMSHAFT............................ 5-14
CHECKING THE CAMSHAFT................................................................. 5-14
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 5-15
INSTALLING THE CAMSHAFT AND ROCKER ARMS .......................... 5-15
VALVES AND VALVE SPRINGS.................................................................. 5-17

REMOVING THE VALVES...................................................................... 5-18
CHECKING THE VALVES AND VALVE GUIDES .................................. 5-18
CHECKING THE VALVE SEATS ............................................................ 5-20
CHECKING THE VALVE SPRINGS........................................................ 5-21
INSTALLING THE VALVES .................................................................... 5-22
5
CYLINDER AND PISTON.............................................................................. 5-24
REMOVING THE PISTON ...................................................................... 5-25
CHECKING THE CYLINDER AND PISTON ........................................... 5-25
CHECKING THE PISTON RINGS........................................................... 5-26
CHECKING THE PISTON PIN ................................................................ 5-27
CHECKING THE TIMING CHAIN GUIDE ............................................... 5-27
INSTALLING THE PISTON AND CYLINDER ......................................... 5-27
V-BELT AUTOMATIC TRANSMISSION ....................................................... 5-29

REMOVING THE PRIMARY SHEAVE.................................................... 5-33
REMOVING THE SECONDARY SHEAVE ............................................. 5-33
DISASSEMBLING THE SECONDARY SHEAVE.................................... 5-34
CHECKING THE CLUTCH HOUSING .................................................... 5-34
CHECKING THE CLUTCH SHOES ........................................................ 5-34
CHECKING THE V-BELT........................................................................ 5-34
CHECKING THE PRIMARY SHEAVE .................................................... 5-35
CHECKING THE PRIMARY SHEAVE WEIGHTS................................... 5-35
CHECKING THE PRIMARY SHEAVE SLIDERS .................................... 5-35
CHECKING THE SECONDARY SHEAVE .............................................. 5-35
ASSEMBLING THE PRIMARY SHEAVE ................................................ 5-36
ASSEMBLING THE SECONDARY SHEAVE.......................................... 5-36
INSTALLING THE V-BELT...................................................................... 5-37
STARTER CLUTCH AND GENERATOR...................................................... 5-39
REMOVING THE GENERATOR ............................................................. 5-41
REMOVING THE STARTER CLUTCH ................................................... 5-41
CHECKING THE STARTER CLUTCH .................................................... 5-41
INSTALLING THE STARTER CLUTCH .................................................. 5-42
INSTALLING THE GENERATOR............................................................ 5-42
ELECTRIC STARTER ................................................................................... 5-44

CHECKING THE STARTER MOTOR ..................................................... 5-46
ASSEMBLING THE STARTER MOTOR................................................. 5-47
OIL PUMP...................................................................................................... 5-48

CHECKING THE OIL PUMP ................................................................... 5-50
ASSEMBLING THE OIL PUMP............................................................... 5-50
INSTALLING THE OIL PUMP ................................................................. 5-51
TRANSMISSION............................................................................................ 5-52
REMOVING THE TRANSMISSION ........................................................ 5-54
CHECKING THE TRANSMISSION ......................................................... 5-54
CRANKSHAFT .............................................................................................. 5-55

DISASSEMBLING THE CRANKCASE.................................................... 5-57
REMOVING THE CRANKSHAFT ASSEMBLY ....................................... 5-57
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDES .......... 5-58
CHECKING THE CRANKSHAFT AND CONNECTING ROD ................. 5-58
CHECKING THE CRANKCASE .............................................................. 5-59
INSTALLING THE CRANKSHAFT .......................................................... 5-59
ASSEMBLING THE CRANKCASE.......................................................... 5-60
ENGINE REMOVAL
EAS23710
ENGINE REMOVAL
Removing the muffler and exhaust pipe
3
1
45 Nm (4.5 m • kg, 32 ft • Ib)

T.
R.
4 New 2
5
6 New
65 Nm (6.5 m • kg, 47 ft • Ib)

T.
R.
14 Nm (1.4 m • kg, 10 ft • Ib)

T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)

T.
R.

Right center panel/Right footrest board 4-1.
1 O2 sensor coupler 1 Disconnect.
2 O2 sensor 1
3 Muffler 1
4 Gasket 1
5 Exhaust pipe 1
6 Gasket 1
dure.
5-1
ENGINE REMOVAL
Disconnecting the leads and hoses
12 Nm (1.2 m • kg, 8.7 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
T.
R.
R.
7
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
3
9
2 8
6
4
5

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-9.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-14.
Air filter case 4-1.
Throttle body/Fuel injector assembly Refer to “THROTTLE BODY” on page 7-3.
1 Spark plug cap 1 Disconnect.
2 Coolant temperature sensor coupler 1 Disconnect.
Crankshaft position sensor/stator assembly
3 2 Disconnect.
coupler
4 Thermostat inlet hose 1 Disconnect.
5 Radiator outlet hose 1 Disconnect.
6 Crankcase breather hose 1
7 Starter motor lead 1 Disconnect.
8 Ground lead 1 Disconnect.
5-2
ENGINE REMOVAL
Disconnecting the leads and hoses
12 Nm (1.2 m • kg, 8.7 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
T.
R.
R.
7
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
3
9
2 8
6
4
5

9 Fuel hose holder 1
dure.
5-3
ENGINE REMOVAL
Removing the engine

7 40 Nm (4.0 m • kg, 29 ft • Ib)
8
T.
R.
59 Nm (5.9 m • kg, 43 ft • Ib) 7
T.
R.
21 Nm (2.1 m • kg, 15 ft • Ib)
T.
R.
32 Nm (3.2 m • kg, 23 ft • Ib)
T.
R.
1
7
2
3
5
4
64 Nm (6.4 m • kg, 46 ft • Ib)
T.
R.
5
6
2
4
64 Nm (6.4 m • kg, 46 ft • Ib)
T.
R.

Rear brake caliper Refer to “REAR BRAKE” on page 4-26.
NOTE:
Place a suitable stand under the engine.
1 Rear shock absorber 2

2 Engine mounting nut/washer/bolt 1/1/1
3 Spacer 1
4 Engine bracket rod bolt/washer 2/2
5 Engine bracket rod 2
6 Engine 1
7 Engine bracket nut/bolt 2/2
8 Engine bracket 1
dure.
5-4
ENGINE REMOVAL
EAS23720
INSTALLING THE ENGINE

1. Install:
• Engine bracket “1” 3
• Engine bracket nuts/bolts “2”
• Engine bracket rods “3”
• Engine bracket rod bolts/washers “4”
• Engine “5”
• Spacer “6”
• Engine mounting nut/washer/bolt “7” a
• Rear shock absorber assemblies “8”
NOTE: 3. Tighten:
• Do not fully tighten the bolts and nuts. • Rear shock absorber assembly upper bolts
• Be sure to install each engine bracket rod “3” • Rear shock absorber assembly lower bolts
with the white mark “a” on the rod facing for-
ward. Rear shock absorber assembly
upper bolt
T.
R.
2. Tighten: 40 Nm (4.0 m·kg, 29 ft·lb)
• Engine bracket rod bolts “4” Rear shock absorber assembly
• Engine bracket nuts “2” lower bolt
• Engine mounting nut “7” 21 Nm (2.1 m·kg, 15 ft·lb)
Engine bracket rod bolt 4. Install:

64 Nm (6.4 m·kg, 46 ft·lb) • Gasket New
T.
R.
Engine bracket nut • Exhaust pipe

59 Nm (5.9 m·kg, 43 ft·lb) • Exhaust pipe nuts
Engine mounting nut
32 Nm (3.2 m·kg, 23 ft·lb)
5. Install:
• Muffler
2 1 • Muffler mounting bolts
NOTE:
2 Install the muffler mounting bolts in the proper in-
stalling sequence as shown.
6. Tighten:
• Muffler mounting bolts
8 Muffler mounting bolt

2 65 Nm (6.5 m·kg, 47 ft·lb)
8
T.
R.
7
NOTE:
6 Tighten the muffler mounting bolts in the proper
tightening sequence as shown.
3
4
3 1
7
5 4
2
3
5-5
ENGINE REMOVAL
7. Tighten:
• Exhaust pipe nuts
Exhaust pipe nut

20 Nm (2.0 m·kg, 14 ft·lb)
T.
R.
8. Tighten:
• Muffler joint bolt
• O2 sensor
Muffler joint bolt

14 Nm (1.4 m·kg, 10 ft·lb)
T.
R.
O2 sensor
45 Nm (4.5 m·kg, 32 ft·lb)
5-6
CYLINDER HEAD
EAS24100
CYLINDER HEAD
Removing the cylinder head
10 Nm (1.0 m • kg, 7.2 ft • Ib) 1
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib)
T.
R.
8 Nm (0.8 m • kg, 5.8 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
New
R.
T.
R.
4
8 6 LS
New 2 New
LS New
E 60 Nm (6.0 m • kg, 43 ft • Ib)
13
T.
R.
5
18 Nm (1.8 m • kg, 13 ft • Ib) (4)
T.
R.
New New
22 Nm (2.2 m • kg, 16 ft • Ib) 12 7
11
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib) 14 LS

T.
R.
New 8 Nm (0.8 m • kg, 5.8 ft • Ib)

T.
R.
9 LS
LS
8 New 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

10 New T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
New 15
3
16

Thermostat Refer to “THERMOSTAT” on page 6-4.
Engine Refer to “ENGINE REMOVAL” on page 5-1.
1 Intake manifold 1
2 Intake manifold joint 1
3 V-belt case air filter cover 1
4 Timing mark accessing plug 1
5 Spark plug 1
6 Coolant temperature sensor 1
7 Camshaft sprocket cover 1
8 Tappet cover 2
9 Timing chain tensioner 1
10 Timing chain tensioner gasket 1
11 Camshaft sprocket plate 1
12 Camshaft sprocket 1
13 Dowel pin 1
14 Cylinder head 1
5-7
CYLINDER HEAD
Removing the cylinder head

10 Nm (1.0 m • kg, 7.2 ft • Ib) 1
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib)
T.
R.
8 Nm (0.8 m • kg, 5.8 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
New
R.
T.
R.
4
8 6 LS
New 2 New
LS New
E 60 Nm (6.0 m • kg, 43 ft • Ib)
13
T.
R.
5
18 Nm (1.8 m • kg, 13 ft • Ib) (4)
T.
R.
New New
22 Nm (2.2 m • kg, 16 ft • Ib) 12 7
11
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib) 14 LS

T.
R.
New 8 Nm (0.8 m • kg, 5.8 ft • Ib)

T.
R.
9 LS
LS
8 New 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

10 New
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
New 15
3
16

15 Cylinder head gasket 1
16 Dowel pin 2
dure.
5-8
CYLINDER HEAD
EAS24130
3. Remove:
REMOVING THE CYLINDER HEAD
• Timing chain tensioner
1. Align:
(along with the gasket)
• “I” mark “a” on the generator rotor
• Camshaft sprocket plate
(with the stationary pointer “b” on the genera-
• Camshaft sprocket
tor cover)
• Timing chain
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the primary sheave nut on the left side NOTE:
of the crankshaft counterclockwise to turn the To prevent the timing chain from falling into the
crankshaft. crankcase, fasten it with a wire.
4. Remove:
• Cylinder head
NOTE:
• Loosen the bolts and nuts in the proper se-
quence as shown.
• Loosen each bolt and nut 1/2 of a turn at a
time. After all of the bolts and nuts are fully
loosened, remove them.
b. When the piston is at TDC on the compres-

sion stroke, align the “I” mark “c” on the cam-
shaft sprocket with the mark “d” on the
cylinder head.
EAS24160
CHECKING THE CYLINDER HEAD

1. Eliminate:
• Combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Remove: Do not use a sharp instrument to avoid damag-
• Camshaft sprocket bolt “1” ing or scratching:
• Spark plug bore threads
NOTE:
• Valve seats
While holding the primary sheave nut with a
wrench, remove the camshaft sprocket bolt.
2. Check:
• Cylinder head
Damage/scratches → Replace.
5-9
CYLINDER HEAD
• Cylinder head water jacket

Mineral deposits/rust → Eliminate.
3. Measure:
• Cylinder head warpage
Out of specification → Resurface the cylinder
head.
Warpage limit
0.05 mm (0.0020 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge “1” and a thickness a. 1/4 tooth
gauge “2” across the cylinder head. b. Correct
1. Timing chain roller
2. Camshaft sprocket
EAS24190
CHECKING THE TIMING CHAIN TENSIONER

1. Check:
• Timing chain tensioner
2. Check:
• One-way cam operation
Rough movement → Replace the timing
b. Measure the warpage. chain tensioner.
c. If the limit is exceeded, resurface the cylinder
head as follows.
d. Place 400–600 grit wet sandpaper on the sur-
face plate and resurface the cylinder head
using a figure-eight sanding pattern.
NOTE:
To ensure an even surface, rotate the cylinder
head several times.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS23870 3. Check:
CHECKING THE CAMSHAFT SPROCKET • Cap bolt
1. Check: • Copper washer
• Camshaft sprocket • Spring
More than 1/4 tooth wear “a” → Replace the • One-way cam
camshaft sprocket and the timing chain as a Damage/wear → Replace the defective
set. part(s).
EAS24230
INSTALLING THE CYLINDER HEAD

1. Tighten:
• Cylinder head nuts “1”
Cylinder head nut

22 Nm (2.2 m·kg, 16 ft·lb)
T.
R.
• Cylinder head bolts “2”
Cylinder head bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
5-10
CYLINDER HEAD
NOTE: d. Install the timing chain onto the camshaft

• Lubricate the cylinder head nuts and washers sprocket, and then install the camshaft
with engine oil. sprocket onto the camshaft.
• Tighten the cylinder head nuts and bolts in the NOTE:
proper tightening sequence as shown and • When installing the camshaft sprocket, be sure
torque them in two stages. to keep the timing chain as tight as possible on
the exhaust side.
• Align the dowel pin “1” on the camshaft with the
slot in the camshaft sprocket.
ECA5B21015
CAUTION:
Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
e. Install the camshaft sprocket plate and cam-
shaft sprocket bolt.
2. Install: f. While holding the primary sheave nut, tempo-
• Dowel pin “1” rarily tighten the camshaft sprocket bolt.
• Camshaft sprocket “2” g. Remove the wire from the timing chain.
• Timing chain “3” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Camshaft sprocket plate 3. Install:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the primary sheave nut on the left side • Timing chain tensioner gasket New
of the crankshaft counterclockwise to turn the • Timing chain tensioner
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
crankshaft. a. Remove the timing chain tensioner cap bolt
b. Align the “I” mark “a” on the generator rotor “1” and spring “2”.
with the stationary pointer “b” on the genera- b. Release the timing chain tensioner one-way
tor cover. cam “3” and push the timing chain tensioner
c. Align the “I” mark “c” on the camshaft sprock- rod “4” all the way into the timing chain ten-
et with the stationary pointer “d” on the cylin- sioner housing.
der head. c. Install the timing chain tensioner and gasket
“5” onto the cylinder.
Timing chain tensioner bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
d. Install the spring and timing chain tensioner

cap bolt.
Timing chain tensioner cap bolt

8 Nm (0.8 m·kg, 5.8 ft·lb)
T.
R.
5-11
CYLINDER HEAD
Refer to “ADJUSTING THE VALVE CLEAR-

ANCE” on page 3-3.
1
2 EAS5B21010
INSTALLING THE INTAKE MANIFOLD

3 1. Install:
• Intake manifold joint “1”
5 New
NOTE:
4 Make sure that the groove “a” on the intake man-
ifold joint is facing down.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Turn:
• Crankshaft
(turn the primary sheave nut on the left side
of the crankshaft several turns counterclock-
wise) 1
5. Check:
• “I” mark “a”
Make sure the “I” mark “a” on the generator a a
rotor is aligned with the stationary pointer “b”
on the generator cover.
• “I” mark “c”
Make sure the “I” mark “c” on the camshaft
sprocket is aligned with the mark “d” on the
cylinder head.
Out of alignment → Correct.
Refer to the installation steps above.
6. Tighten:
• Camshaft sprocket bolt
Camshaft sprocket bolt

60 Nm (6.0 m·kg, 43 ft·lb)
T.
R.
ECA5B21016
CAUTION:
Be sure to tighten the camshaft sprocket bolt
to the specified torque to avoid the possibil-
ity of the bolt coming loose and damaging
the engine.
7. Measure:
• Valve clearance
5-12
CAMSHAFT
EAS23730
CAMSHAFT
Removing the rocker arms and camshaft

Cylinder head Refer to “CYLINDER HEAD” on page 5-7.
1 Locknut 2 Loosen.
2 Adjusting screw 2 Loosen.
3 Lock plate 1
4 Camshaft retainer 1
5 Intake rocker arm shaft 1
6 Exhaust rocker arm shaft 1
7 Rocker arm 2
8 Camshaft 1
dure.
5-13
CAMSHAFT
EAS23770
REMOVING THE ROCKER ARMS AND

CAMSHAFT
1. Straighten the lock plate tabs “a”.
2. Remove:
• Lock plate “1”
• Camshaft retainer “2”
EAS23840
CHECKING THE CAMSHAFT

1. Check:
• Camshaft bushings
2. Check:
• Camshaft lobes
3. Remove: Blue discoloration/pitting/scratches → Re-
• Rocker arm shafts place the camshaft.
• Rocker arms 3. Measure:
NOTE: • Camshaft lobe dimensions “a” and “b”
Remove the rocker arm shafts with the slide Out of specification → Replace the camshaft.
hammer bolt “1” and weight “2”.
Camshaft lobe dimensions
Intake A
Slide hammer bolt
37.050–37.150 mm (1.4587–
90890-01083
1.4626 in)
Slide hammer bolt 6 mm
Limit
YU-01083-1
36.955 mm (1.4550 in)
Weight
Intake B
90890-01084
30.074–30.174 mm (1.1840–
YU-01083-3
1.1880 in)
Limit
29.973 mm (1.1800 in)
Exhaust A
37.053–37.153 mm (1.4588–
1.4627 in)
Limit
36.956 mm (1.4550 in)
Exhaust B
30.091–30.191 mm (1.1847–
1.1886 in)
Limit
29.194 mm (1.1494 in)
4. Remove:
• Camshaft “1”
NOTE:
Screw a 10-mm bolt “2” into the threaded end of
the camshaft, and then pull out the camshaft.
5-14
CAMSHAFT
Rocker arm shaft outside diame-

ter
11.981–11.991 mm (0.4717–
0.4721 in)
Limit
11.950 mm (0.4705 in)
4. Check:
• Camshaft oil passage
EAS23880
CHECKING THE ROCKER ARMS AND

ROCKER ARM SHAFTS
rocker arms and rocker arm shafts. 5. Calculate:
1. Check: • Rocker-arm-to-rocker-arm-shaft clearance
• Rocker arm NOTE:
Damage/wear → Replace. Calculate the clearance by subtracting the rock-
2. Check: er arm shaft outside diameter from the rocker
• Rocker arm shaft arm inside diameter.
Blue discoloration/excessive wear/pit-
Out of specification → Replace the defective
ting/scratches → Replace or check the lubri-
part(s).
cation system.
3. Measure: Rocker-arm-to-rocker-arm-shaft
• Rocker arm inside diameter “a” clearance
Out of specification → Replace. 0.009–0.037 mm (0.0004–0.0015
in)
Rocker arm inside diameter Limit
12.000–12.018 mm (0.4724– 0.080 mm (0.0031 in)
0.4731 in)
Limit EAS24040
12.030 mm (0.4736 in) INSTALLING THE CAMSHAFT AND ROCKER
ARMS
1. Lubricate:
• Camshaft
Camshaft
Molybdenum disulfide oil
Camshaft bearing
Engine oil
2. Lubricate:
• Rocker arms
4. Measure:
• Rocker arm shafts
• Rocker arm shaft outside diameter “a”
Out of specification → Replace. Recommended lubricant
Rocker arm inner surface
Rocker arm shaft
Engine oil
5-15
CAMSHAFT
3. Install:
• Exhaust rocker arm
• Exhaust rocker arm shaft
NOTE:
Make sure the exhaust rocker arm shaft is com-
pletely pushed into the cylinder head.
4. Install:
• Intake rocker arm
• Intake rocker arm shaft “1”
NOTE:
Insert a guide stud (8 mm) “2” into the stud-bolt
hole in the cylinder head and install the intake
rocker arm shaft as shown.
ECA13780
CAUTION:
Make sure the threaded part of the rocker
arm shaft faces out.
5. Install:
• Camshaft retainer “1”
• Lock plate “2” New
Camshaft retainer bolt

8 Nm (0.8 m·kg, 5.8 ft·lb)
T.
R.
NOTE:
Bend the lock plate tabs along a flat side of the
bolts “3”.
5-16
VALVES AND VALVE SPRINGS
EAS24270

Removing the valves and valve springs

Rocker arms/Camshaft Refer to “CAMSHAFT” on page 5-13.
1 Valve cotter 4
2 Upper spring seat 2
3 Outer valve spring 2
4 Inner valve spring 2
5 Intake valve 1
6 Exhaust valve 1
7 Valve stem seal 2
8 Lower spring seat 2
9 Valve guide 2
dure.
5-17
EAS24280
REMOVING THE VALVES

valves and related components.
NOTE:
Before removing the internal parts of the cylinder
head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal.
1. Check:
• Valve sealing
Leakage at the valve seat → Check the valve 3. Remove:
face, valve seat, and valve seat width. • Upper spring seat “1”
Refer to “CHECKING THE VALVE SEATS” • Outer valve spring “2”
on page 5-20. • Inner valve spring “3”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Valve “4”
a. Pour a clean solvent “a” into the intake and • Valve stem seal “5”
exhaust ports. • Lower spring seat “6”
b. Check that the valves properly seal.
NOTE:
NOTE:
Identify the position of each part very carefully so
There should be no leakage at the valve seat “1”. that it can be reinstalled in its original place.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24290
2. Remove: CHECKING THE VALVES AND VALVE

• Valve cotters “1” GUIDES
NOTE: The following procedure applies to all of the
Remove the valve cotters by compressing the valves and valve guides.
valve spring with the valve spring compressor 1. Measure:
and the valve spring compressor attachment “2”. • Valve-stem-to-valve-guide clearance
Out of specification → Replace the valve
guide.
Valve spring compressor
90890-04019 • Valve-stem-to-valve-guide clearance =
YM-04019 Valve guide inside diameter “a” -
Valve spring compressor attach- Valve stem diameter “b”
ment
90890-04108
Valve spring compressor adapt-
er 22 mm
YM-04108
5-18
b. Install the new valve guide with the valve

Valve-stem-to-valve-guide clear- guide installer “2” and valve guide remover
ance (intake) “1”.
0.010–0.037 mm (0.0004–0.0015
in)
Limit
0.080 mm (0.0031 in)
Valve-stem-to-valve-guide clear-
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.
Valve guide remover (ø6)

