Service Manual

2007
MT01(W)
SERVICE MANUAL
5YU-28197-E2
EAS20040
MT01(W) 2007
SERVICE MANUAL
©2006 by Yamaha Motor Co., Ltd.
First edition, September 2006
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS20070
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
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 motorcycle operator, a bystander or a person checking or repairing the
motorcycle.
A CAUTION indicates special precautions that must be taken to avoid dam-

CAUTION: age to the motorcycle.
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
FUEL SYSTEM 6
ELECTRICAL SYSTEM 7
TROUBLESHOOTING 8
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
on the right side of the steering head pipe.
EAS20150
MODEL LABEL
The model label “1” is affixed to the lead holder
under the seat. This information will be needed
to order spare parts.
1-1
FEATURES
EAS20170
FEATURES
ET5YU1009
OUTLINE OF THE FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum
air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In
the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion
chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the
respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating con-
ditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the
fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-
fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the en-
gine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases increase,
it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accom-
modate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place
of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by
the engine at all times by using a microprocessor that regulates the fuel injection volume according to
the engine operating conditions detected by various sensors.
The adoption of the FI system has 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 9 10 11 12 13 14 15 16
17
27
22 26 25 24 23 22 21 20 19 18
1. Air temperature sensor 15. Relay unit (fuel pump relay)
2. Cylinder-#1 intake air pressure sensor 16. Muffler cooling fan temperature sensor
3. Cylinder-#2 intake air pressure sensor 17. Muffler cooling fan motor
4. Cylinder-#2 left ignition coil 18. Cylinder-#1 right ignition coil
5. Cylinder-#2 right ignition coil 19. Cylinder-#1 left ignition coil
6. Throttle position sensor 20. Speed sensor
7. Intake solenoid 21. O2 sensor
8. ISC (idle speed control) unit 22. Spark plug
9. Fuel pump 23. Decompression solenoid
10. EXUP servo motor 24. Crankshaft position sensor
11. Lean angle cut-off switch 25. Injector #2
12. Fuel pump relay 26. Injector #1
13. Muffler cooling fan motor relay 27. Engine temperature sensor
14. ECU (electronic control unit)
1-2
FEATURES
ET5YU1010
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 392 kPa (3.92 kg/cm², 55.7 psi). Accordingly,
when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing
the fuel to be injected into the intake manifold only during the time the passage remains open. 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, crankshaft position sensor, intake air pressure sensor, air temperature sensor,
engine 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.
Illustration is for reference only.
6
7
1 8
2 C
A 5
3
#2 #1
4 9
15 10
B
14
13 11
12
1. Pressure regulator 13. Intake air pressure sensor

2. Fuel pump 14. Throttle body
3. Fuel injector 15. Air filter case
4. Ignition coil
A. Fuel system
B. Air system
6. Air temperature sensor
C. Control system
7. ISC (idle speed control) unit
8. Throttle position sensor
9. O2 sensor
10. Catalytic converter
11. Engine temperature sensor
12. Crankshaft position sensor
1-3
FEATURES
ET5YU1011
Tachometer
INSTRUMENT FUNCTIONS
Multi-function display 1
EW5YU1005
WARNING
Be sure to stop the vehicle before making
any setting changes to the multi-function 2
display.
3
1. Tachometer
2 4 2. Tachometer red zone
The electric tachometer allows the rider to mon-
5
itor the engine speed and keep it within the ideal
1 6 power range.
When the key is turned to “ON”, the tachometer
needle will sweep once across the r/min range
1. Clock and then return to zero r/min in order to test the
2. “RESET” button electrical circuit.
EC5YU1009
3. Tachometer
CAUTION:
4. “SELECT” button
5. Speedometer Do not operate the engine in the tachometer
6. Odometer/Tripmeter/Fuel reserve tripmeter red zone.
Red zone: 5500 r/min and above
The multi-function display is equipped with the
The tachometer needle flashes when it reaches
following:
and exceeds the red zone.
• a speedometer (which shows the riding speed)
• a tachometer (which shows engine speed)
Clock mode
• an odometer (which shows the total distance
traveled)
• two tripmeters (which show the distance trav-
eled since they were last set to zero)
• a fuel reserve tripmeter (which shows the dis-
tance traveled since the fuel level warning light
come on)
• a clock
• a self-diagnosis device 1
• a brightness control mode
NOTE:
• Be sure to turn the key to “ON” before using the 1. Clock
“SELECT” and “RESET” buttons except for
setting the brightness control.
• For the U.K. only: To switch the speedometer
and odometer/tripmeter/fuel reserve tripmeter
displays between kilometers and miles, press
the “SELECT” button for at least two seconds.
1-4
FEATURES
To set the clock: If the multi-function display indicates an error

1. Push the “SELECT” button and “RESET” but- code, note the code number, and then check the
ton together for at least two seconds. vehicle. Refer to “FUEL INJECTION SYSTEM”
2. When the hour digits start flashing, push the on page 7-25.
“RESET” button to set the hours. EC5YU1010
3. Push the “SELECT” button, and the minute CAUTION:

digits will start flashing. If the multi-function display indicates an er-
4. Push the “RESET” button to set the minutes. ror code, the vehicle should be checked as
5. Push the “SELECT” button and then release soon as possible in order to avoid engine
it to start the clock. damage.
This model is also equipped with a self-diagno-
Odometer and tripmeter modes sis device for the immobilizer system.
If any of the immobilizer system circuits are de-
fective, the immobilizer system indicator light will
flash, and then the multi-function display will in-
dicate a two-digit error code (e.g., 51, 52, 53)
when the key is turned to “ON”.
1 NOTE:
If the multi-function display indicates error code
52, this could be caused by transponder interfer-
ence. If this error appears, try the following.
1. Odometer/Tripmeter/Fuel reserve tripmeter

1. Use the code re-registering key to start the
engine.
Pushing the “SELECT” button switches the dis- NOTE:
play between the odometer mode “ODO” and Make sure there are no other immobilizer keys
the tripmeter modes “TRIP 1” and “TRIP 2” in the close to the main switch, and do not keep more
following order: than one immobilizer key on the same key ring!
ODO → TRIP 1 → TRIP 2 → ODO Immobilizer system keys may cause signal inter-
If the fuel level warning light comes on, the ference, which may prevent the engine from
odometer display will automatically change to starting.
the fuel reserve tripmeter mode “F-TRIP” and
start counting the distance traveled from that 2. If the engine starts, turn it off, and try starting
point. In that case, pushing the “SELECT” button the engine with the standard keys.
switches the display between the various tripme- 3. If one or both of the standard keys do not start
ter and odometer modes in the following order: the engine, re-register the standard keys.
F-TRIP → TRIP 1 → TRIP 2 → ODO → F-TRIP If the multi-function display indicates an error
To reset a tripmeter, select it by pushing the “SE- code, note the code number, and then check the
LECT” button, and then push the “RESET” but- vehicle. Refer to “IMMOBILIZER SYSTEM” on
ton for at least one second. If you do not reset page 7-75.
the fuel reserve tripmeter manually, it will reset
itself automatically and the display will return to
the prior mode after refueling and traveling 5 km
(3 mi).
Self-diagnosis device
This model is equipped with a self-diagnosis de-
vice for various electrical circuits.
If any of those circuits are defective, the engine
trouble warning light will come on, and then the
multi-function display will indicate a two-digit er-
ror code (e.g., 12, 13, 14).
1-5
FEATURES
Brightness control mode
3 1
2 2 3
1. LCD
1. Tachometer panel 2. Item number
2. LCD 3. Brightness level
3. Tachometer needle
6. Push the “SELECT” button to select the ta-
The brightness can be adjusted for the following: chometer needle.
• the tachometer panel (item number “1”) Item number “3” is displayed.
• the LCD (item number “2”) Adjust the tachometer needle brightness lev-
• the tachometer needle (item number “3”) el by pushing the “RESET” button.
Select the brightness control mode as follows.
1. Turn the key to “OFF”.
2. Push and hold the “SELECT” button. 1
3. Turn the key to “ON”, and then release the
“SELECT” button after five seconds.
Item number “1” is displayed.
1 2 3
1. Tachometer needle
2. Item number
3. Brightness level
2 3 7. Push the “SELECT” button and the multi-
function display will return to the odometer or
tripmeter mode.
1. Tachometer panel
2. Item number
3. Brightness level
4. Adjust the tachometer panel brightness level
by pushing the “RESET” button.
5. Push the “SELECT” button to select the LCD.
Item number “2” is displayed.
Adjust the LCD brightness level by pushing
the “RESET” button.
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 number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part number starting with “90890-”.
Reference
Tool name/Tool No. Illustration
pages
Pocket tester 1-9, 5-73, 7-91,
90890-03112 7-92, 7-93,
Analog pocket tester 7-96, 7-98,
YU-03112-C 7-99, 7-100,
7-101, 7-102,
7-103, 7-104,
7-106, 7-107,
7-108
Thickness gauge 3-4, 3-5, 5-57
90890-03079
Narrow gauge set
YM-34483
Locknut wrench 3-5

90890-04150
YM-04150
10
Tappet adjusting tool 3-5

90890-04149
YM-04149 4
Vacuum gauge 3-6

90890-03094
Carburetor synchronizer
YU-44456
YU-44456
1-10
SPECIAL TOOLS
Reference
pages
Timing light 3-9
90890-03141
Inductive clamp timing light
YU-03141
Compression gauge 3-10

90890-03081
Engine compression tester
YU-33223
Extension 3-10
90890-04082
Oil filter wrench 3-12

90890-01426
YU-38411
Steering nut wrench 3-26, 4-58

90890-01403
Spanner wrench
YU-33975
Vacuum/pressure pump gauge set 4-5, 6-9

90890-06756
Mityvac brake bleeding tool
YS-42423
Fork spring compressor 4-49, 4-54

90890-01441
YM-01441
Rod holder 4-49, 4-54

90890-01434
Damper rod holder double ended
YM-01434
Damper rod holder 4-50, 4-51

90890-01504
YM-01504
1-11
SPECIAL TOOLS
Reference
pages
Fork seal driver 4-52
90890-01442
Adjustable fork seal driver (36–46 mm)
YM-01442
Rod puller 4-53, 4-54

90890-01437
Universal damping rod bleeding tool set
YM-A8703
YM-A8703
Rod puller attachment (M10) 4-53, 4-54

90890-01436
Universal damping rod bleeding tool set
YM-A8703
YM-A8703
Ring nut wrench 4-58

90890-01268
Spanner wrench
YU-01268
Pivot shaft wrench 5-13

90890-01485
Frame mount insert wrench
YM-01485
Valve spring compressor 5-35, 5-40

90890-04019
YM-04019
1-12
SPECIAL TOOLS
Reference
pages
Valve guide remover (ø6) 5-37
90890-04064
Valve guide remover (6.0 mm)
YM-04064-A
Valve guide installer (ø6) 5-37

90890-04065
Valve guide installer (6.0 mm)
YM-04065-A
Valve guide reamer (ø6) 5-37

90890-04066
Valve guide reamer (6.0 mm)
YM-04066
Piston pin puller set 5-43

90890-01304
Piston pin puller
YU-01304
YU-01304
Universal clutch holder 5-56, 5-59

90890-04086
YM-91042
Sheave holder 5-56, 5-58,

90890-01701 5-69, 5-70,
Primary clutch holder 5-78, 5-80
YS-01880-A
1-13
SPECIAL TOOLS
Reference
pages
Yamaha bond No. 1215 5-58, 5-70,
90890-85505 5-79
(Three Bond No.1215®)
Rotor puller 5-69

90890-01080
Stator rotor puller
YM-01080-A
Pressure gauge 6-9

90890-03153
YU-03153
Fuel pressure adapter 6-9

90890-03176
YM-03176
Digital circuit tester 6-10

90890-03174
Model 88 Multimeter with tachometer
YU-A1927
Ignition checker 7-100

90890-06754
Opama pet-4000 spark checker
YM-34487
1-14
SPECIAL TOOLS
1-15
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....................................................... 2-22
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-27

ENGINE................................................................................................... 2-27
CHASSIS................................................................................................. 2-29
LUBRICATION SYSTEM CHART AND DIAGRAMS.................................... 2-31

ENGINE OIL LUBRICATION CHART ..................................................... 2-31
LUBRICATION DIAGRAMS .................................................................... 2-33
CABLE ROUTING ......................................................................................... 2-41

GENERAL SPECIFICATIONS
EAS20280
GENERAL SPECIFICATIONS
Model
Model 5YU8 (Europe) (ZA)
5YUA (AUS)
5YUB (Europe) (ZA)
5YUC (AUS)
Dimensions
Overall length 2185 mm (86.0 in)
Overall width 800 mm (31.5 in)
Overall height 1105 mm (43.5 in)
Seat height 825 mm (32.5 in)
Wheelbase 1525 mm (60.0 in)
Ground clearance 145 mm (5.71 in)
Minimum turning radius 3200 mm (126.0 in)
Weight
With oil and fuel 262.0 kg (578 lb)
Maximum load 199 kg (439 lb)
2-1
ENGINE SPECIFICATIONS
EAS20290
Engine
Engine type Air cooled 4-stroke, OHV
Displacement 1670.0 cm³
Cylinder arrangement V-type 2-cylinder
Bore × stroke 97.0 × 113.0 mm (3.82 × 4.45 in)
Compression ratio 8.40 :1
Standard compression pressure (at sea level) 1200 kPa/200 r/min (170.7 psi/200 r/min) (12.0
kgf/cm²/200 r/min)
Minimum–maximum 1000–1400 kPa (142.2–199.1 psi) (10.0–14.0
kgf/cm²)
Starting system Electric starter
Fuel
Recommended fuel Regular unleaded gasoline only (Europe) (ZA)
Unleaded gasoline only (AUS)
Fuel tank capacity 15.0 L (3.96 US gal) (3.30 Imp.gal)
Fuel reserve amount 3.0 L (0.79 US gal) (0.66 Imp.gal)
Engine oil
Lubrication system Dry sump
Type SAE20W40
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Engine oil quantity
Total amount 5.00 L (5.29 US qt) (4.40 Imp.qt)
Engine 2.2 L (2.33 US qt) (1.94 Imp.qt)
Oil tank 2.8 L (2.96 US qt) (2.46 Imp.qt)
Without oil filter cartridge replacement 3.70 L (3.91 US qt) (3.26 Imp.qt)
With oil filter cartridge replacement 4.10 L (4.33 US qt) (3.61 Imp.qt)
Oil filter
Oil filter type Cartridge (paper)
Oil pump
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance Less than 0.12 mm (0.0047 in)
Limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance 0.09–0.15 mm (0.0035–0.0059 in)
Limit 0.220 mm (0.0087 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.03–0.08 mm (0.0012–0.0032 in)
Limit 0.150 mm (0.0059 in)
Bypass valve opening pressure 80.0–120.0 kPa (11.6–17.4 psi) (0.80–1.20
kgf/cm²)
Relief valve operating pressure 60.0 kPa (8.7 psi) (0.60 kgf/cm²)
Spark plug (s)

Manufacturer/model NGK/DPR7EA-9
Manufacturer/model DENSO/X22EPR-U9
Spark plug gap 0.8–0.9 mm (0.031–0.035 in)
2-2
Cylinder head
Volume 98.60–103.60 cm³ (6.02–6.32 cu.in)
Warpage limit 0.03 mm (0.0012 in)
Camshaft
Drive system Gear drive
Crankcase hole inside diameter 25.000–25.021 mm (0.9843–0.9851 in)
Camshaft journal diameter (crankcase side) 24.942–24.965 mm (0.9820–0.9829 in)
Camshaft to crankcase clearance 0.035–0.079 mm (0.0014–0.0031 in)
Camshaft cover hole inside diameter 28.000–28.021 mm (1.1024–1.1032 in)
Camshaft journal diameter (camshaft cover side) 27.967–27.980 mm (1.1011–1.1016 in)
Camshaft to camshaft cover clearance 0.020–0.054 mm (0.0008–0.0021 in)
Camshaft lobe dimensions
Intake A 38.241–38.341 mm (1.5055–1.5095 in) (cylinder
#1)
38.243–38.343 mm (1.5056–1.5096 in) (cylinder
#2)
Limit 38.141 mm (1.5016 in) (cylinder #1)
38.143 mm (1.5017 in) (cylinder #2)
Intake B 31.950–32.050 mm (1.2579–1.2618 in)
Limit 31.850 mm (1.2539 in)
Exhaust A 38.236–38.336 mm (1.5054–1.5093 in)
Limit 38.136 mm (1.5014 in)
Exhaust B 31.950–32.050 mm (1.2579–1.2618 in)
Limit 31.850 mm (1.2539 in)
Rocker arm/rocker arm shaft

Rocker arm inside diameter 18.000–18.018 mm (0.7087–0.7094 in)
Limit 18.036 mm (0.7101 in)
Rocker arm shaft outside diameter 17.976–17.991 mm (0.7077–0.7083 in)
Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.042 mm (0.0004–0.0017 in)
Limit 0.080 mm (0.0032 in)
Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.00–0.04 mm (0.0000–0.0016 in)
Exhaust 0.00–0.04 mm (0.0000–0.0016 in)
2-3
Valve dimensions
Valve head diameter A (intake) 33.90–34.10 mm (1.3346–1.3425 in)
Valve head diameter A (exhaust) 27.90–28.10 mm (1.0984–1.1063 in)
Valve face width B (intake) 1.300–2.300 mm (0.0512–0.0906 in)

Valve face width B (exhaust) 1.200–2.400 mm (0.0472–0.0945 in)
Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in)

Limit 2.0 mm (0.08 in)
Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)
Valve margin thickness D (intake) 0.70–1.30 mm (0.0276–0.0512 in)

Valve margin thickness D (exhaust) 0.70–1.30 mm (0.0276–0.0512 in)
Valve stem diameter (intake) 5.975–5.990 mm (0.2352–0.2358 in)

Limit 5.945 mm (0.2341 in)
Valve stem diameter (exhaust) 5.960–5.975 mm (0.2346–0.2352 in)
Limit 5.930 mm (0.2335 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 (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in)
Limit 0.100 mm (0.0039 in)
2-4
Valve stem runout 0.010 mm (0.0004 in)
Valve spring
Inner spring
Free length (intake) 38.26 mm (1.51 in)
Limit 36.26 mm (1.43 in)
Free length (exhaust) 38.26 mm (1.51 in)
Limit 36.26 mm (1.43 in)
Installed length (intake) 29.00 mm (1.14 in)
Installed length (exhaust) 29.00 mm (1.14 in)
Spring rate K1 (intake) 7.30 N/mm (41.68 lb/in) (0.74 kgf/mm)
Spring rate K1 (exhaust) 7.30 N/mm (41.68 lb/in) (0.74 kgf/mm)
Installed compression spring force (intake) 63.00–73.00 N (14.16–16.41 lb) (6.42–7.44 kgf)
Installed compression spring force (exhaust) 63.00–73.00 N (14.16–16.41 lb) (6.42–7.44 kgf)
Spring tilt (intake) 2.5°/1.7 mm (2.5°/0.067 in)
Spring tilt (exhaust) 2.5°/1.7 mm (2.5°/0.067 in)
Winding direction (intake) Counterclockwise

Winding direction (exhaust) Counterclockwise
Outer spring
Limit 41.26 mm (1.62 in)
Free length (exhaust) 43.25 mm (1.70 in)
Limit 41.26 mm (1.62 in)
Installed length (intake) 31.00 mm (1.22 in)
Installed length (exhaust) 31.00 mm (1.22 in)
Installed compression spring force (intake) 139.00–161.00 N (31.25–36.19 lb) (14.17–
16.42 kgf)
Installed compression spring force (exhaust) 139.00–161.00 N (31.25–36.19 lb) (14.17–
16.42 kgf)
Spring tilt (intake) 2.5°/1.9 mm (2.5°/0.075 in)
Spring tilt (exhaust) 2.5°/1.9 mm (2.5°/0.075 in)
Winding direction (intake) Clockwise
Winding direction (exhaust) Clockwise
2-5
Valve lifter
Valve lifter outside diameter (intake) 22.962–22.974 mm (0.9040–0.9045 in)
Valve lifter outside diameter (exhaust) 22.962–22.974 mm (0.9040–0.9045 in)
Valve lifter hole inside diameter (intake) 23.000–23.021 mm (0.9055–0.9063 in)
Valve lifter hole inside diameter (exhaust) 23.000–23.021 mm (0.9055–0.9063 in)
Valve-lifter-to-valve-lifter-hole clearance 0.0260–0.0590 mm (0.0010–0.0023 in)
Valve push rod

Valve push rod 1 length 288.5 mm (11.358 in)
Valve push rod 2 length 290.5 mm (11.437 in)
Valve push rod runout 0.3 mm (0.012 in)
Cylinder
Bore 97.000–97.010 mm (3.8189–3.8193 in)
Taper limit 0.050 mm (0.0020 in)
Out of round limit 0.050 mm (0.0020 in)
Piston
Piston-to-cylinder clearance 0.025–0.050 mm (0.0010–0.0020 in)
Limit 0.15 mm (0.0059 in)
Diameter D 96.960–96.975 mm (3.8173–3.8179 in)
Height H 10.0 mm (0.39 in)
H
D
Offset 1.00 mm (0.0394 in)

Piston pin bore inside diameter 22.004–22.015 mm (0.8663–0.8667 in)
Limit 22.045 mm (0.8679 in)
Piston pin outside diameter 21.991–22.000 mm (0.8658–0.8661 in)
Limit 21.971 mm (0.8650 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) 1.20 × 3.80 mm (0.05 × 0.15 in)
B
T
End gap (installed) 0.30–0.50 mm (0.0118–0.0197 in)

Limit 0.70 mm (0.0276 in)
Ring side clearance 0.030–0.080 mm (0.0012–0.0032 in)
Limit 0.120 mm (0.0047 in)
2nd ring
Ring type Taper
2-6
B
T

Limit 0.80 mm (0.0315 in)
Ring side clearance 0.030–0.070 mm (0.0012–0.0028 in)
Limit 0.120 mm (0.0047 in)
Oil ring
B
T
Connecting rod
Oil clearance (using plastigauge®) 0.050–0.074 mm (0.0020–0.0029 in)
Bearing color code 1.Blue 2.Black 3.Brown 4.Green 5.Yellow
Crankshaft
Width A 132.80–133.20 mm (5.228–5.244 in)
Runout limit C 0.040 mm (0.0016 in)
Big end side clearance D 0.320–0.474 mm (0.0126–0.0187 in)
Big end radial clearance E 0.037–0.074 mm (0.0015–0.0029 in)
Limit 0.09 mm (0.0035 in)
C C
E
D
A
Journal oil clearance (using plastigauge®) 0.030–0.062 mm (0.0012–0.0024 in)

Limit 0.09 mm (0.0035 in)
Clutch
Clutch type Wet, multiple-disc
Clutch release method Hydraulic inner push
Operation Left hand operation
Friction plate thickness 2.92–3.08 mm (0.115–0.121 in)
Wear limit 2.82 mm (0.1110 in)
Plate quantity 10 pcs
Clutch plate thickness 1.90–2.10 mm (0.075–0.083 in)
Plate quantity 9 pcs
Warpage limit 0.20 mm (0.0079 in)
2-7
Clutch spring free length 6.88 mm (0.27 in)

Minimum length 6.38 mm (0.25 in)
Spring quantity 1 pc
Clutch housing thrust clearance 0.100–0.110 mm (0.0039–0.0043 in)
Clutch housing radial clearance 0.020–0.066 mm (0.0008–0.0026 in)
Transmission
Transmission type Constant mesh 5-speed
Primary reduction system Spur gear
Primary reduction ratio 71/48 (1.479)
Secondary reduction system Chain drive
Secondary reduction ratio 39/17 (2.294)
Operation Left foot operation
Gear ratio
1st 38/16 (2.375)
2nd 30/19 (1.579)
3rd 29/25 (1.160)
4th 24/25 (0.960)
5th 24/30 (0.800)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Shifting mechanism
Shift mechanism type Guide bar
Shift fork guide bar bending limit 0.025 mm (0.0010 in)
Shift fork thickness 6.26–6.39 mm (0.2465–0.2516 in)
Air filter
Air filter element Oil-coated paper element
Fuel pump
Pump type Electrical
Model/manufacturer 5YU/DENSO
Maximum consumption amperage 4.6 A
Output pressure 392.0 kPa (56.8 psi) (3.92 kgf/cm²)
Fuel injector
Model/quantity INP-101/2
Manufacturer NIPPON INJECTOR
Throttle body
Type/quantity AC40/2
Manufacturer MIKUNI
ID mark 5YU1 00
Throttle valve size #100
Throttle position sensor

Resistance 4.0–6.0 kΩ/blue-black
Output voltage (at idle) 0.63–0.73 V
Fuel injection sensor