90890-04064
Valve guide remover (6.0 mm)
2. Replace: YM-04064-A
• Valve guide Valve guide installer (ø6)
NOTE: 90890-04065
To ease valve guide removal and installation, Valve guide installer (6.0 mm)
and to maintain the correct fit, heat the cylinder YM-04065-A
head to 100 °C (212 °F) in an oven. Valve guide reamer (ø6)
90890-04066
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Valve guide reamer (6.0 mm)
a. Remove the valve guide with the valve guide YM-04066
remover “1”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
4. Check:
• Valve face
Pitting/wear → Grind the valve face.
5-19
• 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
head.
Valve margin thickness D (intake)
0.80–1.20 mm (0.0315–0.0472 in) Valve seat width C (intake)
Valve margin thickness D (ex- 0.90–1.10 mm (0.0354–0.0433 in)
haust) Limit
0.80–1.20 mm (0.0315–0.0472 in) 1.6 mm (0.06 in)
Valve seat width C (exhaust)
0.90–1.10 mm (0.0354–0.0433 in)
Limit
1.6 mm (0.06 in)
6. Measure:
• Valve stem runout
Out of specification → Replace the valve.
NOTE:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• When installing a new valve, always replace a. Apply Mechanic’s blueing dye (Dykem) “b”
the valve guide. onto the valve face.
• If the valve is removed or replaced, always re-
place the valve stem seal.
Valve stem runout

0.010 mm (0.0004 in)
b. Install the valve into the cylinder head.

c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat width.
NOTE:
EAS24300
CHECKING THE VALVE SEATS Where the valve seat and valve face contacted
The following procedure applies to all of the one another, the blueing will have been re-
valves and valve seats. moved.
1. Eliminate: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Carbon deposits 4. Lap:
(from the valve face and valve seat) • Valve face
• Valve seat
5-20
NOTE:
After replacing the cylinder head or replacing the
valve and valve guide, the valve seat and valve
face should be lapped.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound “a” to the
valve face.
ECA13790
CAUTION:
Do not let the lapping compound enter the
h. Install the valve into the cylinder head.
gap between the valve stem and the valve
i. Press the valve through the valve guide and
guide.
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width again. If the
valve seat width is out of specification, reface
and lap the valve seat.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24310
CHECKING THE VALVE SPRINGS

valve springs.
1. Measure:
b. Apply molybdenum disulfide oil onto the • Valve spring free length “a”
valve stem. Out of specification → Replace the valve
c. Install the valve into the cylinder head. spring.
d. Turn the valve until the valve face and valve
seat are evenly polished, and then clean off Inner spring
all of the lapping compound. Free length (intake)
NOTE: 38.10 mm (1.50 in)
Limit
For the best lapping results, lightly tap the valve 36.10 mm (1.42 in)
seat while rotating the valve back and forth be- Free length (exhaust)
tween your hands. 38.10 mm (1.50 in)
Limit
36.10 mm (1.42 in)
Outer spring
Free length (intake)
36.93 mm (1.45 in)
Limit
35.00 mm (1.38 in)
Free length (exhaust)
36.93 mm (1.45 in)
Limit
35.00 mm (1.38 in)
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from the
valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) “b”
onto the valve face.
5-21
3. Measure:
• Valve spring tilt “a”
Out of specification → Replace the valve
spring.
Inner spring
Spring tilt (intake)
2.5°/1.7 mm
Spring tilt (exhaust)
2.5°/1.7 mm
Outer spring
2. Measure: Spring tilt (intake)
• Compressed valve spring force “a” 2.5°/1.6 mm
Out of specification → Replace the valve Spring tilt (exhaust)
spring. 2.5°/1.6 mm
Inner spring
Installed compression spring
force (intake)
76–88 N (17.20–19.85 lbf) (7.80–
9.00 kgf)
force (exhaust)
76–88 N (17.20–19.85 lbf) (7.80–
9.00 kgf)
Installed length (intake)
30.10 mm (1.19 in)
Installed length (exhaust) EAS24340
30.10 mm (1.19 in) INSTALLING THE VALVES

Outer spring The following procedure applies to all of the
Installed compression spring valves and related components.
force (intake) 1. Deburr:
115–133 N (25.85–29.90 lbf) • Valve stem end
(11.73–13.56 kgf) (with an oil stone)
force (exhaust)
115–133 N (25.85–29.90 lbf)
(11.73–13.56 kgf)
Installed length (intake)
31.60 mm (1.24 in)
Installed length (exhaust)
31.60 mm (1.24 in)
2. Lubricate:
• Valve stem “1”
• Valve stem seal “2”
(with the recommended lubricant)
b. Installed length
5-22
Valve spring compressor

90890-04019
YM-04019
Valve spring compressor attach-
ment
90890-04108
Valve spring compressor adapt-
er 22 mm
YM-04108
3. Install:
• Lower spring seat “1”
• Valve stem seal “2”
• Valve “3”
• Inner valve spring “4”
• Outer valve spring “5”
• Upper spring seat “6”
(into the cylinder head)
NOTE:
• Make sure each valve is installed in its original
place. 5. To secure the valve cotters onto the valve
• Install the valve springs with the larger pitch “a” stem, lightly tap the valve tip with a soft-face
facing up. hammer.
ECA13800
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.
b. Smaller pitch
4. Install:
• Valve cotters “1”
NOTE:
Install the valve cotters by compressing the
valve spring with the valve spring compressor
and the valve spring compressor attachment “2”.
5-23
CYLINDER AND PISTON
EAS24350
CYLINDER AND PISTON

Removing the cylinder and piston
4 New
3 5
6 New
11
New 10 2
E 9
LS
8 7 6 New
1 LS
New E
7 Nm (0.7 m • kg, 5.1 ft • Ib) E

T.
R.

1 Water pump outlet pipe 1
2 Timing chain guide (exhaust side) 1
3 Cylinder 1
4 Cylinder gasket 1
5 Dowel pin 2
6 Circlip 2
7 Piston pin 1
8 Piston 1
9 Top ring 1
10 2nd ring 1
11 Oil ring 1
dure.
5-24
CYLINDER AND PISTON
EAS24380
REMOVING THE PISTON NOTE:

1. Remove: When removing a piston ring, open the end gap
• Piston pin clips “1” with your fingers and lift the other side of the ring
• Piston pin “2” over the piston crown.
• Piston “3”
ECA13810
CAUTION:
Do not use a hammer to drive the piston pin
out.
NOTE:
• Before removing the piston pin clips, cover the
crankcase opening with a clean rag to prevent
them from falling into the crankcase.
• Before removing the piston pin, deburr the pis-
ton pin clip groove and the piston pin bore ar- EAS24390
ea. If both areas are deburred and the piston CHECKING THE CYLINDER AND PISTON
pin is still difficult to remove, remove it with the 1. Check:
piston pin puller set “4”. • Piston wall
• Cylinder wall
Vertical scratches → Rebore or replace the
Piston pin puller set cylinder, and replace the piston and piston
90890-01304 rings as a set.
Piston pin puller
2. Measure:
YU-01304
• Piston-to-cylinder clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore “C” with the cylinder
bore gauge.
NOTE:
Measure cylinder bore “C” by taking side-to-side
and front-to-back measurements of the cylinder.
Then, find the average of the measurements.
Bore
69.000–69.005 mm (2.7165–
2.7167 in)
Taper limit
0.030 mm (0.0012 in)
Out of round limit
0.030 mm (0.0012 in)
“C” = maximum of D1–D2

“T” = maximum of D1 or D2 - maximum of D5
or D6
“R” = maximum of D1, D3 or D5 - minimum of
2. Remove: D2, D4 or D6
• Top ring
• 2nd ring
• Oil ring
5-25
CYLINDER AND PISTON
EAS24430
CHECKING THE PISTON RINGS

1. Measure:
• Piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set.
NOTE:
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston
ring grooves and piston rings.
b. If out of specification, rebore or replace the
cylinder, and replace the piston and piston Piston ring
rings as a set. Top ring
c. Measure piston skirt diameter D “a” with the Ring side clearance
micrometer. 0.040–0.080 mm (0.0016–
0.0031 in)
Limit
0.120 mm (0.0047 in)
2nd ring
Ring side clearance
0.030–0.070 mm (0.0012–
0.0028 in)
Limit
0.120 mm (0.0047 in)
b. 5 mm (0.20 in) from the bottom edge of the

piston
Piston
Diameter D
68.965–68.980 mm (2.7152–
2.7157 in)
d. If out of specification, replace the piston and

piston rings as a set. 2. Install:
e. Calculate the piston-to-cylinder clearance • Piston ring
with the following formula. (into the cylinder)
• Piston-to-cylinder clearance = NOTE:
Cylinder bore “C” - Level the piston ring into the cylinder with the
Piston skirt diameter “D”
piston crown.
Piston-to-cylinder clearance
0.020–0.040 mm (0.0008–0.0016
in)
Limit
0.15 mm (0.0059 in)
f. If out of specification, rebore or replace the

cylinder, and replace the piston and piston
rings as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. 5 mm (0.20 in)
5-26
CYLINDER AND PISTON
3. Measure: 3. Measure:
• Piston ring end gap • Piston pin bore diameter “b”
Out of specification → Replace the piston Out of specification → Replace the piston.
ring.
NOTE:
Piston pin bore inside diameter
17.004–17.015 mm (0.6694–
The oil ring expander spacer end gap cannot be 0.6699 in)
measured. If the oil ring rail gap is excessive, re- Limit
place all three piston rings. 17.045 mm (0.6711 in)
Piston ring
Top ring
End gap (installed)
0.15–0.30 mm (0.0059–0.0118
in)
Limit
0.45 mm (0.0177 in)
2nd ring
End gap (installed)
0.30–0.45 mm (0.0118–0.0177
in)
Limit 4. Calculate:
0.70 mm (0.0276 in) • Piston-pin-to-piston-pin-bore clearance
Oil ring Out of specification → Replace the piston pin
End gap (installed) and piston as a set.
0.20–0.70 mm (0.0079–0.0276 • Piston-pin-to-piston-pin-bore clearance =
in) Piston pin bore diameter “b” -
Piston pin outside diameter “a”
EAS24440
CHECKING THE PISTON PIN

1. Check: Piston-pin-to-piston-pin-bore
• Piston pin clearance
Blue discoloration/grooves → Replace the 0.004–0.024 mm (0.0002–0.0009
in)
piston pin, and then check the lubrication sys-
tem.
EAS5B21011
2. Measure: CHECKING THE TIMING CHAIN GUIDE
• Piston pin outside diameter “a” 1. Check:
Out of specification → Replace the piston pin. • Timing chain guide (exhaust side)
Piston pin outside diameter
16.991–17.000 mm (0.6689– EAS24450
0.6693 in) INSTALLING THE PISTON AND CYLINDER

Limit 1. Install:
16.971 mm (0.6681 in) • Top ring “1”
• 2nd ring “2”
• Oil ring expander “3”
• Lower oil ring rail “4”
• Upper oil ring rail “5”
NOTE:
Be sure to install the piston rings so that the
manufacturer marks or numbers face up.
5-27
CYLINDER AND PISTON
e 120˚ a
120˚ 120˚
f f
d c b
A
2. Install: a. Top ring

• Piston “1” b. Upper oil ring rail
• Piston pin “2” c. Oil ring expander
• Piston pin clips “3” New d. Lower oil ring rail
NOTE: e. 2nd ring
f. 20 mm (0.79 in)
• Apply engine oil to the piston pin.
A. Intake side
• Make sure the arrow mark “a” on the piston
points towards the exhaust side of the cylinder. 5. Install:
• Before installing the piston pin clip, cover the • Dowel pins
crankcase opening with a clean rag to prevent • Cylinder gasket New
the clip from falling into the crankcase. • Cylinder
NOTE:
• While compressing the piston rings with one
hand, install the cylinder with the other hand.
• Pass the timing chain and timing chain guide
(intake side) through the timing chain cavity.
3. Lubricate:
• Piston
• Piston rings
• Cylinder
Engine oil
4. Offset:
• Piston ring end gaps
5-28
V-BELT AUTOMATIC TRANSMISSION
EAS24610

Removing the V-belt case cover

Air filter case 4-1.
1 V-belt case air filter cover 1
2 V-belt case cover 1
3 V-belt case 1
4 V-belt case gasket 1
5 Dowel pin 2
dure.
5-29
Removing the V-belt, primary sheave and secondary sheave
22 Nm (2.2 m • kg, 16 ft • Ib)
T.
R.
8
7
B
LT
6
(4) (4)
11 5
16
4
12 2 3
1
15 13
14 B 17 New New
New 10 9
60 Nm (6.0 m • kg, 43 ft • Ib)
T.
B
R.
80 Nm (8.0 m • kg, 58 ft • Ib)

T.
R.

1 Primary sheave nut/washer 1/1
2 Primary fixed sheave 1
3 Secondary sheave bracket 1
4 Secondary sheave nut 1
5 Collar 1
6 Clutch housing 1
7 Secondary sheave assembly 1
8 V-belt 1
9 Primary sliding sheave 1
10 O-ring 1
11 Spacer 1
12 Primary sheave cap 1
13 Cam 1
14 Weight 8
15 Slider 4
16 Spacer 4
5-30
Removing the V-belt, primary sheave and secondary sheave
22 Nm (2.2 m • kg, 16 ft • Ib)
T.
R.
8
7
B
LT
6
(4) (4)
11 5
16
4
12 2 3
1
15 13
14 B 17 New New
New 10 9
60 Nm (6.0 m • kg, 43 ft • Ib)
T.
B
R.
80 Nm (8.0 m • kg, 58 ft • Ib)

T.
R.

17 Oil seal 1
dure.
* Apply Shell BT grease 3® (Yamaha grease G 90793-40016).
Yamaha grease G
90793-40016
5-31
Disassembling the secondary sheave

1 Clutch carrier nut 1
2 Clutch carrier 1
3 Clip 3
4 Clutch carrier plate 1
5 Clutch shoe spring 3
6 Spacer 1
7 Compression spring 1
8 Spring seat 1
9 Guide pin 4
10 Secondary sliding sheave 1
11 O-ring 2
12 Oil seal 2
13 Secondary fixed sheave 1
cedure.
* Apply BEL-RAY assembly lube®.
5-32
EAS24620
REMOVING THE PRIMARY SHEAVE

1. Remove:
• V-belt case
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:
• Primary sheave nut “1”
• Washer 2. Loosen:
• Primary fixed sheave “2” • Clutch carrier nut “1”
ECA13860
NOTE:
CAUTION:
While holding the primary fixed sheave with the
rotor holding tool “3”, loosen the primary sheave Do not remove the clutch carrier nut at this
nut. stage.
NOTE:
Rotor holding tool While holding the clutch carrier with the sheave
90890-01235 holder “2”, loosen the clutch carrier nut one full
Universal magneto & rotor holder turn with the locknut wrench “3”.
YU-01235
Sheave holder
90890-01701
YS-01880-A
Locknut wrench
90890-01348
YM-01348
EAS24630
REMOVING THE SECONDARY SHEAVE

1. Remove:
• Secondary sheave nut “1”
• Collar
• Clutch housing “2”
NOTE:
While holding the clutch housing with the sheave 3. Remove:
holder “3”, loosen the secondary sheave nut. • Secondary sheave assembly “1”
• V-belt “2”
Sheave holder NOTE:
90890-01701 Remove the V-belt and secondary sheave as-
Primary clutch holder sembly from the primary sheave side.
YS-01880-A
5-33
EAS24640 EAS24660
DISASSEMBLING THE SECONDARY CHECKING THE CLUTCH SHOES

SHEAVE The following procedure applies to all of the
1. Remove: clutch shoes.
• Clutch carrier nut “1” 1. Check:
• Spacer • Clutch shoe
NOTE: Damage/wear → Replace the clutch shoes
While compressing the compression spring with and springs as a set.
the clutch spring holder “2” and clutch spring Glazed areas → Sand with coarse sandpa-
holder arm “3”, remove the clutch carrier nut. per.
NOTE:
Clutch spring holder After sanding the glazed areas, clean the clutch
90890-01337 with a cloth.
Clutch spring holder arm 2. Measure:
90890-01464
• Clutch shoe thickness “a”
Out of specification → Replace the clutch
shoes and springs as a set.
Clutch shoe thickness

3.3 mm (0.13 in)
Wear limit
2.0 mm (0.08 in)
EAS24650
CHECKING THE CLUTCH HOUSING

1. Check:
• Clutch housing
2. Measure:
• Clutch housing inside diameter “a”
Out of specification → Replace the clutch EAS24670
housing. CHECKING THE V-BELT

1. Check:
Clutch housing inside diameter • V-belt “1”
145.0 mm (5.71 in) Cracks/damage/wear → Replace.
Limit Grease/oil → Clean the primary and second-
145.5 mm (5.73 in) ary sheave.
5-34
2. Measure:
• V-belt width “2”
Out of specification → Replace.
V-belt width
23.0 mm (0.91 in)
Limit
21.0 mm (0.83 in)
EAS24700
CHECKING THE PRIMARY SHEAVE

SLIDERS
1. Check:
• Primary sheave slider
EAS24710
CHECKING THE SECONDARY SHEAVE

EAS24680
1. Check:
CHECKING THE PRIMARY SHEAVE • Secondary fixed sheave
1. Check: • Secondary sliding sheave
• Primary sliding sheave Cracks/damage/wear → Replace the sec-
• Primary fixed sheave ondary fixed and sliding sheaves as a set.
• Spacer 2. Check:
Cracks/damage/wear → Replace the primary • Torque cam groove “1”
sliding sheave and primary fixed sheave as a Damage/wear → Replace the secondary
set. fixed and sliding sheaves as a set.
EAS24690 3. Check:
CHECKING THE PRIMARY SHEAVE • Guide pin “2”
WEIGHTS Damage/wear → Replace the secondary
The following procedure applies to all of the pri- fixed and sliding sheaves as a set.
mary sheave weights.
1. Check:
• Primary sheave weight
2. Measure:
• Primary sheave weight outside diameter
Weight outside diameter

20.0 mm (0.79 in)
Limit
19.5 mm (0.77 in) 4. Check:
• Spring free length
Out of specification → Replace the spring.
Compression spring free length

102.4 mm (4.03 in)
Limit
90.0 mm (3.54 in)
5-35
EAS24720 2. Install:
ASSEMBLING THE PRIMARY SHEAVE • Secondary sliding sheave “1”
1. Clean: NOTE:
• Primary fixed sheave Install the secondary sliding sheave onto the
• Primary sliding sheave secondary fixed sheave “2” with the oil seal
• Spacer guide “3”.
• Primary sheave weights
• Cam
2. Install: Oil seal guide (ø41)
90890-01396
• Primary sheave weights “1”
• Spacer “2”
NOTE:
Before installing the primary sheave weights, lu- 3
bricate the inside and outside of each weight
with Shell BT grease 3®.
1
Recommended lubricant 2
Shell BT grease 3®
3. Install:
• Guide pins “1”
4. Lubricate:
• Guide pin grooves “2”
• O-rings “3” New
BEL-RAY assembly lube®
EAS24730
ASSEMBLING THE SECONDARY SHEAVE

1. Lubricate:
• Secondary fixed sheave’s inner surface “1”
• Secondary sliding sheave’s inner surface “2”
• Oil seals
• Bearing
BEL-RAY assembly lube®
5. Install:
• Spring seat
5-36
• Compression spring
• Spacer Clutch carrier nut
• Clutch carrier “1” 90 Nm (9.0 m·kg, 65 ft·lb)
T.
R.
• Clutch carrier nut “2”
NOTE:
NOTE:
While holding the clutch carrier with the sheave
While compressing the compression spring with
holder “2”, tighten the clutch carrier nut with the
the clutch spring holder “3” and clutch spring
locknut wrench “3”.
holder arm “4”, install the clutch carrier nut.
Sheave holder
Clutch spring holder
90890-01701
90890-01337
Clutch spring holder arm
YS-01880-A
90890-01464
Locknut wrench
90890-01348
YM-01348
EAS24740
INSTALLING THE V-BELT

1. Install: 3. Install:
• V-belt “1” • Clutch housing “1”
• Secondary sheave assembly “2” • Collar
ECA5B21020
• Secondary sheave nut “2”
CAUTION:
Do not allow grease to come in contact with Secondary sheave nut
the V-belt or secondary sheave assembly. 60 Nm (6.0 m·kg, 43 ft·lb)
T.
R.
NOTE:
NOTE:
• Install the V-belt with the printed arrow mark on While holding the clutch housing with the sheave
the V-belt facing in the direction shown in the il- holder “3”, tighten the secondary sheave nut.
lustration.
• Install the V-belt onto the primary sheave side.
Sheave holder
90890-01701
YS-01880-A
2. Install:
• Clutch carrier nut “1”
5-37
4. Position: 6. Install:
• V-belt “1” • V-belt case
NOTE: NOTE:
Position the V-belt in the primary sheave “2” • Make sure that the V-belt case gasket lip fits
(when the pulley is at its widest position) and in properly around the V-belt case.
the secondary sheave “3” (when the pulley is at • Tighten the V-belt case bolts in stages and in a
its narrowest position), and make sure the V-belt crisscross pattern.
is tight.
5. Install:
• Primary fixed sheave “1”
• Washer
• Primary sheave nut “2”
Primary sheave nut

80 Nm (8.0 m·kg, 58 ft·lb)
T.
R.
NOTE:
While holding the primary fixed sheave with the
rotor holding tool “3”, tighten the primary sheave
nut.
Rotor holding tool

90890-01235
Universal magneto & rotor holder
YU-01235
5-38
STARTER CLUTCH AND GENERATOR
EAS24480

Removing the generator cover and stator coil
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
1
R.
LT
LT
4
5
New
LS
4 LT LS
10 Nm (1.0 m • kg, 7.2 ft • Ib) 6 2

T.
R.
New
LS
New 3
New
8 Nm (0.8 m • kg, 5.8 ft • Ib)

T.
R.
(10)
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-9.
Muffler/Exhaust pipe Refer to “ENGINE REMOVAL” on page 5-1.
Crankshaft position sensor coupler/Stator as-
1 1/1 Disconnect.
sembly coupler
2 Generator cover 1
3 Generator cover gasket 1
4 Dowel pin 2
5 Crankshaft position sensor 1
6 Stator coil 1
dure.
5-39
Removing the generator rotor and starter clutch
80 Nm (8.0 m • kg, 58 ft • Ib)

T.
R.

1 Circlip 1
2 Washer 1
3 Starter clutch idle gear shaft 1
4 Starter clutch idle gear 1
5 Generator rotor 1
6 Woodruff key 1
7 Starter clutch gear 1
8 Starter clutch 1
dure.
5-40
EAS24490
REMOVING THE GENERATOR