Crankshaft position sensor resistance 248–372 Ω/gray-black
Intake air pressure sensor output voltage 3.75–4.25 V
2-8
Engine temperature sensor resistance 0.90–1.10 kΩ at 100 °C (212 °F)
Idling condition
Engine idling speed 850–950 r/min
Intake vacuum 26.6 kPa (7.9 inHg) (200 mmHg)
Oil temperature 80.0–90.0 °C (176.00–194.00 °F)
Throttle cable free play 3.0–5.0 mm (0.12–0.20 in)
2-9
CHASSIS SPECIFICATIONS
EAS20300
Chassis
Frame type Double cradle
Caster angle 25.00°
Trail 103.0 mm (4.06 in)
Front wheel
Wheel type Cast wheel
Rim size 17M/C × MT3.50
Rim material Aluminum
Wheel travel 120.0 mm (4.72 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Rear wheel
Wheel type Cast wheel
Rim size 17M/C × MT6.00
Rim material Aluminum
Wheel travel 117.0 mm (4.61 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Front tire
Type Tubeless
Size 120/70 ZR17 M/C (58W)
Manufacturer/model METZELER/ROADTEC Z6 E FRONT
MICHELIN/PILOT ROAD S
Wear limit (front) 1.6 mm (0.06 in)
Rear tire
Type Tubeless
Size 190/50 ZR17 M/C (73W)
Manufacturer/model METZELER/ROADTEC Z6 E
MICHELIN/PILOT ROAD
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 250 kPa (36 psi) (2.50 kgf/cm²)
Rear 290 kPa (42 psi) (2.90 kgf/cm²)
Loading condition 90–199 kg (198–439 lb)
High-speed riding
Front brake
Type Dual disc brake
Operation Right hand operation
2-10
Front disc brake

Disc outside diameter × thickness 310.0 × 5.5 mm (12.20 × 0.22 in)
Brake disc thickness limit 5.0 mm (0.20 in)
Brake disc deflection limit 0.10 mm (0.0039 in)
Brake pad lining thickness (inner) 4.5 mm (0.18 in)
Brake pad lining thickness (outer) 4.5 mm (0.18 in)
Master cylinder inside diameter 16.00 mm (0.63 in)
Caliper cylinder inside diameter 24.05 mm × 3 (0.95 in × 3)
Recommended fluid DOT 4
Rear brake
Type Single disc brake
Operation Right foot operation
Rear disc brake
Disc outside diameter × thickness 267.0 × 6.0 mm (10.51 × 0.24 in)
Brake disc thickness limit 5.5 mm (0.22 in)
Brake disc deflection limit 0.15 mm (0.0059 in)
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 14.0 mm (0.55 in)
Caliper cylinder inside diameter 27.00 mm × 2 (1.06 in × 2)
Recommended fluid DOT 4
Steering
Steering bearing type Angular bearing
Lock to lock angle (left) 33.0°
Lock to lock angle (right) 33.0°
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 120.0 mm (4.72 in)
Fork spring free length 251.0 mm (9.88 in)
Limit 246.0 mm (9.69 in)
Collar length 100.8 mm (3.97 in)
Installed length 235.0 mm (9.25 in)
Spring rate K1 9.30 N/mm (53.10 lb/in) (0.95 kgf/mm)
Spring stroke K1 0.0–120.0 mm (0.00–4.72 in)
Inner tube outer diameter 43.0 mm (1.69 in)
Inner tube bending limit 0.2 mm (0.01 in)
Optional spring available No
Recommended oil Suspension oil M1 or ohlins R & T43
Quantity 586.0 cm³ (19.82 US oz) (20.67 Imp.oz)
Level 65.0 mm (2.56 in)
Spring preload adjusting positions
Minimum 0
Standard 2
Maximum 5
2-11
Rebound damping adjusting positions

*With the adjusting screw fully turned in
Minimum 17 click(s) out*
Standard 15 click(s) out*
Maximum 1 click(s) out*
Compression damping adjusting positions
Rear suspension
Type Swingarm (link suspension)
Spring/shock absorber type Coil spring/gas-oil damper
Rear shock absorber assembly travel 50.0 mm (1.97 in)
Spring free length 159.5 mm (6.28 in)
Limit 156.0 mm (6.14 in)
Installed length 150.0 mm (5.91 in)
Spring rate K1 186.30 N/mm (1063.77 lb/in) (19.00 kgf/mm)
Spring stroke K1 0.0–50.0 mm (0.00–1.97 in)
Optional spring available No
Enclosed gas/air pressure (STD) 1200 kPa (170.7 psi) (12.0 kgf/cm²)
Spring preload adjusting positions Installed spring length
Minimum 155.0 mm (6.10 in)
Standard 150.0 mm (5.91 in)
Maximum 145.0 mm (5.71 in)
Rebound damping adjusting positions
*With the adjusting knob fully turned in
Compression damping adjusting positions
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)
Drive chain
Type/manufacturer 50VM3/DAIDO
Link quantity 114
Drive chain slack 40.0–50.0 mm (1.57–1.97 in)
15-link length limit 239.3 mm (9.42 in)
2-12
ELECTRICAL SPECIFICATIONS
EAS20310
Voltage
System voltage 12 V
Ignition system
Ignition system Transistorized coil ignition (digital)
Advancer type Electrical
Ignition timing (B.T.D.C.) 10.0°/900 r/min
Engine control unit

Model/manufacturer F8T830/MITSUBISHI
Ignition coil
Model/manufacturer 2JN/MORIC
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 2.16–2.64 Ω
Secondary coil resistance 8.64–12.96 kΩ
Spark plug cap

Material Resin
Resistance 10.0 kΩ
AC magneto
Model/manufacturer F5YU/MORIC
Standard output 14.0 V 430 W 5000 r/min
Stator coil resistance 0.128–0.192 Ω
Rectifier/regulator
Regulator type Semi conductor-short circuit
Model/manufacturer FH010AA/SHINDENGEN
No load regulated voltage 14.3–15.1 V
Rectifier capacity 50.0 A
Withstand voltage 40.0 V
Battery
Model GT14B-4
Voltage, capacity 12 V, 12.0 Ah
Manufacturer GS YUASA
Ten hour rate amperage 1.20 A
Headlight
Bulb type Halogen bulb
Bulb voltage, wattage × quantity

Low beam headlight 12 V, 51.0 W × 1
High beam headlight 12 V, 55.0 W × 1
Auxiliary light 12 V, 5.0 W × 3
Tail/brake light LED
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
Neutral indicator light LED
Turn signal indicator light LED
High beam indicator light LED
Fuel level warning light LED
Engine trouble warning light LED
Immobilizer system indicator light LED
Electric starting system

System type Constant mesh
Starter motor
Model/manufacturer 5YU/MORIC
Power output 0.90 kW
Armature coil resistance 0.0081–0.0099 Ω
Brush overall length 9.8 mm (0.39 in)
Limit 5.00 mm (0.20 in)
Brush spring force 7.36–11.04 N (26.49–39.74 oz) (750–1126 gf)
Commutator diameter 28.5 mm (1.12 in)
Limit 27.5 mm (1.08 in)
Mica undercut (depth) 1.50 mm (0.06 in)
Starter relay
Model/manufacturer 2768093-A/JIDECO
Amperage 180.0 A
Coil resistance 4.18–4.62 Ω
Horn
Horn type Plane
Quantity 1 pc
Model/manufacturer HF-12/NIKKO
Maximum amperage 3.0 A
Coil resistance 1.01–1.11 Ω at 20 °C (68 °F)
Performance 108–116 dB/2 m
Turn signal/hazard relay

Relay type Full transistor
Model/manufacturer FE218BM/DENSO
Built-in, self-canceling device No
Turn signal blinking frequency 75.0–95.0 cycles/min
Wattage 10W × 2.0 + LED
Starting circuit cut-off relay

Model/manufacturer G8R-30Y-U3/OMRON
Headlight relay
Model/manufacturer ACM33211M05/MATSUSHITA
2-14
Fuel pump relay

Model/manufacturer G8R-30Y-U3/OMRON
Fuses
Main fuse 50.0 A
Headlight fuse 15.0 A
Signaling system fuse 10.0 A
Ignition fuse 25.0 A
Parking lighting fuse 10.0 A
ECU fuse 10.0 A
Fuel injection system fuse 15.0 A
Backup fuse 10.0 A
Muffler cover fan fuse 15.0 A
Auto-decompression fuse 15.0 A
Reserve fuse 25.0 A
Reserve fuse 15.0 A
Reserve fuse 10.0 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 tank:
Oil pipe bolt M6 11 13 Nm (1.3 m·kg, 9.4 ft·lb)
Oil tank and oil tank bracket nut M6 1 13 Nm (1.3 m·kg, 9.4 ft·lb)
Oil tank bolt M6 2 13 Nm (1.3 m·kg, 9.4 ft·lb)
Oil tank and down tube bolt M6 16 10 Nm (1.0 m·kg, 7.2 ft·lb)
Engine oil drain bolt (oil tank) M14 1 35 Nm (3.5 m·kg, 25 ft·lb)
Oil strainer cover bolt (oil tank) M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil tank breather hose holder bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Muffler and exhaust pipe:
Muffler bolt M8 2 24 Nm (2.4 m·kg, 17 ft·lb)
Front exhaust pipe and front ex-
M8 2 20 Nm (2.0 m·kg, 14 ft·lb)
haust pipe joint bolt
Front exhaust pipe and rear ex-
M8 1 20 Nm (2.0 m·kg, 14 ft·lb)
haust pipe bolt
Rear exhaust pipe and rear ex-
M8 1 20 Nm (2.0 m·kg, 14 ft·lb)
Rear exhaust pipe bolt M8 1 20 Nm (2.0 m·kg, 14 ft·lb)
Rear exhaust pipe and catalyst
M8 1 20 Nm (2.0 m·kg, 14 ft·lb)
pipe bolt
Catalyst pipe nut M8 1 20 Nm (2.0 m·kg, 14 ft·lb)
Catalyst pipe and muffler bolt M8 2 20 Nm (2.0 m·kg, 14 ft·lb)
Front exhaust pipe joint nut M8 2 20 Nm (2.0 m·kg, 14 ft·lb)
Rear exhaust pipe joint nut M8 2 20 Nm (2.0 m·kg, 14 ft·lb)
Rear exhaust pipe joint cover bolt M6 3 7 Nm (0.7 m·kg, 5.1 ft·lb)
EXUP valve pulley cover bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
O2 sensor cover bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
O2 sensor M18 1 45 Nm (4.5 m·kg, 32 ft·lb)
Locknut (EXUP cable) M6 2 6 Nm (0.6 m·kg, 4.3 ft·lb)
Muffler cover bolt M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)
Camshaft:
Decompression solenoid cover
M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
bolt
Decompression solenoid bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
Decompression solenoid lever

M4 2 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
bolt
Camshaft sprocket cover bolt M6 6 10 Nm (1.0 m·kg, 7.2 ft·lb)
Tappet cover bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)
Cylinder head cover bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Cylinder head cover bolt M6 24 10 Nm (1.0 m·kg, 7.2 ft·lb)
2-17
TIGHTENING TORQUES
Thread
size
Rocker arm base bolt M6 8 10 Nm (1.0 m·kg, 7.2 ft·lb)
Rocker arm base bolt M8 4 24 Nm (2.4 m·kg, 17 ft·lb)
Locknut (rocker arm adjusting
M7 4 20 Nm (2.0 m·kg, 14 ft·lb)
screw)
Valve lifter case bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Camshaft cover bolt M6 7 10 Nm (1.0 m·kg, 7.2 ft·lb)

Front cylinder camshaft end cov-
M5 2 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
er bolt
Camshaft drive gear bolt M10 1 30 Nm (3.0 m·kg, 22 ft·lb)
Camshaft driven gear nut M14 1 52 Nm (5.2 m·kg, 37 ft·lb)
Oil gallery bolt M5 3 4 Nm (0.4 m·kg, 2.9 ft·lb)
Cylinder heads:
Spark plug M12 4 18 Nm (1.8 m·kg, 13 ft·lb)
Oil pipe 1 union bolt M10 2 21 Nm (2.1 m·kg, 15 ft·lb)
Oil pipe 1 union bolt M8 1 18 Nm (1.8 m·kg, 13 ft·lb)
Engine temperature sensor - 1 20 Nm (2.0 m·kg, 14 ft·lb)
Cylinder head nut M12 8 45 Nm (4.5 m·kg, 32 ft·lb) E
Cylinder head nut M10 4 39 Nm (3.9 m·kg, 28 ft·lb) E
Cylinder head stud bolt (exhaust

M8 4 15 Nm (1.5 m·kg, 11 ft·lb)
pipe)
Clutch:
Crankshaft end cover plug M32 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Timing mark accessing screw M16 1 8 Nm (0.8 m·kg, 5.8 ft·lb)
Clutch cover bolt M6 17 10 Nm (1.0 m·kg, 7.2 ft·lb)
Crankshaft position sensor lead
M6 7 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
holder screw
Crankshaft position sensor screw M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Clutch spring plate retainer bolt M6 6 8 Nm (0.8 m·kg, 5.8 ft·lb)

Stake
Clutch boss nut M20 1 125 Nm (12.5 m·kg, 90 ft·lb)
E
Primary drive gear bolt M12 1 100 Nm (10.0 m·kg, 72 ft·lb) LT
Clutch hose union bolt M10 1 30 Nm (3.0 m·kg, 22 ft·lb)

Clutch pipe union bolt M10 1 26 Nm (2.6 m·kg, 19 ft·lb)
Clutch release cylinder bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Bleed screw (clutch release cylin-
M8 1 6 Nm (0.6 m·kg, 4.3 ft·lb)
der)
Shift shaft:
Shift shaft spring stopper bolt M8 1 22 Nm (2.2 m·kg, 16 ft·lb) LT
Stopper lever bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
2-18
TIGHTENING TORQUES
Thread
size
Generator and starter clutch:
Oil pipe 2 bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)
Generator cover bolt M6 11 10 Nm (1.0 m·kg, 7.2 ft·lb)
Stator coil assembly lead holder
M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
screw
Stator coil assembly screw M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Generator rotor bolt M12 1 80 Nm (8.0 m·kg, 58 ft·lb) E
Starter clutch bolt M8 6 24 Nm (2.4 m·kg, 17 ft·lb) LT
Crankcase:
Crankcase stud bolt M12 8 See NOTE.
Crankcase stud bolt M10 4 See NOTE.
Speed sensor bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil filter cartridge M20 1 17 Nm (1.7 m·kg, 12 ft·lb)
Oil filter cartridge bracket bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Oil filter cartridge union bolt M20 1 30 Nm (3.0 m·kg, 22 ft·lb)

Generator shaft end cover bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil delivery pipe 2/oil pump driv-
M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
en gear stopper bolt
Oil pump driven gear stopper bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Generator shaft bolt M8 1 28 Nm (2.8 m·kg, 20 ft·lb)
Crankcase bolt M8 3 24 Nm (2.4 m·kg, 17 ft·lb)
Crankcase bolt M6 18 10 Nm (1.0 m·kg, 7.2 ft·lb)
Engine oil drain bolt (crankcase) M14 1 43 Nm (4.3 m·kg, 31 ft·lb)
Engine oil filler plug M20 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil baffle plate bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Main axle bearing retainer bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Drive axle bearing retainer screw M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb) LT
Shift drum segment bolt M6 1 12 Nm (1.2 m·kg, 8.7 ft·lb) LT
Oil pump:
Oil strainer bolt (crankcase) M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Oil pump bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil pump housing cover 2 screw M4 2 4 Nm (0.4 m·kg, 2.9 ft·lb)
Oil pump housing cover 1 screw M4 2 4 Nm (0.4 m·kg, 2.9 ft·lb)
Spring retainer bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Crankshaft:
See
Connecting rod bolt (1st) M8 4 15 Nm (1.5 m·kg, 11 ft·lb) NOTE.
M
2-19
TIGHTENING TORQUES
Thread
size
See
Connecting rod bolt (final) M8 4 Specified angle 120°–150° NOTE.
M
Chain drive:
Drive sprocket cover bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Drive chain guide bolt (drive
M8 3 24 Nm (2.4 m·kg, 17 ft·lb) LT
sprocket side)
Stake
Drive sprocket nut M22 1 95 Nm (9.5 m·kg, 68 ft·lb)
E
Fuel injection system (sur-

rounding parts):
Throttle body joint clamp screw M4 2 4 Nm (0.4 m·kg, 2.9 ft·lb)
Throttle position sensor screw M5 2 5 Nm (0.5 m·kg, 3.6 ft·lb)
Intake manifold assembly bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)
Injector joint screw M6 4 5 Nm (0.5 m·kg, 3.6 ft·lb)
Fuel pipe bolt M12 2 30 Nm (3.0 m·kg, 22 ft·lb)
ISC (idle speed control) unit bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Others:
Rectifier/regulator bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Horn nut M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
EXUP servo motor bracket bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
EXUP servo motor bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
NOTE:
• Tighten the connecting rod bolts to 15 Nm (1.5 m·kg, 11 ft·lb), and then tighten them further to reach
the specified angle 120°–150°.
• Install the crankcase stud bolts (M12) so that their installed length is 217.5 mm (8.56 in).
• Install the crankcase stud bolts (M10) so that their installed length is 141.5 mm (5.57 in).
2-20
TIGHTENING TORQUES
Oil tank tightening sequence:
8
10 6
4 2
16
12 15
13
14
11
1
9
5
7 3
Cylinder head tightening sequence:
A. Front cylinder
B. Rear cylinder
2-21
TIGHTENING TORQUES
EAS20350
CHASSIS TIGHTENING TORQUES

Thread
size
Engine mounting:
Engine mounting bolt (left upper
M10 2 53 Nm (5.3 m·kg, 38 ft·lb)
side)
Engine mounting bolt (right upper L=80 mm
M10 1 53 Nm (5.3 m·kg, 38 ft·lb)
side) (3.15 in)
Engine mounting bolt (right upper L=65 mm
M10 1 53 Nm (5.3 m·kg, 38 ft·lb)
side) (2.56 in)
Engine bracket bolt (left upper
M10 2 53 Nm (5.3 m·kg, 38 ft·lb)
side)
Engine bracket bolt (right upper
M10 2 53 Nm (5.3 m·kg, 38 ft·lb)
side)
Engine mounting nut (rear upper
M12 1 74 Nm (7.4 m·kg, 53 ft·lb)
side)
Engine bracket nut (rear upper
M10 2 53 Nm (5.3 m·kg, 38 ft·lb)
side)
Engine mounting nut (front upper
M12 1 94 Nm (9.4 m·kg, 68 ft·lb)
side)
Engine bracket nut (front upper
M10 4 53 Nm (5.3 m·kg, 38 ft·lb)
side)
Down tube nut (front side) M12 2 74 Nm (7.4 m·kg, 53 ft·lb)
Down tube nut (rear side) M10 2 55 Nm (5.5 m·kg, 40 ft·lb)
Engine mounting nut (front lower
M12 1 94 Nm (9.4 m·kg, 68 ft·lb)
side)
Engine mounting nut (rear lower
M12 1 74 Nm (7.4 m·kg, 53 ft·lb)
side)
Down tube spacer bolt M18 2 8 Nm (0.8 m·kg, 5.8 ft·lb)
Engine mounting spacer bolt
M18 1 8 Nm (0.8 m·kg, 5.8 ft·lb)
(rear upper side)
M18 1 8 Nm (0.8 m·kg, 5.8 ft·lb)
(rear lower side)
Frame and engine (surround-
ing parts):
Main frame and sub-frame nut
M10 2 55 Nm (5.5 m·kg, 40 ft·lb)
(upper side)
Main frame and sub-frame nut
M12 1 75 Nm (7.5 m·kg, 54 ft·lb)
(lower side)
Lead holder and down tube bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
Lead holder and down tube bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Cylinder-#1 left ignition coil bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Cylinder-#1 right ignition coil bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Cylinder-#1 ignition coil bracket
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
bolt
2-22
TIGHTENING TORQUES
Thread
size
Cylinder-#2 right ignition coil
M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
bracket bolt
Cylinder-#2 left ignition coil
M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
bracket bolt
Engine bracket (right upper side)
M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
and holder bolt
Fuel tank bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Air filter case bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Air filter case bracket bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil catch tank bolt M6 2 9 Nm (0.9 m·kg, 6.5 ft·lb) LT
ISC (idle speed control) unit cov-

M6 2 9 Nm (0.9 m·kg, 6.5 ft·lb)
er bolt
Pressure regulator cover bolt M6 2 9 Nm (0.9 m·kg, 6.5 ft·lb)
Pressure regulator bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Rollover valve bracket bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Left side cover inner panel bolt M6 3 9 Nm (0.9 m·kg, 6.5 ft·lb) LT
Right side cover inner panel bolt M6 3 9 Nm (0.9 m·kg, 6.5 ft·lb) LT
Intake solenoid bracket bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Air duct bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Air duct bracket bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Positive battery lead bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Starter motor lead bolt (starter
M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
relay side)
Battery box bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Lead holder and sub-frame bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Fuel pump bolt M5 6 4 Nm (0.4 m·kg, 2.9 ft·lb)

Seat lock bracket bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Rear brake fluid reservoir nut M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Rear brake fluid reservoir cap
M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
holder bolt
Muffler cooling fan motor assem-
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
bly bolt
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
bly bolt
M6 5 7 Nm (0.7 m·kg, 5.1 ft·lb)
bly and sub-frame bolt
bly, rear brake fluid reservoir M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
bracket and sub-frame bolt
Locknut (shift rod) M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Shift arm bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
2-23
TIGHTENING TORQUES
Thread
size
Left rider footrest assembly bolt M8 2 30 Nm (3.0 m·kg, 22 ft·lb)
Right rider footrest assembly bolt M8 2 30 Nm (3.0 m·kg, 22 ft·lb)
Footrest cover bracket M6 3 7 Nm (0.7 m·kg, 5.1 ft·lb)
Passenger footrest nut M10 2 28 Nm (2.8 m·kg, 20 ft·lb)
Front wheel:
Front wheel axle M18 1 72 Nm (7.2 m·kg, 52 ft·lb)
Front wheel axle pinch bolt M8 1 23 Nm (2.3 m·kg, 27 ft·lb)
Front brake disc bolt M6 12 18 Nm (1.8 m·kg, 13 ft·lb) LT
Rear wheel:
Rear wheel axle nut M24 1 150 Nm (15.0 m·kg, 110 ft·lb)
Rear brake disc bolt M6 6 18 Nm (1.8 m·kg, 13 ft·lb) LT
Rear wheel sprocket nut M10 6 100 Nm (10.0 m·kg, 72 ft·lb) LT
Front brake:
Front brake master cylinder hold-
M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
er bolt
Front brake hose union bolt M10 2 30 Nm (3.0 m·kg, 22 ft·lb)
Front brake caliper bolt M10 4 35 Nm (3.5 m·kg, 25 ft·lb)
Front brake hose holder bolt M6 2 6 Nm (0.6 m·kg, 4.3 ft·lb)
Bleed screw (front brake caliper) M8 2 6 Nm (0.6 m·kg, 4.3 ft·lb)
Rear brake:
Rear brake master cylinder bolt M8 2 23 Nm (2.3 m·kg, 27 ft·lb)
Locknut (rear brake master cylin-
M8 1 16 Nm (1.6 m·kg, 11 ft·lb)
der)
Rear brake hose union bolt M10 2 30 Nm (3.0 m·kg, 22 ft·lb)
Rear brake hose guide bolt 1 M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Rear brake hose guide bolt 2 M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Rear brake pad pin M10 1 17 Nm (1.7 m·kg, 12 ft·lb)
Rear brake screw plug M10 1 3 Nm (0.3 m·kg, 2.2 ft·lb)
Rear brake caliper bolt M8 1 22 Nm (2.2 m·kg, 16 ft·lb) LT
Rear brake caliper bolt M12 1 27 Nm (2.7 m·kg, 19 ft·lb) LS
Bleed screw (rear brake caliper) M8 1 6 Nm (0.6 m·kg, 4.3 ft·lb)

Handlebar:
Upper handlebar holder bolt M8 4 20 Nm (2.0 m·kg, 14 ft·lb)
Lower handlebar holder nut M12 2 40 Nm (4.0 m·kg, 29 ft·lb)
Main switch/immobilizer unit bolt M8 2 32 Nm (3.2 m·kg, 23 ft·lb)
Grip end M16 2 29 Nm (2.9 m·kg, 21 ft·lb)
Clutch master cylinder holder bolt M6 2 14 Nm (1.4 m·kg, 10 ft·lb)
Rearview mirror M10 2 13 Nm (1.3 m·kg, 9.4 ft·lb)
2-24
TIGHTENING TORQUES
Thread
size
Front fork and steering head:
Upper bracket pinch bolt M8 2 26 Nm (2.6 m·kg, 19 ft·lb)
Steering stem nut M22 1 110 Nm (11.0 m·kg, 80 ft·lb)
Lower ring nut (initial tightening See
M25 1 52 Nm (5.2m·kg, 37 ft·lb)
torque) NOTE.
Lower ring nut (final tightening See
M25 1 23 Nm (2.3 m·kg, 27 ft·lb)
torque) NOTE.
Cap bolt M47 2 20 Nm (2.0 m·kg, 14 ft·lb) LS
Cap bolt (damper rod assembly

M10 2 25 Nm (2.5 m·kg, 18 ft·lb)
and nut)
Damper rod assembly M24 2 35 Nm (3.5 m·kg, 25 ft·lb)
Lower bracket pinch bolt M8 4 28 Nm (2.8 m·kg, 20 ft·lb)
Front brake hose joint bracket
M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
bolt
Front brake hose joint bolt M6 1 9 Nm (0.9 m·kg, 6.5 ft·lb)
Headlight assembly bolt M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)
Meter assembly bracket bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Headlight assembly bracket bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Front fork guard bolt M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)
Front fender bolt M6 4 6 Nm (0.6 m·kg, 4.3 ft·lb)
Swingarm and rear shock ab-
sorber:
Swingarm pivot shaft nut M18 1 125 Nm (12.5 m·kg, 90 ft·lb)
Footrest bracket pinch bolt M8 2 25 Nm (2.5 m·kg, 18 ft·lb)
Relay arm nut (relay arm and
M10 1 40 Nm (4.0 m·kg, 29 ft·lb)
swingarm)
M12 1 49 Nm (4.9 m·kg, 35 ft·lb)
connecting arm)
Rear shock absorber assembly
M10 1 40 Nm (4.0 m·kg, 29 ft·lb)
nut (rear side)
M12 1 49 Nm (4.9 m·kg, 35 ft·lb)
nut (front side)
Rear fender bolt M6 3 9 Nm (0.9 m·kg, 6.5 ft·lb) LT
Locknut (rear shock absorber

M20 1 42 Nm (4.2 m·kg, 30 ft·lb)
spring preload adjusting nut)
Drive chain guard bolt (swingarm
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
side)
Drive chain guide bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Locknut (drive chain adjusting
M8 2 16 Nm (1.6 m·kg, 11 ft·lb)
bolt)
2-25
TIGHTENING TORQUES
NOTE:
1. First, tighten the lower ring nut to approximately 52 Nm (5.2 m·kg, 37 ft·lb) with a torque wrench, then
loosen the lower ring nut completely.
2. Retighten the lower ring nut to 23 Nm (2.3 m·kg, 17 ft·lb) with a torque wrench.
2-26
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20360

EAS20370
ENGINE
Lubrication point Lubricant
Oil seal lips LS
O-rings LS
Bearings E
Cylinder head nuts and washers E
Connecting rod small end and big end E
Crankshaft journals E
Piston surfaces E
Piston pins E
Connecting rod bolts M
Camshaft cam lobes and camshaft journals M
Valve push rods E
Valve push rod end balls E
Valve stems (intake and exhaust) M
Valve stem ends (intake and exhaust) E
Valve lifters E
Rocker arms E
Rocker arm shafts E
Oil pump rotors (inner and outer) and oil pump housing E
Oil pump driven gear shaft E
Crankcase stud bolt ends E
Crankcase bush (generator shaft journal) E
Starter clutch idle gear inner surface E
Starter clutch idle gear shafts E
Starter clutch roller and starter clutch gears outer surface E
Crankshaft journal E
Primary driven gear inner surface E
Clutch push rods and ball LS
Clutch boss nut and washer E
Transmission gears (wheel and pinion) and collar M
Drive sprocket nut and washer E
Shift forks and shift fork guide bars E
Shift drum E
Shift shaft and shift shaft oil seal lip LS
2-27

Yamaha bond
Crankcase mating surface No.1215 (Three Bond
No.1215®)
Yamaha bond
Stator coil lead grommet No.1215 (Three Bond
No.1215®)
Yamaha bond
Crankshaft position sensor lead grommet No.1215 (Three Bond
No.1215®)
2-28
EAS20380
CHASSIS
Down tube bolt (front and rear) E
Steering bearings and upper bearing dust cover lip LS
Lower bearing dust seal lip LS
Steering ring nut thread (upper and lower) LS
Main switch bracket spacer outer surfaces LS
Front wheel oil seal lips (left and right) LS
Rear wheel oil seal lips (left and right) LS
Rear wheel drive hub oil seal lip LS
Rear wheel drive hub mating surface LS
Tube guide (throttle grip) inner surface and throttle cables LS
Brake lever pivoting point and metal-to-metal moving parts Silicone grease
Clutch lever pivoting point and metal-to-metal moving parts LS
Brake pedal shaft pivoting point LS
Passenger footrest pivoting point and ball LS
Sidestand pivoting point and metal-to-metal moving parts LS
Sidestand switch striker and sidestand switch contact point LS
Sidestand hook and spring LS
Swingarm pivot shaft LS
Bearing, spacer and oil seal lips (swingarm pivot shaft) LS
Bearing, spacer and oil seal lips (swingarm and relay arm) LS
Bearing, spacer and oil seal lips (rear shock absorber) LS
Bearing, spacer and oil seal lips (relay arm) LS
Bearing, spacer and oil seal lips (connecting arm) LS
Shift pedal pivoting point LS
Shift rod pivoting point LS
Seat lock lever pivoting point LS
O-rings (oil delivery pipe and oil filler cap) LS
2-29
2-30
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20390

EAS20400
ENGINE OIL LUBRICATION CHART
40
39
37
30 29 28 36
35 34 33 32 38
27
35 34 33 32 31
30 29 28 26
25
23
24
22 21
20
17
16 14 18
15 19
13 12
4
7
9
8
6 10
5 11
2 1
2-31
1. Oil pan
2. Engine oil drain bolt (crankcase)
3. Oil strainer (crankcase)
4. Oil pump
5. Oil pump rotor 1
6. Oil pump rotor 2
7. Check ball
8. Relief valve
9. Oil tank
10. Oil strainer (oil tank)
11. Engine oil drain bolt (oil tank)
12. Drive axle
13. Drive axle gears
14. Main axle
15. Oil pump drive gear
16. Main axle gears
17. Clutch
18. Bypass valve
19. Oil filter cartridge
20. Generator shaft journal (left)
21. Generator shaft journal (right)
22. Starter clutch
23. Crankshaft journal (camshaft cover side)
24. Camshaft journal (camshaft cover side)
25. Camshaft lobe faces
26. Crankshaft journal (right)
27. Front cylinder
28. Crank pin
29. Connecting rod
30. Piston
31. Front camshaft
32. Valve lifter
33. Push rod
34. Rocker arm
35. Valve stem end
36. Crankshaft journal (left)
37. Rear cylinder
38. Rear camshaft
39. Front cylinder intake valve
40. Rear cylinder intake valve
A. Pressure feed
2-32
EAS20410
LUBRICATION DIAGRAMS
2
1
4
A
B 2
B
E D
3
E
C
D
B-B D-D
3 E-E
C
2-33
1. Oil delivery pipe

2. Push rod
3. Oil filter cartridge
4. Rocker arm shaft
5. Oil delivery pipe 2
2-34
2-35
1. Rocker arm shaft

2. Crankshaft
3. Valve lifter
4. Push rod
2-36
A
1
A
B
A-A
1 B-B
2-37
1. Oil pump
3. Oil pipe 1
2-38
1 2
4 3
2-39
1. Main axle
2. Drive axle
3. Oil pump
A. To oil filter cartridge
2-40
CABLE ROUTING
EAS20430
CABLE ROUTING
A 3
2
4
1
J 7
17
8
16
15
I B
14
6
C
H
6
G
13
F 9
12
D
10
11
2-41
CABLE ROUTING
1. Air temperature sensor coupler

2. Sub-wire harness 3 coupler
3. Front turn signal light coupler
4. Headlight assembly coupler
5. Headlight coupler (low beam)
6. Wire harness
7. Clutch fluid reservoir hose
8. Left handlebar switch lead
9. Starter motor lead
10. Rectifier/regulator
11. Stator coil assembly lead
12. Horn
13. Horn lead
14. Front brake hose
15. Throttle cable (accelerator cable)
16. Throttle cable (decelerator cable)
17. Front brake fluid reservoir hose
A. Fasten the air temperature sensor lead and sub-
wire harness 3 with the harness holder.
B. Pass the brake hose through the guide on the
meter assembly bracket, making sure to fit the
grommet on the hose in the guide.
C. Make sure that the brake hose three-way joint
contacts the tab on the front brake hose joint
bracket.
D. Fasten the wire harness, stator coil assembly lead,
rectifier/regulator lead, and horn lead with the
holder. Face the fastener of the holder forward.
E. Fasten the horn leads with the holder. Face the
open ends of the holder upward.
F. There should be no slack in the horn leads
between the holder and the guide on the horn
bracket.
G. Pass the horn lead through the guide on the horn
bracket.
H. Pass the wire harness between the guide and the
down tube.
I. Route the right handlebar switch lead behind the
throttle cables.
J. Route the right handlebar switch lead and front
brake light switch lead over and in front of the front
brake hose.
2-42
CABLE ROUTING
2
F
7
H
A 4 6 C I
5 G J K
1 B E 8
D M
9 O
P
A
L Q
R
M
N 10
S
AD T
F S
U
11
18 V
E
AC
17
17
16 D W
AB 12
D
Y
X
C B 13
C B
15 Z
AA
14
19 AL
AH
15 AM
13 15
20
A 14
12 AN
15 AG 21
C-C
16
15 AK
AF
AE
AI AO
20 15
AG AJ
B-B E F
D-D
2-43
CABLE ROUTING
1. Meter assembly lead O. The wire harness should not protrude to the inside
2. Clutch hose of the frame.
3. Left handlebar switch lead P. The rubber sheet should hang down over the wire
harness, clutch hose, cylinder-#1 left spark plug
4. Cylinder-#1 intake air pressure sensor lead, EXUP servo motor lead and negative battery
5. Cylinder-#1 intake air pressure sensor hose lead. Be sure not to cover the fuel hose.
6. Cylinder-#2 right spark plug lead Q. Route the cylinder-#1 left spark plug lead under
7. Cylinder-#2 right ignition coil the frame boss and to the outside of the wire
harness and clutch hose.
8. Cylinder-#2 right ignition coil lead
R. Route the clutch hose to the outside of the wire
9. Cylinder-#1 left spark plug lead harness.
10. EXUP servo motor lead S. Fasten the clutch hose and EXUP servo motor
11. Cylinder-#1 left ignition coil lead with the plastic locking ties. Face the buckle of
12. Negative battery lead the plastic locking tie forward, with the end facing
outward, and then cut off the excess end of the tie.
13. Crankshaft position sensor lead
T. Fasten the EXUP servo motor lead at the white
14. Sidestand switch lead tape and the grommet on the clutch hose with a
15. Starter motor lead plastic band, making sure that the EXUP servo
16. Oil tank breather hose motor lead is routed towards the front of the
vehicle.
17. Throttle cable (decelerator cable)
U. Route the negative battery lead to the inside of the
18. Throttle cable (accelerator cable) starter motor lead and over the battery box.
19. Engine bracket (rear upper side) V. Route the sidestand switch lead and crankshaft
20. Down tube position sensor lead to the outside of the engine
21. Wire harness bracket (rear upper side).
A. To meter assembly W. Route the crankshaft position sensor lead and
sidestand switch lead behind the engine boss,
B. Route the cylinder-#1 intake air pressure sensor making sure not to route the leads over the boss.
hose to the outside of the clutch hose, wire
harness, meter assembly lead, cylinder-#2 right X. Fasten the starter motor lead, sidestand switch
spark plug lead and left handlebar switch lead. lead, and crankshaft position sensor lead with the
lead holder.
C. Route the cylinder-#2 right spark plug lead to the
inside of the left handlebar switch lead and under Y. Fasten the sidestand switch lead and the starter
the wire harness. motor lead together with the plastic clamp at the
white paint mark on the sidestand switch lead.
D. Route the cylinder-#1 intake air pressure sensor
lead to the inside of the cylinder-#2 right spark plug Z. Pass the plastic band through the hole in the down
lead, left handlebar switch lead, meter assembly tube, and then fasten the starter motor lead with
lead, and wire harness. the band. Face the end of the plastic band inward.
E. Install the throttle cables so that the metal section AA.Align the white tape on the starter motor lead with
of each outer cable is in a straight line when the bend in the down tube, and then fasten the lead
viewed from the side. at the white tape with the plastic band. Face the
end of the plastic band inward.
F. Fasten the cylinder-#2 right spark plug lead, left
handlebar switch lead, meter assembly lead, and AB.Fasten the starter motor lead with the plastic band.
wire harness with the plastic band. Fasten the left AC.Route the wire harness to the inside of the left
handlebar switch lead and meter assembly lead at handlebar switch lead and meter assembly lead.
the white tape on each lead and face the end of the AD.Route the clutch hose under the left handlebar
plastic band downward. switch lead and meter assembly lead.
G. Route the cylinder-#1 intake air pressure sensor AE.Down tube hole
hose under the cylinder-#2 right spark plug lead.
AF. The starter motor lead should not protrude to the
H. Wrap the protective covering around the wire outside of the down tube.
harness, left handlebar switch coupler, and meter
assembly couplers, making sure to cover the leads AG.The buckle of the plastic band should be under the
that are not covered by their protective sleeves. down tube.
Wrap the protective covering around the wire AH.The starter motor lead should not protrude past
harness, left handlebar switch coupler, and meter the line shown in the illustration.
assembly couplers, making sure to cover the AI. Face the end of the plastic band inward.
sections of the leads that are not covered by their
protective sleeves. Face the hook and loop AJ. Pass the plastic band through the hole in the
fastener of the protective covering upward or engine bracket (front upper side).
outward. AK.90°
I. Fasten the wire harness by sliding the plastic AL. Pass the wire harness between the guide and the
holder on the wire harness onto the stud on the down tube.
cylinder-#2 right ignition coil bracket. AM.Fasten the wire harness and oil tank breather
J. White connector hose with the holder.
K. Black connector AN.Align the lower edge of the white tape on the wire
L. To throttle body harness with the lower edge of the holder.
M. Pass the wire harness between the clutch hose AO.Fasten the wire harness with the holder.
bracket and the frame.
N. To engine
2-44
CABLE ROUTING
9 10
Q
8 O 11
J M
12
K L N 7 13
6
H I P
5
4 14
G
3
2
B
F D
E R
D 1
C
S D
B A C
A 15
Y
24
23 16
T
B
U 28
22
X 17
V 1 AF
20 19 18
21 W
AG
E
18
AC
25 AB
C
21 AH
26 3
Z 13
AA AD 27 AE
A B 29
AD 14 30
12
D-D E
2-45
CABLE ROUTING
1. Fuel pump lead L. Wrap the protective covering around the right
2. Cylinder-#1 right spark plug lead handlebar switch coupler, headlight coupler,
immobilizer unit coupler, and main switch coupler,
3. Sub-wire harness 2 making sure to cover the sections of the leads that
4. Cylinder-#2 left ignition coil lead are not covered by the protective sleeves. Face the
5. Sub-wire harness 2 coupler hook and loop fastener of the protective covering
upward or outward.
6. Cylinder-#2 left ignition coil
M. 70–110 mm (2.76–4.33 in)
7. Cylinder-#2 left spark plug lead
N. Fasten the cylinder-#2 left spark plug lead and
8. Cylinder-#2 intake air pressure sensor hose cylinder-#2 intake air pressure sensor hose.
9. Cylinder-#2 intake air pressure sensor O. Route the cylinder-#2 intake air pressure sensor
10. Main switch lead hose to the outside of the wire harness.
11. Front brake hose P. Route the cylinder-#2 intake air pressure sensor
12. Throttle cable (decelerator cable) lead to the outside of the wire harness, headlight
lead, right handlebar switch lead, main switch lead,
13. Throttle cable (accelerator cable) and cylinder-#2 left spark plug lead.
14. Right handlebar switch lead Q. Fasten the wire harness, right handlebar switch
15. Intake solenoid lead lead, main switch lead, and cylinder-#2 left spark
16. ISC (idle speed control) unit lead plug lead with the plastic band. Fasten the wire
harness where the cylinder-#2 intake air pressure
17. Stator coil assembly lead sensor lead branches off from the wire harness.
18. Decompression solenoid lead Fasten the headlight lead and right handlebar
19. O2 sensor lead switch lead at the white tape on each lead. Face
the end of the plastic band outward.
20. EXUP cables
R. Route the wire harness under the throttle cables.
21. Neutral switch lead
S. To engine
22. Rear brake light switch lead
T. Route the intake solenoid lead to the inside of the
23. Rear brake fluid reservoir hose intake solenoid vacuum hose (air filter case valve
24. Rear brake hose to intake solenoid).
25. Right side panel U. Route the stator coil assembly lead to the inside of
26. Speed sensor lead the engine bracket (front upper side).
27. Wire harness V. Fasten the stator coil assembly lead at the white
tape with the holder.
28. Fuel hose
W. Route the EXUP cables under the engine bracket
29. Throttle position sensor (rear upper side).
30. Engine temperature sensor lead X. Route the rear brake light switch lead and O2
A. Fasten the sidestand switch lead, decompression sensor lead to the outside of the engine bracket
solenoid lead, crankshaft position sensor lead, (rear upper side).
neutral switch lead and speed sensor lead with the Y. Fasten the rear brake light switch lead and brake
lead holder. fluid reservoir hose with the plastic clamp next to
B. Route the cylinder-#1 right spark plug lead under the bolt hole in the frame, making sure that the
the frame boss and to the inside of the rear brake lead is fastened under the hose.
fluid reservoir hose. Z. Route the O2 sensor lead under the right side
C. Wrap the protective covering around the rear brake panel, making sure that the lead is not pinched
light switch coupler, sidestand switch coupler, O2 between the panel and the right side panel bracket.
sensor coupler, decompression solenoid coupler, AA.Route the decompression solenoid lead, neutral
crankshaft position sensor coupler, neutral switch switch lead, and speed sensor lead to the inside of
coupler, and speed sensor coupler. Be sure to the rear brake hose and engine bracket (rear upper
cover the sections of the leads that are not covered side), making sure not to pinch the leads between
by the protective sleeves and cover the taped the EXUP cables and the engine.
sections of the leads.
AB.Install the plastic band with its buckle facing
D. Pass the fuel pump lead through the hole in the rearward and its end facing downward.
rubber sheet.
AC.Route the sub-wire harness 2 in front of the
E. To fuel tank cylinder-#2 ISC (idle speed control) unit outlet
F. The rubber sheet should hang down over the wire hose.
harness, fuel pump lead, and cylinder-#1 right AD.Route the wire harness and right handlebar switch
spark plug lead. Be sure not to cover the fuel hose. lead to the outside of the throttle cable holder.
G. Fasten the sub-wire harness 2, intake solenoid AE.Fasten the throttle cables with the holder, making
lead, and ISC (idle speed control) unit lead with the sure that the accelerator cable is routed above the
lead holder, making sure to align the tape on the decelerator cable.
harness with the holder.
AF. Route the fuel pump lead to the right of the fuel
H. Black connector hose.
I. White connector AG.Align the indentations in the throttle cables with
J. Fasten the wire harness with the plastic locking tie the front edge of the holder.
to the cylinder-#2 left ignition coil bracket. AH.Fasten the sub-wire harness 2, ISC (idle speed
K. Fasten the wire harness and sub-wire harness 2 control) unit lead, and ISC (idle speed control) unit
with the plastic band at the section just before the inlet hose with the plastic band, making sure not to
split in the wire harness. Face the end of the plastic pinch the hose. Fasten the plastic band behind the
band outward. hose clamp.
2-46
CABLE ROUTING
S
R
A
T
21 24
20 22
B U
1 V
2
3 X W
19 23
4 Y
25
AF 26
29 23
C 24
D A
AE
5 27
D AD U
6
6 AC AA
7
Q E 28
F
18 AB
P 8
O
17 G
N
9
M
16
15 A
14 10 AG
H
I
L
K 13 J 12 11
2-47
CABLE ROUTING
1. Sub-wire harness 2 H. Route the tail/brake light lead and rear turn signal
2. Intake solenoid lead light leads along the side of the rear brake fluid
reservoir, making sure that “UPPER” on the
3. ISC (idle speed control) unit lead reservoir is visible. There should be no slack in the
4. Cylinder-#2 left ignition coil tail/brake light lead and the rear turn signal light
5. Lean angle cut-off switch lead between the wire harness and the plastic
locking tie next to the hole in the frame.
6. Wire harness
I. When installing the rear brake fluid reservoir, be
7. Starter relay sure not to pinch the tail/brake light lead and
8. ECU (electronic control unit) muffler cooling fan motor lead between the rear
9. Rear turn signal light couplers brake fluid reservoir and the rear brake fluid
reservoir bracket. Route the leads under the
10. Muffler cooling fan temperature sensor lead damper that is attached to the frame.
11. Tail/brake light lead J. Fasten the rear turn signal light leads, tail/brake
12. Muffler cooling fan motor lead light lead coupler, muffler cooling fan motor lead
13. License plate light coupler coupler and license plate light lead with the plastic
locking tie. Face the end of the plastic locking tie
14. Headlight relay rearward, and then cut off the excess end of the tie.
15. Relay unit Be sure to pass the plastic locking tie through the
16. Turn signal/hazard relay hole in the frame before installing the holder.
17. Muffler cooling fan motor relay K. Fasten the tail/brake light coupler and muffler
cooling fan motor coupler with a plastic locking tie.
18. Fuse box If the plastic locking tie slips off of one of the
19. Cylinder-#2 right ignition coil couplers when installing it, the tie does not need to
20. Throttle cable (accelerator cable) be cut off and replaced, provided that the couplers
are not positioned higher than the bottom of the
21. Throttle cable (decelerator cable) damper.
22. Positive battery lead L. Fasten the rear turn signal light leads, tail/brake
23. Sub-wire harness 1 light lead, license plate light lead, muffler cooling
24. Negative battery lead fan motor lead, and muffler cooling fan
temperature sensor lead with the plastic clamp,
25. Cylinder-#1 right ignition coil making sure to fasten the muffler cooling fan
26. Cylinder-#1 left ignition coil temperature sensor lead at the gray tape. Fasten
27. Rear brake fluid reservoir hose the plastic clamp in front of the brake fluid reservoir
and face the ends of the clamp inward. When
28. Seat lock cable installing the rear brake fluid reservoir, make sure
29. Starter motor lead that the lead couplers are not positioned under the
A. Route the cylinder-#2 left spark plug lead to the reservoir.
rear of the cylinder-#2 right spark plug lead. M. Fasten the relay unit lead, anti-theft alarm coupler
B. Fasten the sub-wire harness 2, ISC (idle speed (optional), anti-theft alarm leads (optional), joint
control) unit lead, and intake solenoid lead with the coupler lead, and turn signal/hazard relay lead with
holder, making sure that the sub-wire harness 2 is the plastic locking tie near the right front corner of
fastened closest to the frame. the relay unit. Face the end of the plastic locking tie
forward, and then cut off the excess end of the tie.
C. Route the wire harness along the frame so that the
leads that branch off from the wire harness are N. Place the anti-theft alarm couplers (optional) under
routed inward. the relay unit lead.
D. Route the wire harness along the side of the O. Route the seat lock cable over the ECU, making
battery, making sure that it does protrude past the sure that the cable is not pinched on the side of the
top of the frame. ECU.
E. Fasten the wire harness, ECU leads, and sub-wire P. Route the fuse box leads over the wire harness.
harness 1 with the plastic locking tie next to the Q. Fasten the sub-wire harness 1, muffler cooling fan
starter relay. Face the end of the plastic locking tie motor relay lead, wire harness, and lean angle cut-
outward, and then cut off the excess end of the tie. off switch lead with the plastic band in the range
Be sure not to pinch the end of the plastic locking shown in the illustration, making sure to align the
tie when installing the holder. tape on the sub-wire harness with the band. Face
F. Route the sub-wire harness 1 below the ECU the end of the plastic band inward. Do not fasten
leads and starter relay lead. Place the sub-wire the starter relay lead.
harness 1 coupler in the area shown in the R. Route the throttle cable (accelerator cable) over
illustration with oblique lines so that it does not rest the throttle cable (decelerator cable).
on top of the section of the fuse box lead that is not S. Route the throttle cables over the cylinder-#2 right
covered by its protective sleeve. Do not place the spark plug lead.
sub-wire harness 1 coupler between the main wire
harness and the rear brake fluid reservoir hose. T. Fasten the negative battery lead and negative
battery lead coupler with the battery band.
G. Fasten the relay unit lead, headlight relay lead, and
turn signal/hazard relay lead with the plastic band U. Install the positive battery lead terminal with the
in front of the headlight relay. Face the end of the lead routed upward.
plastic band forward. Do not fasten the anti-theft V. 40–50°
alarm couplers (optional) and anti-theft alarm leads W. Route the positive battery lead under the main-
(optional). fuse-starter-relay lead.
X. Route the main-fuse-to-starter-relay lead over the
wire-harness-to-main-fuse lead.
2-48
CABLE ROUTING
S
R
A
T
21 24
20 22
B U
1 V
2
3 X W
19 23
4 Y
25
AF 26
29 23
C 24
D A
AE
5 27
D AD U
6
6 AC AA
7
Q E 28
F
18 AB
P 8
O
17 G
N
9
M
16
15 A
14 10 AG
H
I
L
K 13 J 12 11
2-49
CABLE ROUTING
Y. Route the sub-wire harness 1 under the wire-

harness-to-main-fuse lead.
Z. To cylinder-#1 right spark plug
AA.Route the rear brake fluid reservoir hose under the
wire harness to the right of the battery box. Be sure
not to pinch the rear brake fluid reservoir hose
when installing the battery box.
AB.Route the starter motor lead under the lean angle
cut-off switch lead.
AC.Route the starter motor lead and sub-wire harness
1 under the battery box, making sure that they are
routed between the bolt holes in the battery box.
AD.Route the seat lock cable under the wire harness
to the left of the battery box. Be sure not to pinch
the seat lock cable when installing the battery box.
AE.Fasten the sub-wire harness 1 at the white tape
with the plastic locking tie. Face the end of the
plastic locking tie rearward, and then cut off the
excess end of the tie.
AF. To cylinder-#1 left spark plug
AG.Fasten the starter motor lead at the white tape with
the holder on the cylinder-#1 left ignition coil
bracket.
2-50
CABLE ROUTING
4
C
B
3
D
E D
3 6
A A
7
4
2-51
CABLE ROUTING
1. Fuel tank
2. Pressure regulator
3. Fuel return hose
4. Fuel hose
5. Fuel return pipe
6. Fuel return hose (fuel return pipe to fuel pump)
7. Fuel pump
8. Fuel pipe
9. Fuel hose (intake manifold assembly to pressure
regulator)
A. Face the ends of the hose clamps downward.
B. Install the fuel return hose onto the fuel return pipe
until the hose contacts the paint mark on the pipe.
C. Connect the end of the fuel hose that has a black
connector to the fuel pipe.
D. Install the end of the fuel return hose (fuel return
pipe to fuel pump) with a yellow paint mark onto
the fuel return pipe until the hose contacts the
yellow paint mark on the pipe.
E. Face the end of the hose clamp inward, angled
slightly downward.
F. Install the fuel return hose (fuel return pipe to fuel
pump) with its white paint mark facing downward.
G. Connect the end of the fuel hose that has an
orange connector to the fuel pump.
2-52
CABLE ROUTING
C 1
B
1 2 2
D
3
D
A A
4 A
5 A
A 6
8
7 F
G
I
H
9
10
11 10 9
J
A
K A
2-53
CABLE ROUTING
1. Fuel tank overflow hose