1. Remove:
• Generator cover
NOTE:
2. Remove:
• Generator rotor nut “1”
• Washer EAS24560
REMOVING THE STARTER CLUTCH

NOTE:
1. Remove:
• While holding the generator rotor “2” with the • Starter clutch bolts “1”
sheave holder “3”, loosen the generator rotor • Starter clutch
nut.
NOTE:
• Do not allow the sheave holder to touch the
projection on the generator rotor. • While holding the generator rotor “2” with the
sheave holder “3”, remove the starter clutch
bolts.
Sheave holder • Do not allow the sheave holder to touch the
90890-01701
projection on the generator rotor.
YS-01880-A
Sheave holder
90890-01701
YS-01880-A
3. Remove:
• Generator rotor “1”
(with the flywheel puller “2”)
• Woodruff key
ECA13880 EAS24570
CAUTION: CHECKING THE STARTER CLUTCH

To protect the end of the crankshaft, place an 1. Check:
appropriate sized socket between the fly- • Starter clutch rollers “1”
wheel puller set’s center bolt and the crank- Damage/wear → Replace.
shaft.
NOTE:
Make sure the flywheel puller is centered over
the generator rotor.
Flywheel puller
90890-01362
Heavy duty puller 1
YU-33270-B
5-41
2. Check:
• Starter clutch idle gear Sheave holder
• Starter clutch gear 90890-01701
Burrs/chips/roughness/wear → Replace the Primary clutch holder
YS-01880-A
defective part(s).
3. Check:
• Starter clutch gear’s contacting surfaces
Damage/pitting/wear → Replace the starter
clutch gear.
4. Check:
• Starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch gear “1” onto the
starter clutch “2” and hold the starter clutch.
b. When turning the starter clutch gear clock-
wise “A”, the starter clutch and the starter
clutch gear should engage, otherwise the EAS24500
starter clutch is faulty and must be replaced. INSTALLING THE GENERATOR

c. When turning the starter clutch gear counter- 1. Install:
clockwise “B”, it should turn freely, otherwise • Starter clutch gear
the starter clutch is faulty and must be re- • Woodruff key
placed. • Generator rotor
• Washer
• Generator rotor nut
NOTE:
• Clean the tapered portion of the crankshaft and
the generator rotor hub.
• When installing the generator rotor, make sure
the woodruff key is properly seated in the key-
way of the crankshaft.
2. Tighten:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Generator rotor nut “1”
EAS24600
Generator rotor nut
INSTALLING THE STARTER CLUTCH 80 Nm (8.0 m·kg, 58 ft·lb)
T.
1. Install:
R.
• Starter clutch
NOTE:
• Starter clutch bolts “1”
• While holding the generator rotor “2” with the
Starter clutch bolt sheave holder “3”, tighten the generator rotor
30 Nm (3.0 m·kg, 22 ft·lb) nut.
T.
R.
LOCTITE® • Do not allow the sheave holder to touch the

NOTE:
• While holding the generator rotor “2” with the Sheave holder
sheave holder “3”, tighten the starter clutch 90890-01701
bolts. Primary clutch holder
• Do not allow the sheave holder to touch the YS-01880-A
5-42
NOTE:
Tighten the generator cover bolts in stages and
in a crisscross pattern.
3. Apply:
• Sealant
(onto the crankshaft position sensor/stator
assembly lead grommet)
Yamaha bond No. 1215

90890-85505
4. Install:
• Oil seal “1” New
Installed depth “a”

6.0–7.3 mm (0.24–0.29 in)
1 New
5. Install:
• Generator cover
Generator cover bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
5-43
ELECTRIC STARTER
EAS24780
ELECTRIC STARTER
Removing the starter motor
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
LS
2 New
1

Storage box/Air filter case 4-1.
1 Starter motor lead 1 Disconnect.
2 Ground lead 1 Disconnect.
3 Starter motor 1
dure.
5-44
ELECTRIC STARTER
Disassembling the starter motor

1 Starter motor front cover 1
2 O-ring 1
3 Shim 1
4 Lock washer 1
5 Starter motor rear cover 1
6 O-ring 1
7 Shim 1
8 Brush holder set 1
9 Armature assembly 1
10 Starter motor yoke 1
cedure.
5-45
ELECTRIC STARTER
EAS24790
CHECKING THE STARTER MOTOR Pocket tester

1. Check: 90890-03112
• Commutator Analog pocket tester
Dirt → Clean with 600 grit sandpaper. YU-03112-C
2. Measure:
• Commutator diameter “a”
Out of specification → Replace the starter Armature coil
Commutator resistance “1”
motor.
0.0017–0.0027 Ω at 20 °C (68 °F)
Limit Insulation resistance “2”
27.0 mm (1.06 in) Above 1 MΩ at 20 °C (68 °F)
3. Measure: b. If any resistance is out of specification, re-

• Mica undercut “a” place the starter motor.
Out of specification → Scrape the mica to the ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
proper measurement with a hacksaw blade 5. Measure:

that has been grounded to fit the commutator. • Brush length “a”
Out of specification → Replace the brushes
Mica undercut (depth) as a set.
0.70 mm (0.03 in)
Limit
NOTE: 4.00 mm (0.16 in)
The mica of the commutator must be undercut to
ensure proper operation of the commutator.
6. Measure:
• Brush spring force
4. Measure: Out of specification → Replace the brush
• Armature assembly resistances (commutator springs as a set.
and insulation)
Out of specification → Replace the starter Brush spring force
motor. 7.65–10.01 N (27.5–36.0 oz)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
(780–1020 gf)
a. Measure the armature assembly resistances
with the pocket tester.
5-46
ELECTRIC STARTER
7. Check:
• Gear teeth
Damage/wear → Replace the gear.
8. Check:
• Bearing
• Oil seal
• Bushing
Damage/wear → Replace the defective
part(s).
EAS24800
ASSEMBLING THE STARTER MOTOR

1. Install:
• Starter motor yoke “1”
• Starter motor front cover “2”
• Starter motor rear cover “3”
NOTE:
Align the match marks “a” on the starter motor
yoke with the match marks “b” on the starter mo-
tor front and rear covers.
5-47
OIL PUMP
EAS24910
OIL PUMP
Removing the oil pump
LS
3 New
8 11 E
12
13
9
14
2
10 7
6
9 5
4
E
New
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
12 Nm (1.2 m • kg, 8.7 ft • Ib)

T.
R.

Refer to “STARTER CLUTCH AND GENER-
Starter clutch gear ATOR” on page 5-39.
1 Oil baffle plate 1
2 Oil pump assembly 1
3 Oil pump gasket 1
4 Circlip 1
5 Washer 1
6 Oil pump driven gear 1
7 Pin 1
8 Oil pump housing cover 1
9 Pin 2
10 Pin 1
11 Oil pump shaft 1
12 Oil pump inner rotor 1
13 Oil pump outer rotor 1
5-48
OIL PUMP
Removing the oil pump
LS
3 New
8 11 E
12
13
9
14
2
10 7
6
9 5
4
E
New
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
12 Nm (1.2 m • kg, 8.7 ft • Ib)

T.
R.

14 Oil pump housing 1
dure.
5-49
OIL PUMP
EAS24960
CHECKING THE OIL PUMP Inner-rotor-to-outer-rotor-tip

1. Check: clearance
• Oil pump drive gear Less than 0.15 mm (0.0059 in)
• Oil pump driven gear Limit
• Oil pump housing 0.23 mm (0.0091 in)
• Oil pump housing cover Outer-rotor-to-oil-pump-housing
Cracks/damage/wear → Replace the defec- clearance
tive part(s). 0.013–0.036 mm (0.0005–0.0014
2. Measure: in)
Limit
• Inner-rotor-to-outer-rotor-tip clearance “a”
0.106 mm (0.0042 in)
• Outer-rotor-to-oil-pump-housing clearance Oil-pump-housing-to-inner-and-
“b” outer-rotor clearance
• Oil-pump-housing-to-inner-rotor-and-outer- 0.04–0.09 mm (0.0016–0.0035 in)
rotor clearance “c” Limit
Out of specification → Replace the oil pump. 0.16 mm (0.0063 in)
3. Check:
• Oil pump operation
Rough movement → Repeat steps (1) and
(2) or replace the defective part(s).
EAS25000
ASSEMBLING THE OIL PUMP

1. Lubricate:
• Inner rotor
• Outer rotor
• Oil pump shaft
1. Inner rotor (with the recommended lubricant)
2. Outer rotor
3. Oil pump housing Recommended lubricant
Engine oil
2. Install:
• Oil pump housing “1”
• Outer rotor “2”
• Inner rotor “3”
• Oil pump shaft “4”
• Pin “5”
• Pins “6”
• Oil pump housing cover “7”
• Pin “8”
• Oil pump driven gear “9”
• Washer “10”
5-50
OIL PUMP
• Circlip “11” New

NOTE:
When installing the oil pump shaft, align the pin
“5” in the oil pump shaft with the groove in the in-
ner rotor.
7 4
3 2
6
1
8
9
5 10
6 11
New
3. Check:
• Oil pump operation
Refer to “CHECKING THE OIL PUMP” on
page 5-50.
EAS25020
INSTALLING THE OIL PUMP

1. Install:
• Oil pump assembly
Oil pump assembly 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.
5-51
TRANSMISSION
EAS26240
TRANSMISSION
Removing the transmission
G
G
A B
LS
New
G
16 Nm (1.6 m • kg, 11 ft • Ib)

T.
R.

Rear wheel Refer to “REAR WHEEL” on page 4-12.
Drain.
Final transmission oil Refer to “CHANGING THE FINAL TRANS-
MISSION OIL” on page 3-11.
Refer to “V-BELT AUTOMATIC TRANSMIS-
Secondary sheave assembly SION” on page 5-29.
1 Transmission case cover 1
2 Gasket 1
3 Dowel pin 2
4 Primary drive gear 1
5 Washer 2
6 Washer 1
7 1st wheel gear 1
8 Conical spring washer 1
9 Drive axle 1
10 Main axle 1
11 Conical spring washer 1
5-52
TRANSMISSION
Removing the transmission
G
G
A B
LS
New
G
16 Nm (1.6 m • kg, 11 ft • Ib)

T.
R.

12 Primary driven gear 1
dure.
5-53
TRANSMISSION
EAS26250
REMOVING THE TRANSMISSION

1. Remove:
• Transmission case cover
NOTE:
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
(each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission
axle assemblies.
3. Check:
• Transmission gear movement
Rough movement → Replace the defective
part(s).
4. Check:
• Circlip
Bends/damage/looseness → Replace.
5-54
CRANKSHAFT
EAS25960
CRANKSHAFT
Removing the crankshaft
7
8
9 E
22 Nm (2.2 m • kg, 16 ft • Ib)
T.
R.
LS
8 1
11
4
LS
3
New New
2
6
32 Nm (3.2 m • kg, 23 ft • Ib) 12
T.
R.
5
New
10
LS
10 Nm (1.0 m • kg, 7.2 ft • Ib) New
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)

T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

Water pump assembly Refer to “WATER PUMP” on page 6-6.
Engine Refer to “ENGINE REMOVAL” on page 5-1.
Refer to “CYLINDER AND PISTON” on page
Piston 5-24.
Refer to “V-BELT AUTOMATIC TRANSMIS-
Belt drive SION” on page 5-29.
Oil pump assembly Refer to “OIL PUMP” on page 5-48.
Transmission Refer to “TRANSMISSION” on page 5-52.
1 Transmission case breather hose 1
2 Oil strainer cover 1
3 Spring 1
4 Oil strainer 1
5 Timing chain guide retaining bolt 1
6 Timing chain guide (intake side) 1
7 Right crankcase 1
8 Dowel pin 2
5-55
CRANKSHAFT
Removing the crankshaft
7
8
9 E
22 Nm (2.2 m • kg, 16 ft • Ib)
T.
R.
LS
8 1
11
4
LS
3
New New
2
6
32 Nm (3.2 m • kg, 23 ft • Ib) 12
T.
R.
5
New
10
LS
10 Nm (1.0 m • kg, 7.2 ft • Ib) New
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)

T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

9 Crankshaft assembly 1
10 Timing chain 1
11 Left crankcase 1
12 Oil seal 1
dure.
5-56
CRANKSHAFT
EAS25560 EAS26020
DISASSEMBLING THE CRANKCASE REMOVING THE CRANKSHAFT ASSEMBLY

1. Remove: 1. Remove:
• Crankcase bolts • Timing chain “1”
NOTE: NOTE:
Loosen each bolt 1/4 of a turn at a time, in stag- • Before removing the crankshaft assembly, re-
es and in a crisscross pattern. After all of the move the timing chain from the crankshaft
bolts are fully loosened, remove them. sprocket.
• The crankshaft assembly cannot be removed if
the timing chain is attached onto the crankshaft
sprocket.
2. Remove:
• Right crankcase “1”
NOTE:
• Remove the right crankcase with the crank- 2. Remove:
case separating tool “2” and M6 bolts “3”. • Crankshaft assembly “1”
• Make sure that the crankcase separating tool NOTE:
is centered over the crankshaft. • Remove the crankshaft assembly with the
ECA5B21017
crankcase separating tool “2” and M6 bolts “3”.
CAUTION: • Make sure that the crankcase separating tool
• To protect the end of the crankshaft, place is centered over the crankshaft assembly.
an appropriate sized socket “4” between ECA5B21017
the crankcase separating tool bolt and the CAUTION:

crankshaft. • To protect the end of the crankshaft, place
• Do not tap on the crankshaft. an appropriate sized socket “4” between
the crankcase separating tool bolt and the
Crankcase separating tool crankshaft.
90890-01135 • Do not tap on the crankshaft.
Crankcase separator
YU-01135-B Crankcase separating tool
90890-01135
Crankcase separator
YU-01135-B
5-57
CRANKSHAFT
EAS24180
CHECKING THE TIMING CHAIN AND TIMING Big end side clearance D
CHAIN GUIDES 0.350–0.850 mm (0.0138–0.0335
The following procedure applies to all of the tim- in)
ing chain guides.
1. Check:
• Timing chain
Damage/stiffness → Replace the timing
chain and camshaft sprocket as a set.
3. Measure:
• Crankshaft width
Out of specification → Replace the crank-
shaft.
2. Check:
• Timing chain guide (intake side) Width A
Damage/wear → Replace. 59.75–59.80 mm (2.352–2.354 in)
EAS26060
CHECKING THE CRANKSHAFT AND

CONNECTING ROD
1. Measure:
• Crankshaft runout
Out of specification → Replace the crank-
shaft, bearing or both.
NOTE:
Turn the crankshaft slowly.
Runout limit C 4. Check:

0.030 mm (0.0012 in) • Crankshaft sprocket “1”
Damage/wear → Replace the crankshaft.
• Bearings “2”
Cracks/damage/wear → Replace the crank-
shaft.
• Oil pump drive gear “3”
Damage/wear → Replace the crankshaft.
2. Measure:
• Big end side clearance
Out of specification → Replace the big end
bearing, crankshaft pin, or connecting rod.
5-58
CRANKSHAFT
5. Check:
• Crankshaft journal
Scratches/wear → Replace the crankshaft.
• Crankshaft journal oil passage
3. Install:
• Crankshaft assembly “1”
(to the left crankcase)
NOTE:
Install the crankshaft assembly with the crank-
EAS25580
shaft installer pot “2”, crankshaft installer bolt “3”,
CHECKING THE CRANKCASE adapter “4”, and spacer “5”.
1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and Crankshaft installer pot
90890-01274
crankcase mating surfaces.
Installing pot
3. Check: YU-90058
• Crankcase Crankshaft installer bolt
Cracks/damage → Replace. 90890-01275
• Oil delivery passages Bolt
Obstruction → Blow out with compressed air. YU-90060
Adapter (M14)
EAS26210
INSTALLING THE CRANKSHAFT 90890-01478

Adapter #6
1. Lubricate:
YM-90066
• Oil seals Spacer (crankshaft installer)
• Bearings 90890-04081
• Oil pump drive gear Pot spacer
YM-91044
Oil seal
Bearing, oil pump drive gear 5
Engine oil 1
4
2. Install: 3
• Timing chain “1”
NOTE:
Install the timing chain so it is not visible through
the opening “a” in the left crankcase “2”. 2
ECA13970
CAUTION:
To avoid scratching the crankshaft and to
ease the installation procedure, lubricate the
oil seal lips with lithium-soap-based grease
and each bearing with engine oil.
5-59
CRANKSHAFT
NOTE:
Crankshaft installer pot
Hold the connecting rod at top dead center 90890-01274
(TDC) with one hand while turning the nut of the Installing pot
crankshaft installer bolt with the other. Turn the YU-90058
crankshaft installer bolt until the crankshaft as- Crankshaft installer bolt
sembly bottoms against the bearing. 90890-01275
Bolt
EAS25700 YU-90060
ASSEMBLING THE CRANKCASE Adapter (M16)
1. Thoroughly clean all the gasket mating sur- 90890-01280
faces and crankcase mating surfaces. Adapter #7
2. Apply: YM-90067
• Sealant Spacer
(onto the crankcase mating surfaces) 90890-01288

90890-85505
NOTE:
Do not allow any sealant to come into contact
with the oil gallery.
4. Install:
• Water pump assembly
• Crankcase bolts “1”, “2”
Crankcase bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
NOTE:
3. Install: Tighten the crankcase bolts in stages and in a
• Right crankcase “1” crisscross pattern.
NOTE:
• M6 × 100 mm (3.94 in) bolts: “1”
Install the crankshaft assembly with the crank- • M6 × 70 mm (2.76 in) bolts: “2”
shaft installer pot “2”, crankshaft installer bolt “3”,
adapter “4”, and spacer “5”.
5-60
CRANKSHAFT
5-61
COOLING SYSTEM
RADIATOR ...................................................................................................... 6-1

CHECKING THE RADIATOR.................................................................... 6-3
INSTALLING THE RADIATOR.................................................................. 6-3
THERMOSTAT ................................................................................................ 6-4

CHECKING THE THERMOSTAT.............................................................. 6-5
INSTALLING THE THERMOSTAT............................................................ 6-5
WATER PUMP................................................................................................. 6-6

DISASSEMBLING THE WATER PUMP.................................................... 6-8
CHECKING THE WATER PUMP .............................................................. 6-8
ASSEMBLING THE WATER PUMP.......................................................... 6-8
INSTALLING THE WATER PUMP ............................................................ 6-9
6
RADIATOR
EAS26380
RADIATOR
Removing the radiator
3
4 1
New
12
5
New
2
6
9
(3)
(3)
7
8
(3)
11
10

Front cowling/Footrest boards/Under cover 4-1.
Drain.
page 3-14.
1 Radiator cap 1
2 Coolant reservoir hose 1
3 Coolant reservoir breather hose 1
4 Coolant reservoir 1
5 Radiator filler hose 1
6 Radiator inlet hose 1
7 Radiator outlet hose 1
8 Radiator fan motor coupler 1 Disconnect.
9 Radiator 1
10 Radiator fan motor cover 1
11 Radiator fan motor 1
6-1
RADIATOR
Removing the radiator

3
4 1
New
12
5
New
2
6
9
(3)
(3)
7
8
(3)
11
10

12 Air shroud 1
dure.
6-2
RADIATOR
EAS26390
CHECKING THE RADIATOR

1. Check:
• Radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the radia-
tor.
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 motor
Damage → Replace.
Malfunction → Check and repair.
Refer to “CHECKING THE RADIATOR FAN
MOTOR” on page 8-79.
EAS26400
INSTALLING THE RADIATOR

2. Check: 1. Fill:
• Radiator hoses • Cooling system
Cracks/damage → Replace. (with the specified amount of the recom-
3. Measure: mended coolant)
• Radiator cap opening pressure Refer to “CHANGING THE COOLANT” on
Below the specified pressure → Replace the page 3-14.
radiator cap. 2. Check:
• Cooling system
Radiator cap opening pressure
Leaks → Repair or replace any faulty part.
110.0–140.0 kPa (16.0–20.3 psi)
(1.10–1.40 kgf/cm²)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the radiator cap tester “1” and radiator
cap tester adapter “2” to the radiator cap “3”.
Radiator cap tester

90890-01325
Radiator pressure tester
YU-24460-01
Radiator cap tester adapter
90890-01352
Radiator pressure tester adapter
YU-33984
6-3
THERMOSTAT
EAS26440
THERMOSTAT
Removing the thermostat
New
3 2

Storage box/Center panels 4-1.
Drain.
page 3-14.
1 Radiator inlet hose 1 Disconnect.
2 Thermostat inlet hose 1
3 Thermostat cover 1
4 Thermostat 1
dure.
6-4
THERMOSTAT
EAS26450
CHECKING THE THERMOSTAT

1. Check:
• Thermostat
Does not open at 82–95 °C (179.6–203.0 °F)
→ Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Suspend the thermostat “1” in a container “2”
filled with water. a
b. Slowly heat the water “3”.
c. Place a thermometer “4” in the water.
d. While stirring the water, observe the thermo- 2. Fill:
stat and thermometer’s indicated tempera- • Cooling system
ture. (with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-14.
3. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
4. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-3.
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Thermostat cover
EAS26460
INSTALLING THE THERMOSTAT

1. Install:
• Thermostat
NOTE:
Install the thermostat with its breather hole “a” in
the position shown in the illustration.
6-5
WATER PUMP
EAS26500
WATER PUMP
Removing the water pump
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.
R.
1
4
New LS 3
LS
2
LS 10
13
14
6 9
New 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
New 12
7
T.
R.
LS 8
11
5
New
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

It is not necessary to remove the water
pump unless the coolant level is extremely
low or the coolant contains engine oil.
Footrest boards 4-1.
Refer to “STARTER CLUTCH AND GENER-
Generator rotor ATOR” on page 5-39.
Drain.
page 3-14.
1 Oil baffle plate 1
2 Impeller shaft gear 1
3 Dowel pin/Washer 1/1
4 Shaft 1
5 Radiator outlet hose 1 Disconnect.
6 Water pump outlet pipe 1
7 Water pump housing cover 1
8 Gasket 1
6-6
WATER PUMP
Removing the water pump
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.
R.
1
4
New LS 3
LS
2
LS 10
13
14
6 9
New 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
New 12
7
T.
R.
LS 8
11
5
New
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

9 Water pump housing 1
10 Circlip 1
11 Impeller shaft 1
12 Water pump seal 1
13 Bearing 1
14 Oil seal 1
dure.
A: Oil pump side
6-7
WATER PUMP
EAS26510 EAS26550
DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP

1. Remove: 1. Check:
• Rubber damper holder “1” • Water pump housing cover
• Rubber damper “2” • Water pump housing
(from the impeller, with a thin, flat-head • Impeller shaft
screwdriver) Cracks/damage/wear → Replace.
NOTE: 2. Check:
Do not scratch the impeller shaft. • Bearing
Rough movement → Replace.
EAS26570
ASSEMBLING THE WATER PUMP