2. Fuel tank breather hose
3. Rollover valve hose 1
5. Rollover valve 1
6. Rollover valve 2
9. Fuel tank breather/overflow hose
10. Oil tank
11. Bottom cover
A. Face the ends of the hose clamps in the directions
shown in the illustration.
B. Install the fuel tank overflow hose onto the front
pipe of the fuel tank with its yellow paint mark
facing outward.
C. Install the fuel tank breather hose onto the rear
pipe of the fuel tank with its white paint mark facing
rearward.
D. Install the rollover valve hoses with their paint
marks facing outward.
E. Fasten the fuel tank breather hose at the white
paint mark, fuel tank overflow hose at the yellow
paint mark, and fuel return pipe with the holder.
Fasten the hoses in the order listed with the fuel
tank breather hose fastened towards the front of
the vehicle.
F. Install the rollover valve hoses with their paint
marks facing downward.
G. Face the ends of the hose clamps forward.
H. Face the ends of the hose clamp rearward.
I. Install the fuel tank overflow hose and fuel tank
breather/overflow hose with their paint marks
facing rearward.
J. Route the fuel tank breather/overflow hose behind
the mounting boss on the oil tank.
K. The end of the fuel tank breather/overflow hose
should protrude past the edge of the bottom cover.
2-54
CABLE ROUTING
2 B 3 A 4 5 C
1 6
I 13
H 7
D
G
E
12
11
A 8 F
10
B 9
15 8
14
17
E 3 J
H 10
16
A K B
C
M
2-55
CABLE ROUTING
1. Cylinder-#2 intake air pressure sensor

2. Cylinder-#2 ISC (idle speed control) unit outlet
hose
4. Intake solenoid vacuum hose (one-way valve to
throttle body)
5. Cylinder-#1 ISC (idle speed control) unit outlet
hose
7. Throttle body
8. Cylinder-#1 intake air pressure sensor hose
9. Fuel return hose
10. Pressure regulator
12. Clutch hose
13. Cylinder-#2 intake air pressure sensor hose
14. Fuel hose
15. Air filter case
16. Pressure regulator joint
17. Fuel hose (intake manifold assembly to pressure
regulator)
A. Face the ends of the hose clamp outward.
B. Install the ends of the cylinder-#2 ISC (idle speed
control) unit outlet hose with a green paint mark
onto the throttle body.
C. Install the end of the cylinder-#1 ISC (idle speed
control) unit outlet hose with a blue paint mark onto
the throttle body.
D. Face the ends of the hose clamp to the left, angled
45° towards the rear of the vehicle.
E. Face the ends of the hose clamp forward.
F. Install the end of the cylinder-#1 intake air
pressure sensor hose with a white paint mark onto
the throttle body.
G. Face the ends of the hose clamp to the right, angle
45° towards the front of the vehicle.
H. Face the ends of the hose clamp rearward.
I. Install the ends of the cylinder-#2 intake air
pressure sensor hose with a white paint mark onto
the throttle body.
J. Face the ends of the hose clamp inward.
K. Install the end of the intake solenoid vacuum hose
(one-way valve to throttle body) with a white paint
mark onto the throttle body. Be sure to install the
end of the hose all the way onto the throttle body
and position the hose clamp as shown in the
illustration.
L. 45°
M. 1 mm (0.04 in)
2-56
CABLE ROUTING
2-57
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
SYNCHRONIZING THE THROTTLE BODIES.......................................... 3-5
ADJUSTING THE THROTTLE CABLE FREE PLAY ................................ 3-7
CHECKING THE SPARK PLUGS ............................................................. 3-8
CHECKING THE IGNITION TIMING......................................................... 3-8
MEASURING THE COMPRESSION PRESSURE.................................... 3-9
CHECKING THE ENGINE OIL LEVEL.................................................... 3-11
CHANGING THE ENGINE OIL ............................................................... 3-11
ADJUSTING THE CLUTCH LEVER........................................................ 3-13
CHECKING THE CLUTCH FLUID LEVEL .............................................. 3-14 3
BLEEDING THE HYDRAULIC CLUTCH SYSTEM ................................. 3-14
REPLACING THE AIR FILTER ELEMENT ............................................. 3-15
CHECKING THE THROTTLE BODY JOINTS ........................................ 3-16
CHECKING THE FUEL LINE .................................................................. 3-16
CHECKING THE CYLINDER HEAD BREATHER HOSES ..................... 3-16
CHECKING THE OIL TANK BREATHER HOSE .................................... 3-17
CHECKING THE EXHAUST SYSTEM.................................................... 3-17
ADJUSTING THE EXUP CABLES .......................................................... 3-18
CHASSIS ....................................................................................................... 3-20

ADJUSTING THE FRONT DISC BRAKE................................................ 3-20
ADJUSTING THE REAR DISC BRAKE .................................................. 3-20
CHECKING THE BRAKE FLUID LEVEL................................................. 3-21
CHECKING THE FRONT BRAKE PADS ................................................ 3-22
CHECKING THE REAR BRAKE PADS .................................................. 3-22
CHECKING THE FRONT BRAKE HOSES ............................................. 3-22
CHECKING THE REAR BRAKE HOSE .................................................. 3-22
ADJUSTING THE REAR BRAKE LIGHT SWITCH ................................. 3-23
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-23
ADJUSTING THE SHIFT PEDAL............................................................ 3-24
ADJUSTING THE DRIVE CHAIN SLACK ............................................... 3-25
LUBRICATING THE DRIVE CHAIN ........................................................ 3-26
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-26
CHECKING THE FRONT FORK ............................................................. 3-27
ADJUSTING THE FRONT FORK LEGS ................................................. 3-27
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY.................. 3-29
CHECKING THE TIRES.......................................................................... 3-30
CHECKING THE WHEELS ..................................................................... 3-32
CHECKING AND LUBRICATING THE CABLES .................................... 3-32
LUBRICATING THE LEVERS ................................................................. 3-32
LUBRICATING THE PEDAL ................................................................... 3-32
LUBRICATING THE SIDESTAND........................................................... 3-32
LUBRICATING THE REAR SUSPENSION............................................. 3-32
ELECTRICAL SYSTEM................................................................................. 3-33
CHECKING AND CHARGING THE BATTERY....................................... 3-33
CHECKING THE FUSES ........................................................................ 3-33
REPLACING THE HEADLIGHT BULBS ................................................. 3-33
ADJUSTING THE HEADLIGHT BEAM ................................................... 3-34
PERIODIC MAINTENANCE
EAS20450
EAS20460
INTRODUCTION
This chapter includes all information necessary to perform the recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer 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.
EAU17705
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 plugs
• Replace. √ √
• Check valve clearance.
3 * Valves • Adjust. √ √
4 * Air filter element • Replace. √

• Check operation, fluid level and vehicle for fluid
5 * Clutch leakage. √ √ √ √ √
• 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. √ √ √ √
12 * Swingarm • Check operation and for excessive play. √ √ √ √
• Check chain slack, alignment and condition. Every 1000 km and after washing the motorcy-
13 Drive chain • Adjust and lubricate chain with a special O-ring
chain lubricant thoroughly. cle or riding in the rain
• Check bearing play and steering for roughness. √ √ √ √ √

14 * Steering bearings
• Lubricate with lithium-soap-based grease. Every 20000 km
• Make sure that all nuts, bolts and screws are prop-
15 * Chassis fasteners √ √ √ √ √
erly tightened.
• Check operation.
16 Sidestand • Lubricate. √ √ √ √ √
17 * Sidestand switch • Check operation. √ √ √ √ √ √

18 * Front fork • Check operation and for oil leakage. √ √ √ √
3-1
ODOMETER READING (× 1000 km) ANNU-

NO. ITEM CHECK OR MAINTENANCE JOB AL
1 10 20 30 40 CHECK
Shock absorber as-

19 * sembly • Check operation and shock absorber for oil leakage. √ √ √ √
Rear suspension re-

lay arm and connect-
20 * ing arm pivoting • Check operation. √ √ √ √
points
21 * Fuel injection system • Adjust synchronization. √ √ √ √ √
22 Engine oil • Change. √ √ √ √ √ √

• Check oil level and vehicle for oil leakage.
Engine oil filter car-
23 • Replace. √ √ √
tridge
Front and rear brake
24 * switches • Check operation. √ √ √ √ √ √
25 Moving parts and ca- • Lubricate. √ √ √ √ √

bles
• Check operation and free play.
Throttle grip hous-
26 * ing and cable • Adjust the throttle cable free play if necessary. √ √ √ √ √
• Lubricate the throttle grip housing and cable.
Muffler and exhaust
27 * • Check the screw clamp for looseness. √ √ √ √ √
pipe
Lights, signals and • Check operation.
28 * switches • Adjust headlight beam. √ √ √ √ √ √
EAU36771
NOTE:
• Air filter
• This model’s air filter is equipped with a disposable oil-coated paper element, which must not be
cleaned with compressed air to avoid damaging it.
• The air filter element needs to be replaced more frequently when riding in unusually wet or dusty
areas.
• Hydraulic brake and clutch service
• Regularly check and, if necessary, correct the brake fluid and clutch fluid levels.
• Every two years replace the internal components of the brake master cylinders and calipers as well
as clutch master and release cylinders, and change the brake and clutch fluids.
• Replace the brake and clutch hoses every four years and if cracked or damaged.
3-2
ENGINE
EAS20470
• Fuel tank
ENGINE Refer to “FUEL TANK” on page 6-1.
EAS20530
• Air filter case
ADJUSTING THE VALVE CLEARANCE Refer to “GENERAL CHASSIS” on page 4-1.
The following procedure applies to all of the 2. Disconnect:
valves. • Spark plug caps
NOTE: 3. Remove:
• Spark plugs
• The valve clearance is automatically adjusted
4. Remove:
by the hydraulic valve lifter. However, there are
• Oil catch tank “1”
times that the valve clearance needs to be ad-
• Tappet covers “2”
justed manually. If this is the case, adjust the
• Front cylinder head cover “3”
clearance of the two maladjusted or worn
valves using the adjusting screw on the rocker
arm.
If clearance is on the slip side “1”, loosen the 3
adjusting screw and bring the valve clearance 1
“a” within specification. Check if the valve
clearance “b” on the adjusting screw “2” side is
within specification.
2
2
5. Remove:
• Air duct “1”
• Timing mark accessing screw “2”
• Crankshaft end cover “3”
If clearance is on the adjusting screw “2” side,

tighten the adjusting screw and bring the valve
clearance “b” within specification.
1
2 3
6. Remove:
• Camshaft sprocket cover “1”
• Valve clearance adjustment should be made

on a cold engine, at room temperature.
• When the valve clearance is to be measured or
adjusted, the piston must be at top dead center 1
(TDC) on the compression stroke.
1. Remove:
7. Measure:
• Seat
• Valve clearance
Refer to “GENERAL CHASSIS” on page 4-1.
Out of specification → Adjust.
3-3
ENGINE
Valve clearance (cold) Thickness gauge

Intake 90890-03079
0.00–0.04 mm (0.0000–0.0016 in) Narrow gauge set
Exhaust YM-34483
0.00–0.04 mm (0.0000–0.0016 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Piston #1 TDC (rear cylinder) Piston #2 TDC (front cylinder)
a. Turn the crankshaft counterclockwise. a. Turn the crankshaft counterclockwise from
the piston #1 TDC by 408 degrees.
b. When piston #2 is at TDC on the compres-
sion stroke, align the TDC mark “e” on the
crankshaft position sensor rotor with the
pointer “b” on the clutch cover.
b e

sion stroke, align the TDC mark “a” on the
b a
c. Check the camshaft drive gear mark “c” posi-
tion and camshaft driven gear mark “d” posi-
tion as shown.
c
c. Check the camshaft drive gear mark “c” posi-
tion and camshaft driven gear mark “d” posi-
tion as shown.
If the marks are not aligned, turn the crank-
shaft counterclockwise 360 degrees and re- d. Measure the valve clearance with a thickness
check step (b). gauge.
Thickness gauge
90890-03079
Narrow gauge set
d YM-34483
c ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Adjust:
• Valve clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “1” with the locknut
d. Measure the valve clearance with a thickness wrench “2”.
gauge.
3-4
ENGINE
NOTE:
Locknut wrench
90890-04150 Set the torque wrench at a right angle to the
YM-04150 locknut wrench.
Locknut (rocker arm adjusting

2 1 screw)
T.
R.
20 Nm (2.0 m·kg, 14 ft·lb)
Locknut wrench
90890-04150
YM-04150
b. Insert a thickness gauge “3” between the end

of the adjusting screw and the valve tip.
6
Thickness gauge
90890-03079
Narrow gauge set
YM-34483
c. Turn the adjusting screw “4” in direction “a” or

“b” with the tappet adjusting tool “5” until the e. Measure the valve clearance again.
specified valve clearance is obtained. f. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance adjust-
Tappet adjusting tool ment steps until the specified clearance is
90890-04149 obtained.
YM-04149 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9. Install:
Adjusting • All removed parts
Slip side
screw side
NOTE:
Valve clear- Valve clear- For installation, reverse the removal procedure.
Direction “a” ance is in- ance is de-
creased. creased. • Front cylinder head cover
• Tappet covers
Valve clear- Valve clear-
Refer to “CAMSHAFTS” on page 5-16.
Direction “b” ance is de- ance is in-
creased. creased. EAS20570
SYNCHRONIZING THE THROTTLE BODIES

4 NOTE:
Prior to synchronizing the throttle bodies, the
valve clearance and the engine idling speed
should be properly adjusted and the ignition tim-
5
a b ing should be checked.
1. Stand the vehicle on a level surface.
NOTE:
3 Place the vehicle on a suitable stand.
2. Remove:
d. Hold the adjusting screw to prevent it from • Seat
moving and tighten the locknut to specifica- Refer to “GENERAL CHASSIS” on page 4-1.
tion with the locknut wrench “6”.
3-5
ENGINE
• Fuel tank ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

Refer to “FUEL TANK” on page 6-1. a. Start the engine, warm it up for several min-
• Air filter case utes, and then let it run at the specified en-
Refer to “GENERAL CHASSIS” on page 4-1. gine idling speed.
3. Disconnect:
Engine idling speed
• Intake solenoid vacuum hose (one-way valve
850–950 r/min
to throttle body) “1”
• Cylinder-#1 intake air pressure sensor hose b. With throttle body #1 as standard, adjust
“2” throttle body #2 using the air screw “1” (for
throttle body #2).
1
2
4. Install:
• Fuel hose “1” (Parts No.: 5JW-24311-00)
NOTE:
• 3-way joint “2” (Parts No.: 90413-05014)
• Cylinder-#1 intake air pressure sensor hose • After each step, rev the engine two or three
“3” times, each time for less than a second, and
• Vacuum gauge hose for #1 “4” check the synchronization again.
• Vacuum gauge hose for #2 “5” • If the air screw is removed, turn the screw 3/4
• Vacuum gauge turn in and be sure to synchronize the throttle
• Digital tachometer body.
EC5YU1027
Vacuum gauge CAUTION:

90890-03094 Do not use the throttle valve adjusting
Carburetor synchronizer screws to adjust the throttle body synchroni-
YU-44456
zation.
Intake vacuum
26.6 kPa (7.9 inHg) (200 mmHg)
4
NOTE:
5 The difference in vacuum pressure between two
throttle bodies should not exceed 1.33 kPa (10
3 1 mm Hg).
2 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Stop the engine and remove the measuring
5. Install: equipment.
• Air filter case 8. Adjust:
Refer to “GENERAL CHASSIS” on page 4-1. • Throttle cable free play
• Fuel tank Refer to “ADJUSTING THE THROTTLE CA-
Refer to “FUEL TANK” on page 6-1. BLE FREE PLAY” on page 3-7.
6. Adjust:
• Throttle body synchronization Throttle cable free play
3.0–5.0 mm (0.12–0.20 in)
3-6
ENGINE
9. Install: NOTE:
• Air filter case
Apply locking agent (LOCTITE®) to the threads
of the adjusting nut “3”.
• Fuel tank
Refer to “FUEL TANK” on page 6-1. c. Loosen the locknut “4” on the accelerator ca-
• Seat ble.
Refer to “GENERAL CHASSIS” on page 4-1. d. Turn the adjusting nut “5” in direction “a” or “b”
until the specified throttle cable free play is
EAS20630
ADJUSTING THE THROTTLE CABLE FREE obtained.

PLAY
Direction “a”
1. Check:
Throttle cable free play is increased.
• Throttle cable free play “a” Direction “b”
Out of specification → Adjust. Throttle cable free play is decreased.
Throttle cable free play
3.0–5.0 mm (0.12–0.20 in) e. Tighten the locknuts “2”, “4”.
1 4 5
a
b
a
2
b
3
NOTE:
2. Remove: If the specified throttle cable free play cannot be
• Pressure regulator cover “1” obtained on the throttle body side of the cable,
use the adjusting nut on the handlebar side.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Handlebar side
a. Loosen the locknut “1”.
1 b. Turn the adjusting nut “2” in direction “a” or “b”
until the specified throttle cable free play is
obtained.
Direction “a”
3. Adjust: Throttle cable free play is increased.
• Throttle cable free play Direction “b”
NOTE: Throttle cable free play is decreased.
When the throttle is opened, the accelerator ca-
ble “1” is pulled. c. Tighten the locknut “1”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Throttle body side
a. Loosen the locknut “2” on the decelerator ca-
ble.
b. Turn the adjusting nut “3” in direction “a” or “b”
to take up any slack on the decelerator cable.
3-7
ENGINE
5. Check:
• Electrode “1”
Damage/wear → Replace the spark plug.
• Insulator “2”
Abnormal color → Replace the spark plug.
a Normal color is medium-to-light tan.
6. Clean:
• Spark plug
1 b (with a spark plug cleaner or wire brush)
2 7. Measure:
EWA12910 • Spark plug gap “a”
WARNING (with a wire thickness gauge)
After adjusting the throttle cable free play, Out of specification → Regap.
start the engine and turn the handlebar to the
Spark plug gap
right and to the left to ensure that this does 0.8–0.9 mm (0.031–0.035 in)
not cause the engine idling speed to change.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• Pressure regulator cover
Pressure regulator cover bolt

9 Nm (0.9 m·kg, 6.5 ft·lb)
T.
R.
EAS20680
CHECKING THE SPARK PLUGS

The following procedure applies to all of the
spark plugs.
1. Remove: 8. Install:
• Seat • Spark plug
Refer to “GENERAL CHASSIS” on page 4-1. Spark plug
• Fuel tank 18 Nm (1.8 m·kg, 13 ft·lb)
T.
Refer to “FUEL TANK” on page 6-1.

R.
2. Disconnect: NOTE:
• Spark plug cap
Before installing the spark plug, clean the spark
3. Remove:
plug and gasket surface.
• Spark plug
ECA13320
9. Connect:
CAUTION: • Spark plug cap
Before removing the spark plugs, blow away 10.Install:
any dirt accumulated in the spark plug wells • Fuel tank
with compressed air to prevent it from falling Refer to “FUEL TANK” on page 6-1.
into the cylinders. • Seat
4. Check: Refer to “GENERAL CHASSIS” on page 4-1.
• Spark plug type EAS20700
Incorrect → Change. CHECKING THE IGNITION TIMING

NOTE:
Manufacturer/model
NGK/DPR7EA-9 Prior to checking the ignition timing, check the
Manufacturer/model wiring connections of the entire ignition system.
DENSO/X22EPR-U9 Make sure all connections are tight and free of
corrosion.
3-8
ENGINE

2. Remove: a b
• Air duct “1”
• Timing mark accessing screw “2”
1 NOTE:
The ignition timing is not adjustable.
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Connect: 5. Install:
• Timing light “1” • Timing mark accessing screw
• Digital tachometer
Timing mark accessing screw
Timing light 8 Nm (0.8 m·kg, 5.8 ft·lb)
T.
90890-03141 R.
Inductive clamp timing light • Air duct

YU-03141
Air duct bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
Air duct bracket bolt

7 Nm (0.7 m·kg, 5.1 ft·lb)
EAS20710
MEASURING THE COMPRESSION

PRESSURE
The following procedure applies to all of the cyl-
inders.
1
NOTE:
Insufficient compression pressure will result in a
4. Check: loss of performance.
• Ignition timing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1. 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 2. Start the engine, warm it up for several min-
850–950 r/min utes, and then turn it off.
3. Remove:
b. Check that pointer “a” on the clutch cover is
• Seat
within the firing range “b” on the crankshaft
position sensor. • Fuel tank
Incorrect firing range → Check the ignition
system.
4. Disconnect:
• Decompression solenoid couplers “1”
3-9
ENGINE
Standard compression pressure

(at sea level)
1200 kPa/200 r/min (170.7
1 psi/200 r/min) (12.0 kgf/cm²/200
r/min)
Minimum–maximum
1000–1400 kPa (142.2–199.1 psi)
(10.0–14.0 kgf/cm²)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “ON”.
5. Disconnect: b. With the throttle wide open, crank the engine
• Spark plug cap until the reading on the compression gauge
6. Remove: stabilizes.
• Spark plug EWA12940
ECA13340
WARNING
CAUTION:
To prevent sparking, ground all spark plug
Before removing the spark plugs, use com- leads before cranking the engine.
pressed air to blow away any dirt accumulat-
ed in the spark plug wells to prevent it from NOTE:
falling into the cylinders. The difference in compression pressure be-
7. Install: tween cylinders should not exceed 100 kPa (1
• Compression gauge “1” kg/cm², 14 psi).
• Extension “2” c. If the compression pressure is above the
maximum specification, check the cylinder
Compression gauge head, valve surfaces and piston crown for
90890-03081
carbon deposits.
Engine compression tester
YU-33223 Carbon deposits → Eliminate.
Extension d. If the compression pressure is below the min-
90890-04082 imum specification, pour a teaspoonful of en-
gine oil into the spark plug bore and measure
again.
2 Refer to the following table.
Compression pressure (with oil applied into
1 the cylinder)
Reading Diagnosis
Higher than without Piston ring(s) wear or
oil damage → Repair.
Piston ring(s), valves,
cylinder head gasket
Same as without oil
or piston possibly de-
8. Measure: fective → Repair.
• Compression pressure
Out of specification → Refer to steps (c) and ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
(d). 9. Install:
• Spark plug
Spark plug
18 Nm (1.8 m·kg, 13 ft·lb)
T.
R.
10.Connect:
• Spark plug cap
3-10
ENGINE
11.Connect: add any chemical additives, or use engine

• Decompression solenoid couplers oils with a grade of CD “a” or higher, and do
12.Install: not use oils labeled “ENERGY CONSERV-
• Fuel tank ING II” “b”.
Refer to “FUEL TANK” on page 6-1. • Do not allow foreign materials to enter the
• Seat crankcase.
EAS20730
CHECKING THE ENGINE OIL LEVEL

NOTE:
• Place the vehicle on a suitable stand.
• Make sure the vehicle is upright.
2. Start the engine, warm it up for approximately
15 minutes until the oil temperature rises to
60 °C (140 °F), and then turn it off. 5. Start the engine, warm it up for several min-
3. Remove: utes, and then turn it off.
• Dipstick “1” 6. Check the engine oil level again.
4. Check:
NOTE:
• Engine oil level
The engine oil level should be between the Before checking the engine oil level, wait a few
minimum level mark “a” and maximum level minutes until the oil has settled.
mark “b”. 7. Install:
Below the minimum level mark → Add the • Dipstick
recommended engine oil to the proper level.
EAS20780
NOTE: CHANGING THE ENGINE OIL
• Before checking the engine oil level, wait a few 1. Start the engine, warm it up for several min-
minutes until the oil has settled. utes, and then turn it off.
• Do not screw the dipstick in when inspecting 2. Remove:
the oil level. • Bottom cover
3. Place a container under the engine oil drain
bolts.
b 4. Remove:
a • Engine oil filler cap “1”
1
Type
SAE20W40
Recommended engine oil grade
API service SG type or higher,
JASO standard MA 5. Remove:
EC5YU1003
• Engine oil drain bolt (oil tank) “1”
CAUTION:
• Since engine oil also lubricates the clutch,
the wrong oil types or additives could
cause clutch slippage. Therefore, do not
3-11
ENGINE
1 2
6. Remove: c. Lubricate the O-ring “1” of the new oil filter

• Engine oil drain bolt (crankcase) “1” cartridge with a thin coat of engine oil.
EC5YU1019
CAUTION:
Make sure the O-ring “1” is positioned cor-
rectly in the groove of the oil filter cartridge.
7. Drain:
• Engine oil
(completely from the oil tank and crankcase)
8. If the oil filter cartridge is also to be replaced,
perform the following procedure. d. Tighten the new oil filter cartridge to specifi-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ cation with an oil filter wrench.
a. Remove the rectifier/regulator “1”.
Oil filter cartridge
17 Nm (1.7 m·kg, 12 ft·lb)
T.
R.
e. Install the rectifier/regulator.
Rectifier/regulator bolt
7 Nm (0.7 m·kg, 5.1 ft·lb)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
11
9. Check:
• Engine oil drain bolt gaskets
b. Remove the oil filter cartridge “1” with an oil Damage → Replace.
filter wrench “2”. 10.Install:
• Engine oil drain bolt (crankcase)
Oil filter wrench (along with the gasket)
90890-01426
YU-38411 Engine oil drain bolt (crankcase)
43 Nm (4.3 m·kg, 31 ft·lb)
T.
R.
• Engine oil drain bolt (oil tank)

(along with the gasket)
Engine oil drain bolt (oil tank)

35 Nm (3.5 m·kg, 25 ft·lb)
T.
R.
3-12
ENGINE
11.Fill: 13.Install:
• Oil tank • Engine oil filler cap
(with the specified amount of the recom- 14.Start the engine, warm it up for several min-
mended engine oil) utes, and then turn it off.
15.Check:
Engine oil quantity • Engine
Total amount (for engine oil leaks)
5.00 L (5.29 US qt) (4.40 Imp.qt) 16.Check:
Without oil filter cartridge re-
• Engine oil level
placement
3.70 L (3.91 US qt) (3.26 Imp.qt) Refer to “CHECKING THE ENGINE OIL
With oil filter cartridge replace- LEVEL” on page 3-11.
ment 17.Check:
4.10 L (4.33 US qt) (3.61 Imp.qt) • Engine oil pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
NOTE:
a. Slightly loosen the oil gallery bolts “1”.
Pour the engine oil in two stages. First, pour in
2.5 L of oil, then start the engine and rev it 3 to 5
times. Stop the engine, and then pour in the re-
mainder of the specified amount.
EC5YU1004
CAUTION:
When starting the engine make sure the dip- 1
stick is securely fitted into the oil tank.
12.Fill: (when engine is disassembled)
• Crankcase and oil tank b. Start the engine and keep it idling until engine
(with the specified amount of the recom- oil starts to seep from the oil gallery bolts. If
mended engine oil) no engine oil comes out after one minute, turn
the engine off so that it will not seize.
Engine oil quantity c. Check the engine oil passages, the oil filter
Total amount
cartridge and the oil pump for damage or
5.00 L (5.29 US qt) (4.40 Imp.qt)
Engine leakage. Refer to “OIL PUMP” on page 5-82.
2.2 L (2.33 US qt) (1.94 Imp.qt) d. Start the engine after solving the problem(s)
Oil tank and check the engine oil pressure again.
2.8 L (2.96 US qt) (2.46 Imp.qt) e. Tighten the oil gallery bolts to specification.
NOTE:
Oil gallery bolt
4 Nm (0.4 m·kg, 2.9 ft·lb)
T.
After the engine has been disassembled, pour

R.
the specified amount of engine oil into the crank- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

case and the oil tank. When pouring engine oil
EAS20860
into the crankcase, pour it into the hole of the re- ADJUSTING THE CLUTCH LEVER
moved bolt “1”. 1. Adjust:
• Clutch lever position
(distance “a” from the handlebar grip to the
clutch lever)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
a. While pushing the clutch lever forward, turn
the adjusting dial “1” until the clutch lever is in
the desired position.
3-13
ENGINE
EWA13370
NOTE:
WARNING
Be sure to align the setting on the adjusting dial
• Use only the designated clutch fluid. Other
with the arrow mark “2” on the clutch lever hold-
clutch fluids may cause the rubber seals to
er.
deteriorate, causing leakage and poor
clutch performance.
Position #1 • Refill with the same type of clutch fluid that
Distance “a” increases. is already in the system. Mixing clutch flu-
Position #4 ids may result in a harmful chemical reac-
Distance “a” decreases.
tion, leading to poor clutch performance.
• When refilling, be careful that water does
not enter the clutch fluid reservoir. Water
will significantly lower the boiling point of
the clutch fluid and could cause vapor lock.
ECA13420
CAUTION:
Clutch fluid may damage painted surfaces or
plastic parts. Therefore, always clean up any
spilt clutch fluid immediately.
NOTE:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ In order to ensure a correct reading of the clutch
EAS20890
fluid level, make sure the top of the reservoir is
CHECKING THE CLUTCH FLUID LEVEL horizontal.
1. Stand the vehicle on a level surface. 4. Install:
NOTE: • Clutch master cylinder reservoir diaphragm
• Place the vehicle on a suitable stand. • Clutch master cylinder reservoir diaphragm
• Make sure the vehicle is upright. holder
2. Remove: • Clutch master cylinder reservoir cap
• Clutch master cylinder reservoir cap Refer to “CLUTCH” on page 5-47.
• Clutch master cylinder reservoir diaphragm EAS20910
holder BLEEDING THE HYDRAULIC CLUTCH

• Clutch master cylinder reservoir diaphragm SYSTEM
EWA13000
Refer to “CLUTCH” on page 5-47.
WARNING
3. Check:
• Clutch fluid level Bleed the hydraulic clutch system whenever:
Below the minimum level mark “a” → Add the • the system was disassembled,
recommended clutch fluid to the proper level. • a clutch hose was loosened or removed,
• the clutch fluid level is very low,
Recommended clutch fluid • clutch operation is faulty.
Brake fluid DOT4
NOTE:
• Be careful not to spill any clutch fluid or allow
the clutch fluid reservoir to overflow.
UPPER • When bleeding the hydraulic clutch system,
a
LOWER make sure there is always enough clutch fluid
before applying the clutch lever. Ignoring this
precaution could allow air to enter the hydraulic
clutch system, considerably lengthening the
bleeding procedure.
3-14
ENGINE
• If bleeding is difficult, it may be necessary to let EAS20960
REPLACING THE AIR FILTER ELEMENT

the clutch fluid settle for a few hours. Repeat
1. Remove:
the bleeding procedure when the tiny bubbles
• Seat
in the hose have disappeared.
1. Bleed: 2. Lift the front of the fuel tank, and then tilt it
• Hydraulic clutch system back and away from the air filter case. (Do not
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ disconnect the fuel hoses.)
a. Add the recommended clutch fluid to the
proper level.
b. Install the clutch master cylinder reservoir di-
aphragm.
c. Connect a clear plastic hose “1” tightly to the
bleed screw “2”.
3. Remove:
1 • Air filter case cover “1”
d. Place the other end of the hose into a con-

tainer.
e. Slowly squeeze the clutch lever several
times. 1
f. Fully squeeze the clutch lever without releas-
ing it.
g. Loosen the bleed screw. This will release the
tension and cause the clutch lever to contact 4. Remove:
the handlebar grip. • Air filter element “1”
h. Tighten the bleed screw and then release the
clutch lever.
i. Repeat steps (e) to (h) until all of the air bub-
bles have disappeared from the clutch fluid in
the plastic hose.
j. Tighten the bleed screw to specification.
Bleed screw (clutch release cylin- 1

der)
T.
R.
6 Nm (0.6 m·kg, 4.3 ft·lb)
k. Add the recommended clutch fluid to the 5. Check:

proper level. • Air filter element
Refer to “CHECKING THE CLUTCH FLUID Damage → Replace.
LEVEL” on page 3-14. NOTE:
EWA13010
• Replace the air filter element every 40000 km
WARNING
of operation.
After bleeding the hydraulic clutch system, • The air filter needs more frequent service if you
check the clutch operation. are riding in unusually wet or dusty areas.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-15
ENGINE
6. Install: EAS21030
CHECKING THE FUEL LINE

• Air filter case cover
EC5YU1005 1. Remove:
CAUTION: • Seat
Never operate the engine without the air filter Refer to “GENERAL CHASSIS” on page 4-1.
element installed. Unfiltered air will cause • Fuel tank
rapid wear of engine parts and may damage Refer to “FUEL TANK” on page 6-1.
the engine. Operating the engine without the • Air filter case
air filter element will also affect the throttle Refer to “GENERAL CHASSIS” on page 4-1.
body synchronization, leading to poor en- 2. Check:
gine performance and possible overheating. • Fuel hoses “1”
• Breather hose “2”
NOTE: • Vacuum hose
When installing the air filter element into the air Cracks/damage → Replace.
filter case, make sure that the sealing surfaces Loose connection → Connect properly.
ECA14940
are aligned to prevent any air leaks.
CAUTION:
7. Install: Make sure the fuel tank breather hose is rout-
• Fuel tank ed correctly.
• Seat
EAS21010
CHECKING THE THROTTLE BODY JOINTS

1. Remove:
• Seat 2
Refer to “GENERAL CHASSIS” on page 4-1. 1
• Fuel tank
• Air filter case
2. Check: 3. Install:
• Throttle body joints “1” • Air filter case
Cracks/damage → Replace. Refer to “GENERAL CHASSIS” on page 4-1.
• Fuel tank
1 Refer to “FUEL TANK” on page 6-1.
• Seat
EAS21050
CHECKING THE CYLINDER HEAD

BREATHER HOSES
1. Remove:
1 • Seat
3. Install: • Fuel tank
• Air filter case Refer to “FUEL TANK” on page 6-1.
Refer to “GENERAL CHASSIS” on page 4-1. • Air filter case
• Fuel tank Refer to “GENERAL CHASSIS” on page 4-1.
Refer to “FUEL TANK” on page 6-1. 2. Check:
• Seat • Cylinder head breather hose (air filter case to
Refer to “GENERAL CHASSIS” on page 4-1. oil catch tank) “1”
• Cylinder head breather hose (cylinder head
to oil catch tank) “2”
Cracks/damage → Replace.
3-16
ENGINE
Loose connection → Connect properly. 2. Check:

EC5YU1028
• Front exhaust pipe “1”
CAUTION: • Rear exhaust pipe “2”
Make sure the cylinder head breather hoses • Catalyst pipe “3”
are routed correctly. • Mufflers “4”
• Gaskets “5”
Exhaust gas leaks → Replace.
3. Check:
1 Tightening torques
• Front exhaust pipe and front exhaust pipe
joint bolts “6”
• Front exhaust pipe and rear exhaust pipe bolt
2 “7”
• Rear exhaust pipe and rear exhaust pipe joint
bolt “8”
3. Install: • Rear exhaust pipe bolt “9”
• Air filter case • Rear exhaust pipe and catalyst pipe bolt “10”
Refer to “GENERAL CHASSIS” on page 4-1. • Catalyst pipe nut “11”
• Fuel tank • Catalyst pipe and muffler bolts “12”
Refer to “FUEL TANK” on page 6-1. • Muffler bolts “13”
• Seat
Refer to “GENERAL CHASSIS” on page 4-1. Front exhaust pipe and front ex-
T.
R.
EAS21060
20 Nm (2.0 m·kg, 14 ft·lb)
CHECKING THE OIL TANK BREATHER
Front exhaust pipe and rear ex-
HOSE haust pipe bolt
1. Check: 20 Nm (2.0 m·kg, 14 ft·lb)
• Oil tank breather hose “1” Rear exhaust pipe and rear ex-
Cracks/damage → Replace. haust pipe joint bolt
Loose connection → Connect properly. 20 Nm (2.0 m·kg, 14 ft·lb)
ECA14930
Rear exhaust pipe bolt
CAUTION: 20 Nm (2.0 m·kg, 14 ft·lb)
Make sure the oil tank breather hose is rout- Rear exhaust pipe and catalyst
ed correctly. pipe bolt
20 Nm (2.0 m·kg, 14 ft·lb)
Catalyst pipe nut
1 20 Nm (2.0 m·kg, 14 ft·lb)
Catalyst pipe and muffler bolt
20 Nm (2.0 m·kg, 14 ft·lb)
Muffler bolt
24 Nm (2.4 m·kg, 17 ft·lb)
EAS21080
CHECKING THE EXHAUST SYSTEM

The following procedure applies to all of the ex-
haust pipes and gaskets.
1. Remove:
• Seat
3-17
ENGINE
13 4
13
12
5
1
5
2. Check:
5 1
• EXUP system operation
12
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
9 a. Turn the main switch to “ON”.
4
5 6 b. Check that the EXUP valve operates proper-
5 ly.
11 8 5 NOTE:
3 2 Check that the projections “a” on the EXUP
valve pulley contact the stopper “b” (fully-open
10
7 position) and the stopper “c” (fully-closed posi-
tion).
NOTE:
When installing the EXUP cables, make sure
they are parallel and not twisted.
• Upper cable: Black metal section “14”
• Lower cable: White metal section “15”
a
14
c
b
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
15 • EXUP cable free play (at the EXUP valve pul-
ley) “a”
4. Install: EXUP cable free play (at the

• Seat EXUP valve pulley)
Refer to “GENERAL CHASSIS” on page 4-1. a: 3 mm (0.12 in) or less
b: 0 mm
EAS21100
ADJUSTING THE EXUP CABLES

1. Remove:
• EXUP valve pulley cover “1”
a
b
ab
3-18
ENGINE
4. Adjust: check that the notch in the EXUP valve pulley

• EXUP cable free play is aligned with the hole in the EXUP valve
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ cover.
a. Slide back the rubber cover. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. Loosen both locknuts “1”.
5. Install:
• EXUP valve pulley cover
1
EXUP valve pulley cover bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
1
c. Insert a 3.5 mm (0.14 in) pin “2” through the

projections “a” in the EXUP valve pulley and
into the hole “b” in the EXUP valve cover.
a b
d. Turn both adjusting nuts “3” in or out until the

specification.
Turn in “c” →
Free play is increased.
Turn out “d” →
Free play is decreased.
3
d c
c
d
3
e. Tighten both locknuts and then slide the rub-

ber cover to its original position.
f. Remove the pin.
g. Turn the main switch to “ON”, check that the
EXUP valve pulley contacts the stoppers (ful-
ly-open and fully-closed positions), and then
3-19
CHASSIS
EAS21140
1. Measure:
CHASSIS • Installed rear brake master cylinder length “a”
EAS21160
Incorrect → Adjust.
ADJUSTING THE FRONT DISC BRAKE
1. Adjust: Installed rear brake master cylin-
der length
• Brake lever position
145.3–145.7 mm (5.72–5.74 in)
(distance “a” from the throttle grip to the brake
lever)
NOTE:
• While pushing the brake lever forward, turn the
adjusting knob “1” until the brake lever is in the
a
desired position.
• Be sure to align the setting on the adjusting
knob with the arrow mark “2” on the brake le-
ver.
Direction “b”
Distance “a” increases. 2. Adjust:
Direction “c” • Installed rear brake master cylinder length
Distance “a” decreases. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b. Turn the adjusting bolt “2” in direction “a” or
“b” until the specified installed rear brake
master cylinder length is obtained.
Direction “a”
Installed rear brake master cylinder
length increases.
Direction “b”
Installed rear brake master cylinder
length decreases.
EWA13050 EW5YU1011
WARNING WARNING
A soft or spongy feeling in the brake lever After adjusting the installed rear brake mas-
can indicate the presence of air in the brake ter cylinder length, check that the end of the
system. Before the vehicle is operated, the adjusting bolt “c” is visible through the hole
air must be removed by bleeding the brake “d”.
system. Air in the brake system will consid-
erably reduce braking performance.
ECA13490
b 2
CAUTION:
1 a
After adjusting the brake lever position,
c
make sure there is no brake drag.
d
EAS21190
ADJUSTING THE REAR DISC BRAKE

NOTE:
The brake pedal position is determined by the in-
stalled rear brake master cylinder length “a”. c. Tighten the locknut to specification.
3-20
CHASSIS
Locknut (rear brake master cylin- È

der)
T.
R.
16 Nm (1.6 m·kg, 11 ft·lb)

EW5YU1001
WARNING a
A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will consid-
erably reduce braking performance and B
could result in loss of control and possibly
an accident. Therefore, check and, if neces-
sary, bleed the brake system.
EC5YU1024
CAUTION: a
After adjusting the installed rear master cyl-
inder length, make sure there is no brake
drag.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust: A. Front brake
• Rear brake light switch B. Rear brake
Refer to “ADJUSTING THE REAR BRAKE EWA13090
LIGHT SWITCH” on page 3-23. WARNING

• Use only the designated brake fluid. Other
EAS21240
CHECKING THE BRAKE FLUID LEVEL brake fluids may cause the rubber seals to
1. Stand the vehicle on a level surface. deteriorate, causing leakage and poor
brake performance.
NOTE:
• Refill with the same type of brake fluid that
• Place the vehicle on a suitable stand. is already in the system. Mixing brake fluids
• Make sure the vehicle is upright. may result in a harmful chemical reaction,
2. Remove: leading to poor brake performance.
• Seat • When refilling, be careful that water does
Refer to “GENERAL CHASSIS” on page 4-1. not enter the brake fluid reservoir. Water
3. Check: will significantly lower the boiling point of
• Brake fluid level the brake fluid and could cause vapor lock.
Below the minimum level mark “a” → Add the ECA13540
recommended brake fluid to the proper level. CAUTION:

Brake fluid may damage painted surfaces
Recommended fluid and plastic parts. Therefore, always clean up
DOT 4
any spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the brake
fluid level, make sure the top of the brake fluid
reservoir is horizontal.
4. Install:
• Seat
3-21
CHASSIS
EAS21250 EAS21280
CHECKING THE FRONT BRAKE PADS CHECKING THE FRONT BRAKE HOSES
The following procedure applies to all of the The following procedure applies to all of the
brake pads. brake hoses and brake hose holders.
1. Operate the brake. 1. Check:
2. Check: • Brake hoses “1”
• Front brake pad lining thickness “1” Cracks/damage/wear → Replace.
Out of specification → Replace the brake 2. Check:
pads as a set. • Brake hose holders
Refer to “FRONT BRAKE” on page 4-18. Loose → Tighten the clamp bolt.
Brake pad lining thickness (in-

ner) 1
4.5 mm (0.18 in)
Limit
0.8 mm (0.03 in)
Brake pad lining thickness (out- 1
er)
4.5 mm (0.18 in)
Limit
0.8 mm (0.03 in)
3. Hold the vehicle upright and apply the brake
several times.
4. Check:
• Brake hoses
Brake fluid leakage → Replace the damaged
hoses.
Refer to “FRONT BRAKE” on page 4-18.
EAS21290
CHECKING THE REAR BRAKE HOSE

1. Remove:
• Seat
EAS21260
CHECKING THE REAR BRAKE PADS
2. Check:
• Brake hoses “1”
brake pads.
Cracks/damage/wear → Replace.
1. Operate the brake.
3. Check:
2. Check:
• Brake hose guide “2”
• Rear brake pad
Loose → Tighten the clamp bolt.
Wear indicator grooves “1” almost disap-
peared → Replace the brake pads as a set. 1
Refer to “REAR BRAKE” on page 4-30.
1 2 1
3-22
CHASSIS
4. Hold the vehicle upright and apply the brake • a brake hose is loosened, disconnected or
several times. replaced.
5. Check: • the brake fluid level is very low.
• Brake hoses • brake operation is faulty.
Brake fluid leakage → Replace the damaged
NOTE:
hose.
Refer to “REAR BRAKE” on page 4-30. • Be careful not to spill any brake fluid or allow
6. Install: the brake master cylinder reservoir or brake
• Seat fluid reservoir to overflow.
Refer to “GENERAL CHASSIS” on page 4-1. • When bleeding the hydraulic brake system,
make sure there is always enough brake fluid
EAS21330
before applying the brake. Ignoring this pre-
ADJUSTING THE REAR BRAKE LIGHT caution could allow air to enter the hydraulic
SWITCH brake system, considerably lengthening the
NOTE: bleeding procedure.
The rear brake light switch is operated by move- • If bleeding is difficult, it may be necessary to let
ment of the brake pedal. The rear brake light the brake fluid settle for a few hours. Repeat
switch is properly adjusted when the brake light the bleeding procedure when the tiny bubbles
comes on just before the braking effect starts. in the hose have disappeared.
1. Check: 1. Remove:
• Rear brake light operation timing • Seat
Incorrect → Adjust. Refer to “GENERAL CHASSIS” on page 4-1.
2. Adjust: 2. Bleed:
• Rear brake light operation timing • Hydraulic brake system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the main body “1” of the rear brake light a. Fill the brake fluid reservoir to the proper level
switch so that it does not rotate and turn the with the recommended brake fluid.
adjusting nut “2” in direction “a” or “b” until the b. Install the brake master cylinder reservoir di-
rear brake light comes on at the proper time. aphragm and brake fluid reservoir dia-
phragm.
Direction “a” c. Connect a clear plastic hose “1” tightly to the
Brake light comes on sooner. bleed screw “2”.
Direction “b”
Brake light comes on later.
1 2
a b
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21360
BLEEDING THE HYDRAULIC BRAKE

SYSTEM
EWA13100
WARNING
Bleed the hydraulic brake system whenever:
• the system is disassembled.
3-23
CHASSIS
EWA13110
A
2 WARNING
After bleeding the hydraulic brake system,
check the brake operation.
1 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Seat
EAS21380
B ADJUSTING THE SHIFT PEDAL

2
NOTE:
The shift pedal position is determined by the in-
stalled shift rod length “a”.
1
1. Measure:
• Installed shift rod length “a”
Incorrect → Adjust.
Installed shift rod length

309.2–311.2 mm (12.17–12.25 in)
A. Front brake caliper
B. Rear brake caliper
d. Place the other end of the hose into a con-
tainer. a
e. Slowly apply the brake several times.
f. Fully pull the brake lever or fully press down
the brake pedal and hold it in position.
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release the pres-
sure and cause the brake lever to contact the 2. Adjust:
throttle grip or the brake pedal to fully extend. • Installed shift rod length
h. Tighten the bleed screw and then release the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
brake lever or brake pedal. a. Loosen both locknuts “1”.
i. Repeat steps (e) to (h) until all of the air bub- b. Turn the shift rod “2” in direction “a” or “b” until
bles have disappeared from the brake fluid in the specified installed shift rod length is ob-
the plastic hose. tained.
j. Tighten the bleed screw to specification.
Direction “a”
Bleed screw (front brake caliper) Installed shift rod length increases.
6 Nm (0.6 m·kg, 4.3 ft·lb) Direction “b”
T.
Installed shift rod length decreases.

R.
Bleed screw (rear brake caliper)

6 Nm (0.6 m·kg, 4.3 ft·lb)
k. Fill the brake fluid reservoir to the proper level

with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-21.
3-24
CHASSIS
b
a
a
1 b
c. Tighten both locknuts to specification. 3. Adjust:

• Drive chain slack
Locknut (shift rod) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
7 Nm (0.7 m·kg, 5.1 ft·lb) a. Loosen the wheel axle nut “1”.
T.
R.
b. Loosen both locknuts “2”.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ c. Turn both adjusting bolts “3” in direction “a” or
EAS21390 “b” until the specified drive chain slack is ob-
ADJUSTING THE DRIVE CHAIN SLACK tained.
ECA13550
CAUTION: Direction “a”

A drive chain that is too tight will overload Drive chain is tightened.
the engine and other vital parts, and one that Direction “b”
is too loose can skip and damage the swing- Drive chain is loosened.
arm or cause an accident. Therefore, keep
the drive chain slack within the specified lim-
its. 2 31
EWA13120 b
WARNING
Securely support the vehicle so that there is
no danger of it falling over. a
NOTE:
Place the vehicle on a suitable stand so that the
rear wheel is elevated.
NOTE:
2. Check: • To maintain the proper wheel alignment, adjust
• Drive chain slack “a” both sides evenly.
Out of specification → Adjust. • Push the rear wheel forward to make sure
there is no clearance between the swingarm
Drive chain slack
end plates and the ends of the swingarm.
40.0–50.0 mm (1.57–1.97 in)
d. Tighten the locknuts to specification.
NOTE:
Measure the drive chain slack 85 mm (3.35 in) Locknut (drive chain adjusting
bolt)
T.
“b” from the end of the drive chain guide.

R.
16 Nm (1.6 m·kg, 11 ft·lb)
e. Tighten the wheel axle nut to specification.
Rear wheel axle nut

150 Nm (15.0 m·kg, 110 ft·lb)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-25
CHASSIS
EAS21440
LUBRICATING THE DRIVE CHAIN

The drive chain consists of many interacting
parts. If the drive chain is not maintained proper-
ly, it will wear out quickly. Therefore, the drive
chain should be serviced, especially when the
vehicle is used in dusty areas.
This vehicle has a drive chain with small rubber
O-rings between each side plate. Steam clean-
ing, high-pressure washing, certain solvents,
and the use of a coarse brush can damage
these O-rings. Therefore, use only kerosene to b. Loosen the lower ring nut “4”, and then tight-
clean the drive chain. Wipe the drive chain dry en it to the specified torque with a steering nut
and thoroughly lubricate it with engine oil or wrench “5”.
chain lubricant that is suitable for O-ring chains. NOTE:
Do not use any other lubricants on the drive Set a torque wrench at a right angle to the steer-
chain since they may contain solvents that could ing nut wrench.
damage the O-rings.
Recommended lubricant Steering nut wrench

Engine oil or chain lubricant 90890-01403
suitable for O-ring chains Spanner wrench
YU-33975
EAS21510
CHECKING AND ADJUSTING THE

Lower ring nut (initial tightening
STEERING HEAD
torque)
T.