1. Install:
• Oil seal “1” New
(into the water pump housing)
NOTE:
• Before installing the oil seal, apply tap water or
coolant onto its outer surface.
• Install the oil seal with a socket that matches its
2. Remove: outside diameter.
• Water pump seal “1”
NOTE: Installed depth of oil seal “a”
Remove the water pump seal from the inside of 8.1–8.7 mm (0.32–0.34 in)
the water pump housing.
1 New
3. Remove: 2. Install:
• Oil seal “1” • Water pump seal “1” New
• Bearing “2” ECA14080
NOTE: CAUTION:
Remove the bearing and oil seal from the out- Never lubricate the water pump seal surface
side of the water pump housing. with oil or grease.
NOTE:
• Install the water pump seal with the special
2 tools.
• Before installing the water pump seal, apply
Yamaha bond No.1215 (Three Bond
No.1215®) “2” to the water pump housing “3”.
6-8
WATER PUMP
Mechanical seal installer Impeller shaft tilt limit

90890-04132 0.15 mm (0.0059 in)
Water pump seal installer
YM-33221-A
Middle driven shaft bearing driv-
er
90890-04058
Bearing driver 40 mm
YM-04058
90890-85505
1. Straightedge
2. Impeller
5. Install:
• Impeller shaft
• Circlip New
NOTE:
After installation, check that the impeller shaft ro-
tates smoothly.
A. Push down
EAS26580
4. Mechanical seal installer INSTALLING THE WATER PUMP
5. Middle driven shaft bearing driver 1. Install:
3. Install: • Shaft “1”
NOTE:
• Rubber damper “1” New
Align the slot on the impeller shaft with the pro-
• Rubber damper holder “2” New jection on the shaft when installing.
NOTE:
Before installing the rubber damper, apply tap
water or coolant onto its outer surface.
2. Fill:
• Cooling system
4. Measure:
mended coolant)
• Impeller shaft tilt
Refer to “CHANGING THE COOLANT” on
Out of specification → Repeat steps (3) and
page 3-14.
(4).
ECA14090 3. Check:
CAUTION: • Cooling system
Make sure the rubber damper and rubber Leaks → Repair or replace any faulty part.
damper holder are flush with the impeller.
6-9
WATER PUMP
4. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-3.
6-10
WATER PUMP
6-11
FUEL SYSTEM
FUEL TANK..................................................................................................... 7-1

REMOVING THE FUEL TANK .................................................................. 7-2
INSTALLING THE FUEL HOSE ................................................................ 7-2
THROTTLE BODY........................................................................................... 7-3

REMOVING THE FUEL HOSE ................................................................. 7-5
CHECKING THE FUEL INJECTOR .......................................................... 7-5
CHECKING THE THROTTLE BODY ........................................................ 7-5
INSTALLING THE FUEL HOSE ................................................................ 7-5
INSTALLING THE THROTTLE BODY ...................................................... 7-6
CHECKING THE FUEL PRESSURE ........................................................ 7-6
CHECKING THE THROTTLE POSITION SENSOR ................................. 7-6
CHECKING THE ISC (IDLE SPEED CONTROL) UNIT............................ 7-7
7
FUEL TANK
EAS26620
FUEL TANK
Removing the fuel tank
1
9
4
6
LT
13 Nm (1.3 m • kg, 9.4 ft • Ib) (4)

T.
R.

Front cowling/Storage box/Under cover 4-1.
Radiator Refer to “RADIATOR” on page 6-1.
1 ECU (engine control unit) 1
2 Fuel sender coupler 1 Disconnect.
3 Fuel pump coupler 1 Disconnect.
4 Fuel hose connector cover 1
5 Fuel hose 1 Disconnect.
6 Sidestand switch coupler 1 Disconnect.
7 Fuel tank bracket 1
8 Fuel tank 1
9 Fuel tank overflow hose 1
dure.
7-1
FUEL TANK
EAS26630
• After installing the fuel hose connector cover
REMOVING THE FUEL TANK
“2”, make sure that it is installed securely.
1. Extract the fuel in the fuel tank through the
fuel tank filler hole with a pump.
2. Remove: 1
• Fuel hose connector cover “1”
3. Disconnect:
• Fuel hose “2”
ECA5B21005
CAUTION:
• Be sure to disconnect the fuel hose by
a
hand. Do not forcefully disconnect the
hose with tools.
• Although the fuel has been removed from
the fuel tank, be careful when removing the
fuel hose, since there may be fuel remain-
ing in it.
• Do not disconnect the fuel hose from the
fuel hose connector. Disconnect the con- 2
nector from the fuel pump.
NOTE:
Before removing the hose, place a few rags in
the area under where it will be removed.
1
2
4. Remove:
• Fuel tank
EAS26710
INSTALLING THE FUEL HOSE

1. Install:
• Fuel hose
• Fuel hose connector cover
ECA5B21006
CAUTION:
When installing the fuel hose, make sure that
it is securely connected, and that the fuel
hose connector cover is in the correct posi-
tion, otherwise the fuel hose will not be prop-
erly installed.
NOTE:
• Wipe up any fuel remaining in the recess “a” in
the fuel pump with a dry rag “1”.
7-2
THROTTLE BODY
EAS26970
THROTTLE BODY
Removing the throttle body
10 Nm (1.0 m • kg, 7.2 ft • Ib)
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.
R.
T.
R.
16 5
2 12
4
New
3
LS
13
17
10 Nm (1.0 m • kg, 7.2 ft • Ib) 14

T.
R.
6
10 9
15 1
7
11

Storage box/Footrest board 4-1.
1 ISC (idle speed control) unit coupler 1 Disconnect.
2 Intake air pressure sensor coupler 1 Disconnect.
3 Intake air pressure sensor hose 1
4 Intake air pressure sensor 1
5 Intake air pressure sensor bracket 1
6 Throttle position sensor coupler 1 Disconnect.
7 Throttle cable 2 Disconnect.
8 Air filter case to throttle body hose 1
9 Air filter case joint clamp screw 1 Loosen.
10 Throttle body joint clamp screw 1 Loosen.
11 Throttle body 1
12 Vacuum chamber cover 1
13 Piston valve spring 1
14 Piston valve 1
7-3
THROTTLE BODY
Removing the throttle body

10 Nm (1.0 m • kg, 7.2 ft • Ib)
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.
R.
T.
R.
16 5
2 12
4
New
3
LS
13
17
10 Nm (1.0 m • kg, 7.2 ft • Ib) 14
T.
R.
6
10 9
15 1
7
11

15 Throttle position sensor 1
16 Fuel injector coupler 1 Disconnect.
17 Fuel injector assembly 1
dure.
7-4
THROTTLE BODY
EAS5B21001
b. Blow out all of the passages with compressed
REMOVING THE FUEL HOSE
air.
1. Extract the fuel in the fuel tank through the
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
fuel tank filler hole with a pump.
2. Remove: 3. Check:
• Fuel hose connector cover “1” • Piston valve
3. Disconnect: Damage/scratches/wear → Replace.
• Fuel hose “2” • Piston valve diaphragm
ECA5B21005 Cracks/tears → Replace.
CAUTION: 4. Check:
• Be sure to disconnect the fuel hose by • Vacuum chamber cover
hand. Do not forcefully disconnect the • Piston valve spring
hose with tools. Cracks/damage → Replace.
• Although the fuel has been removed from 5. Check:
the fuel tank, be careful when removing the • Piston valve movement
fuel hose, since there may be fuel remain- Insert the piston valve into the throttle body
ing in it. and move it up and down.
• Do not disconnect the fuel hose from the Tightness → Replace the piston valve.
fuel hose connector. Disconnect the con-
nector from the fuel pump.
NOTE:
Before removing the hose, place a few rags in
EAS5B21002
INSTALLING THE FUEL HOSE

1. Install:
• Fuel hose
1
• Fuel hose connector cover
2 ECA5B21006
CAUTION:
EAS26980
When installing the fuel hose, make sure that
CHECKING THE FUEL INJECTOR
it is securely connected, and that the fuel
1. Check:
hose connector cover is in the correct posi-
• Fuel injector
tion, otherwise the fuel hose will not be prop-
Damage → Replace.
erly installed.
EAS26990
CHECKING THE THROTTLE BODY NOTE:

1. Check: • Wipe up any fuel remaining in the recess “a” in
• Throttle body the fuel pump with a dry rag “1”.
Cracks/damage → Replace the throttle body. • After installing the fuel hose connector cover
2. Check: “2”, make sure that it is installed securely.
• Fuel passages
Obstructions → Clean.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the throttle body in a petroleum-based
solvent.
Do not use any caustic carburetor cleaning
solution.
7-5
THROTTLE BODY
NOTE:
1 Before removing the hose, place a few rags in
1
2
b. Connect the pressure gauge “3” and fuel

2
pressure adapter “4”.
Pressure gauge
90890-03153
YU-03153
Fuel pressure adapter
90890-03181
EAS5B21003
INSTALLING THE THROTTLE BODY

1. Install:
• Throttle body
NOTE:
Align the projection “a” on the throttle body with
the slot “b” in the throttle body joint.
3
4
a
c. Start the engine.
d. Measure the fuel pressure.
b
Output pressure
250.0 kPa (36.5 psi) (2.50
kgf/cm²)
EAS27010 Faulty → Replace the fuel tank (with fuel

CHECKING THE FUEL PRESSURE pump).
1. Check: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Pressure regulator operation
EAS5B21004
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ CHECKING THE THROTTLE POSITION
a. Remove the fuel hose connector cover “1”
SENSOR
and disconnect the fuel hose “2” from the fuel
1. Check:
pump.
ECA5B21007 • Throttle position sensor
CAUTION: Refer to “CHECKING THE THROTTLE PO-
Although the fuel has been removed from SITION SENSOR” on page 8-80.
the fuel tank, be careful when removing the
fuel hose, since there may be fuel remaining
in it.
7-6
THROTTLE BODY
EAS5B21005
CHECKING THE ISC (IDLE SPEED

CONTROL) UNIT
1. Check:
• ISC (idle speed control) unit
Refer to “CHECKING THE ISC (IDLE
SPEED CONTROL) UNIT” on page 8-82.
7-7
ELECTRICAL SYSTEM
IGNITION SYSTEM ......................................................................................... 8-1

CIRCUIT DIAGRAM .................................................................................. 8-1
TROUBLESHOOTING .............................................................................. 8-3
ELECTRIC STARTING SYSTEM .................................................................... 8-5

CIRCUIT DIAGRAM .................................................................................. 8-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .......................... 8-7
TROUBLESHOOTING .............................................................................. 8-9
CHARGING SYSTEM.................................................................................... 8-11

CIRCUIT DIAGRAM ................................................................................ 8-11
TROUBLESHOOTING ............................................................................ 8-13
LIGHTING SYSTEM ...................................................................................... 8-15

CIRCUIT DIAGRAM ................................................................................ 8-15
SIGNALING SYSTEM ................................................................................... 8-19

CIRCUIT DIAGRAM ................................................................................ 8-19
COOLING SYSTEM....................................................................................... 8-25

CIRCUIT DIAGRAM ................................................................................ 8-25
FUEL INJECTION SYSTEM.......................................................................... 8-29

CIRCUIT DIAGRAM ................................................................................ 8-29
ECU SELF-DIAGNOSTIC FUNCTION.................................................... 8-31
SELF-DIAGNOSTIC FUNCTION TABLE ................................................ 8-32
TROUBLESHOOTING METHOD............................................................ 8-34
DIAGNOSTIC MODE .............................................................................. 8-34
TROUBLESHOOTING DETAILS ............................................................ 8-42
FUEL PUMP SYSTEM................................................................................... 8-59

CIRCUIT DIAGRAM ................................................................................ 8-59
8
ELECTRICAL COMPONENTS...................................................................... 8-63
CHECKING THE SWITCHES ................................................................. 8-65
CHECKING THE BULBS AND BULB SOCKETS ................................... 8-68
CHECKING THE FUSES ........................................................................ 8-69
CHECKING AND CHARGING THE BATTERY....................................... 8-70
CHECKING THE RELAYS ...................................................................... 8-73
CHECKING THE TURN SIGNAL RELAY ............................................... 8-73
CHECKING THE SPARK PLUG CAP ..................................................... 8-74
CHECKING THE IGNITION COIL ........................................................... 8-74
CHECKING THE IGNITION SPARK GAP............................................... 8-75
CHECKING THE CRANKSHAFT POSITION SENSOR.......................... 8-76
CHECKING THE LEAN ANGLE SENSOR.............................................. 8-76
CHECKING THE STARTER MOTOR OPERATION ............................... 8-76
CHECKING THE STATOR COIL ............................................................ 8-77
CHECKING THE RECTIFIER/REGULATOR .......................................... 8-77
CHECKING THE HORN.......................................................................... 8-78
CHECKING THE FUEL SENDER ........................................................... 8-78
CHECKING THE SPEED SENSOR ........................................................ 8-79
CHECKING THE RADIATOR FAN MOTOR ........................................... 8-79
CHECKING THE COOLANT TEMPERATURE SENSOR....................... 8-79
CHECKING THE THROTTLE POSITION SENSOR ............................... 8-80
CHECKING THE INTAKE AIR PRESSURE SENSOR ........................... 8-81
CHECKING THE INTAKE AIR TEMPERATURE SENSOR .................... 8-81
CHECKING THE ISC (IDLE SPEED CONTROL) UNIT.......................... 8-82
EAS27100
O O/B B P G/B Lg Y/W R/B Gy R/G Y/L Gy/B Gy/R Gy/G Y G/R EAS27090
W/B B G B/R Sb L/R L/W L/Y W/R B/W L Br/W Y/G P/W
R/B
4 23
O O
R R/G R/G
2 24
Gy/B W/R R W W/R W/R
Gy/B L
P P
W W R Gy/R Gy/B Y Lg Lg Lg Sb
W W G G 25
CIRCUIT DIAGRAM
1 W W
3 B
Gy
Sb Sb P G
Gy/R Gy/R
W W W W R R L/Y G/Y Y Y
R 18
W W R/B W/Y Gy/B Gy/B 26
R/B
R W/Y Gy/G Gy/G Gy/B
B R B L/W
IGNITION SYSTEM
W W W Gy/B P/W Gy/R

9 R/B L/R Sb O/W B/R B/R R/B
8 (BLACK)
L/W
15
Gy/R
B P/W P/W B B B/R R/B
10 R/B Sb 19
B L/W Gy/B W L Gy/G Gy/B
R 7 B B B 22
G/Y (BLACK) (BLACK) 27
L/Y O/B O/B R/B
B/W L/W 16 17 Br/W Gy/B
R R
5 B B
B B 12 (BLACK)
B R/L O/B O/B R/B
Br/L Br/L ON
OFF B 11 (BLACK) (BLACK) (BLACK)
L/R O/W 20
B Gy/B Br/W Br/W
Br/L
B
Gy/R Y/G Gy/B Y/W

6 G/R
Br/L R/B Gy/R Y/L
21 Y/G Y/G
Gy/B L/W
G/B
B
W/B
L/R
L/Y
R/B
B/W R/L
Y/L
L/Y
B/W L/W
B B/W
69 R/L W/Y
B L/Y
Y/L 13 B B
14 L/W L/W
(BLUE) (BLUE) W/Y W/Y
68
8-1
R R/L B (BLUE) (BLUE)
67
R R/W
66
Br/L R/Y
65
Br/L Br
R/Y Br
Br/W
R/Y R/Y Br
L/B Br
G/R Gy/B
34 R/Y W/B
32 R/W
(BLACK)
33
Br Br L
51 R/B R/B G/B
Gy/B G/R W/B R/W
35 L/B R/Y P Br/W 28

31 30
36 37 38 L/B G R/Y R/Y G L/B
P Y B B Y P G/B
52 R/L O/W Sb Br G/R Y/W B/W G/B Ch Br/W Br/W Ch Dg

G/Y G/Y L
Gy G Y B Ch Dg
Gy/R Br/G 57 58 59
Gy/B Gy 29 B B
R L
64 53 54
63 (BLACK)
Gy Y B
L B 47 Y G Br
Br/G 60 61 62 Ch
Gy/B
55 56 Dg Br Dg
B Br/G B Ch B Dg B Br Ch
Br G/Y B Br
Gy/R R G/Y B B Br
43 Dg G/Y (BLACK) 40 Ch G/Y Br
48 49 50 50 (BLACK)
Br/G Ch Dg
44 42 Dg Br 41 42 Ch Br L B 39
Br G G Br
B G/Y B G/Y
Y/W Dg Y Sb O/W Br/G Br/G Ch B Y Y B 46 45 (BLACK)
G/R B/W Gy Br R/L
B B B
B B B
IGNITION SYSTEM
IGNITION SYSTEM

5. Main switch
6. Ignition fuse
7. Ground lead
8. Battery
9. Main fuse
13.Sidestand switch
15.Starting circuit cut-off relay
21.Lean angle sensor
22.ECU (engine control unit)
23.Ignition coil
24.Spark plug
8-2
IGNITION SYSTEM
EAS27120
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
NOTE:
• Before troubleshooting, remove the following part(s):
1. Storage box
2. Footrest board
3. Front cowling
1. Check the fuses. NG →

(Main and ignition)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-69.
OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-70.
OK ↓
3. Check the spark plug. NG →
Refer to “CHECKING THE SPARK Re-gap or replace the spark plug.
PLUG” on page 3-6.
OK ↓
4. Check the ignition spark gap. OK →
Refer to “CHECKING THE IGNI- Ignition system is OK.
TION SPARK GAP” on page 8-75.
NG ↓
5. Check the spark plug cap. NG →
Refer to “CHECKING THE SPARK Replace the spark plug cap.
PLUG CAP” on page 8-74.
OK ↓
6. Check the ignition coil. NG →
Refer to “CHECKING THE IGNI- Replace the ignition coil.
TION COIL” on page 8-74.
OK ↓
7. Check the crankshaft position sen- NG →
sor.
Replace the crankshaft position sen-
Refer to “CHECKING THE CRANK-
sor/stator assembly.
SHAFT POSITION SENSOR” on
page 8-76.
OK ↓
8. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-65.
OK ↓
8-3
IGNITION SYSTEM
9. Check the sidestand switch. NG →

Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
10.Check the starting circuit cut-off re- NG →
lay.
Replace the starting circuit cut-off relay.
Refer to “CHECKING THE RE-
LAYS” on page 8-73.
OK ↓
11.Check the lean angle sensor. NG →
Refer to “CHECKING THE LEAN Replace the lean angle sensor.
ANGLE SENSOR” on page 8-76.
OK ↓
12.Check the entire ignition system NG →
wiring. Properly connect or repair the ignition sys-
Refer to “CIRCUIT DIAGRAM” on tem wiring.
page 8-1.
OK ↓
Replace the ECU.
8-4
EAS27170
R/B
4 23
O O
R R/G R/G
2 24
Gy/B L
P P
W W G G 25
CIRCUIT DIAGRAM
1 W W
3 B
Gy
Sb Sb P G
Gy/R Gy/R
R 18
R/B
B R B L/W
W W W Gy/B P/W Gy/R
8 (BLACK)
L/W
15
Gy/R
10 R/B Sb 19
R 7 B B B 22
L/Y O/B O/B R/B
R R
5 B B
B B 12 (BLACK)
B R/L O/B O/B R/B
Br/L Br/L ON
L/R O/W 20
B Gy/B Br/W Br/W
Br/L
B
Gy/R Y/G Gy/B Y/W

6 G/R
Br/L R/B Gy/R Y/L
21 Y/G Y/G
Gy/B L/W
G/B
B
ELECTRIC STARTING SYSTEM
W/B
L/R
L/Y
R/B
B/W R/L
Y/L
L/Y
B/W L/W
B B/W
69 R/L W/Y
B L/Y
Y/L 13 B B
14 L/W L/W
68
8-5
67
R R/W
66
Br/L R/Y
65
Br/L Br
R/Y Br
Br/W
R/Y R/Y Br
L/B Br
G/R Gy/B
34 R/Y W/B
32 R/W
(BLACK)
33
Br Br L
51 R/B R/B G/B
Gy/B G/R W/B R/W

31 30
36 37 38 L/B G R/Y R/Y G L/B
P Y B B Y P G/B

G/Y G/Y L
Gy G Y B Ch Dg
Gy/R Br/G 57 58 59
Gy/B Gy 29 B B
R L
64 53 54
63 (BLACK)
Gy Y B
L B 47 Y G Br
Br/G 60 61 62 Ch
Gy/B
55 56 Dg Br Dg
Br G/Y B Br
Gy/R R G/Y B B Br
48 49 50 50 (BLACK)
Br/G Ch Dg
44 42 Dg Br 41 42 Ch Br L B 39
Br G G Br
B G/Y B G/Y
G/R B/W Gy Br R/L
B B B
B B B
5. Main switch
6. Ignition fuse
7. Ground lead
8. Battery
9. Main fuse
10.Starter relay
11.Starter motor
12.Diode
13.Sidestand switch
14.Start switch
30.Rear brake light switch
31.Front brake light switch
65.Signaling system fuse
8-6
EAS27180
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the main switch is set to “ON” (switch is closed), the starter motor can only operate if the following
conditions are 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 this condition has not
been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the starter
motor. When the above condition has been met, the starting circuit cut-off relay is closed and the engine
can be started by pressing the start switch “ ”.
13
12
11
1
10
2 4
5
3
7 8 9
8-7
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
6. Sidestand switch
7. Signaling system fuse
8. Front brake light switch
9. Rear brake light switch
10. Start switch
11. Diode
12. Starter relay
13. Starter motor
8-8
EAS27190
TROUBLESHOOTING
The starter motor fails to turn.
NOTE:
1. Storage box
2. Footrest board
3. Front cowling
4. Air filter case

(Main, ignition, and signaling sys-
tem) Replace the fuse(s).
ES” on page 8-69.
OK ↓
page 8-70.
OK ↓
3. Check the starter motor operation. OK →
Starter motor is OK. Perform the electric
Refer to “CHECKING THE START-
starting system troubleshooting, starting
ER MOTOR OPERATION” on page
with step 5.
8-76.
NG ↓
4. Check the starter motor. NG →
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-46.
OK ↓
5. Check the starting circuit cut-off re- NG →
lay.
Replace the starting circuit cut-off relay.
Refer to “CHECKING THE RE-
OK ↓
6. Check the starter relay. NG →
Refer to “CHECKING THE RE- Replace the starter relay.
OK ↓
OK ↓
8-9
8. Check the sidestand switch. NG →

Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
9. Check the brake light switches NG →
(front and rear).
Replace the brake light switch(es).
Refer to “CHECKING THE
OK ↓
10.Check the start switch. NG →
Refer to “CHECKING THE Replace the start switch.
OK ↓
11.Check the entire starting system NG →
wiring. Properly connect or repair the starting sys-
page 8-5.
OK ↓
The starting system circuit is OK.
8-10
EAS27210
EAS27200
4
R R/G
CIRCUIT DIAGRAM
2
Gy/B W/R R W W/R
Gy/B
W W R
CHARGING SYSTEM
1 W W 3
W W B
W W W W R R L/Y G/Y
R
W W R/B W/Y
R/B
R W/Y
B R B L/W
W W W 9 R/B L/R Sb O/W
8 (BLACK)
L/W
15
B
10 R/B Sb
B B L/W
R 7 B B
G/Y
L/Y
B/W L/W 16 17
R R
5 B B
B B 12
Br/L Br/L ON B
OFF B 11 (BLACK)
L/R O/W
B
8-11
Br/L
B
6
Br/L R/B
B/W R/L
Y/L
L/Y
B/W L/W
69 R/L W/Y
B L/Y
Y/L 13 B B
14 L/W L/W
68
67
R R/W
66
Br/L R/Y
65
Br/L Br
R/Y Br
CHARGING SYSTEM
CHARGING SYSTEM
1. AC magneto
3. Rectifier/regulator
7. Ground lead
8. Battery
9. Main fuse
8-12
CHARGING SYSTEM
EAS27230
TROUBLESHOOTING
The battery is not being charged.
NOTE:
1. Storage box
2. Footrest board
1. Check the fuse. NG →

(Main)
Replace the fuse.
ES” on page 8-69.
OK ↓
page 8-70.
OK ↓
3. Check the stator coil. NG →
Replace the crankshaft position sen-
Refer to “CHECKING THE STATOR
sor/stator assembly.
COIL” on page 8-77.
OK ↓
4. Check the rectifier/regulator. NG →
Refer to “CHECKING THE RECTI- Replace the rectifier/regulator.
FIER/REGULATOR” on page 8-77.
OK ↓
5. Check the entire charging system NG →
wiring. Properly connect or repair the charging
Refer to “CIRCUIT DIAGRAM” on system wiring.
page 8-11.
OK ↓
The charging system circuit is OK.
8-13
CHARGING SYSTEM
8-14
EAS27250
EAS27240
W/B B G B/R Sb L/R L/W L/Y W/R B/W L
Gy/B W/R R W
Gy/R Gy/B Y
CIRCUIT DIAGRAM
W W W W L/Y G/Y
W W R/B W/Y
R
B R B L/W
W W W Gy/B P/W Gy/R
R/B L/R Sb O/W
(BLACK)
LIGHTING SYSTEM
B B
L/W Br/W Gy/B

R R B (BLACK)
Br/L Br/L
(BLACK)
Gy/R Y/G Gy/B
B L/Y
B B
L/W L/W
(BLUE) (BLUE)
8-15
G/B
B B
R L
(BLACK)
Br/G B
Br/G B
LIGHTING SYSTEM
LIGHTING SYSTEM
5. Main switch
7. Ground lead
8. Battery
9. Main fuse
34.Headlight relay
36.Dimmer/pass switch
39.License plate light
42.Tail/brake light
48.Headlight (high beam)
49.Headlight (low beam)
50.Auxiliary light
58.Meter light
59.High beam indicator light
66.Headlight fuse
8-16
LIGHTING SYSTEM
EAS27260
TROUBLESHOOTING
Any of the following fail to light: headlight, high beam indicator light, taillights, license plate light, auxiliary
lights or meter light.
NOTE:
1. Battery cover
2. Front cowling
1. Check the condition of each bulb NG →

and bulb socket.
Refer to “CHECKING THE BULBS Replace the bulb(s) and bulb socket(s).
AND BULB SOCKETS” on page
8-68.
OK ↓
(Main, headlight, and signaling sys-
tem) Replace the fuse(s).
ES” on page 8-69.
OK ↓
page 8-70.
OK ↓
OK ↓
5. Check the dimmer/pass switch. NG →
The dimmer/pass switch is faulty. Replace
the handlebar switch.
OK ↓
6. Check the headlight relay. NG →
Refer to “CHECKING THE RE- Replace the headlight relay.
OK ↓
7. Check the entire lighting system NG →
wiring. Properly connect or repair the lighting sys-
page 8-15.
OK ↓
Replace the ECU or meter assembly.
8-17
LIGHTING SYSTEM
8-18
EAS27280
R/B
4 23
O O
R R/G R/G
2 24
Gy/B L
P P
W R Gy/R Gy/B Y Lg Lg
W Lg Sb
W W G G 25
CIRCUIT DIAGRAM
1 W W
3 B
Gy
Sb Sb P G
Gy/R Gy/R
R 18
R/B
B R B L/W
W W W Gy/B P/W Gy/R
8 (BLACK)
L/W
15
Gy/R
R/B Sb
SIGNALING SYSTEM
10 19 Gy/B W L Gy/G Gy/B

B B L/W
R 7 B B 22
L/Y O/B O/B R/B
R R
5 B B
B B 12 (BLACK)
B R/L O/B O/B R/B
Br/L Br/L ON
L/R O/W 20
B Gy/B Br/W Br/W
Br/L
B
Gy/R Y/G Gy/B Y/W

6 G/R
Br/L R/B Gy/R Y/L
21 Y/G Y/G
Gy/B L/W
G/B
B
W/B
L/R
L/Y
R/B
B/W R/L
Y/L
L/Y
B/W L/W
B B/W
69 R/L W/Y
B L/Y
Y/L 13 B B
14 L/W L/W
68
8-19
67
R R/W
66
Br/L R/Y
65
Br/L Br
R/Y Br Br/W
R/Y R/Y Br
L/B Br
G/R Gy/B
34 R/Y W/B
32 R/W
(BLACK)
33
Br Br L
51 R/B R/B G/B
Gy/B G/R W/B R/W
35 L/B R/Y P Br/W

28
31 30
36 37 38 L/B G R/Y R/Y G L/B
P Y B B Y P G/B

G/Y G/Y L
Gy G Y B Ch Dg
Gy/R Br/G 57 58 59
Gy/B Gy 29 B B
R L
64 53 54
63 (BLACK)
Gy Y B
L B 47 Y G Br
Br/G 60 61 62 Ch
Gy/B
55 56 Dg Br Dg
Br G/Y B Br
Gy/R R G/Y B B Br
48 49 50 50 (BLACK)
Br/G Ch Dg
44 42 Dg Br 41 42 Ch Br L B 39
Br G G Br
B G/Y B G/Y
G/R B/W Gy Br R/L
B B B
B B B
SIGNALING SYSTEM
SIGNALING SYSTEM
5. Main switch
7. Ground lead
8. Battery
9. Main fuse
17.Fuel sender
30.Rear brake light switch
31.Front brake light switch
32.Turn signal relay
33.Horn
37.Horn switch
38.Turn signal switch
41.Left rear turn signal light
42.Tail/brake light
44.Right rear turn signal light
45.Right front turn signal light
46.Left front turn signal light
54.Fuel gauge
55.Speedometer
56.Multi-function meter
57.Right turn signal indicator light
60.Left turn signal indicator light
61.Fuel level warning light
63.Air temperature sensor
64.Speed sensor
68.Backup fuse (meter assembly)
8-20
SIGNALING SYSTEM
EAS27290
TROUBLESHOOTING
• Any of the following fail to light: turn signal lights, brake lights, warning light or indicator lights.
• The horn fails to sound.
• The speedometer fails to operate.
NOTE:
1. Battery cover
2. Fuel tank cover
3. Front cowling
4. Storage compartment
5. Rear cover

(Main, signaling system, and back-
up) Replace the fuse(s).
ES” on page 8-69.
OK ↓
page 8-70.
OK ↓
OK ↓
4. Check the entire signaling system NG →
wiring. Properly connect or repair the signaling
page 8-19.
OK ↓
Check the condition of each of the sig-
naling system circuits. Refer to
“Checking the signaling system”.
Checking the signaling system

The horn fails to sound.
1. Check the horn switch. NG →
The horn switch is faulty. Replace the han-
dlebar switch.
OK ↓
8-21
SIGNALING SYSTEM
2. Check the horn. NG →

Refer to “CHECKING THE HORN” Replace the horn.
on page 8-78.
OK ↓
page 8-19.
OK ↓
This circuit is OK.
The tail/brake light fails to come on.

1. Check the tail/brake light bulb and NG →
socket.
Replace the tail/brake light bulb, socket or
Refer to “CHECKING THE BULBS
both.
8-68.
OK ↓
2. Check the front brake light switch. NG →
Refer to “CHECKING THE Replace the front brake light switch.
OK ↓
3. Check the rear brake light switch. NG →
Refer to “CHECKING THE Replace the rear brake light switch.
OK ↓
page 8-19.
OK ↓
This circuit is OK.
The turn signal light, turn signal indicator light or both fail to blink.
1. Check the turn signal light bulb and NG →
socket.
Replace the turn signal light bulb, socket or
Refer to “CHECKING THE BULBS
both.
8-68.
OK ↓
8-22
SIGNALING SYSTEM
2. Check the turn signal switch. NG →

The turn signal switch is faulty. Replace
the handlebar switch.
OK ↓
3. Check the turn signal relay. NG →
Refer to “CHECKING THE TURN Replace the turn signal relay.
SIGNAL RELAY” on page 8-73.
OK ↓
page 8-19.
OK ↓
Replace the meter assembly.
The fuel level warning light fails to come on.

1. Check the fuel sender. NG →
Refer to “CHECKING THE FUEL Replace the fuel tank (with fuel pump).
SENDER” on page 8-78.
OK ↓
page 8-19.
OK ↓
Replace the meter assembly.
The speedometer fails to operate.

1. Check the speed sensor. NG →
Refer to “CHECKING THE SPEED Replace the speed sensor.
SENSOR” on page 8-79.
OK ↓
page 8-19.
OK ↓
8-23
SIGNALING SYSTEM
The air temperature meter fails to operate.

page 8-19.
OK ↓
Replace the air temperature sensor or
meter assembly.
8-24
EAS27310
R/B
4 23
O O
R R/G R/G
2 24
Gy/B L
P P
W Lg Sb
W W G G 25
CIRCUIT DIAGRAM
1 W W
3 B
Gy
Sb Sb P G
Gy/R Gy/R
R 18
R/B
B R B L/W
W W W Gy/B P/W Gy/R
9 Sb O/W
COOLING SYSTEM
8 (BLACK) R/B L/R B/R B/R R/B

L/W
15
Gy/R
10 R/B Sb 19
R 7 B B B 22
L/Y O/B O/B R/B
R R
5 B B
B B 12 (BLACK)
B R/L O/B O/B R/B
Br/L Br/L ON
L/R O/W 20
B Gy/B Br/W Br/W
Br/L
B
Gy/R Y/G Gy/B Y/W

6 G/R
Br/L R/B Gy/R Y/L
21 Y/G Y/G
Gy/B L/W
G/B
B
W/B
L/R
L/Y
R/B
B/W R/L
Y/L
L/Y
B/W L/W
B B/W
69 R/L W/Y
B L/Y
Y/L 13 B B
14 L/W L/W
68
8-25
67
R R/W
66
Br/L R/Y
65
Br/L Br
R/Y Br Br/W
R/Y R/Y Br
L/B Br
G/R Gy/B
34 R/Y W/B
32 R/W
(BLACK)
33
Br Br L
51 R/B R/B G/B
Gy/B G/R W/B R/W
35 L/B R/Y P Br/W

28
31 30
36 37 38 L/B G R/Y R/Y G L/B
P Y B B Y P G/B

G/Y G/Y L
Gy G Y B Ch Dg
Gy/R Br/G 57 58 59
Gy/B Gy 29 B B
R L
64 53 54
63 (BLACK)
Gy Y B
L B 47 Y G Br
Br/G 60 61 62 Ch
Gy/B
55 56 Dg Br Dg
Br G/Y B Br
Gy/R R G/Y B B Br
48 49 50 50 (BLACK)
Br/G Ch Dg
44 42 Dg Br 41 42 Ch Br L B 39
Br G G Br
B G/Y B G/Y
G/R B/W Gy Br R/L
B B B
B B B
COOLING SYSTEM
COOLING SYSTEM
5. Main switch
6. Ignition fuse
7. Ground lead
8. Battery
9. Main fuse
28.Radiator fan motor relay
29.Radiator fan motor
51.Coolant temperature sensor
53.Coolant temperature gauge
67.Radiator fan motor fuse
8-26
COOLING SYSTEM
EAS27320
TROUBLESHOOTING
• The radiator fan motor fails to turn.
• The coolant temperature gauge fails to indicate.
NOTE:
1. Storage box
2. Footrest board
3. Storage compartment

(Main, ignition, and radiator fan mo-
tor) Replace the fuse(s).
ES” on page 8-69.
OK ↓
page 8-70.
OK ↓
OK ↓
4. Check the radiator fan motor. NG →
Refer to “CHECKING THE RADIA- Replace the radiator fan motor.
TOR FAN MOTOR” on page 8-79.
OK ↓
5. Check the radiator fan motor relay. NG →
Refer to “CHECKING THE RE- Replace the radiator fan motor relay.
OK ↓
6. Check the coolant temperature sen- NG →
sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 8-79.
OK ↓
7. Check the entire cooling system NG →
wiring. Properly connect or repair the cooling sys-
page 8-25.
OK ↓
8-27
COOLING SYSTEM
8-28
EAS27340
O O/B B P G/B Lg Y/W R/B Gy R/G Y/L Gy/B Gy/R Gy/G Y G/R
EAS27330
R/B
4 23
O O
R R/G R/G
2 24
Gy/B L
P P
W W G G 25
CIRCUIT DIAGRAM
1 W W
3 B
Gy
Sb Sb P G
Gy/R Gy/R
R 18
R/B
B R B L/W
W W W Gy/B P/W Gy/R
8 (BLACK)
L/W
15
Gy/R
10 R/B Sb 19
R 7 B B B 22
L/Y O/B O/B R/B
R R
5 B B
B B 12 (BLACK)
B R/L O/B O/B R/B
Br/L Br/L ON
L/R O/W 20
B Gy/B Br/W Br/W
FUEL INJECTION SYSTEM
Br/L
B
Gy/R Y/G Gy/B Y/W

6 G/R
Br/L R/B Gy/R Y/L
21 Y/G Y/G
Gy/B L/W
G/B
B
W/B
L/R
L/Y
R/B
B/W R/L
Y/L
L/Y
B/W L/W
B B/W
69 R/L W/Y
B L/Y
Y/L 13 B B
14 L/W L/W
68
(BLUE) (BLUE)
8-29
R R/L B
67
R R/W
66
Br/L R/Y
65
Br/L Br
R/Y Br
Br/W
R/Y R/Y Br
L/B Br
G/R Gy/B
34 R/Y W/B
32 R/W
(BLACK)
33
Br Br L
51 R/B R/B G/B
Gy/B G/R W/B R/W

31 30
36 37 38 L/B G R/Y R/Y G L/B
P Y B B Y P G/B

G/Y G/Y L
Gy G Y B Ch Dg
Gy/R Br/G 57 58 59
Gy/B Gy 29 B B
R L
64 53 54
63 (BLACK)
Gy Y B
L B 47 Y G Br
Br/G 60 61 62 Ch
Gy/B
55 56 Dg Br Dg
Br G/Y B Br
Gy/R R G/Y B B Br
48 49 50 50 (BLACK)
Br/G Ch Dg
44 42 Dg Br 41 42 Ch Br L B 39
Br G G Br
B G/Y B G/Y
G/R B/W Gy Br R/L
B B B
B B B

4. ECU fuse
5. Main switch
6. Ignition fuse
7. Ground lead
8. Battery
9. Main fuse
13.Sidestand switch
16.Fuel pump
18.Throttle position sensor
19.Intake air pressure sensor
20.Intake air temperature sensor
21.Lean angle sensor
23.Ignition coil
24.Spark plug
25.ISC (idle speed control) unit
26.O2 sensor
27.Fuel injector
28.Radiator fan motor relay
29.Radiator fan motor
34.Headlight relay
51.Coolant temperature sensor
62.Engine trouble warning light
64.Speed sensor
66.Headlight fuse
67.Radiator fan motor fuse
68.Backup fuse (meter assembly)
69.Self-diagnosis signal coupler
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 FI diagnostic tool.
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 fuel injection system operation
Warning light indica-
ECU operation FI operation Vehicle operation
tion
Warning provided
Flashing* when unable to start Operation stopped Cannot be operated
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:
Lean angle sensor
12: Crankshaft position sensor 30:
(latch up detected)
Intake air pressure sensor
13: 33: Faulty ignition
(open or short circuit)
Intake air pressure sensor Fuel injector
14: 39:
(clogged or detached hose) (open or short circuit)
Throttle position sensor Lean angle sensor
15: 41:
(open or short circuit) (open or short circuit)
Throttle position sensor ECU internal malfunction
16: 50:
(stuck) (memory check error)
Blue/yellow ECU lead
19:
(broken or disconnected)
Checking for a defective engine trouble warning light

The engine trouble warning light comes on for 2.0 seconds after the main switch has been set to “ON”
and when the start switch is being pushed. If the warning light does not come on under these conditions,
the warning light bulb (LED) may be defective.
8-31
a. Main switch “OFF” d. Engine trouble warning light on for 2.0

b. Main switch “ON” seconds
c. Engine trouble warning light off
EAS27380
SELF-DIAGNOSTIC FUNCTION TABLE

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.
Self-Diagnostic Function table

Able / un-
Fault Able / un-
Item Symptom able to
code No. able to start
drive
No normal signals are received
Crankshaft position
12 from the crankshaft position sen- Unable Unable
sensor
sor.
Intake air pressure
Intake air pressure sensor: open
13 sensor Able Able
or short circuit detected.
Intake air pressure
sensor Intake air pressure sensor: hose
14 Able Able
(clogged or detached system malfunction.
hose)
Throttle position sen-
Throttle position sensor: open or
15 sor Able Able
short circuit detected.
Throttle position sen-
Stuck throttle position sensor de-
16 sor Able Able
tected.
(stuck)
Blue/yellow ECU lead A break or disconnection of the
19 (broken or discon- blue/yellow lead of the ECU is de- Unable Unable
nected) tected.
Coolant temperature
Coolant temperature sensor: open
21 sensor Able Able
8-32
Able / un-
Fault Able / un-
drive
Intake air tempera-
Intake air temperature sensor:
22 ture sensor Able Able
open or short circuit detected.
No normal signal is received from
24 O2 sensor Able Able
the O2 sensor.
Latch up detected.
Lean angle sensor
30 No normal signal is received from Unable Unable
(latch up detected)
the lean angle sensor.
The amount of air-fuel ratio feed-
O2 sensor back compensation is maintained
31 Able Able
continuously in the vicinity of the
upper limit (lean air-fuel ratio).
The amount of air-fuel ratio feed-
O2 sensor back compensation is maintained
32 Able Able
continuously in the vicinity of the
lower limit (rich air-fuel ratio).
Ignition coil Malfunction detected in the prima-
33 Unable Unable
(faulty ignition) ry wire of the ignition coil.
ISC (idle speed con-
Engine speed is high when the en-
37 trol) valve (stuck fully Able Able
gine is idling.
open)
Fuel injector: open or short circuit
39 Fuel injector Unable Unable
detected.
Lean angle sensor Lean angle sensor: open or short
41 Unable Unable
(open or short circuit) circuit detected.
No normal signals are received
42 Speed sensor Able Able
from the speed sensor.
Fuel system voltage Supply power to the fuel injector
43 Able Able
(monitor voltage) and fuel pump is not normal.
Error is detected while reading
Error in reading from
from or writing on EEPROM (CO
44 or writing on EE- Able Able
adjustment value and throttle valve
PROM
fully closed notification value).
Vehicle system power
Power supply to the fuel injection
46 supply Able Able
system is not normal.
(monitor voltage)
Faulty ECU memory. (When this
ECU internal malfunc- malfunction is detected in the
50 tion ECU, the fault code number might Unable Unable
(memory check error) not appear on the FI diagnostic
tool.)
ISC (idle speed con-
ISC (idle speed control) unit: open
61 trol) unit Able Able
8-33
Able / un-
Fault Able / un-
drive
Relay is not activated even if the
crank signal is input while the start
switch is pushed. The start switch
— Start unable warning Unable Unable
is pushed when fault code No.12,
19, 30, 33, 39, 41, or 50 is dis-
played to indicate an error.
EAS27400
4. Set the main switch to “OFF” and back to
TROUBLESHOOTING METHOD
“ON”, then check that no fault code number is
displayed.
The engine operation is not normal and the
engine trouble warning light comes on. NOTE:
1. Check: If another fault code is displayed, repeat steps
• Fault code number (1) to (4) until no fault code number is displayed.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
5. Erase the malfunction history in the diagnos-
a. Check the fault code number displayed on
tic mode. Refer to “Sensor operation table
the FI diagnostic tool.
(Diagnostic code No. 62)”.
b. Identify the system with the fault code. Refer
to “Self-Diagnostic Function table”. NOTE:
c. Identify the probable cause of the malfunc- Setting the main switch to “OFF” will not erase
tion. Refer to “Fault code table”. the malfunction history.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check and repair the probable cause of the The engine operation is not normal but the
malfunction. engine trouble warning light does not come
Fault code No. YES Fault code No. NO on.
1. Check the operation of the following sensors
Check and repair. Check and repair. and actuators in the Diagnostic mode. Refer
Refer to “TROUBLE- Refer to “Self-Diag- to “Sensor operation table” and “Actuator op-
SHOOTING DE- nostic Function ta- eration table”.
TAILS” on page 8-42. ble”.
Monitor the opera- 01: Throttle position sensor (throttle angle)
tion of the sensors 30: Ignition coil
and actuators in the 36: Fuel injector
diagnostic mode. Re-
fer to “Sensor opera- If a malfunction is detected in the sensors or
tion table” and actuators, repair or replace all faulty parts.
“Actuator operation If no malfunction is detected in the sensors
table”. and actuators, check and repair the inner
parts of the engine.
3. Perform fuel injection system reinstatement
action.
Refer to “Reinstatement method” of table in
“TROUBLESHOOTING DETAILS”.
EAS27441
DIAGNOSTIC MODE
It is possible to monitor the sensor output data or check the activation of actuators with the FI diagnostic
tool connected to the vehicle and set to the normal mode or the diagnostic monitoring mode.
FI diagnostic tool
90890-03182
8-34
Setting the normal mode

NOTE:
The engine speed, engine temperature, and fault codes, if detected, can be displayed on the LCD of
the FI diagnostic tool when the tool is connected to the vehicle and is set to the normal mode.
1. Set the main switch to “OFF”.
2. Remove the self-diagnosis signal coupler cap, and then connect the FI diagnostic tool “1” as shown.
1
3. Set the main switch to “ON” and start the engine.