R.
EWA13120
52 Nm (5.2 m·kg, 37 ft·lb)
WARNING
no danger of it falling over.
NOTE:
front wheel is elevated.
2. Check:
• Steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness → Adjust the steering c. Loosen the lower ring nut completely, and
head. then tighten it to specification with a steering
3. Remove: nut wrench.
EWA13140
• Upper bracket WARNING
Refer to “STEERING HEAD” on page 4-56.
Do not overtighten the lower ring nut.
4. Adjust:
• Steering head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Lower ring nut (final tightening
a. Remove the lock washer “1”, the upper ring torque)
T.
R.
nut “2”, and the rubber washer “3”. 23 Nm (2.3 m·kg, 17 ft·lb)
d. Check the steering head for looseness or

binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and check the upper and
lower bearings.
3-26
CHASSIS
Refer to “STEERING HEAD” on page 4-56. 3. Hold the vehicle upright and apply the front
e. Install the rubber washer “3”. brake.
f. Install the upper ring nut “2”. 4. Check:
g. Finger tighten the upper ring nut “2”, then • Front fork operation
align the slots of both ring nuts. If necessary, Push down hard on the handlebar several
hold the lower ring nut and tighten the upper times and check if the front fork rebounds
ring nut until their slots are aligned. smoothly.
h. Install the lock washer “1”. Rough movement → Repair.
NOTE: Refer to “FRONT FORK” on page 4-46.
Make sure the lock washer tabs “a” sit correctly
in the ring nut slots “b”.
EAS21580
ADJUSTING THE FRONT FORK LEGS

The following procedure applies to both of the
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ front fork legs.
EW5YU1008
5. Install:
WARNING
• Upper bracket
Refer to “STEERING HEAD” on page 4-56. • Always adjust both front fork legs evenly.
Uneven adjustment can result in poor han-
EAS21530
dling and loss of stability.
CHECKING THE FRONT FORK
• Securely support the vehicle so that there
EWA13120
is no danger of it falling over.
WARNING
Securely support the vehicle so that there is Spring preload
ECA13570
CAUTION:
2. Check: • Grooves are provided to indicate the ad-
• Inner tube “1” justment position.
Damage/scratches → Replace. • Never go beyond the maximum or mini-
• Oil seal “2” mum adjustment positions.
Oil leakage → Replace.
1. Adjust:
• Spring preload
2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting bolt “1” in direction “a” or
1 “b”.
Direction “a”
Spring preload is increased (suspen-
sion is harder).
Direction “b”
Spring preload is decreased (suspen-
sion is softer).
3-27
CHASSIS
Spring preload adjusting positions Rebound damping adjusting posi-

Minimum tions
0 Minimum
2 Standard
5 Maximum
1 click(s) out*
* With the adjusting screw fully turned in
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Compression damping
ECA13590
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
• Compression damping
2. Current setting ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3. Cap bolt collar a. Turn the adjusting screw “1” in direction “a” or
“b”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Rebound damping Direction “a” (turn in)

ECA13590 Compression damping is increased
CAUTION: (suspension is harder).
Direction “b” (turn out)
Compression damping is decreased
adjustment positions. (suspension is softer).
1. Adjust:
• Rebound damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Compression damping adjusting
a. Turn the adjusting screw “1” in direction “a” or positions
“b”. Minimum
16 click(s) out*
Direction “a” (turn in) Standard
Rebound damping is increased (sus- 7 click(s) out*
pension is harder). Maximum
Direction “b” (turn out) 1 click(s) out*
Rebound damping is decreased (sus- * With the adjusting screw fully turned in
pension is softer).
3-28
CHASSIS
a
3
2
b
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21620
ADJUSTING THE REAR SHOCK ABSORBER

ASSEMBLY
EWA13120
WARNING
c
Spring preload
ECA13590
CAUTION: c. Installed spring length

Never go beyond the maximum or minimum c. Tighten the locknut to specification.
Locknut (rear shock absorber
1. Adjust:
spring preload adjusting nut)
T.
• Spring preload
R.
42 Nm (4.2 m·kg, 30 ft·lb)

NOTE:
ECA13600
Adjust the spring preload with the special
CAUTION:
wrench “1”.
Always tighten the locknut against the ad-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
justing nut and torque it to specification.
b. Turn the adjusting nut “3” in direction “a” or ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
“b”.
Rebound damping
ECA13590
Direction “a”
CAUTION:
Spring preload is increased (suspen-
sion is harder). Never go beyond the maximum or minimum
Direction “b” adjustment positions.
Spring preload is decreased (suspen- 1. Adjust:
sion is softer).
• Rebound damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting knob “1” in direction “a” or
Spring preload adjusting posi-
“b”.
tions
Installed spring length
Direction “a” (turn in)
Minimum
Rebound damping is increased (sus-
155.0 mm (6.10 in)
pension is harder).
Standard
Direction “b” (turn out)
150.0 mm (5.91 in)
Rebound damping is decreased (sus-
Maximum
pension is softer).
145.0 mm (5.71 in)
3-29
CHASSIS
Rebound damping adjusting posi-

tions
Minimum
20 click(s) out* b a
Standard
12 click(s) out*
Maximum
3 click(s) out* 1
* With the adjusting knob fully turned in
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21650
CHECKING THE TIRES

a tires.
1. Check:
• Tire pressure
b Out of specification → Regulate.
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Compression damping
ECA13590
CAUTION:
1. Adjust:
• Compression damping EWA13180
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ WARNING
a. Turn the adjusting screw “1” in direction “a” or
• The tire pressure should only be checked
“b”.
and regulated when the tire temperature
Direction “a” (turn in) equals the ambient air temperature.
Compression damping is increased • The tire pressure and the suspension must
(suspension is harder). be adjusted according to the total weight
Direction “b” (turn out) (including cargo, rider, passenger and ac-
Compression damping is decreased cessories) and the anticipated riding
(suspension is softer). speed.
• Operation of an overloaded vehicle could
cause tire damage, an accident or an injury.
Compression damping adjusting NEVER OVERLOAD THE VEHICLE.
positions
Minimum
12 click(s) out*
Standard
10 click(s) out*
Maximum
1 click(s) out*
* With the adjusting screw fully turned in
3-30
CHASSIS
EWA14080
Tire air pressure (measured on WARNING

cold tires) • Do not use a tubeless tire on a wheel de-
Loading condition signed only for tube tires to avoid tire fail-
0–90 kg (0–198 lb) ure and personal injury from sudden
Front deflation.
250 kPa (36 psi) (2.50 kgf/cm²)
• When using a tube tire, be sure to install the
Rear
290 kPa (42 psi) (2.90 kgf/cm²) correct tube.
Loading condition • Always replace a new tube tire and a new
90–199 kg (198–439 lb) tube as a set.
Front • To avoid pinching the tube, make sure the
250 kPa (36 psi) (2.50 kgf/cm²) wheel rim band and tube are centered in the
Rear wheel groove.
290 kPa (42 psi) (2.90 kgf/cm²) • Patching a punctured tube is not recom-
High-speed riding mended. If it is absolutely necessary to do
Front so, use great care and replace the tube as
250 kPa (36 psi) (2.50 kgf/cm²) soon as possible with a good quality re-
Rear placement.
290 kPa (42 psi) (2.90 kgf/cm²)
Maximum load
199 kg (439 lb)
* Total weight of rider, passenger, cargo
and accessories
EWA13190
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit, re-
place the tire immediately.
2. Check: A. Tire
• Tire surfaces B. Wheel
Damage/wear → Replace the tire.
Tube wheel Tube tire only
Wear limit (front)
1.6 mm (0.06 in) Tubeless wheel Tube or tubeless tire
Wear limit (rear) EWA14090
1.6 mm (0.06 in) WARNING
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufacturer
and of the same design. No guarantee con-
cerning handling characteristics can be giv-
en if a tire combination other than one
approved by Yamaha is used on this vehicle.
Front tire
Size
1. Tire tread depth 120/70 ZR17 M/C (58W)
2. Side wall Manufacturer/model
3. Wear indicator METZELER/ROADTEC Z6 E
FRONT
MICHELIN/PILOT ROAD S
3-31
CHASSIS
EWA13270
Rear tire WARNING

Size Damaged outer cable may cause the cable to
190/50 ZR17 M/C (73W) corrode and interfere with its movement. Re-
Manufacturer/model place damaged outer cable and inner cables
METZELER/ROADTEC Z6 E as soon as possible.
MICHELIN/PILOT ROAD
1. Check:
EWA13210
• Outer cable
WARNING Damage → Replace.
New tires have a relatively low grip on the 2. Check:
road surface until they have been slightly • Cable operation
worn. Therefore, approximately 100 km Rough movement → Lubricate.
should be traveled at normal speed before
any high-speed riding is done. Recommended lubricant
Engine oil or a suitable cable lu-
NOTE: bricant
For tires with a direction of rotation mark “1”:
• Install the tire with the mark pointing in the di- NOTE:
rection of wheel rotation. Hold the cable end upright and pour a few drops
• Align the mark “2” with the valve installation of lubricant into the cable sheath or use a suit-
point. able lubricating device.
EAS21700
LUBRICATING THE LEVERS

Lubricate the pivoting point and metal-to-metal
moving parts of the levers.
Recommended lubricant
Lithium-soap-based grease
EAS21710
LUBRICATING THE PEDAL

EAS21670
moving parts of the pedal.
CHECKING THE WHEELS
The following procedure applies to both of the Recommended lubricant
wheels. Lithium-soap-based grease
1. Check:
• Wheel EAS21720
Damage/out-of-round → Replace. LUBRICATING THE SIDESTAND

EWA13260
WARNING moving parts of the sidestand.
Never attempt to make any repairs to the
wheel. Recommended lubricant
NOTE:
After a tire or wheel has been changed or re- EAS21740
placed, always balance the wheel. LUBRICATING THE REAR SUSPENSION

EAS21690
moving parts of the rear suspension.
CHECKING AND LUBRICATING THE
CABLES Recommended lubricant
The following procedure applies to all of the in- Lithium-soap-based grease
ner and outer cables.
3-32
ELECTRICAL SYSTEM
EAS21750 ECA13690
ELECTRICAL SYSTEM CAUTION:

Avoid touching the glass part of the head-
EAS21760
CHECKING AND CHARGING THE BATTERY light bulb to keep it free from oil, otherwise
Refer to “ELECTRICAL COMPONENTS” on the transparency of the glass, the life of the
page 7-85. bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
EAS21770
thoroughly clean it with a cloth moistened
CHECKING THE FUSES with alcohol or lacquer thinner.
Refer to “ELECTRICAL COMPONENTS” on
page 7-85. d. Connect:
• Headlight coupler
EAS21790
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
REPLACING THE HEADLIGHT BULBS
1. Remove: 3. Replace:
• Headlight assembly bolts “1” • High beam headlight bulb
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove:
• Headlight bulb cover “1”
1
1
2. Replace:
• Low beam headlight bulb
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect: b. Disconnect:
• Headlight coupler “1” • Headlight coupler “1”
b. Remove: c. Detach:
• Headlight bulb “2” • Headlight bulb holder “2”
EWA13320
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
1 2
2
1
d. Remove:
• Headlight bulb
EWA13320
WARNING
Since the headlight bulb gets extremely hot,
c. Install: away from the bulb until it has cooled down.
• Headlight bulb New e. Install:
Secure the new headlight bulb with the head-
light bulb holder.
3-33
ELECTRICAL SYSTEM
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Headlight bulb New
Secure the new headlight bulb with the head-
“b”.
light bulb holder.
ECA13690
CAUTION: Direction “a”

Headlight beam moves to the right.
Avoid touching the glass part of the head- Direction “b”
light bulb to keep it free from oil, otherwise Headlight beam moves to the left.
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.
f. Attach: b
• Headlight bulb holder 1
g. Connect: a
• Headlight coupler
h. Install:
• Headlight bulb cover
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• Headlight assembly
Headlight assembly bolt

7 Nm (0.7 m·kg, 5.1 ft·lb)
T.
R.
EAS21810
ADJUSTING THE HEADLIGHT BEAM

1. Adjust:
• Headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
“b”.
Direction “a”
Headlight beam is raised.
Direction “b”
Headlight beam is lowered.
b
1
a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
• Headlight beam (horizontally)
3-34
ELECTRICAL SYSTEM
3-35
CHASSIS
GENERAL CHASSIS....................................................................................... 4-1

CHECKING THE AIR FILTER CASE VALVE............................................ 4-5
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
CHECKING THE FRONT BRAKE DISCS............................................... 4-10
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) ............... 4-10
REAR WHEEL ............................................................................................... 4-12

REMOVING THE REAR WHEEL ............................................................ 4-15
DISASSEMBLING THE REAR WHEEL .................................................. 4-15
CHECKING THE REAR WHEEL............................................................. 4-15
CHECKING THE REAR WHEEL DRIVE HUB ........................................ 4-15
CHECKING AND REPLACING THE REAR WHEEL SPROCKET ......... 4-15
ASSEMBLING THE REAR WHEEL ........................................................ 4-16
ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-16
4
CHECKING THE REAR BRAKE DISC.................................................... 4-16
INSTALLING THE REAR WHEEL (REAR BRAKE DISC) ...................... 4-16
FRONT BRAKE ............................................................................................. 4-18

INTRODUCTION ..................................................................................... 4-23
CHECKING THE FRONT BRAKE DISCS............................................... 4-23
REPLACING THE FRONT BRAKE PADS .............................................. 4-24
REMOVING THE FRONT BRAKE CALIPERS ....................................... 4-25
DISASSEMBLING THE FRONT BRAKE CALIPERS.............................. 4-25
CHECKING THE FRONT BRAKE CALIPERS ........................................ 4-26
ASSEMBLING THE FRONT BRAKE CALIPERS.................................... 4-26
INSTALLING THE FRONT BRAKE CALIPERS ...................................... 4-26
REMOVING THE FRONT BRAKE MASTER CYLINDER ....................... 4-27
CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 4-27
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-28
INSTALLING THE FRONT BRAKE MASTER CYLINDER...................... 4-28
REAR BRAKE ............................................................................................... 4-30
INTRODUCTION ..................................................................................... 4-35
CHECKING THE REAR BRAKE DISC.................................................... 4-35
REPLACING THE REAR BRAKE PADS................................................. 4-35
REMOVING THE REAR BRAKE CALIPER ............................................ 4-36
DISASSEMBLING THE REAR BRAKE CALIPER .................................. 4-36
CHECKING THE REAR BRAKE CALIPER............................................. 4-37
ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-37
INSTALLING THE REAR BRAKE CALIPER........................................... 4-38
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-39
CHECKING THE REAR BRAKE MASTER CYLINDER .......................... 4-39
ASSEMBLING THE REAR BRAKE MASTER CYLINDER...................... 4-39
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-39
HANDLEBAR ................................................................................................ 4-41

REMOVING THE HANDLEBAR.............................................................. 4-43
CHECKING THE HANDLEBAR .............................................................. 4-43
INSTALLING THE HANDLEBAR ............................................................ 4-43
FRONT FORK................................................................................................ 4-46

REMOVING THE FRONT FORK LEGS.................................................. 4-49
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-49
CHECKING THE FRONT FORK LEGS .................................................. 4-50
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-51
INSTALLING THE FRONT FORK LEGS ................................................ 4-55
STEERING HEAD.......................................................................................... 4-56

REMOVING THE LOWER BRACKET..................................................... 4-58
CHECKING THE STEERING HEAD ....................................................... 4-58
INSTALLING THE STEERING HEAD ..................................................... 4-58
REAR SHOCK ABSORBER ASSEMBLY .................................................... 4-60

HANDLING THE REAR SHOCK ABSORBER ........................................ 4-61
DISPOSING OF A REAR SHOCK ABSORBER ..................................... 4-61
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY................... 4-61
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-61
CHECKING THE CONNECTING ARM AND RELAY ARM..................... 4-61
INSTALLING THE CONNECTING ARM AND RELAY ARM................... 4-62
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ................. 4-63
SWINGARM................................................................................................... 4-64
REMOVING THE SWINGARM................................................................ 4-66
CHECKING THE SWINGARM ................................................................ 4-66
INSTALLING THE SWINGARM .............................................................. 4-66
CHAIN DRIVE................................................................................................ 4-68
REMOVING THE DRIVE CHAIN............................................................. 4-69
CHECKING THE DRIVE CHAIN ............................................................. 4-69
CHECKING THE DRIVE SPROCKET..................................................... 4-70
CHECKING THE REAR WHEEL SPROCKET........................................ 4-70
CHECKING THE REAR WHEEL DRIVE HUB ........................................ 4-70
INSTALLING THE DRIVE CHAIN ........................................................... 4-70
GENERAL CHASSIS
EAS21830
GENERAL CHASSIS
Removing the seat and battery
5 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
6
4 1
8
9
7 3
10 Nm (1.0 m • kg, 7.2 ft • Ib) 2

T.
R.
(4)
LT
Order Job/Parts to remove Q’ty Remarks

1 Seat 1
2 Lead holder 1
3 Negative battery lead 1 Disconnect.
4 Positive battery lead 1 Disconnect.
5 Main fuse 1
6 Battery band 1
7 Battery 1
8 Battery seat 1
9 Battery box 1
For installation, reverse the removal proce-
dure.
4-1
GENERAL CHASSIS
Removing the side covers and headlight assembly

9 Nm (0.9 m • kg, 6.5 ft • Ib)
T.
R.
LT
2 9 Nm (0.9 m • kg, 6.5 ft • Ib)
T.
R.
LT 4
LT
79
8
3
1
LT
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
10
5
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
6
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.

1 Left side cover 1
2 Right side cover 1
3 Left side cover inner panel 1
4 Right side cover inner panel 1
5 Air duct 1
6 Bottom cover 1
7 Sub-wire harness 3 coupler (wire harness side) 1 Disconnect.
8 Headlight assembly coupler 1 Disconnect.
9 Air temperature sensor coupler 1 Disconnect.
10 Headlight assembly 1
dure.
4-2
GENERAL CHASSIS
Removing the tail/brake light assembly
7 Nm (0.7 m • kg, 5.1 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
T.
R.
R.
6
1
2
345
LT

Refer to “GENERAL CHASSIS” on page
Seat 4-1.
1 Muffler cooling fan motor coupler 1 Disconnect.
2 Tail/brake light coupler 1 Disconnect.
3 Rear right turn signal light coupler 1 Disconnect.
4 Rear left turn signal light coupler 1 Disconnect.
5 License plate light coupler 1 Disconnect.
6 Tail/brake light assembly 1
7 Muffler cooling fan motor assembly 1
dure.
4-3
GENERAL CHASSIS
Removing the air filter case and oil catch tank

10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 (5)
T.
R.
1
6
2
8 5 5
7
12
3 LT
11 9 Nm (0.9 m • kg, 6.5 ft • Ib)

T.
R.

Fuel tank Refer to “FUEL TANK” on page 6-1.
1 Air filter case cover 1
2 Air filter element 1
Cylinder head breather hose (air filter case to oil
3 1
catch tank)
Cylinder head breather hose (cylinder head to
4 1
oil catch tank)
5 Air filter case joint clamp screw 2 Loosen.
6 Air filter case bracket 1
7 ISC (idle speed control) unit inlet hose 1 Disconnect.
Intake solenoid vacuum hose (air filter case
8 1 Disconnect.
valve to intake solenoid)
9 Air filter case 1
10 Air filter case valve 1
11 Oil catch tank breather hose 1
12 Oil catch tank 1
dure.
4-4
GENERAL CHASSIS
ET5YU1013
CHECKING THE AIR FILTER CASE VALVE

1. Check:
• Air filter case valve operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the air filter case (with the air filter
case valve).
b. Connect the vacuum/pressure pump gauge
set “1” to the air filter case valve “2”.
Vacuum/pressure pump gauge

set
90890-06756
Mityvac brake bleeding tool
YS-42423
c. Check that the air filter case valve operates

when vacuum pressure is applied to the valve
using the vacuum/pressure pump gauge set.
Faulty → Replace the air filter case valve.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-5
FRONT WHEEL
EAS21870
FRONT WHEEL
Removing the front wheel and brake discs
35 Nm (3.5 m • kg, 25 ft • Ib) 35 Nm (3.5 m • kg, 25 ft • Ib)
T.
R.
T.
R.
1
6 Nm (0.6 m • kg, 4.3 ft • Ib)

T.
R.
2 1
72 Nm (7.2 m • kg, 52 ft • lb)

T.
R.
4
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
3 6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.
R.
6 7
(6)
7
LT
6
8
(6)
18 Nm (1.8 m • kg, 13 ft • Ib)

8
18 Nm (1.8 m • kg, 13 ft • Ib)
T.
LT
R.
5
T.
R.

1 Front brake hose holder 2
2 Front brake caliper 2
3 Front wheel axle pinch bolt 1 Loosen.
4 Front wheel axle 1
5 Front wheel 1
6 Collar 2
7 Dust cover 2
8 Front brake disc 2
dure.
4-6
FRONT WHEEL
Disassembling the front wheel
New 1
2
LS
3
2
1 New
LS

1 Oil seal 2
2 Wheel bearing 2
3 Spacer 1
For assembly, reverse the disassembly pro-
cedure.
4-7
FRONT WHEEL
EAS21900 EAS21920
REMOVING THE FRONT WHEEL CHECKING THE FRONT WHEEL

1. Stand the vehicle on a level surface. 1. Check:
EWA13120
• Front 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.
2. Remove:
• Front brake calipers
NOTE:
Do not apply the brake lever when removing the
front brake calipers.
EAS21910
DISASSEMBLING THE FRONT WHEEL

1. Remove:
• Oil seals
• Wheel bearings 2. Check:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Tire
a. Clean the outside of the front wheel hub. • Front wheel
b. Remove the oil seals “1” with a flat-head Damage/wear → Replace.
screwdriver. Refer to “CHECKING THE TIRES” on page
NOTE: 3-30 and “CHECKING THE WHEELS” on
page 3-32.
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-8
FRONT WHEEL
2. Find:
• Front wheel’s heavy spot
NOTE:
Place the front wheel on a suitable balancing
stand.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Spin the front wheel.
b. When the front wheel stops, put an “X1” mark
at the bottom of the wheel.
• Oil seals
Damage/wear → Replace.
EAS21960
ASSEMBLING THE FRONT WHEEL

1. Install:
• Wheel bearings New
• Oil seals New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the new wheel bearings and oil seals in
the reverse order of disassembly. c. Turn the front wheel 90° so that the “X1” mark
EC5YU1001
is positioned as shown.
CAUTION:
d. Release the front wheel.
Do not contact the wheel bearing inner race e. When the wheel stops, put an “X2” mark at
“1” or balls “2”. Contact should be made
the bottom of the wheel.
only with the outer race “3”.
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)
4-9
FRONT WHEEL
EAS22000
INSTALLING THE FRONT WHEEL (FRONT

BRAKE DISCS)
front brake discs.
1. Install:
• Front brake disc
Front brake disc bolt

18 Nm (1.8 m·kg, 13 ft·lb)
T.
R.
LOCTITE®
b. Turn the front wheel 90° so that the heavy
spot is positioned as shown. NOTE:
Tighten the brake disc bolts in stages and in a
crisscross pattern.
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
2. Check:
is balanced.
• Front brake discs
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Refer to “CHECKING THE FRONT BRAKE
4. Check: DISCS” on page 4-23.
• Front wheel static balance 3. Lubricate:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Oil seal lips
a. Turn the front wheel and make sure it stays at
• Collars
each position shown.
4. Install:
• Front wheel
NOTE:
Install the tire and wheel with the mark “1” point-
ing in the direction of wheel rotation.
b. If the front wheel does not remain stationary

at all of the positions, rebalance it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET5YU1001
CHECKING THE FRONT BRAKE DISCS

DISCS” on page 4-23.
4-10
FRONT WHEEL
5. Tighten:
• Front wheel axle
Front wheel axle

72 Nm (7.2 m·kg, 52 ft·lb)
T.
R.
• Front wheel axle pinch bolt
Front wheel axle pinch bolt

23 Nm (2.3 m·kg, 17 ft·lb)
T.
R.
EC5YU1002
CAUTION:
Before tightening the wheel axle, push down
hard on the handlebar several times and
check if the front fork rebounds smoothly.
6. Install:
• Front brake calipers
Front brake caliper bolt

35 Nm (3.5 m·kg, 25 ft·lb)
T.
R.
EWA13500
WARNING
Make sure the brake hose is routed properly.
NOTE:
Make sure that there is enough space between
the brake pads before installing the brake cali-
pers onto the brake discs.
4-11
REAR WHEEL
EAS22020
REAR WHEEL
Removing the rear wheel
10
6
8
1
LS
7
5
4
LT
9
27 Nm (2.7 m • kg, 19 ft • Ib)

T.
R.
22 Nm (2.2 m • kg, 16 ft • Ib)

T.
R.
2
150 Nm (15.0 m • kg, 110 ft • lb)
T.
R.
16 Nm (1.6 m • kg, 11 ft • Ib)

T.
R.
NOTE:
Place the vehicle on a suitable stand so that
the rear wheel is elevated.
1 Rear brake caliper 1

2 Drive chain adjusting locknut 2 Loosen.
3 Drive chain adjusting bolt 2 Loosen.
4 Rear wheel axle nut 1
5 Washer 1
6 Rear wheel axle 1
7 Left drive chain puller 1
8 Right drive chain puller 1
9 Rear brake caliper bracket 1
10 Rear wheel 1
dure.
4-12
REAR WHEEL
Removing the rear brake disc and rear wheel sprocket
4 100 Nm (10.0 m • kg, 72 ft • lb)
T.
R.
5
6
7
(6) 2
New 8
LS 9
LT
LS
5
3
(6)
LT
18 Nm (1.8 m • kg, 13 ft • Ib)