NOTE:
• The coolant temperature and engine speed appear on the LCD of the FI diagnostic tool.
• The “POWER” LED (green) comes on.
• If a malfunction is detected in the system, the “WARNING” LED (orange) comes on.
4. Turn the engine off.

NOTE:
If a malfunction is detected in the system, the fault code appears on the LCD of the FI diagnostic tool.
In addition, the “WARNING” LED (orange) comes on.
5. Set the main switch to “OFF” to cancel the normal mode.

6. Disconnect the FI diagnostic tool and connect the self-diagnosis signal coupler cap.
8-35
Setting the diagnostic mode

1. Set the main switch to “OFF”.
2. Remove the self-diagnosis signal coupler cap, and then connect the FI diagnostic tool “1” as shown.
1
3. While pressing the “MODE” button, set the main switch to “ON”.
NOTE:
• “DIAG” appears on the LCD of the FI diagnostic tool.
• The “POWER” LED (green) comes on.
4. Press the “UP” button to select the CO adjustment mode “CO” or the diagnostic mode “DIAG”.
5. After selecting “DIAG”, press the “MODE” button.
6. Select the diagnostic code number corresponding to the fault code number by pressing the “UP” and
“DOWN” buttons.
NOTE:
• The diagnostic code number appears on the LCD (01-70).
• To decrease the selected diagnostic code number, press the “DOWN” button. Press the “DOWN” but-
ton for 1 second or longer to automatically decrease the diagnostic code numbers.
• To increase the selected diagnostic code number, press the “UP” button. Press the “UP” button for 1
second or longer to automatically increase the diagnostic code numbers.
7. Verify the operation of the sensor or actuator.

• Sensor operation
The data representing the operating conditions of the sensor appear on the LCD.
• Actuator operation
Press the “MODE” button.
8. Set the main switch to “OFF” to cancel the diagnostic mode.
9. Disconnect the FI diagnostic tool and connect the self-diagnosis signal coupler cap.
8-36
Diagnostic code table

Fault
Diagnostic
code Symptom Probable cause of malfunction
code No.
No.
• Open or short circuit in wire harness.
• Defective crankshaft position sensor.
No normal signals are re-
• Malfunction in generator rotor.
12 ceived from the crankshaft —
• Malfunction in ECU.
position sensor.
• Improperly installed crankshaft position
sensor.
Intake air pressure sensor: • Open or short circuit in wire harness.
13 open or short circuit detect- • Defective intake air pressure sensor. 03
ed. • Malfunction in ECU.
• Intake air pressure sensor hose is de-
Intake air pressure sensor:
14 tached, clogged, kinked, or pinched. 03
hose system malfunction.
Throttle position sensor:
• Defective throttle position sensor.
15 open or short circuit detect- 01
ed.
• Improperly installed throttle position sensor.
Stuck throttle position sen- • Stuck throttle position sensor.
16 01
sor detected. • Malfunction in ECU.
A break or disconnection of • Open or short circuit in wire harness (ECU
19 the blue/yellow lead of the coupler). 20
ECU is detected. • Malfunction in ECU.
Coolant temperature sen- • Defective coolant temperature sensor.
21 sor: open or short circuit • Malfunction in ECU. 06
detected. • Improperly installed coolant temperature
sensor.
Intake air temperature sen- • Defective intake air temperature sensor.
22 sor: open or short circuit • Malfunction in ECU. 05
detected. • Improperly installed intake air temperature
sensor.
No normal signal is re- • Defective O2 sensor.
24 ceived from the O2 sensor. —
• Improperly installed O2 sensor.
Latch up detected. • The vehicle has overturned.
No normal signal is re- • Defective lean angle sensor.
30 08
ceived from the lean angle • Malfunction in ECU.
sensor. • Improperly installed lean angle sensor.
8-37
Fault
Diagnostic
code No.
No.
• Fuel pressure too low.
The amount of air-fuel ratio • Clogged injector.
feedback compensation is • Defective O2 sensor (unable to output a rich
31 maintained continuously in signal). —
the vicinity of the upper lim- • Improperly installed sensor.
it (lean air-fuel ratio). • Malfunction in other areas of the fuel sys-
tem.
• Fuel pressure too high.
The amount of air-fuel ratio • Faulty injector (excessive injection volume).
feedback compensation is • Defective O2 sensor (unable to output a
32 maintained continuously in lean signal). —
the vicinity of the lower limit • Improperly installed sensor.
(rich air-fuel ratio). • Malfunction in other areas of the fuel sys-
tem.
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 sys-
tem.
• Open circuit in wire harness.
• Malfunction in throttle body.
• Malfunction in throttle cables.
• ISC valve is stuck fully open due to discon-
nected ISC unit coupler. (High engine idle
Engine speed is high when
37 speed is detected with the ISC valve stuck 54
the engine is idling.
fully open even though signals for the valve
to close are continuously being transmitted
by the ECU.)
• ECU fuse is blown.
Fuel injector: open or short • Defective fuel injector.
39 36
circuit detected. • Malfunction in ECU.
• Improperly installed fuel injector.
Lean angle sensor: open or
41 • Defective lean angle sensor. 08
short circuit detected.
No normal signals are re- • Defective speed sensor.
42 ceived from the speed sen- • Malfunction in vehicle speed sensor detect- 07
sor. ed.
Supply power to the fuel in-
• Open circuit in wire harness.
43 jector and fuel pump is not 09
normal.
8-38
Fault
Diagnostic
code No.
No.
Error is detected while
• Malfunction in ECU. (The CO adjustment
reading from or writing on
value and throttle valve fully closed notifica-
44 EEPROM (CO adjustment 60
tion value are not properly written on or
value and throttle valve fully
read from the internal memory.)
closed notification value).
Power supply to the fuel in-
• Malfunction in charging system. Refer to
46 jection system is not nor- —
“CHARGING SYSTEM” on page 8-11.
mal.
Faulty ECU memory.
(When this malfunction is
• Malfunction in ECU. (The program and data
detected in the ECU, the
50 are not properly written on or read from the —
fault code number might
internal memory.)
not appear on the FI diag-
nostic tool.)
ISC (idle speed control) • Open or short circuit in wire harness.
61 unit: open or short circuit • Defective ISC (idle speed control) unit. 54
detected. • Malfunction in ECU.
Sensor operation table

Diag-
nostic
Item FI diagnostic tool display Checking method
code
No.
01 Throttle angle
• Fully closed position 9–22 Check with throttle fully
closed.
• Fully open position 93–106 Check with throttle fully
open.
03 Intake air pressure Displays the intake air pres- Operate the throttle while
sure. pulling the brake lever and
pushing the start switch
“ ”. (If the display value
changes, the performance
is OK.)
05 Intake air temperature Displays the intake air tem- Compare the actually mea-
perature. sured intake air tempera-
ture with the FI diagnostic
tool display value.
06 Coolant temperature Displays the coolant temper- Compare the actually mea-
ature. sured coolant temperature
with the FI diagnostic tool
display value.
07 Vehicle speed pulse 0–999 Check that the number in-
creases when the front
wheel is rotated. The num-
ber is cumulative and does
not reset each time the
wheel is stopped.
8-39
Diag-
nostic
code
No.
08 Lean angle sensor Remove the lean angle
• Upright 0.4–1.4 sensor and incline it more
than 45 degrees.
• Overturned 3.7–4.4
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 Extend and retract the side-
• Stand retracted ON stand.
• Stand extended OFF

60 EEPROM fault code dis- —
play
• No fault 00
• Fault detected 01 (CO adjustment value is
detected.)
03 (Code re-registering key
(immobilizer) is detected.)
04 (Throttle valve fully closed
notification value is detect-
ed.)
• (If more than one code
number is detected, the dis-
play alternates every two
seconds to show all the de-
tected code numbers.
When all code numbers are
shown, the display repeats
the same process.)
61 Malfunction history code —
display
• No history 00
• History exists Fault codes 12–61
• (If more than one code
number is detected, the dis-
play alternates every two
seconds to show all the de-
tected code numbers.
When all code numbers are
shown, the display repeats
the same process.)
62 Malfunction history code
erasure
• No history 0 —
• History exists Up to 22 fault codes To erase the history, press
the “MODE” button of the
FI diagnostic tool.
8-40
Diag-
nostic
code
No.
70 Control number 0–255 —
Actuator operation table

Diag-
nostic
Item Actuation Checking method
code
No.
Actuates the ignition coil five
times at one-second inter-
vals. Check the spark five times.
30 Ignition coil Illuminates the “WARNING” • Connect an ignition
LED on the FI diagnostic tool checker.
and the engine trouble warn-
ing light.
Actuates the injector five
times at one-second inter-
vals.
Check the operating sound
36 Fuel injector Illuminates the “WARNING”
of the injector five times.
LED on the FI diagnostic tool
ing light.
Actuates the radiator fan mo-
tor relay for five cycles of five
seconds. (ON 2 seconds,
OFF 3 seconds) Check the operating sound
51 Radiator fan motor relay Illuminates the “WARNING” of the radiator fan motor re-
LED on the FI diagnostic tool lay five times.
ing light and rotates the radi-
ator fan motor.
Actuates the headlight relay
for five cycles of five sec-
onds. (ON 2 seconds, OFF 3
Check the operating sound
seconds)
52 Headlight relay of the headlight relay five
Illuminates the “WARNING”
times.
LED on the FI diagnostic
tool, the engine trouble warn-
ing light and headlight.
Actuates and fully closes the
ISC valve, then opens it to
the standby opening position
ISC (idle speed control) The ISC unit vibrates when
54 when the engine is started.
unit the ISC valve operates.
This operation takes approxi-
mately 12 seconds until it is
completed.
8-41
Communication error with the FI diagnostic tool

LCD Display Symptom Probable cause of malfunction
• Improper connection in connecting lead.
Waiting for con- No signals are received • The main switch is set to “OFF”.
nection.... from the ECU. • Malfunction in FI diagnostic tool.
• Set the main switch to “OFF” once, and then set
the FI diagnostic tool to the CO adjustment mode
Commands from the FI
or the diagnostic mode.
ERROR 4 diagnostic tool are not
• Vehicle battery is insufficiently charged.
accepted by the ECU.
• Malfunction in FI diagnostic tool.
EAS27481
TROUBLESHOOTING DETAILS
This section describes the measures per fault code number displayed on the FI diagnostic tool. Check
and service the items or components that are the probable cause of the malfunction following the order
given.
After the check and service of the malfunctioning part have been completed, reset the FI diagnostic tool
display according to the reinstatement method.
Fault code No.:
Fault code number displayed on the FI diagnostic tool when the engine failed to work normally. Refer
to “Diagnostic code table”.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOSTIC
MODE” on page 8-34.
Fault code No. 12 Symptom No normal signals are received from the crankshaft posi-
tion sensor.
Diagnostic code No. — —
Order Item/components and probable Check or maintenance job Reinstatement
cause method
1 Installed condition of crankshaft posi- Check for looseness or pinching. Crank the en-
tion sensor. gine.
2 Connections • Check the coupler for any pins
• Crankshaft position sensor coupler that may have pulled out.
• Wire harness ECU coupler • Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler se-
curely.
3 Open or short circuit in wire harness. • Repair or replace if there is an
open or short circuit.
• Between the crankshaft position
sensor coupler and ECU cou-
pler.
(white/red–white/red)
(gray/black–gray/black)
4 Defective crankshaft position sensor. • Replace if defective.
CRANKSHAFT POSITION
8-42
Fault code No. 13 Symptom Intake air pressure sensor: open or short circuit detected.
Diagnostic code No. 03 Intake air pressure sensor
cause method
1 Connections • Check the coupler for any pins Set the main
• Intake air pressure sensor coupler that may have pulled out. switch to “ON”.
the coupler.
curely.
• Between intake air pressure
pler.
(gray/red–gray/red)
(pink/white–pink/white)
3 Defective intake air pressure sensor. • Execute the diagnostic mode.
(Code No. 03)
• Replace if defective.
Refer to “CHECKING THE IN-
TAKE AIR PRESSURE SEN-
SOR” on page 8-81.
8-43
Fault code No. 14 Symptom Intake air pressure sensor: hose system malfunction.
Diagnostic code No. 03 Intake air pressure sensor
cause method
1 Intake air pressure sensor hose • Check the intake air pressure Start the en-
sensor hose condition. gine and let it
• Repair or replace the sensor run at idle.
hose.
2 Intake air pressure sensor malfunction • Check and repair the connec-
at intermediate electrical potential. tion.
• Replace it if there is a malfunc-
tion.
• Intake air pressure sensor coupler that may have pulled out.
the coupler.
curely.
4 Defective intake air pressure sensor. • Execute the diagnostic mode.
(Code No. 03)
TAKE AIR PRESSURE SEN-
8-44
Fault code No. 15 Symptom Throttle position sensor: open or short circuit detected.
Diagnostic code No. 01 Throttle position sensor
cause method
1 Installed condition of throttle position • Check for looseness or pinch- Set the main
sensor. ing. switch to “ON”.
• Check that the sensor is in-
stalled in the specified position.
• Throttle position sensor coupler that may have pulled out.
the coupler.
curely.
• Between throttle position sen-
sor coupler and ECU coupler.
(yellow–yellow)
4 Throttle position sensor lead wire • Check for open circuit and re-
open circuit output voltage check. place the throttle position sen-
sor.
(gray/red–gray/black)
Open circuit Output voltage
item
Ground wire 5V
open circuit
Output wire 0V
open circuit
Power supply 0V
wire open cir-
cuit
5 Defective throttle position sensor. • Execute the diagnostic mode.
(Code No. 01)
THROTTLE POSITION SEN-
8-45
Fault code No. 16 Symptom Stuck throttle position sensor detected.

Diagnostic code No. 01 Throttle position sensor
cause method
1 Installed condition of throttle position • Check for looseness or pinch- Set the main
sensor. ing. switch to “ON”.
• Check that the sensor is in-
stalled in the specified position.
2 Defective throttle position sensor. • Execute the diagnostic mode.
(Code No. 01)
THROTTLE POSITION SEN-
Fault code No. 19 Symptom A break or disconnection of the blue/yellow lead of the
ECU is detected.
Diagnostic code No. 20 Sidestand switch
cause method
1 Connections • Execute the diagnostic mode. Reconnect the
• Wire harness ECU coupler (Code No. 20) wiring and re-
• Check the coupler for any pins tract the side-
that may have pulled out. stand.
• Check the locking condition of
the coupler.
curely.
• Between ECU and blue/yellow
lead.
3 Defective sidestand switch. • Replace if defective.
8-46
Fault code No. 21 Symptom Coolant temperature sensor: open or short circuit detect-
ed.
Diagnostic code No. 06 Coolant temperature sensor
cause method
1 Installed condition of coolant tempera- Check for looseness or pinching. Set the main
ture sensor. switch to “ON”.
• Coolant temperature sensor coupler that may have pulled out.
the coupler.
curely.
• Between coolant temperature
pler.
(green/red–green/red)
4 Defective coolant temperature sensor. • Execute the diagnostic mode.
(Code No. 06)
COOLANT TEMPERATURE
8-47
Fault code No. 22 Symptom Intake air temperature sensor: open or short circuit de-
tected.
Diagnostic code No. 05 Intake air temperature sensor
cause method
1 Installed condition of intake air tem- Check for looseness or pinching. Set the main
perature sensor. switch to “ON”.
• Intake air temperature sensor cou- that may have pulled out.
pler • Check the locking condition of
• Wire harness ECU coupler the coupler.
curely.
• Between intake air temperature
pler.
(brown/white–brown/white)
4 Defective intake air temperature sen- • Execute the diagnostic mode.
sor. (Code No. 05)
TAKE AIR TEMPERATURE
8-48
Fault code No. 24 Symptom No normal signal is received from the O2 sensor.
Diagnostic monitor- — —
ing code No.
cause method
1 Installed condition of O2 sensor. Check for looseness or pinching. Start the en-
gine and let it
2 Connections • Check the coupler for any pins run at idle.
• O2 sensor coupler that may have pulled out.
the coupler.
curely.
• Between O2 sensor coupler and
ECU coupler.
(gray/green–gray/green)
(black/red–black/red)
ignition fuse terminal.
(red/black–red/black)
4 Check the fuel pressure. Refer to “THROTTLE BODY” on
page 7-3.
5 Defective O2 sensor. Replace if defective.
Fault code No. 30 Symptom Latch up detected.

No normal signal is received from the lean angle sensor.
Diagnostic code No. 08 Lean angle sensor
cause method
1 The vehicle has overturned. Raise the vehicle upright. Set the main
2 Installed condition of lean angle sen- Check the installed direction and switch to “ON”
sor. condition of the sensor. (however, the
engine cannot
3 Connections • Check the coupler for any pins be restarted
• Lean angle sensor coupler that may be pulled out. unless the main
• Main wire harness ECU coupler • Check the locking condition of switch is first
the coupler. set to “OFF”).
curely.
4 Defective lean angle sensor. • Execute the diagnostic mode.
(Code No. 08)
LEAN ANGLE SENSOR” on
page 8-76.
8-49
Fault code No. 31 Symptom The amount of air-fuel ratio feedback compensation is
maintained continuously in the vicinity of the upper limit
(lean air-fuel ratio).
cause method
gine and let it
• O2 sensor coupler that may be pulled out.
the coupler.
curely.
ECU coupler.
page 7-3.
(Unable to output a rich signal)
8-50
Fault code No. 32 Symptom The amount of air-fuel ratio feedback compensation is
maintained continuously in the vicinity of the lower limit
(air-fuel ratio is rich).
cause method
gine and let it
• O2 sensor coupler that may be pulled out.
the coupler.
curely.
ECU coupler.
page 7-3.
(Unable to output a lean signal)
8-51
Fault code No. 33 Symptom Malfunction detected in the primary wire of the ignition
coil.
Diagnostic code No. 30 Ignition coil
cause method
1 Connections • Check the connector and cou- Start the en-
• Ignition coil connector (primary coil pler for any pins that may have gine and let it
side) pulled out. run at idle.
the connector and coupler.
and connect the connector and
coupler securely.
• Between ignition coil connector
and ECU coupler.
(orange–orange)
• Between ignition coil connector
and ignition fuse terminal.
3 Defective ignition coil. • Execute the diagnostic monitor-
ing mode. (Code No. 30)
• Test the primary and secondary
coils for continuity.
Refer to “CHECKING THE IG-
NITION COIL” on page 8-74.
8-52
Fault code No. 37 Symptom Engine speed is high when the engine is idling.
Diagnostic code No. 54 ISC (idle speed control) unit
cause method
1 Throttle valve does not fully close. • Check the throttle body. ISC valve re-
Refer to “THROTTLE BODY” on turns to its orig-
page 7-3. inal position by
• Check the throttle cables. setting the main
Refer to “ADJUSTING THE switch to “ON”
THROTTLE CABLE FREE and back to
PLAY” on page 3-5. “OFF”.
2 ISC valve is stuck fully open due to • Check that the ISC unit coupler Reinstated if
disconnected ISC unit coupler. is not disconnected. the engine
(High engine idle speed is detected • The ISC valve is stuck fully idling speed is
with the ISC valve stuck fully open open if it does not operate when within specifi-
even though signals for the valve to the main switch is set to “OFF”. cation after
close are continuously being transmit- (Touch the ISC unit with your starting the en-
ted by the ECU.) hand and check if it is vibrating gine.
to confirm if the ISC valve is op-
erating.)
NOTE:
Do not remove the ISC unit.
3 ISC valve is not moving correctly. • Execute the diagnostic mode.

(Code No. 54)
• After the ISC valve is fully
closed, it opens to the standby
opening position when the en-
gine is started. This operation
takes approximately 12 sec-
onds. Start the engine. If the er-
ror recurs, replace the throttle
body assembly.
8-53
Fault code No. 39 Symptom Fuel injector: open or short circuit detected.
Diagnostic code No. 36 Fuel injector
cause method
1 Connections • Check the coupler for any pins Start the en-
• Fuel injector coupler that may have pulled out. gine.
the coupler.
curely.
• Between fuel injector coupler
and ECU coupler.
(red/black–blue)
(orange/black–orange/black)
3 Defective fuel injector. • Execute the diagnostic mode.
(Code No. 36)
FUEL INJECTOR” on page 7-5.
Fault code No. 41 Symptom Lean angle sensor: open or short circuit detected.
Diagnostic code No. 08 Lean angle sensor
cause method
• Lean angle sensor coupler that may have pulled out. switch to “ON”.
the coupler.
curely.
• Between switch coupler and
ECU coupler.
(yellow/green–yellow/green)
3 Defective lean angle sensor. • Execute the diagnostic mode.
(Code No. 08)
LEAN ANGLE SENSOR” on
page 8-76.
8-54
Fault code No. 42 Symptom No normal signals are received from the speed sensor.
Diagnostic code No. 07 Speed sensor
cause method
• Speed sensor coupler that may have pulled out. gine, and input
• Wire harness ECU coupler • Check the locking condition of the vehicle
the coupler. speed signals
• If there is a malfunction, repair it by operating
and connect the coupler se- the vehicle at
curely. 20 to 30 km/h.
2 Open or short circuit in speed sensor • Repair or replace if there is an
lead. open or short circuit.
• Between speed sensor coupler
and ECU coupler.
(gray–gray)
3 Defective speed sensor. • Execute the diagnostic mode.
(Code No. 07)
SPEED SENSOR” on page
8-79.
Fault code No. 43 Symptom Supply power to the fuel injector and fuel pump is not nor-
mal.
Diagnostic code No. 09 Fuel system voltage
cause method
• Fuel pump coupler that may have pulled out. gine and let it
• Fuel injector coupler • Check the locking condition of run at idle.
• Wire harness ECU coupler the coupler.
curely.
2 Open or short circuit in wire harness. • Between ignition fuse terminal
and ECU coupler.
(red/black–blue)
3 Malfunction or open circuit in fuel in- • Execute the diagnostic mode.
jection system. (Code No. 09)
• If there is no malfunction in the
fuel injection system, replace
the ECU.
8-55
Fault code No. 44 Symptom Error is detected while reading from or writing on EE-
PROM (CO adjustment value and throttle valve fully
closed notification value).
Diagnostic code No. 60 EEPROM improper cylinder indication
cause method
1 Malfunction in ECU. Execute the diagnostic mode. Set the main
(Code No. 60) switch to “ON”.
FI di- Maintenance job
agnos-
tic tool
display
01 • Readjust the CO of the
displayed cylinder.
Refer to “ADJUSTING
THE EXHAUST GAS
VOLUME” on page
3-5.
• Replace ECU if defec-
tive.
03 Replace the ECU.
04 • Set the main switch to
“ON”, and turn the
throttle grip to the fully
open, then to the fully
closed position.
• Replace ECU if defec-
tive.
8-56
Fault code No. 46 Symptom Power supply to the fuel injection system is not normal.
cause method
• ECU coupler that may have pulled out. gine and let it
• Check the locking condition of run at idle.
the coupler.
curely.
2 Faulty battery. • Replace or charge the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 8-70.
3 Malfunction in rectifier/regulator. • Replace if defective.
RECTIFIER/REGULATOR” on
page 8-77.
4 Open or short circuit in wire harness. Repair or replace if there is an
• Between battery and ECU fuse
terminal.
(red–red)
• Between ECU fuse terminal
and ECU.
(red/green–red/green)
Fault code No. 50 Symptom Faulty ECU memory. (When this malfunction is detected in
the ECU, the fault code number might not appear on the FI
diagnostic tool.)
cause method
1 Malfunction in ECU. Replace the ECU. Set the main
NOTE: switch to “ON”.
Do not perform this procedure
with the main switch set to “ON”.
8-57
Fault code No. 61 Symptom ISC (idle speed control) unit: open or short circuit detect-
ed.
Diagnostic code No. 54 ISC (idle speed control) unit
cause method
• ISC (idle speed control) unit coupler that may have pulled out. switch to “ON”.
the coupler.
curely.
• Between ISC (idle speed con-
trol) unit coupler and ECU cou-
pler.
(pink–pink)
(light green–light green)
(green–green)
(sky blue–sky blue)
3 Defective ISC (idle speed control) • Execute the diagnostic monitor-
unit. ing mode. (Code No. 54)
Refer to “THROTTLE BODY” on
page 7-3.
8-58
EAS27560
R/B
4 23
O O
R R/G R/G
2 24
Gy/B L
P P
W Lg Sb
W W G G 25
CIRCUIT DIAGRAM
1 W W
3 B
Gy
Sb Sb P G
Gy/R Gy/R
R 18
R/B
B R B L/W
W W W Gy/B P/W Gy/R
8 (BLACK)
L/W
15
Gy/R
10 R/B Sb 19 Gy/B W L Gy/G Gy/B
FUEL PUMP SYSTEM
B B L/W
R 7 B B 22
L/Y O/B O/B R/B
R R
5 B B
B B 12 (BLACK)
B R/L O/B O/B R/B
Br/L Br/L ON
L/R O/W 20
B Gy/B Br/W Br/W
Br/L
B
Gy/R Y/G Gy/B Y/W

6 G/R
Br/L R/B Gy/R Y/L
21 Y/G Y/G
Gy/B L/W
G/B
B
W/B
L/R
L/Y
R/B
B/W R/L
Y/L
L/Y
B/W L/W
B B/W
69 R/L W/Y
B L/Y
Y/L 13 B B
14 L/W L/W
68
8-59
67
R R/W
66
Br/L R/Y
65
Br/L Br
R/Y Br Br/W
R/Y R/Y Br
L/B Br
G/R Gy/B
34 R/Y W/B
32 R/W
(BLACK)
33
Br Br L
51 R/B R/B G/B
Gy/B G/R W/B R/W
35 L/B R/Y P Br/W

28
31 30
36 37 38 L/B G R/Y R/Y G L/B
P Y B B Y P G/B

G/Y G/Y L
Gy G Y B Ch Dg
Gy/R Br/G 57 58 59
Gy/B Gy 29 B B
R L
64 53 54
63 (BLACK)
Gy Y B
L B 47 Y G Br
Br/G 60 61 62 Ch
Gy/B
55 56 Dg Br Dg
Br G/Y B Br
Gy/R R G/Y B B Br
48 49 50 50 (BLACK)
Br/G Ch Dg
44 42 Dg Br 41 42 Ch Br L B 39
Br G G Br
B G/Y B G/Y
G/R B/W Gy Br R/L
B B B
B B B
FUEL PUMP SYSTEM
FUEL PUMP SYSTEM
5. Main switch
6. Ignition fuse
7. Ground lead
8. Battery
9. Main fuse
16.Fuel pump
8-60
FUEL PUMP SYSTEM
EAS27570
TROUBLESHOOTING
If the fuel pump fails to operate.
NOTE:
1. Battery cover
2. Fuel tank cover
3. Front cowling

(Main and ignition)
Replace the fuse(s).
ES” on page 8-69.
OK ↓
page 8-70.
OK ↓
OK ↓
4. Check the fuel pump operation. NG →
Refer to “CHECKING THE FUEL Replace the fuel tank (with fuel pump).
PRESSURE” on page 7-6.
OK ↓
5. Check the entire fuel pump system NG →
wiring. Properly connect or repair the fuel pump
page 8-59.
OK ↓
Replace the ECU.
8-61
FUEL PUMP SYSTEM
8-62
ELECTRICAL COMPONENTS
EAS27970
2 3 4
1
5
6 7 8 9
29
10 11
12
28
13
14
27
15
17
26
24 21 16
25
22
23 20 18
19
8-63
1. Air temperature sensor

2. Main switch
5. ECU (engine control unit)
6. Battery
7. Turn signal relay
8. Headlight relay
9. Radiator fan motor relay
11. Fuse box
12. Main fuse
13. Starter relay
14. Intake air pressure sensor
17. Intake air temperature sensor
18. Stator coil
20. O2 sensor
22. Spark plug cap
23. Ignition coil
24. Sidestand switch
25. Lean angle sensor
26. Radiator fan motor
27. Speed sensor
28. Horn
8-64
EAS27980
CHECKING THE SWITCHES
3 5 6 Br 7 Br
L/B G Y R/Y B P
1 2 4
Ch Br/W G/B L/B G R/Y
R Br/L L/W W/Y L/W
R P Y B
ON W/Y
OFF Br/L G/B Ch Br/W G/Y G/Y
(BLUE)
B
B
(BLUE)
8-65
1. Main switch
2. Start switch
3. Dimmer/pass switch
4. Turn signal switch
5. Horn switch
8. Sidestand switch
8-66
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 switches and their terminal connections are illustrated as in the following example of the main
switch.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in the
top row.
The continuity (i.e., a closed circuit) between switch terminals at a given switch position is indicated by
“ ”. There is continuity between red and brown/blue when the switch is set to “ON”.
b
R Br/L
ON
a OFF
R
Br/L
8-67
EAS27990
1. Remove:
CHECKING THE BULBS AND BULB
• Bulb
SOCKETS EWA5B21003
NOTE: WARNING
Do not check any of the lights that use LEDs. Since headlight bulbs get extremely hot,
keep flammable products and your hands
Check each bulb and bulb socket for damage or
away from them until they have cooled
wear, proper connections, and also for continuity
down.
between the terminals.
Damage/wear → Repair or replace the bulb, ECA5B21008
CAUTION:
bulb socket or both.
Improperly connected → Properly connect. • Be sure to hold the socket firmly when re-
No continuity → Repair or replace the bulb, bulb moving the bulb. Never pull the lead, other-
socket or both. wise it may be pulled out of the terminal in
the coupler.
Types of bulbs • Avoid touching the glass part of a headlight
The bulbs used on this vehicle are shown in the bulb to keep it free from oil, otherwise the
illustration. transparency of the glass, the life of the
• Bulbs “a” and “b” are used for the headlights bulb, and the luminous flux will be adverse-
and usually use a bulb holder that must be de- ly affected. If the headlight bulb gets soiled,
tached before removing the bulb. The majority thoroughly clean it with a cloth moistened
of these types of bulbs can be removed from with alcohol or lacquer thinner.
their respective socket by turning them coun- 2. Check:
terclockwise. • Bulb (for continuity)
• Bulbs “c” are used for turn signal and tail/brake (with the pocket tester)
lights and can be removed from the socket by No continuity → Replace.
pushing and turning the bulb counterclockwise.
• Bulbs “d” and “e” are used for meter and indi- Pocket tester
cator lights and can be removed from their re- 90890-03112
spective sockets by carefully pulling them out. Analog pocket tester
YU-03112-C
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to terminal
“1” and the negative tester probe to terminal
“2”, and check the continuity.
b. Connect the positive tester probe to terminal
“1” and the negative tester probe to terminal
“3”, and check the continuity.
c. If either of the readings indicate no continuity,
replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the condition of the bulbs

bulbs.
8-68
NOTE:
Set the pocket tester selector to “Ω × 1”.
Pocket tester
90890-03112
YU-03112-C
b. If the pocket tester indicates “∞”, replace the

fuse.
Checking the condition of the bulb sockets ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
The following procedure applies to all of the bulb 3. Replace:
sockets. • Blown fuse
1. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Bulb socket (for continuity) a. Set the main switch to “OFF”.
(with the pocket tester) b. Install a new fuse of the correct amperage
No continuity → Replace. rating.
c. Set on the switches to verify if the electrical
Pocket tester circuit is operational.
90890-03112 d. If the fuse immediately blows again, check
Analog pocket tester the electrical circuit.
YU-03112-C
Amperage
Fuses Q’ty
rating
NOTE:
Check each bulb socket for continuity in the Main 30 A 1
same manner as described in the bulb section, Headlight 15 A 1
however, note the following. Signaling system 15 A 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Ignition 10 A 1
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the re- ECU 5A 1
spective leads of the bulb socket. Radiator fan motor 5A 1
c. Check the bulb socket for continuity. If any of Backup (meter assem-
the readings indicate no continuity, replace 5A 1
bly)
the bulb socket.
Spare 30 A 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28000
Spare 15 A 1
CHECKING THE FUSES Spare 10 A 1
The following procedure applies to all of the fus- Spare 5A 1
es.
ECA5B21009 EWA13310
CAUTION: WARNING
To avoid a short circuit, always set the main Never use a fuse with an amperage rating
switch to “OFF” when checking or replacing other than that specified. Improvising or us-
a fuse. ing a fuse with the wrong amperage rating
1. Remove: may cause extensive damage to the electri-
• Battery cover cal system, cause the lighting and ignition
Refer to “GENERAL CHASSIS” on page 4-1. systems to malfunction and could possibly
2. Check: cause a fire.
• Fuse ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
4. Install:
a. Connect the pocket tester to the fuse and
• Battery cover
check the continuity.
8-69
EAS28030
Therefore, the charge of the battery has to be
CHECKING AND CHARGING THE BATTERY
EWA13290
checked by measuring the voltage at the battery
WARNING terminals.
Batteries generate explosive hydrogen gas 1. Remove:
and contain electrolyte which is made of poi- • Battery cover
sonous and highly caustic sulfuric acid. Refer to “GENERAL CHASSIS” on page 4-1.
Therefore, always follow these preventive 2. Disconnect:
measures: • Battery leads
• Wear protective eye gear when handling or (from the battery terminals)
working near batteries. ECA5B21018
• Charge batteries in a well-ventilated area. CAUTION:

• Keep batteries away from fire, sparks or First, disconnect the negative battery lead
open flames (e.g., welding equipment, “1”, then the positive battery lead “2”.
lighted cigarettes).
• DO NOT SMOKE when charging or han-
2 1
dling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes and 3. Remove:
get immediate medical attention. • Battery
INTERNAL 4. Check:
• Drink large quantities of water or milk fol- • Battery charge
lowed with milk of magnesia, beaten egg or ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
vegetable oil. Get immediate medical atten- a. Connect a pocket tester to the battery termi-
tion. nals.
ECA5B21010
• Positive tester probe →
CAUTION: positive battery terminal
• Negative tester probe →
• This is a sealed battery. Never remove the negative battery terminal
sealing caps because the balance between
cells will not be maintained and battery per- NOTE:
formance will deteriorate. • The charge state of an MF battery can be
• Charging time, charging amperage and checked by measuring its open-circuit voltage
charging voltage for an MF battery are dif- (i.e., the voltage when the positive battery ter-
ferent from those of conventional batteries. minal is disconnected).
The MF battery should be charged accord- • No charging is necessary when the open-cir-
ing to the appropriate charging method. If cuit voltage equals or exceeds 12.8 V.
the battery is overcharged, the electrolyte
level will drop considerably. Therefore, b. Check the charge of the battery, as shown in
take special care when charging the bat- the charts and the following example.
tery. Example
Open-circuit voltage = 12.0 V
NOTE: Charging time = 6.5 hours
Since MF batteries are sealed, it is not possible Charge of the battery = 20–30%
to check the charge state of the battery by mea-
suring the specific gravity of the electrolyte.
8-70
• To reduce the chance of sparks, do not

plug in the battery charger until the battery
charger leads are connected to the battery.
• Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
• Make sure the battery charger lead clips are
in full contact with the battery terminal and
that they are not shorted. A corroded bat-
tery charger lead clip may generate heat in
A. Open-circuit voltage (V) the contact area and a weak clip spring may
B. Charging time (hours) cause sparks.
C. Relationship between the open-circuit voltage • If the battery becomes hot to the touch at
and the charging time at 20 °C (68 °F) any time during the charging process, dis-
D. These values vary with the temperature, the connect the battery charger and let the bat-
condition of the battery plates, and the tery cool before reconnecting it. Hot
electrolyte level.
batteries can explode!
• As shown in the following illustration, the
open-circuit voltage of an MF battery stabi-
lizes about 30 minutes after charging has
been completed. Therefore, wait 30 min-
utes after charging is completed before
measuring the open-circuit voltage.
A. Open-circuit voltage (V)

B. Charging condition of the battery (%)
C. Ambient temperature 20 °C (68 °F)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Charge:
• Battery
A. Open-circuit voltage (V)
(refer to the appropriate charging method)
EWA13300 B. Time (minutes)
WARNING C. Charging
Do not quick charge a battery. D. Ambient temperature 20 °C (68 °F)
E. Check the open-circuit voltage.
ECA13670
CAUTION:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Never remove the MF battery sealing caps. Charging method using a variable current
• Do not use a high-rate battery charger (voltage) charger
since it forces a high-amperage current a. Measure the open-circuit voltage prior to
into the battery quickly and can cause bat- charging.
tery overheating and battery plate damage. NOTE:
• If it is impossible to regulate the charging Voltage should be measured 30 minutes after
current on the battery charger, be careful the engine is turned off.
not to overcharge the battery.
• When charging a battery, be sure to remove b. Connect a charger and ammeter to the bat-
it from the vehicle. (If charging has to be tery and start charging.
done with the battery mounted on the vehi-
cle, disconnect the negative battery lead
from the battery terminal.)
8-71
NOTE: NOTE:
Set the charging voltage to 16–17 V. If the set- If the current is lower than the standard charging
ting is lower, charging will be insufficient. If too current written on the battery, this type of battery
high, the battery will be over-charged. charger cannot charge the MF battery. A vari-
able voltage charger is recommended.
c. Make sure that the current is higher than the
standard charging current written on the bat- d. Charge the battery until the battery’s charg-
tery. ing voltage is 15 V.
NOTE: NOTE:
If the current is lower than the standard charging Set the charging time at 20 hours (maximum).
current written on the battery, set the charging
e. Measure the battery open-circuit voltage after
voltage adjusting dial to 20–24 V and monitor
leaving the battery unused for more than 30
the amperage for 3–5 minutes to check the bat-
minutes.
tery.
12.8 V or more --- Charging is complete.
• Standard charging current is reached 12.7 V or less --- Recharging is required.
Battery is good. Under 12.0 V --- Replace the battery.
• Standard charging current is not reached
Replace the battery. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
d. Adjust the voltage so that the current is at the • Battery
standard charging level. 7. Connect:
e. Set the time according to the charging time • Battery leads
suitable for the open-circuit voltage. (to the battery terminals)
f. If charging requires more than 5 hours, it is ECA5B21019
advisable to check the charging current after CAUTION:

a lapse of 5 hours. If there is any change in First, connect the positive battery lead “1”,
the amperage, readjust the voltage to obtain then the negative battery lead “2”.
the standard charging current.
g. Measure the battery open-circuit voltage after
leaving the battery unused for more than 30 1 2
minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Charging method using a constant volt-
age charger 8. Check:
a. Measure the open-circuit voltage prior to • Battery terminals
charging. Dirt → Clean with a wire brush.
NOTE: Loose connection → Connect properly.
9. Lubricate:
Voltage should be measured 30 minutes after
• Battery terminals
the engine is turned off.
b. Connect a charger and ammeter to the bat- Recommended lubricant
tery and start charging. Dielectric grease
c. Make sure that the current is higher than the
10.Install:
standard charging current written on the bat-
• Battery cover
tery.
8-72
EAS28040
CHECKING THE RELAYS Result

Check each switch for continuity with the pocket Continuity
tester. If the continuity reading is incorrect, re- (between “3” and “4”)
place the relay.
Pocket tester Headlight relay

90890-03112
Analog pocket tester 3
YU-03112-C 4 +
1. Disconnect the relay from the wire harness.
2
2. Connect the pocket tester (Ω × 1) and battery 1
(12 V) to the relay terminal as shown. W/B R/Y
Check the relay operation. L/B
Out of specification → Replace. R/Y
Starting circuit cut-off relay

1. Positive battery terminal
2. Negative battery terminal
1 4 3. Positive tester probe
4. Negative tester probe
+ 2 3 Result
Continuity
L/Y G/Y (between “3” and “4”)
R/B W/Y
Radiator fan motor relay

1. Positive battery terminal 3
2. Negative battery terminal
4 +
3. Positive tester probe
4. Negative tester probe
2
1
Result
G/B R/B
Continuity
L
(between “3” and “4”)
R/W
Starter relay
1. Positive battery terminal
3 2. Negative battery terminal
3. Positive tester probe
R 4. Negative tester probe
R
Result
B L/W
Continuity
B (between “3” and “4”)
1 2
4 EAS5B21006
CHECKING THE TURN SIGNAL RELAY

1. Positive battery terminal 1. Check:
2. Negative battery terminal • Turn signal relay input voltage
3. Positive tester probe Out of specification → The wiring circuit from
4. Negative tester probe the main switch to the turn signal relay cou-
pler is faulty and must be repaired.
8-73
Turn signal relay input voltage

DC 12 V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
a. Connect the pocket tester (DC 20 V) to the Br/W
turn signal relay terminal as shown.
Br
Pocket tester
90890-03112
YU-03112-C b. Set the main switch to “ON”.
c. Measure the turn signal relay output voltage.
• Positive tester probe → ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
brown “1” EAS28060
• Negative tester probe → CHECKING THE SPARK PLUG CAP
ground 1. Check:
• Spark plug cap resistance
Resistance
10.0 kΩ
Br/W
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Br a. Remove the spark plug cap from the spark
1 plug lead.
b. Connect the pocket tester (Ω × 1k) to the
spark plug cap as shown.
b. Set the main switch to “ON”.
c. Measure the turn signal relay input voltage. Pocket tester
90890-03112
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check: YU-03112-C
• Turn signal relay output voltage
Turn signal relay output voltage

DC 12 V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the
turn signal relay terminal as shown.
Pocket tester
90890-03112
Analog pocket tester c. Measure the spark plug cap resistance.
YU-03112-C
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28090
• Positive tester probe → CHECKING THE IGNITION COIL
brown/white “1” 1. Check:
• Negative tester probe →
• Primary coil resistance
ground
Primary coil resistance

2.16–2.64 Ω at 20 °C (68 °F)
8-74
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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
• Positive tester probe c. Measure the secondary coil resistance.

red/black “1” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Negative tester probe EAS28930
orange “2” CHECKING THE IGNITION SPARK GAP

1. Check:
• Ignition spark gap
Out of specification → Perform the ignition
system troubleshooting, starting with step 5.
Refer to “TROUBLESHOOTING” on page
8-3.
Minimum ignition spark gap

6.0 mm (0.24 in)
NOTE:
c. Measure the primary coil resistance. If the ignition spark gap is within specification,
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ the ignition system circuit is operating normally.
2. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Secondary coil resistance a. Disconnect the spark plug cap from the spark
Out of specification → Replace. plug.
b. Connect the ignition checker “1” as shown.
Secondary coil resistance
8.64–12.96 Ω at 20 °C (68 °F) Ignition checker
90890-06754
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Opama pet-4000 spark checker
a. Disconnect the spark plug cap from the igni- YM-34487
tion coil.
b. Connect the pocket tester (Ω × 1k) to the ig-
nition coil as shown.
Pocket tester
90890-03112
YU-03112-C
• Positive tester probe

red/black “1”
• Negative tester probe
Spark plug lead “2” 2. Spark plug cap
c. Set the main switch to “ON”.
d. Measure the ignition spark gap “a”.
8-75
e. Crank the engine by pushing the start switch

“ ” and gradually increase the spark gap un- Lean angle sensor output voltage
til a misfire occurs. Less than 45°: 0.4–1.4 V
More than 45°: 3.7–4.4 V
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28120
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHECKING THE CRANKSHAFT POSITION a. Connect the lean angle sensor coupler to the
SENSOR wire harness.
1. Disconnect: b. Connect the pocket tester (DC 20 V) to the
• Crankshaft position sensor coupler lean angle sensor coupler as shown.
(from the wire harness)
2. Check: Pocket tester
• Crankshaft position sensor resistance 90890-03112
Out of specification → Replace the crank- Analog pocket tester
shaft position sensor/stator assembly. YU-03112-C
Crankshaft position sensor resis- • Positive tester probe

tance yellow/green “1”
248–372 Ω at 20 °C (68 °F) • Negative tester probe
gray/black “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 100) to the
crankshaft position sensor coupler as shown. 45˚
45˚
Pocket tester
90890-03112
YU-03112-C
Gy/R Y/G Gy/B
red “1” 1 2
white “2” c. Set the main switch to “ON”.
d. Turn the lean angle sensor 45°.
e. Measure the lean angle sensor output volt-
age.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28940
CHECKING THE STARTER MOTOR

OPERATION
1. Check:
R W
• Starter motor operation
1 2 Does not operate → Perform the electric
starting system troubleshooting, starting with
b. Measure the crankshaft position sensor re- step 4.
sistance. Refer to “TROUBLESHOOTING” on page
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 8-9.
EAS28130
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHECKING THE LEAN ANGLE SENSOR a. Connect the positive battery terminal “1” and
1. Remove: starter motor lead “2” with a jumper lead “3”.
EWA13810
• Lean angle sensor WARNING
2. Check:
• A wire that is used as a jumper lead must
• Lean angle sensor output voltage
have at least the same capacity of the bat-
tery lead, otherwise the jumper lead may
burn.
8-76
• This check is likely to produce sparks,

therefore, make sure no flammable gas or
fluid is in the vicinity.
1 3
W W
W
2
b. Measure the stator coil resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28170
b. Check the starter motor operation. CHECKING THE RECTIFIER/REGULATOR

1. Check:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Charging voltage
Out of specification → Replace the rectifi-
EAS28150
CHECKING THE STATOR COIL