T.
R.

1 Rear brake disc 1
2 Rear wheel sprocket 1
3 Collar (brake disc side) 1
4 Collar (wheel sprocket side) 1
5 Dust cover 2
6 Oil seal 1
7 Bearing 1
8 Rear wheel drive hub 1
9 Rear wheel drive hub damper 6
dure.
4-13
REAR WHEEL
Disassembling the rear wheel
LS
1
2
3
6
5
4
New
LS

1 Collar 1
2 Bearing 1
3 Spacer 1
4 Oil seal 1
5 Circlip 1
6 Bearing 1
cedure.
4-14
REAR WHEEL
EAS22040 EAS22090
REMOVING THE REAR WHEEL CHECKING THE REAR WHEEL

EWA13120
• Rear wheel axle
WARNING • Rear wheel
Securely support the vehicle so that there is • Wheel bearings
no danger of it falling over. • Oil seals
Refer to “CHECKING THE FRONT WHEEL”
NOTE:
on page 4-8.
2. Check:
rear wheel is elevated. • Tire
2. Remove: • Rear wheel
• Rear brake caliper “1” Damage/wear → Replace.
NOTE: Refer to “CHECKING THE TIRES” on page
Do not depress the brake pedal when removing 3-30 and “CHECKING THE WHEELS” on
the rear brake caliper. page 3-32.
3. Measure:
• Radial wheel runout
• Lateral wheel runout
Refer to “CHECKING THE FRONT WHEEL”
on page 4-8.
Radial wheel runout limit

1 1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
EAS22110
3. Remove: CHECKING THE REAR WHEEL DRIVE HUB

• Rear wheel axle nut “1” 1. Check:
• Rear wheel axle “2” • Rear wheel drive hub
• Rear wheel Cracks/damage → Replace.
NOTE: • Rear wheel drive hub dampers
Push the rear wheel forward and remove the Damage/wear → Replace.
drive chain from the rear wheel sprocket. EAS22120
CHECKING AND REPLACING THE REAR

WHEEL SPROCKET
1 1. Check:
• Rear wheel sprocket
More than 1/4 tooth “a” wear → Replace the
2
rear wheel sprocket.
Bent teeth → Replace the rear wheel sprock-
et.
EAS22080
DISASSEMBLING THE REAR WHEEL

1. Remove:
• Oil seals
• Wheel bearings
Refer to “DISASSEMBLING THE FRONT
WHEEL” on page 4-8.
4-15
REAR WHEEL
EAS22150
ADJUSTING THE REAR WHEEL STATIC

BALANCE
NOTE:
• After replacing the tire, wheel or both, the rear
wheel static balance should be adjusted.
• Adjust the rear wheel static balance with the
brake disc and rear wheel drive hub installed.
1. Adjust:
• Rear wheel static balance
b. Correct Refer to “ADJUSTING THE FRONT WHEEL
1. Drive chain roller STATIC BALANCE” on page 4-9.
2. Rear wheel sprocket ET5YU1026
2. Replace: CHECKING THE REAR BRAKE DISC

• Rear wheel sprocket Refer to “CHECKING THE REAR BRAKE
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
DISC” on page 4-35.
a. Remove the self-locking nuts and the rear EAS22160
wheel sprocket. INSTALLING THE REAR WHEEL (REAR
b. Clean the rear wheel drive hub with a clean BRAKE DISC)
cloth, especially the surfaces that contact the 1. Install:
sprocket. • Rear brake disc
c. Install the new rear wheel sprocket.
Rear brake disc bolt
Rear wheel sprocket self-locking 18 Nm (1.8 m·kg, 13 ft·lb)
T.
R.
nut LOCTITE®
T.
R.
100 Nm (10 m·kg, 72 ft·lb)

NOTE:
NOTE:
Tighten the brake disc bolts in stages and in a
Tighten the self-locking nuts in stages and in a crisscross pattern.
crisscross pattern.
2. Check:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Rear brake disc
EAS22140 Refer to “CHECKING THE REAR BRAKE
ASSEMBLING THE REAR WHEEL DISC” on page 4-35.
1. Install: 3. Lubricate:
• Wheel bearings New • Oil seal lips
• Oil seals New • Collars
Refer to “ASSEMBLING THE FRONT Recommended lubricant
WHEEL” on page 4-9. Lithium-soap-based grease
4. Install:
• Collar (wheel sprocket side) “1”
4-16
REAR WHEEL
• Collar (brake disc side) “2”

NOTE:
The collar (brake disc side) has marks “a” to dis-
tinguish it from the collar (wheel sprocket side).
a
1 2
5. Adjust:
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” on page 3-25.
Drive chain slack

40.0–50.0 mm (1.57–1.97 in)
6. Install:
• Rear brake caliper
Rear brake caliper bolt (M12)

27 Nm (2.7 m·kg, 19 ft·lb)
T.
R.

22 Nm (2.2 m·kg, 16 ft·lb)
LOCTITE®
EWA13500
WARNING
Make sure the brake hose is routed properly.
4-17
FRONT BRAKE
EAS22210
FRONT BRAKE
Removing the front brake pads
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.
R.
35 Nm (3.5 m • kg, 25 ft • Ib)
T.
R.
1
6 4
2 3
5 4

The following procedure applies to both of
the front brake calipers.
1 Brake hose holder 1
3 Brake pad clip 4
4 Brake pad pin 2
5 Brake pad spring 2
6 Front brake pad 4
dure.
4-18
FRONT BRAKE
Removing the front brake master cylinder
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
1
2
11
3
4
∗ 12
6
13 Nm (1.3 m • kg, 9.4 ft • Ib)
New 9
T.
R.
10
8 7
30 Nm (3.0 m • kg, 22 ft • Ib)

T.
R.

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-23.
1 Right rearview mirror 1
2 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm hold-
3 1
er
4 Brake master cylinder reservoir diaphragm 1
5 Brake lever 1
6 Front brake light switch connector 2 Disconnect.
7 Front brake light switch 1
8 Front brake hose union bolt 1
9 Copper washer 2
10 Front brake hose 1
11 Front brake master cylinder holder 1
12 Front brake master cylinder 1
dure.
* Apply silicone grease.
4-19
FRONT BRAKE
Disassembling the front brake master cylinder
New 1
LS
1 New

1 Brake master cylinder kit 1
2 Brake master cylinder body 1
cedure.
4-20
FRONT BRAKE
Removing the front brake calipers

35 Nm (3.5 m • kg, 25 ft • Ib)
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
R.
3
2 New

Drain.
1 Front brake hose union bolt 1
2 Copper washer 2
3 Front brake hose 1
dure.
4-21
FRONT BRAKE
Disassembling the front brake calipers
6 Nm (0.6 m • kg, 4.3 ft • Ib) 7 3
T.
R.
5 ∗
6 New 3
6 New 4
∗
1
2
5
1
∗ 6 New
2
New 6 ∗
New 6
∗
5
New 6
∗

1 Brake pad clip 4
2 Brake pad pin 2
4 Front brake pad 4
5 Brake caliper piston 6
6 Brake caliper piston seal 12
7 Bleed screw 1
cedure.
4-22
FRONT BRAKE
EAS22220
INTRODUCTION
EWA14100
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, e. Measure the deflection 1.5 mm (0.06 in) be-
cleaned, properly filled, and bled after reas- low the edge of the brake disc.
sembly. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Never use solvents on internal brake com- 4. Measure:
ponents. • Brake disc thickness
• Use only clean or new brake fluid for clean- Measure the brake disc thickness at a few dif-
ing brake components. ferent locations.
• Brake fluid may damage painted surfaces Out of specification → Replace.
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately. Brake disc thickness limit
• Avoid brake fluid coming into contact with 5.0 mm (0.20 in)
the eyes as it can cause serious injury.
• FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get im-
mediate medical attention.
EAS22240
CHECKING THE FRONT BRAKE DISCS

The following procedure applies to both brake
discs.
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.
Out of specification → Correct the brake disc Front brake disc bolt
deflection or replace the brake disc. 18 Nm (1.8 m·kg, 13 ft·lb)
T.
R.
LOCTITE®
Brake disc deflection limit
0.10 mm (0.0039 in)
NOTE:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Tighten the brake disc bolts in stages and in a
a. Place the vehicle on a suitable stand so that crisscross pattern.
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.
4-23
FRONT BRAKE
a a
d. Measure the brake disc deflection. 2. Install:

e. If out of specification, repeat the adjustment • Brake pads
steps until the brake disc deflection is within • Brake pad springs
specification. NOTE:
f. If the brake disc deflection cannot be brought Always install new brake pads and brake pad
within specification, replace the brake disc. springs as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
6. Install: a. Connect a clear plastic hose “1” tightly to the
• Front wheel bleed screw “2”. Put the other end of the hose
Refer to “FRONT WHEEL” on page 4-6. into an open container.
EAS22270 b. Loosen the bleed screw and push the brake
REPLACING THE FRONT BRAKE PADS caliper pistons into the brake caliper with your
The following procedure applies to both brake finger.
calipers.
NOTE: 2
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem- 1
ble the brake caliper.
1. Measure:
• Brake pad wear limit “a”
Out of specification → Replace the brake
pads as a set.
Brake pad lining thickness (in- c. Tighten the bleed screw.

ner)
4.5 mm (0.18 in) Bleed screw (front brake caliper)
Limit 6 Nm (0.6 m·kg, 4.3 ft·lb)
T.
R.
0.8 mm (0.03 in)

Brake pad lining thickness (out- d. Install new brake pads and new brake pad
er) springs.
4.5 mm (0.18 in) NOTE:
Limit The arrow marks “a” on the brake pad springs
0.8 mm (0.03 in)
must point in the direction of disc rotation.
4-24
FRONT BRAKE
• Copper washers “3”

a • Front brake hose “4”
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
a 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install: 2
• Brake pad pins 3
• Brake pad clips
• Front brake caliper
Front brake caliper bolt EAS22350
35 Nm (3.5 m·kg, 25 ft·lb) DISASSEMBLING THE FRONT BRAKE

T.
R.
CALIPERS
4. Check: The following procedure applies to both of the
• Brake fluid level brake calipers.
Below the minimum level mark “a” → Add the 1. Remove:
recommended brake fluid to the proper level. • Brake caliper pistons “1”
Refer to “CHECKING THE BRAKE FLUID • Brake caliper piston seals “2”
EW5YU1006
WARNING
Do not loosen the bolts.
1 2 1
2
a
2 2
1
1
5. Check: 2 2
• Brake lever operation
Soft or spongy feeling → Bleed the brake sys- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
tem. a. Blow compressed air into the brake hose joint
Refer to “BLEEDING THE HYDRAULIC opening “a” to force out the piston from the
BRAKE SYSTEM” on page 3-23. brake caliper.
EWA13580
EAS22300 WARNING
REMOVING THE FRONT BRAKE CALIPERS
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
brake calipers.
ton is expelled from the brake master cylin-
NOTE: der.
Before removing the brake caliper, drain the • Never try to pry out the brake caliper pis-
brake fluid from the entire brake system. ton.
1. Remove:
• Brake hose holder “1”
• Front brake hose union bolt “2”
4-25
FRONT BRAKE
EAS22410
ASSEMBLING THE FRONT BRAKE

a CALIPERS
EWA13620
WARNING
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake com-
ponents as they will cause the piston seals
to swell and distort.
b. Remove the brake caliper piston seals. • Whenever a brake caliper is disassembled,
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ replace the brake caliper piston seals.
EAS22390
CHECKING THE FRONT BRAKE CALIPERS Recommended fluid

DOT 4
Recommended brake component replace-
ment schedule
EAS22450
Brake pads If necessary INSTALLING THE FRONT BRAKE CALIPERS

Piston seals Every two years
brake calipers.
Brake hoses Every four years 1. Install:
Every two years and • Front brake caliper “1”
Brake fluid whenever the brake (temporarily)
is disassembled
• Copper washers New
1. Check: • Front brake hose “2”
• Brake caliper pistons “1” • Front brake hose union bolt “3”
Rust/scratches/wear → Replace the brake
Front brake hose union bolt
caliper pistons.
30 Nm (3.0 m·kg, 22 ft·lb)
T.
• Brake caliper cylinders “2”

R.
Scratches/wear → Replace the brake caliper EWA13530
assembly. WARNING
• Brake caliper body “3” Proper brake hose routing is essential to in-
Cracks/damage → Replace the brake caliper sure safe vehicle operation. Refer to “CABLE
assembly. ROUTING” on page 2-41.
• Brake fluid delivery passages ECA14170
(brake caliper body) CAUTION:
Obstruction → Blow out with compressed air.
EWA13600
When installing the brake hose onto the
WARNING brake caliper “1”, make sure the brake pipe
“a” touches the projection “b” on the brake
Whenever a brake caliper is disassembled,
caliper.
replace the piston seals.
3 2
a b
2
1 3
2 1
1 1
4-26
FRONT BRAKE
2. Remove:
3. Install:
• Front brake pads
• Brake pad springs
• Brake pad pins a
• Brake pad clips
Front brake caliper bolt

35 Nm (3.5 m·kg, 25 ft·lb)
T.
R.
7. Check:
Refer to “REPLACING THE FRONT BRAKE • Brake lever operation
PADS” on page 4-24. Soft or spongy feeling → Bleed the brake sys-
4. Fill: tem.
• Brake master cylinder reservoir Refer to “BLEEDING THE HYDRAULIC
(with the specified amount of the recom- BRAKE SYSTEM” on page 3-23.
mended brake fluid) EAS22490
REMOVING THE FRONT BRAKE MASTER

Recommended fluid
CYLINDER
DOT 4
NOTE:
EWA13090
Before removing the front brake master cylinder,
WARNING drain the brake fluid from the entire brake sys-
• Use only the designated brake fluid. Other tem.
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor 1. Remove:
brake performance. • Front brake hose union bolt “1”
• Refill with the same type of brake fluid that • Copper washers “2”
is already in the system. Mixing brake fluids • Front brake hose “3”
may result in a harmful chemical reaction, NOTE:
leading to poor brake performance. To collect any remaining brake fluid, place a
• When refilling, be careful that water does container under the master cylinder and the end
not enter the brake fluid reservoir. Water of the brake hose.
the brake fluid and could cause vapor lock.
ECA13540 1
CAUTION: 3
and plastic parts. Therefore, always clean up
5. Bleed:
• Brake system 2
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-23. EAS22510
6. Check: CHECKING THE FRONT BRAKE MASTER
• Brake fluid level CYLINDER
Below the minimum level mark “a” → Add the 1. Check:
recommended brake fluid to the proper level. • Brake master cylinder
Refer to “CHECKING THE BRAKE FLUID Damage/scratches/wear → Replace.
LEVEL” on page 3-21. • Brake fluid delivery passages
(brake master cylinder body)
4-27
FRONT BRAKE
• Brake master cylinder kit • Copper washers New
Damage/scratches/wear → Replace. • Front brake hose “1”
3. Check: • Front brake hose union bolt “2”
• Brake master cylinder reservoir
Cracks/damage → Replace. Front brake hose union bolt
• Brake master cylinder reservoir diaphragm 30 Nm (3.0 m·kg, 22 ft·lb)
T.
R.
EWA13530
4. Check:
WARNING
• Brake hose
Cracks/damage/wear → Replace. Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CABLE
EAS22520
ROUTING” on page 2-41.
ASSEMBLING THE FRONT BRAKE MASTER
CYLINDER NOTE:
EWA13520
• Install the brake hose at 40–50° angle “a” to the
WARNING
front brake master cylinder as shown in the il-
• Before installation, all internal brake com- lustration.
ponents should be cleaned and lubricated • While holding the brake hose, tighten the union
with clean or new brake fluid. bolt.
• Never use solvents on internal brake com- • Turn the handlebar to the left and right to make
ponents. sure the brake hose does not touch other parts
(e.g., wire harness, cables, leads). Correct if
Recommended fluid necessary.
DOT 4
EAS22540
INSTALLING THE FRONT BRAKE MASTER

CYLINDER a
1. Install:
• Front brake master cylinder “1”
• Front brake master cylinder holder “2”
2
Front brake master cylinder hold- 1
er bolt
T.
R.
10 Nm (1.0 m·kg, 7.2 ft·lb)

3. Fill:
NOTE: • Brake master cylinder reservoir
• The front brake master cylinder holder should (with the specified amount of the recom-
be installed with the punch mark “a” forward. mended brake fluid)
• Align the end of the brake master cylinder hold- Recommended fluid
er with the punch mark “b” on the handlebar. DOT 4
• First, tighten the front bolt, then the rear bolt.
EWA13090
a 1 WARNING
brake performance.
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
b 2
leading to poor brake performance.
4-28
FRONT BRAKE

not enter the brake fluid reservoir. Water
ECA13540
CAUTION:
4. Bleed:
• Brake system
5. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the
recommended brake fluid to the proper level.
6. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
tem.
4-29
REAR BRAKE
EAS22550
REAR BRAKE
Removing the rear brake pads
17 Nm (1.7 m • kg, 12 ft • Ib)
T.
R.
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.
R.
3
2
1
7 LS
4
5 LT
27 Nm (2.7 m • kg, 19 ft • Ib)
T.
R.
7 22 Nm (2.2 m • kg, 16 ft • Ib)

T.
R.
6
3 Nm (0.3 m • kg, 2.2 ft • Ib)
5
T.
R.

1 Screw plug 1
2 Brake pad pin 1
4 Brake pad shim 2
5 Brake pad insulator 2
6 Rear brake pad 2
dure.
4-30
REAR BRAKE
Removing the rear brake master cylinder
2
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
3
1 4
5
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
6
23 Nm (2.3 m • kg, 17 ft • Ib)

T.
R.
New
10
9
7
8 New 30 Nm (3.0 m • kg, 22 ft • Ib)

T.
R.

Drain.
Seat/Battery box/Lead holder 4-1.
Drive sprocket cover Refer to “CHAIN DRIVE” on page 4-68.
1 Brake fluid reservoir cap holder 1
2 Brake fluid reservoir cap 1
3 Brake fluid reservoir diaphragm holder 1
4 Brake fluid reservoir diaphragm 1
5 Brake fluid reservoir 1
6 Brake fluid reservoir hose 1
7 Rear brake hose union bolt 1
8 Copper washer 2
9 Rear brake hose 1
10 Rear brake master cylinder 1
dure.
4-31
REAR BRAKE
Disassembling the rear brake master cylinder

1 Brake master cylinder kit 1
2 Brake hose joint 1
3 Bush 1
4 Brake master cylinder body 1
cedure.
4-32
REAR BRAKE
Removing the rear brake caliper
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
R.
1
2 New
22 Nm (2.2 m • kg, 16 ft • Ib)
T.
R.
4
3 LT
LS
27 Nm (2.7 m • kg, 19 ft • Ib)

T.
R.

Drain.
1 Rear brake hose union bolt 1
2 Copper washer 2
3 Rear brake hose 1
dure.
4-33
REAR BRAKE
Disassembling the rear brake caliper
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.
R.
9
2 17 Nm (1.7 m • kg, 12 ft • Ib)
T.
R.
1
LS
6
3 Nm (0.3 m • kg, 2.2 ft • Ib)
T.
R.
3
8 New
4
5
6 4
3
New 8
7

1 Screw plug 1
2 Brake pad pin 1
3 Brake pad shim 2
4 Brake pad insulator 2
5 Rear brake pad 2
7 Brake caliper piston 2
8 Brake caliper piston seal 4
9 Bleed screw 1
cedure.
4-34
REAR BRAKE
EAS22560
INTRODUCTION Brake disc thickness limit

EWA14100
5.5 mm (0.22 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- DISCS” on page 4-23.
• If any connection on the hydraulic brake Rear brake disc bolt
system is disconnected, the entire brake 18 Nm (1.8 m·kg, 13 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:
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 ENTERING 1. Measure:
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.
EAS22570
Brake pad lining thickness (in-
CHECKING THE REAR BRAKE DISC ner)
1. Remove: 6.5 mm (0.26 in)
• Rear wheel Limit
Refer to “REAR WHEEL” on page 4-12. 1.0 mm (0.04 in)
Brake pad lining thickness (out-
2. Check:
er)
• Brake disc 6.5 mm (0.26 in)
Damage/galling → Replace. Limit
3. Measure: 1.0 mm (0.04 in)
Out of specification → Correct the brake disc
deflection or replace the brake disc.
DISCS” on page 4-23.
Brake disc deflection limit a

0.15 mm (0.0059 in)
4. Measure:
• Brake disc thickness
Measure the brake disc thickness at a few dif-
ferent locations. 2. Install:
Out of specification → Replace. • Brake pad shims
Refer to “CHECKING THE FRONT BRAKE (onto the brake pads)
DISCS” on page 4-23. • Brake pads
• Brake pad spring
4-35
REAR BRAKE
NOTE: 4. Check:
Always install new brake pads, brake pad shims, • Brake fluid level
and a brake pad spring as a set. Below the minimum level mark “a” → Add the
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Refer to “CHECKING THE BRAKE FLUID
a. Connect a clear plastic hose “1” tightly to the
bleed screw “2”. Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with your
finger.
a
2 5. Check:
• Brake pedal operation
1 Soft or spongy feeling → Bleed the brake sys-
tem.
c. Tighten the bleed screw.
Bleed screw (rear brake caliper) EAS22590
6 Nm (0.6 m·kg, 4.3 ft·lb) REMOVING THE REAR BRAKE CALIPER

T.
R.
NOTE:
d. Install a new brake pad insulator and new
Before disassembling the brake caliper, drain
brake pad shim “3” onto each new brake pad
the brake fluid from the entire brake system.
“4”.
1. Remove:
4 • Rear brake hose union bolt “1”
• Rear brake hose “3”
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
3
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2
3. Install:
• Brake pad pin
• Screw plug
Rear brake caliper bolt (M12) 3

27 Nm (2.7 m·kg, 19 ft·lb)
T.
R.
Rear brake caliper bolt (M8) EAS22610
22 Nm (2.2 m·kg, 16 ft·lb) DISASSEMBLING THE REAR BRAKE

LOCTITE® CALIPER
1. Remove:
• Brake caliper pistons “1”
• Brake caliper piston seals “2”
4-36
REAR BRAKE
• Brake caliper body “3”

2
Cracks/damage → Replace the brake caliper
assembly.
• Brake fluid delivery passages
2 (brake caliper body)
1 Obstruction → Blow out with compressed air.
EWA13610
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose joint
opening “a” to force out the pistons from the 3
brake caliper.
EWA13550
WARNING 2 2
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper. 1 1
• Never try to pry out the brake caliper pis-
ton.
2. Check:
• Brake caliper bracket “1”
a Cracks/damage → Replace.
b. Remove the brake caliper piston seals.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22640 EAS22650
CHECKING THE REAR BRAKE CALIPER ASSEMBLING THE REAR BRAKE CALIPER
EWA13620
Recommended brake component WARNING
replacement schedule
Brake pads If necessary ponents should be cleaned and lubricated
Piston seals Every two years with clean or new brake fluid.
• Never use solvents on internal brake com-
Brake hoses Every four years
ponents as they will cause the piston seals
Every two years and to swell and distort.
Brake fluid whenever the brake • Whenever a brake caliper is disassembled,
is disassembled replace the brake caliper piston seals.
1. Check:
• Brake caliper pistons “1” Recommended fluid
Rust/scratches/wear → Replace the brake DOT 4
caliper pistons.
• Brake caliper cylinders “2”
Scratches/wear → Replace the brake caliper
assembly.
4-37
REAR BRAKE
EAS22670
INSTALLING THE REAR BRAKE CALIPER Recommended fluid

1. Install: DOT 4
• Rear brake caliper “1”
(temporarily) EWA13090
WARNING
• Rear brake hose “2”
• Rear brake hose union bolt “3”
Rear brake hose union bolt brake performance.
30 Nm (3.0 m·kg, 22 ft·lb) • Refill with the same type of brake fluid that
T.
R.

EWA13530
WARNING leading to poor brake performance.
Proper brake hose routing is essential to in- • When refilling, be careful that water does
sure safe vehicle operation. Refer to “CABLE not enter the brake fluid reservoir. Water
ROUTING” on page 2-41. will significantly lower the boiling point of
ECA14170 the brake fluid and could cause vapor lock.
CAUTION: ECA13540
When installing the brake hose onto the CAUTION:

brake caliper “1”, make sure the brake pipe Brake fluid may damage painted surfaces
“a” touches the projection “b” on the brake and plastic parts. Therefore, always clean up
caliper. any spilt brake fluid immediately.
5. Bleed:
b 3 • Brake system
6. Check:
a Below the minimum level mark “a” → Add the
2 recommended brake fluid to the proper level.
1
2. Remove:
3. Install:
• Rear brake pads
• Brake pad springs
• Brake pad pin a
Refer to “REPLACING THE REAR BRAKE
PADS” on page 4-35.
Rear brake caliper bolt (M12) 7. Check:

27 Nm (2.7 m·kg, 19 ft·lb)
T.

R.