1. Disconnect: er/regulator.
• Stator coil coupler Charging voltage
(from the wire harness) 14 V at 5000 r/min
2. Check:
• Stator coil resistance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Out of specification → Replace the crank- a. Connect the engine tachometer to the spark
shaft position sensor/stator assembly. plug lead.
b. Connect the pocket tester (DC 20 V) to the
Stator coil resistance rectifier/regulator coupler as shown.
0.32–0.48 Ω at 20 °C (68 °F)
Pocket tester
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 90890-03112
a. Connect the pocket tester (Ω × 1) to the stator Analog pocket tester
coil coupler as shown. YU-03112-C
Pocket tester
90890-03112
red “1”
YU-03112-C
black “2”
white “1”
white “2”

white “1”
white “3”

white “2” c. Start the engine and let it run at approximate-
• Negative tester probe ly 5000 r/min.
white “3” d. Measure the charging voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-77
EAS28180
CHECKING THE HORN

1. Check:
• Horn resistance
Coil resistance
1.15–1.25 Ω at 20 °C (68 °F)
a b
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the horn connectors from the
horn terminals.
b. Connect the pocket tester (Ω × 1) to the horn ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
terminals. EAS28230
CHECKING THE FUEL SENDER

Pocket tester 1. Drain the fuel from the fuel tank.
90890-03112 2. Remove:
Analog pocket tester • Fuel tank
YU-03112-C 3. Check:
• Fuel sender resistance
horn terminal “1” Sender unit resistance (full)
• Negative tester probe 0.0–7.0 Ω
horn terminal “2” Sender unit resistance (empty)
90.0–103.0 Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1) to the fuel
1 sender terminal as shown.
Pocket tester
90890-03112
2 YU-03112-C

c. Measure the horn resistance. sky blue “1”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
orange/white “2”
2. Check:
• Horn sound
Faulty sound → Adjust or replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a battery (12 V) to the horn.
b. Turn the adjusting screw in direction “a” or “b”
until the specified horn sound is obtained.
8-78
1
Gy L
Gy/B B
A
Gy/R R
1 2
Sb
O/W
2 c. Elevate the front wheel and slowly rotate it.
d. Measure the voltage of gray and gray/black.
With each full rotation of the front wheel, the
voltage reading should cycle from 0.6 V to 4.8
V to 0.6 V to 4.8 V.
B ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28250
CHECKING THE RADIATOR FAN MOTOR

1. Check:
• Radiator fan motor
A. Full fuel tank position Faulty/rough movement → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
B. Empty fuel tank position
a. Disconnect the radiator fan motor coupler
b. Measure the fuel sender resistance. from the wire harness.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Connect the battery (DC 12 V) as shown.
EAS28240 • Positive tester probe
CHECKING THE SPEED SENSOR red “1”
1. Check: • Negative tester probe
• Speed sensor output voltage black “2”
Output voltage reading cycle

0 V to 5.0 V to 0 V to 5.0 V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the
speed sensor coupler (wire harness end) as
shown.
Pocket tester
90890-03112
Analog pocket tester c. Measure the radiator fan motor movement.
YU-03112-C ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28260
• Positive tester probe CHECKING THE COOLANT TEMPERATURE

gray “1” SENSOR
• Negative tester probe 1. Remove:
gray/black “2” • Coolant temperature sensor
EWA14130
WARNING
• Handle the coolant temperature sensor
with special care.
8-79
• Never subject the coolant temperature sen- EAS28300
CHECKING THE THROTTLE POSITION

sor to strong shocks. If the coolant temper-
SENSOR
ature sensor is dropped, replace it.
1. Check:
2. Check: • Throttle position sensor
• Coolant temperature sensor resistance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Out of specification → Replace. a. Connect the pocket tester (DC 20 V) to the
throttle position sensor as shown.
Coolant temperature sensor re-
sistance Pocket tester
2.32–2.59 kΩ at 20 °C (68 °F) 90890-03112
310–326 Ω at 80 °C (176 °F) Analog pocket tester
YU-03112-C
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 100) to the • Positive tester probe →
coolant temperature sensor terminals as gray/red “1”
shown. • Negative tester probe →
gray/black “2”
Pocket tester
90890-03112
YU-03112-C
Y Gy/B Gy/R
2 1
b. Measure the throttle position sensor voltage.

Out of specification → Replace or repair the
wire harness.
b. Immerse the coolant temperature sensor “1”
in a container filled with coolant “2”. Throttle position sensor voltage
5V
NOTE: (gray/red–gray/black)
Make sure the coolant temperature sensor ter-
minals do not get wet. c. Connect the pocket tester (DC 20 V) to the
c. Place a thermometer “3” in the coolant. throttle position sensor as shown.
d. Slowly heat the coolant, and then let it cool to • Positive tester probe →
the specified temperature indicated in the ta- yellow “1”
ble. • Negative tester probe →
e. Check the coolant temperature sensor resis- gray/black “2”
tance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install: Y Gy/B Gy/R
• Coolant temperature sensor
Coolant temperature sensor

18 Nm (1.8 m·kg, 13 ft·lb)
T.
R.
1 2
8-80
d. While slowly opening the throttle, check that EAS28420
CHECKING THE INTAKE AIR

the throttle position sensor voltage is in-
TEMPERATURE SENSOR
creased.
1. Remove:
Voltage does not change or it changes
• Intake air temperature sensor
abruptly → Replace the throttle position sen-
(from the air filter case)
sor. EWA14110
Out of specification (closed position) → Re- WARNING
place the throttle position sensor. • Handle the intake air temperature sensor
Throttle position sensor voltage with special care.
(closed position) • Never subject the intake air temperature
0.4–0.9 V sensor to strong shocks. If the intake air
(yellow–gray/black) temperature sensor is dropped, replace it.
2. Check:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Intake air temperature sensor resistance
EAS28410
CHECKING THE INTAKE AIR PRESSURE
SENSOR Intake air temperature sensor re-
1. Check: sistance
• Intake air pressure sensor output voltage 2.21–2.69 kΩ at 20 °C (68 °F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Intake air pressure sensor output a. Connect the pocket tester (Ω × 100) to the in-
voltage take air temperature sensor terminal as
3.75–4.25 V at 101 kPa (29.9 in- shown.
Hg) (759.4 mmHg)
Pocket tester
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 90890-03112
a. Connect the pocket tester (DC 20 V) to the in- Analog pocket tester
take air pressure sensor coupler as shown. YU-03112-C
Pocket tester • Positive tester probe

90890-03112 brown/white “1”
Analog pocket tester • Negative tester probe
YU-03112-C gray/black “2”

pink/white “1”
gray/black “2”
Br/W Gy/B
Gy/B P/W Gy/R 2 1
b. Measure the intake air temperature sensor

2 1 resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

c. Measure the intake air pressure sensor out-
put voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-81
EAS5B21007
CHECKING THE ISC (IDLE SPEED

CONTROL) UNIT
NOTE:
Do not remove the ISC unit completely from the
throttle body.
1. Check:
• ISC unit
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the ISC unit coupler from the ISC
unit.
b. Connect the pocket tester (Ω × 10) to the ter-
minals of the ISC unit.
Pocket tester
90890-03112
YU-03112-C

pink “1”
light green “2”

green “3”
sky blue “4”
4 2
Lg Sb
P G
3 1
c. Measure the ISC unit resistance.

Out of specification → Replace the throttle
body.
ISC unit resistance

27–33 Ω at 20 °C (68 °F)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-82
8-83
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
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
9
TROUBLESHOOTING
EAS28450
Electrical system
TROUBLESHOOTING 1. Battery
EAS28460
• Discharged battery
GENERAL INFORMATION • Faulty battery
NOTE: 2. Fuse(s)
• Blown, damaged or incorrect fuse
The following guide for troubleshooting does not
• Improperly installed fuse
cover all the possible causes of trouble. It should
3. Spark plug
be helpful, however, as a guide to basic trouble-
• Incorrect spark plug gap
shooting. Refer to the relative procedure in this
• Incorrect spark plug heat range
manual for checks, adjustments, and replace-
• Fouled spark plug
ment of parts.
• Worn or damaged electrode
EAS28480
• Worn or damaged insulator
STARTING FAILURE/HARD STARTING • Faulty spark plug cap
4. Ignition coil
Engine • Cracked or broken ignition coil body
1. Cylinder and cylinder head • Broken or shorted primary or secondary coils
• Loose spark plug • Faulty spark plug lead
• Loose cylinder head or cylinder 5. Ignition system
• Damaged cylinder head gasket • Faulty ECU
• Damaged cylinder gasket • Faulty crankshaft position sensor
• Worn or damaged cylinder • Broken generator rotor woodruff key
• Incorrect valve clearance 6. Switches and wiring
• Improperly sealed valve • Faulty main switch
• Incorrect valve-to-valve-seat contact • Broken or shorted wiring
• Incorrect valve timing • Faulty front, rear or both brake light switches
• Faulty valve spring • Faulty start switch
• Seized valve • Faulty sidestand switch
2. Piston and piston ring(s) • Improperly grounded circuit
• Improperly installed piston ring • Loose connections
• Damaged, worn or fatigued piston ring 7. Starting system
• Seized piston ring • Faulty starter motor
• Seized or damaged piston • Faulty starter relay
3. Air filter • Faulty starting circuit cut-off relay
• Improperly installed air filter • Faulty starter clutch
• Clogged air filter element EAS28500
4. Crankcase and crankshaft INCORRECT ENGINE IDLING SPEED
• Improperly assembled crankcase
• Seized crankshaft Engine
1. Cylinder and cylinder head
Fuel system • Incorrect valve clearance
1. Fuel tank • Damaged valve train components
• Empty fuel tank 2. Air filter
• Clogged fuel tank cap breather hole • Clogged air filter element
• Deteriorated or contaminated fuel
• Clogged or damaged fuel hose Fuel system
2. Fuel pump 1. Throttle body
• Faulty fuel pump • Damaged or loose throttle body joint
• Improperly routed hose • Improper throttle cable free play
3. Throttle body
• Deteriorated or contaminated fuel Electrical system
1. Battery
• Discharged battery
9-1
TROUBLESHOOTING
• Faulty battery 2. Primary sliding sheave

2. Spark plug • Faulty operation
• Incorrect spark plug gap 3. Clutch shoe(s)
• Incorrect spark plug heat range • Bent, damaged or worn clutch shoe
• Fouled spark plug
• Worn or damaged electrode Poor speed performance
• Worn or damaged insulator 1. V-belt
• Faulty spark plug cap • Oil or grease on the V-belt
3. Ignition coil 2. Primary pulley weight(s)
• Faulty spark plug lead • Faulty operation
4. Ignition system • Worn primary pulley weight
• Faulty ECU 3. Primary fixed sheave
• Faulty crankshaft position sensor • Worn primary fixed sheave
4. Primary sliding sheave
EAS28510
POOR MEDIUM-AND-HIGH-SPEED • Worn primary sliding sheave

PERFORMANCE 5. Secondary fixed sheave
Refer to “STARTING FAILURE/HARD START- • Worn secondary fixed sheave
ING” on page 9-1. 6. Secondary sliding sheave
• Worn secondary sliding sheave
Engine EAS28600
1. Air filter OVERHEATING

• Clogged air filter element
Engine
Fuel system 1. Clogged coolant passages
1. Fuel pump • Cylinder head and piston
• Faulty fuel pump • Heavy carbon buildup
2. Engine oil
EAS28580
FAULTY CLUTCH • Incorrect oil level

• Incorrect oil viscosity
Engine operates but vehicle will not move • Inferior oil quality
1. V-belt
• Bent, damaged or worn V-belt Cooling system
• Slipping V-belt 1. Coolant
2. Primary pulley cam and primary pulley slid- • Low coolant level
er(s) 2. Radiator
• Damaged or worn primary pulley cam • Damaged or leaking radiator
• Damaged or worn primary pulley slider • Faulty radiator cap
3. Transmission gear(s) • Bent or damaged radiator fin
• Damaged transmission gear 3. Water pump
• Damaged or faulty water pump
Clutch slips 4. Thermostat
1. Clutch shoe spring(s) • Thermostat stays closed
• Damaged, loose or worn clutch shoe spring 5. Hose(s)
2. Clutch shoe(s) • Damaged hose
• Damaged or worn clutch shoe • Improperly connected hose
3. Primary sliding sheave
• Seized primary sliding sheave Fuel system
1. Throttle body
Poor starting performance • Damaged or loose throttle body joint
1. V-belt 2. Air filter
• V-belt slips • Clogged air filter element
• Oil or grease on the V-belt
9-2
TROUBLESHOOTING
Chassis EAS28670
UNSTABLE HANDLING
1. Brake(s)
1. Handlebar
• Dragging brake
• Bent or improperly installed handlebar
Electrical system 2. Steering head components
1. Spark plug • Improperly installed lower handlebar holder
• Incorrect spark plug gap • Improperly installed lower bracket
• Incorrect spark plug heat range (improperly tightened ring nut)
2. Ignition system • Bent steering stem
• Faulty ECU • Damaged ball bearing or bearing race
3. Front fork leg(s)
EAS28610 • Uneven oil levels (both front fork legs)
OVERCOOLING • Unevenly tensioned fork spring (both front
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
• 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
• Excessive wheel runout
Leaking oil 8. Frame
• Bent, damaged or rusty inner tube • Bent frame
• Cracked or damaged outer tube • Damaged steering head pipe
• Improperly installed oil seal • Improperly installed bearing race
• Damaged oil seal lip EAS28710
• Incorrect oil level (high) FAULTY LIGHTING OR SIGNALING SYSTEM
• Loose damper rod bolt
• Damaged damper rod bolt copper washer Headlight does not come on
• Cracked or damaged front fork cap O-ring • Wrong headlight bulb
• Too many electrical accessories
Malfunction • Hard charging
• Bent or damaged inner tube • Incorrect connection
• Bent or damaged outer tube • Improperly grounded circuit
• Damaged fork spring • Poor contacts (main switch)
• Worn or damaged outer tube bushing • Burnt-out headlight bulb
• Bent or damaged damper rod
• Incorrect oil viscosity Headlight bulb burnt out
• Incorrect oil level • Wrong headlight bulb
• Faulty battery
• Faulty rectifier/regulator
9-3
TROUBLESHOOTING
• Improperly grounded circuit

• Faulty main 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
• 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
• Improperly grounded circuit
• Faulty battery
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
• Faulty wire harness
9-4
EAS28740
58. Meter light EAS28750
WIRING DIAGRAM 59. High beam indicator light COLOR CODE

VP250 2007 60. Left turn signal indicator light B Black
1. AC magneto 61. Fuel level warning light Br Brown
2. Crankshaft position sensor 62. Engine trouble warning light Ch Chocolate
63. Air temperature sensor Dg Dark green
G Green
4. ECU fuse 64. Speed sensor
L Blue
5. Main switch 65. Signaling system fuse Lg Light green
6. Ignition fuse 66. Headlight fuse O Orange
7. Ground lead 67. Radiator fan motor fuse P Pink
8. Battery 68. Backup fuse (meter assembly) R Red
9. Main fuse 69. Self-diagnosis signal coupler Sb Sky blue
10. Starter relay W White
11. Starter motor Y Yellow
12. Diode B/R Black/Red
B/W Black/White
13. Sidestand switch
Br/B Brown/Black
14. Start switch Br/G Brown/Green
15. Starting circuit cut-off relay Br/L Brown/Blue
16. Fuel pump Br/W Brown/White
17. Fuel sender G/B Green/Black
18. Throttle position sensor G/L Green/Blue
19. Intake air pressure sensor G/R Green/Red
20. Intake air temperature sensor G/Y Green/Yellow
21. Lean angle sensor Gy/B Gray/Black
22. ECU (engine control unit) Gy/G Gray/Green
23. Ignition coil Gy/R Gray/Red
L/B Blue/Black
24. Spark plug
L/R Blue/Red
25. ISC (idle speed control) unit L/W Blue/White
26. O2 sensor L/Y Blue/Yellow
27. Fuel injector O/B Orange/Black
28. Radiator fan motor relay O/W Orange/White
29. Radiator fan motor P/W Pink/White
30. Rear brake light switch R/B Red/Black
31. Front brake light switch R/G Red/Green
32. Turn signal relay R/L Red/Blue
R/W Red/White
33. Horn
R/Y Red/Yellow
34. Headlight relay W/B White/Black
35. Handlebar switch W/R White/Red
36. Dimmer/pass switch W/Y White/Yellow
37. Horn switch Y/G Yellow/Green
38. Turn signal switch Y/L Yellow/Blue
39. License plate light Y/W Yellow/White
40. Left tail/brake light assembly
41. Left rear turn signal light
42. Tail/brake light
43. Right tail/brake light assembly
44. Right rear turn signal light
45. Right front turn signal light
46. Left front turn signal light
47. Headlight assembly
48. Headlight (high beam)
49. Headlight (low beam)
50. Auxiliary light
52. Meter assembly
53. Coolant temperature gauge
54. Fuel gauge
55. Speedometer
56. Multi-function meter
57. Right turn signal indicator light
VP250 2007 VP250 2007 VP250 2007 VP250 2007 VP250 2007
WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO
O O/B B P G/B Lg Y/W R/B Gy R/G Y/L Gy/B Gy/R Gy/G Y G/R
R/B
4 23
O O
R R/G R/G
2 24
Gy/B L
P P
W W R Gy/R Gy/B Y Lg Lg
1 W W 3 Gy
G G 25 Lg Sb
W W B Sb Sb P G
Gy/R Gy/R
W W W W L/Y G/Y
W W
R R R
R/B W/Y
18 Y
Gy/B
Y
Gy/B 26
R/B
B R B L/W
W W W
8 9 (BLACK) R/B L/R Sb O/W
Gy/B P/W Gy/R
B/R B/R R/B
L/W
15
Gy/R
B B B B/R R/B
10 R/B Sb 19 P/W P/W
Gy/G Gy/B
R 7 B B
B B L/W Gy/B
22 W L
L/Y
5 B/W L/W 16 17 Br/W Gy/B O/B O/B R/B
R R B B B
B 12 (BLACK) R/L O/B O/B R/B
Br/L ON B
Br/L
OFF B 11 (BLACK)
L/R O/W 20 (BLACK) (BLACK)
B Gy/B Br/W Br/W
Br/L
B
Gy/R Y/G Gy/B Y/W

6 G/R
Br/L R/B Gy/R Y/L
21 Y/G Y/G
Gy/B L/W
G/B
B
W/B
L/R
L/Y
R/B
B/W R/L
Y/L
L/Y
L/W
69 B/W
R/L W/Y
B B/W
B L/Y
Y/L 13 B B
14 L/W L/W
68
67
R R/W
66
Br/L R/Y
65
Br/L Br
R/Y Br
Br/W
R/Y R/Y Br
L/B Br
G/R Gy/B
34 R/Y W/B
33 32 R/W
(BLACK) Br Br L
51 R/B R/B G/B
Gy/B G/R W/B R/W

31 30
36 37 38 L/B G R/Y R/Y G L/B
P Y B B Y P G/B

G/Y G/Y L
Gy G Y B Ch Dg
Gy/R Br/G 57 58 59
Gy/B Gy 29 B B
R L
64 53 54
63 (BLACK)
Y
Gy L
Br/G B
55 56 60 61 62 Ch 47 Y G Br
B
Gy/B Dg Br Dg
Br G/Y B Br
B Br
Gy/R R
48 49 50 50 (BLACK)
43 Dg G/Y (BLACK) 40 Ch G/Y G/Y B Br
Br/G Ch Dg
Br G G Br
44 42 Dg Br 41 42 Ch Br L B 39
B G/Y B G/Y
G/R B/W Gy Br R/L
B B B
B B B
VP250 2007 VP250 2007 VP250 2007 VP250 2007 VP250 2007
WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO
4 23
2 24
1 3 25
18 26
8 9 (BLACK)
15
10 19
7 22 (BLACK) (BLACK) 27
5 16 17
12 (BLACK)
ON
OFF 11 (BLACK)
20 (BLACK) (BLACK)
6
21
69
13
14
(BLUE) (BLUE)
68
(BLUE) (BLUE)
67
66
65
34
33 32
(BLACK)
51
35 28
31 30
36 37 38
52
57 58 59
29
64 53 54
63 (BLACK)
55 56 60 61 62 47
48 49 50 50 (BLACK)
43 (BLACK) 40
44 42 41 42 39
46 45 (BLACK)

YP250

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YP250

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Droits d'auteur :

Formats disponibles

2007

IMPORTANT MANUAL INFORMATION

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

A CAUTION indicates special precautions that must be taken to avoid dam-

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

HOW TO USE THIS MANUAL

IDENTIFICATION ............................................................................................ 1-1

INSTRUMENT FUNCTIONS............................................................................ 1-4

IMPORTANT INFORMATION ......................................................................... 1-7

CHECKING THE CONNECTIONS .................................................................. 1-9

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

VEHICLE IDENTIFICATION NUMBER

OUTLINE OF THE FI SYSTEM

1. Air temperature sensor 13. Spark plug

1. Fuel pump 14. Intake air pressure sensor

INSTRUMENT FUNCTIONS "Mode"

Ambient temperature display

To reset a tripmeter, select it by pushing the

1. Oil change indicator “OIL”

at the correct time. After resetting, the indicator

PREPARATION FOR REMOVAL AND

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS

CHECKING THE CONNECTIONS Pocket tester

FI diagnostic tool 3-5, 8-34

Timing light 3-7

Compression gauge 3-8

Steering nut wrench 3-19, 3-20,

T-handle 4-44, 4-46

Fork seal driver weight 4-46, 4-47

Fork seal driver attachment (ø38) 4-46

Slide hammer bolt 5-14

Valve spring compressor 5-18, 5-23

Valve spring compressor attachment 5-18, 5-23

Valve guide remover (ø6) 5-19

Valve guide installer (ø6) 5-19

Valve guide reamer (ø6) 5-19

Yamaha grease G 5-31

Rotor holding tool 5-33, 5-38

Sheave holder 5-33, 5-37,

Locknut wrench 5-33, 5-37

Clutch spring holder 5-34, 5-37

Oil seal guide (ø41) 5-36

Flywheel puller 5-41

Yamaha bond No. 1215 5-43, 5-60, 6-9

Crankcase separating tool 5-57

Crankshaft installer pot 5-59, 5-60

Adapter (M14) 5-59

Spacer (crankshaft installer) 5-59

Adapter (M16) 5-60

Radiator cap tester 6-3

Mechanical seal installer 6-9

Middle driven shaft bearing driver 6-9

Pressure gauge 7-6

Fuel pressure adapter 7-6

Ignition checker 8-75

GENERAL SPECIFICATIONS ........................................................................ 2-1

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

CHASSIS SPECIFICATIONS ........................................................................ 2-10

ELECTRICAL SPECIFICATIONS ................................................................. 2-13

TIGHTENING TORQUES .............................................................................. 2-16

LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-22

COOLING SYSTEM DIAGRAMS .................................................................. 2-25