22 Nm (2.2 m·kg, 16 ft·lb) Soft or spongy feeling → Bleed the brake sys-
tem.
LOCTITE®
4. Fill: BRAKE SYSTEM” on page 3-23.
• Brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)
4-38
REAR BRAKE
EAS22700 EAS22730
REMOVING THE REAR BRAKE MASTER ASSEMBLING THE REAR BRAKE MASTER
CYLINDER CYLINDER
EWA13520
NOTE:
WARNING
Before removing the rear brake master cylinder,
drain the brake fluid from the entire brake sys-
ponents should be cleaned and lubricated
tem.
with clean or new brake fluid.
1. Remove: • Never use solvents on internal brake com-
• Rear brake hose union bolt “1” ponents.
• Rear brake hose “3” Recommended fluid
NOTE: DOT 4
To collect any remaining brake fluid, place a
container under the master cylinder and the end EAS22740
INSTALLING THE REAR BRAKE MASTER

of the brake hose.
CYLINDER
1. Install:
1 • Rear brake hose “1”
• Rear brake hose union bolt “2”
3
Rear brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
T.
R.
2 EWA13530
WARNING
Proper brake hose routing is essential to in-
EAS22720
sure safe vehicle operation. Refer to “CABLE
CHECKING THE REAR BRAKE MASTER ROUTING” on page 2-41.
CYLINDER
ECA14160
1. Check:
CAUTION:
• Brake master cylinder
Damage/scratches/wear → Replace. When installing the brake hose onto the
• Brake fluid delivery passages brake master cylinder, make sure the brake
(brake master cylinder body) pipe touches the projection “a” as shown.
2. Check: 1
• Brake master cylinder kit 2
Damage/scratches/wear → Replace.
3. Check:
• Brake fluid reservoir diaphragm
Cracks/damage → Replace. a
4. Check:
• Brake hoses
2. Fill:
Cracks/damage/wear → Replace.
mended brake fluid)
Recommended fluid
DOT 4
4-39
REAR BRAKE
EWA13090
7. Adjust:
WARNING • Rear brake light operation timing
• Use only the designated brake fluid. Other Refer to “ADJUSTING THE REAR BRAKE
brake fluids may cause the rubber seals to LIGHT SWITCH” on page 3-23.
brake performance.
leading to poor brake performance.
not enter the brake fluid reservoir. Water
ECA13540
CAUTION:
3. Bleed:
• Brake system
4. Check:
5. Check:
Soft or spongy feeling → Bleed the brake sys-
tem.
6. Adjust:
• Brake pedal position
Refer to “ADJUSTING THE REAR DISC
BRAKE” on page 3-20.
4-40
HANDLEBAR
EAS22840
HANDLEBAR
Removing the handlebar
20 Nm (2.0 m • kg, 14 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
T.
R.
1
3
1
16 5
13 Nm (1.3 m kg, 9.4 ft Ib)
• •
6
T.
R.
16 13 Nm (1.3 m • kg, 9.4 ft • Ib)
T.
R.
14 Nm (1.4 m • kg, 10 ft • Ib) 10
T.
R.
11 2
14 6 9 8
29 Nm (2.9 m • kg, 21 ft • Ib)
T.
R.
17 18 LS
13 7
15
LS
18 4
40 Nm (4.0 m • kg, 29 ft • Ib)
14
T.
8
R.
12
29 Nm (2.9 m • kg, 21 ft • Ib)
T.
R.
40 Nm (4.0 m • kg, 29 ft • Ib)

T.
R.

1 Rearview mirror 2
2 Front brake light switch connector 2 Disconnect.
3 Front brake master cylinder holder 1
4 Front brake master cylinder assembly 1
5 Spacer 1
6 Right handlebar switch 1
7 Throttle cable 2 Disconnect.
8 Grip end 2
9 Throttle grip 1
10 Clutch switch coupler 1 Disconnect.
11 Clutch master cylinder holder 1
12 Clutch master cylinder assembly 1
13 Spacer 1
14 Left handlebar switch 1
15 Handlebar grip 1
16 Upper handlebar holder 2
4-41
HANDLEBAR
Removing the handlebar

T.
R.
T.
R.
1
3
1
16 5
13 Nm (1.3 m kg, 9.4 ft Ib)
• •
6
T.
R.
16 13 Nm (1.3 m • kg, 9.4 ft • Ib)
T.
R.
14 Nm (1.4 m • kg, 10 ft • Ib) 10
T.
R.
11 2
14 6 9 8
29 Nm (2.9 m • kg, 21 ft • Ib)
T.
R.
17 18 LS
13 7
15
LS
18 4
40 Nm (4.0 m • kg, 29 ft • Ib)
14
T.
8
R.
12
29 Nm (2.9 m • kg, 21 ft • Ib)
T.
R.
40 Nm (4.0 m • kg, 29 ft • Ib)

T.
R.

17 Handlebar 1
18 Lower handlebar holder 2
dure.
4-42
HANDLEBAR
EAS22860
REMOVING THE HANDLEBAR 1

EWA13120
WARNING
2. Remove:
• Handlebar grip “1”
NOTE:
2
Blow compressed air between the handlebar 3. Install:
and the left handlebar grip, and gradually push • Handlebar “1”
the grip off the handlebar. • Upper handlebar holders “2”
Upper handlebar holder bolt

20 Nm (2.0 m·kg, 14 ft·lb)
T.
R.
ECA14250
CAUTION:
• First, tighten the bolts on the front side of
the handlebar holder, and then on the rear
side.
• Turn the handlebar all the way to the left
and right. If there is any contact with the
EAS22880
fuel tank, adjust the handlebar position.
CHECKING THE HANDLEBAR
1. Check: NOTE:
• Handlebar • The upper handlebar holders should be in-
Bends/cracks/damage → Replace. stalled with the punch marks “a” facing for-
EWA13690
ward.
WARNING
• Align the match mark “b” on the handlebar with
Do not attempt to straighten a bent handle- the upper surface of the lower handlebar hold-
bar as this may dangerously weaken it. er.
EAS22930
2
INSTALLING THE HANDLEBAR 1
EWA13120
WARNING
2. Install: b
a
• Lower handlebar holders “1”
NOTE:
Temporarily tighten the nuts “2”. 4. Tighten:
• Lower handlebar holder nuts
Lower handlebar holder nut

40 Nm (4.0 m·kg, 29 ft·lb)
T.
R.
5. Install:
• Handlebar grip “1”
• Grip end “2”
4-43
HANDLEBAR
Grip end Clutch master cylinder holder

29 Nm (2.9 m·kg, 21 ft·lb) bolt
T.
T.
R.
R.
14 Nm (1.4 m·kg, 10 ft·lb)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of rubber adhesive onto the NOTE:
left end of the handlebar.
• Face the slit in the spacer forward, downward,
b. Slide the handlebar grip over the left end of
or in any direction in between.
the handlebar.
• The clutch master cylinder holder should be in-
c. Wipe off any excess rubber adhesive with a
stalled with the punch mark “a” forward.
clean rag.
EWA13700
• Align the mating surfaces of the clutch master
WARNING cylinder holder with the punch mark “b” on the
Do not touch the handlebar grip until the rub- handlebar.
ber adhesive has fully dried. • First, tighten the front bolt, then the rear bolt.
NOTE:
a
There should be 1–3 mm (0.04–0.12 in) of clear-
ance “a” between the handlebar grip and the grip
end.
1 2 b
8. Install:
• Throttle grip
• Throttle cables
• Right handlebar switch “1”
• Grip end “2”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Grip end
6. Install: 29 Nm (2.9 m·kg, 21 ft·lb)
T.
• Left handlebar switch “1”

R.
NOTE: NOTE:
Align the projection “a” on the left handlebar • Align the projection “a” on the right handlebar
switch with the hole “b” in the handlebar. switch with the hole “b” in the handlebar.
• There should be 1–3 mm (0.04–0.12 in) of
clearance “c” between the throttle grip and the
b grip end.
1 b
7. Install:
• Spacer “1” 1
a
• Clutch master cylinder assembly
• Clutch master cylinder holder “2”
4-44
HANDLEBAR
9. Install:
• Front brake master cylinder assembly
• Front brake master cylinder holder “1”
Front brake master cylinder hold-

er bolt
T.
R.
10 Nm (1.0 m·kg, 7.2 ft·lb)
NOTE:
• The front brake master cylinder holder should
be installed with the punch mark “a” forward.
• Align the end of the brake master cylinder hold-
er with the punch mark “b” on the handlebar.
• First, tighten the front bolt, then the rear bolt.
10.Adjust:
• Throttle cable free play
Refer to “ADJUSTING THE THROTTLE CA-
BLE FREE PLAY” on page 3-7.
Throttle cable free play

3.0–5.0 mm (0.12–0.20 in)
4-45
FRONT FORK
EAS22950
FRONT FORK
Removing the front fork legs
26 Nm (2.6 m • kg, 19 ft • Ib)
T.
R.
4
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
3
28 Nm (2.8 m • kg, 20 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
5
1
1 6
2

T.
T.
R.
R.

the front fork legs.
Front wheel Refer to “FRONT WHEEL” on page 4-6.
1 Front fork guard 2
2 Front fender 1
3 Cap bolt 1 Loosen.
4 Upper bracket pinch bolt 1 Loosen.
5 Lower bracket pinch bolt 2 Loosen.
6 Front fork leg 1
dure.
4-46
FRONT FORK
Disassembling the front fork legs
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
1 LS
25 Nm (2.5 m • kg, 18 ft • Ib)

T.
R.
New 2
3
6
5
16
7
15
10
8 4
14
13 New
12 New
11 New
35 Nm (3.5 m • kg, 25 ft • Ib)
T.
R.

the front fork legs.
1 Cap bolt 1
2 O-ring 1
3 Washer 1
4 Damper adjusting rod 1
5 Spacer 1
6 Nut 1
7 Upper spring seat 1
8 Fork spring 1
9 Lower spring seat 1
10 Outer tube 1
11 Dust seal 1
12 Oil seal clip 1
13 Oil seal 1
14 Washer 1
15 Damper rod assembly 1
4-47
FRONT FORK
Disassembling the front fork legs
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
1 LS
25 Nm (2.5 m • kg, 18 ft • Ib)

T.
R.
New 2
3
6
5
16
7
15
10
8 4
14
13 New
12 New
11 New
35 Nm (3.5 m • kg, 25 ft • Ib)
T.
R.

16 Inner tube 1
cedure.
4-48
FRONT FORK
EAS22960
1. Position the collar “1” as shown in the illustra-
REMOVING THE FRONT FORK LEGS
tion by turning the spring preload adjusting
bolt “2” counterclockwise until it stops.
front fork legs.
EWA13120
2
WARNING
1
NOTE:
2. Loosen:
• Upper bracket pinch bolt “1” 2. Remove:
• Cap bolt “2” • Cap bolt “1”
• Lower bracket pinch bolt “3” (from the damper adjusting rod)
EWA13640 • Spacer “2”
WARNING • Nut “3”
Before loosening the upper and lower brack- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
et pinch bolts, support the front fork leg. a. Press down on the spacer with the fork spring
compressor “4”.
b. Install the rod holder “5” between the nut “3”
2 and the spacer “2”.
Fork spring compressor

90890-01441
YM-01441
1 Rod holder
90890-01434
Damper rod holder double ended
YM-01434
NOTE:
Use the side of the rod holder that is marked “B”.
2 5
3
4
EAS22990
DISASSEMBLING THE FRONT FORK LEGS

front fork legs. c. Hold the spring preload adjusting bolt “6” and
loosen the nut “3”.
EC5YU1011
CAUTION:
When loosening the nut “3”, be sure not to
break the projections “a” on the collar “7” of
the cap bolt “1”.
4-49
FRONT FORK
NOTE:
Loosen the nut using a proper tool that has a
thickness of 3 mm (0.12 in) or less.
6
1
7
1
a 5. Remove:
3
• Oil seal clip “1”
(with a flat-head screwdriver)
d. Remove the cap bolt.

e. Remove the rod holder and fork spring com-
pressor.
f. Remove the spacer and nut.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Drain:
• Fork oil
NOTE:
Stroke the damper rod “1” several times while
draining the fork oil. EAS23010
CHECKING THE FRONT FORK LEGS

front fork legs.
1. Check:
• Inner tube
• Outer tube
Bends/damage/scratches → Replace.
EWA13650
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
4. Remove: 2. Measure:
• Damper rod assembly • Spring free length “a”
NOTE: Out of specification → Replace.
Remove the damper rod assembly with the Fork spring free length
damper rod holder “1”. 251.0 mm (9.88 in)
Limit
Damper rod holder 246.0 mm (9.69 in)
90890-01504
YM-01504
4-50
FRONT FORK
NOTE:
• When assembling the front fork leg, be sure to
replace the following parts:
– Oil seal
– Dust seal
– O-ring
• Before assembling the front fork leg, make
sure all of the components are clean.
1. Install:
• Damper rod assembly “1”
3. Check: • Inner tube “2”
• Damper rod ECA14210
Damage/wear → Replace. CAUTION:

Obstruction → Blow out all of the oil passag- Allow the damper rod assembly to slide
es with compressed air. slowly down the inner tube “2” until it pro-
• Damper adjusting rod trudes from the bottom of the inner tube. Be
Bends/damage → Replace. careful not to damage the inner tube.
ECA14200
CAUTION:
• The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly
sensitive to foreign material.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma- 2
terial to enter the front fork.
1
4. Check:
• Cap bolt O-ring “1”
Damage/wear → Replace. 2. Lubricate:
• Cap bolt collar projections “2” • Inner tube’s outer surface
Recommended oil
Suspension oil M1 or ohlins R &
T43
1
3. Tighten:
2 • Damper rod assembly
Damper rod assembly

35 Nm (3.5 m·kg, 25 ft·lb)
T.
R.
NOTE:
Tighten the damper rod assembly with the
EAS23040
ASSEMBLING THE FRONT FORK LEGS damper rod holder “1”.

front fork legs. Damper rod holder
EWA13660 90890-01504
WARNING YM-01504
• Make sure the oil levels in both front fork
legs are equal.
• Uneven oil levels can result in poor han-
dling and a loss of stability.
4-51
FRONT FORK
5. Install:
• Outer tube
(to the inner tube)
6. Install:
• Washer
• Oil seal “1”
(with the fork seal driver “2”)
Fork seal driver

1
90890-01442
Adjustable fork seal driver (36–46
4. Install: mm)
• Dust seal “1” New YM-01442
• Oil seal clip “2” New
• Oil seal “3” New
• Washer “4”
EC5YU1025
CAUTION:
Make sure the numbered side of the oil seal 2
faces bottom side.
1
NOTE:
• Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.
• Lubricate the outer surface of the inner tube 7. Install:
with fork oil. • Oil seal clip “1”
• Before installing the oil seal, cover the top of NOTE:
the front fork leg with a plastic bag to protect Adjust the oil seal clip so that it fits into the outer
the oil seal during installation. tube’s groove.
4
3
2
1
8. Install:
• Dust seal “1”
(with the fork seal driver weight “2”)
Fork seal driver

90890-01442
Adjustable fork seal driver (36–46
mm)
YM-01442
4-52
FRONT FORK
• When disassembling and assembling the

front fork leg, do not allow any foreign ma-
terial to enter the front fork.
12.After filling the front fork leg, slowly stroke the
damper rod “1” up and down (at least ten
times) to distribute the fork oil.
NOTE:
Be sure to stroke the damper rod slowly be-
cause the fork oil may spurt out.
9. Install:
• Rod puller “1”
• Rod puller attachment “2”
(onto the damper rod “3”)
Rod puller
90890-01437
Universal damping rod bleeding
tool set
YM-A8703
Rod puller attachment (M10)
90890-01436 13.Before measuring the fork oil level, wait ten
Universal damping rod bleeding minutes until the oil has settled and the air
tool set bubbles have dispersed.
YM-A8703 NOTE:
Be sure to bleed the front fork leg of any residual
air.
14.Measure:
• Front fork leg oil level “a”
(from the top of the inner tube, with the outer
tube fully compressed and without the fork
spring)
Out of specification → Correct.
Level
65.0 mm (2.56 in)
10.Fully compress the front fork leg.
11.Fill:
• Front fork leg
a
mended fork oil)
Quantity
586.0 cm³ (19.82 US oz) (20.67
Imp.oz)
Recommended oil
Suspension oil M1 or ohlins R &
T43
ECA14230
15.Install:
CAUTION: • Lower spring seat “1”
• Fork spring “2”
• Be sure to use the recommended fork oil.
• Upper spring seat “3”
Other oils may have an adverse effect on
• Nut “4”
front fork performance.
• Spacer “5”
4-53
FRONT FORK
• Damper adjusting rod “6”

• Washer “7” Rod puller
• Cap bolt “8” 90890-01437
(with O-ring) Universal damping rod bleeding
tool set
5 2 1 YM-A8703
7 4
8 Rod puller attachment (M10)
90890-01436
Universal damping rod bleeding
tool set
YM-A8703
3 Fork spring compressor
90890-01441
6 YM-01441
Rod holder
90890-01434
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Damper rod holder double ended
a. Remove the rod puller attachment. YM-01434
b. Install the lower spring seat.
c. Install the fork spring. NOTE:
NOTE: Use the side of the rod holder that is marked “B”.
Install the spring with the smaller pitch “a” facing
up “A”.
4
5 10
i. Remove the rod puller and rod puller attach-

ment.
d. Install the upper spring seat and nut. j. Install the nut “4” all the way onto the damper
e. Reinstall the rod puller attachment. rod assembly.
f. Install the spacer.
g. Press down on the spacer with the fork spring
compressor “9”.
h. Pull up the rod puller and install the rod holder
“10” between the nut “4” and the spacer “5”.
k. Install the damper adjusting rod.

l. Install the washer and cap bolt, and then fin-
ger tighten the cap bolt.
m. Hold the nut and tighten the spring preload
adjusting bolt “11” into the cap bolt to specifi-
cation.
4-54
FRONT FORK
EWA13670
• Cap bolt “2”
WARNING
Always use a new cap bolt O-ring. Cap bolt
20 Nm (2.0 m·kg, 14 ft·lb)
T.
EC5YU1012
R.
CAUTION:
• Upper bracket pinch bolt “3”
When tightening the spring preload adjust-
ing bolt “11” into the cap bolt, be sure not to Upper bracket pinch bolt
break the projections “c” on the collar “12”. 26 Nm (2.6 m·kg, 19 ft·lb)
T.
R.
NOTE: EWA13680
Hold the nut “4” using a proper tool that has a WARNING
thickness of 3 mm (0.12 in) or less. Make sure the brake hoses are routed prop-
erly.
Nut and cap bolt
25 Nm (2.5 m·kg, 18 ft·lb)
T.
R.
2
11 3
12
1
c
4
3. Adjust:
• Spring preload
• Rebound damping
n. Remove the rod holder and fork spring com-
• Compression damping
pressor.
Refer to “ADJUSTING THE FRONT FORK
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
LEGS” on page 3-27.
16.Install:
• Cap bolt
(to the outer tube)
NOTE:
Temporarily tighten the cap bolt.
EAS23050
INSTALLING THE FRONT FORK LEGS

front fork legs.
1. Install:
• Front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts.
NOTE:
Make sure the outer tube is flush with the top of
the handlebar holder.
2. Tighten:
• Lower bracket pinch bolts “1”
Lower bracket pinch bolt

28 Nm (2.8 m·kg, 20 ft·lb)
T.
R.
4-55
STEERING HEAD
EAS23090
STEERING HEAD
Removing the lower bracket
2 4
110 Nm (11.0 m • kg, 80 ft • lb)
T.
R.
1 3
9 5
10
11
12
18
19 1st 52 Nm (5.2 m • kg, 37 ft • lb)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
20 2nd 23 Nm (2.3 m • kg, 17 ft • lb)
R.
T.
R.
21
LS
14
LT
LT 21
7 Nm (0.7 m • kg, 5.1 ft • Ib) 15
T.
17
R.
8
16
LS
9 Nm (0.9 m • kg, 6.5 ft • Ib)

T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
13
FWD

Air filter case/Headlight assembly 4-1.
Lower handlebar holder Refer to “HANDLEBAR” on page 4-41.
Front fork leg Refer to “FRONT FORK” on page 4-46.
1 Meter assembly coupler 2 Disconnect.
2 Meter assembly 1
3 Meter assembly bracket 1
4 Steering stem nut 1
5 Upper bracket 1
6 Headlight assembly bracket 1
7 Front brake hose joint 1
8 Front brake hose joint bracket 1
9 Lock washer 1
10 Upper ring nut 1
11 Rubber washer 1
12 Lower ring nut 1
4-56
STEERING HEAD
Removing the lower bracket
2 4
110 Nm (11.0 m • kg, 80 ft • lb)
T.
R.
1 3
9 5
10
11
12
18
19 1st 52 Nm (5.2 m • kg, 37 ft • lb)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
20 2nd 23 Nm (2.3 m • kg, 17 ft • lb)
R.
T.
R.
21
LS
14
LT
LT 21
7 Nm (0.7 m • kg, 5.1 ft • Ib) 15
T.
17
R.
8
16
LS
9 Nm (0.9 m • kg, 6.5 ft • Ib)

T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
13
FWD

13 Lower bracket 1
14 Washer 1
15 Lower bearing 1
16 Lower bearing dust seal 1
17 Lower bearing inner race 1
18 Upper bearing cover 1
19 Upper bearing inner race 1
20 Upper bearing 1
21 Bearing outer race 2
dure.
4-57
STEERING HEAD
EAS23110
3. Replace:
REMOVING THE LOWER BRACKET
• Bearings
EWA13120
• Bearing races
WARNING ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bearing races from the steering
Securely support the vehicle so that there is head pipe with a long rod “1” and hammer.
no danger of it falling over. b. Remove the bearing race from the lower
2. Remove: bracket with a floor chisel “2” and hammer.
• Upper ring nut “1” c. Install new bearing races.
ECA14270
• Rubber washer
CAUTION:
• Lower ring nut “2”
• Lower bracket If the bearing race is not installed properly,
EWA13730 the steering head pipe could be damaged.
WARNING
NOTE:
Securely support the lower bracket so that
there is no danger of it falling. Always replace the bearings and bearing races
as a set.
NOTE:
Hold the lower ring nut with the ring nut wrench
“3”, and then remove the upper ring nut with the
steering nut wrench “4”.
Ring nut wrench

90890-01268
Spanner wrench
YU-01268
Steering nut wrench
90890-01403
Spanner wrench
YU-33975
2 1 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
EAS23120
• Upper bracket
CHECKING THE STEERING HEAD • Lower bracket
1. Wash: (along with the steering stem)
• Bearings Bends/cracks/damage → Replace.
• Bearing races EAS23140
INSTALLING THE STEERING HEAD

Recommended cleaning solvent
1. Lubricate:
Kerosene
• Upper bearing
2. Check: • Lower bearing
• Bearings • Bearing races
• Bearing races
Damage/pitting → Replace.
4-58
STEERING HEAD
6. Tighten:
Recommended lubricant • Steering stem nut
Steering stem nut
T.
R.
• Lower ring nut “1”
• Rubber washer “2”
• Upper ring nut “3”
• Lock washer “4”
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-26.
3. Install:
• Front brake hose joint bracket “1”
• Front brake hose joint “2”
NOTE:
Make sure that the tab “a” on the front brake
hose joint bracket “1” contacts the side “b” of the
front brake hose joint “2”.
1 a
2 b
4. Install:
• Upper bracket
• Steering stem nut
NOTE:
Temporarily tighten the steering stem nut.
5. Install:
• Front fork legs
Refer to “FRONT FORK” on page 4-46.
NOTE:
Temporarily tighten the upper and lower bracket
pinch bolts.
4-59
REAR SHOCK ABSORBER ASSEMBLY
EAS23160

Removing the rear shock absorber assembly
5 12
5 LS
12
LS
4
2 3
LS 8 40 Nm (4.0 m • kg, 29 ft • Ib)
9
T.
R.
6 8 3
2 1
10 10 40 Nm (4.0 m • kg, 29 ft • Ib)

10 1
T.
R.
LS
11
LS 7 6
LS
49 Nm (4.9 m • kg, 35 ft • Ib) 10

T.
R.

1 Self-locking nut/Bolt 1/1
2 Self-locking nut/Bolt/Spacer 1/1/1
3 Self-locking nut/Bolt 1/1
4 Rear shock absorber assembly 1
5 Collar/Spacer/Oil seal/Bearing 2/1/2/1
6 Self-locking nut/Bolt/Washer 1/1/2
7 Spacer 1
8 Oil seal/Bearing 2/1
9 Relay arm 1
10 Spacer/Oil seal/Bearing 2/8/4
11 Connecting arm 1
12 Collar/Spacer 2/1
dure.
4-60
EAS23180
HANDLING THE REAR SHOCK ABSORBER NOTE:

EWA13740 Place the vehicle on a suitable stand so that the
WARNING rear wheel is elevated.
This rear shock absorber contains highly 2. Remove:
compressed nitrogen gas. Before handling • Relay arm bolt (relay arm and swingarm) “1”
the rear shock absorber, read and make sure • Rear shock absorber assembly bolt (front
you understand the following information. side) “2”
The manufacturer cannot be held responsi-
NOTE:
ble for property damage or personal injury
that may result from improper handling of While removing the relay arm bolt (relay arm and
the rear shock absorber. swingarm), hold the swingarm so that it does not
• Do not tamper or attempt to open the rear drop down.
shock absorber.
• Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion due
to excessive gas pressure.
• Do not deform or damage the rear shock 1
absorber in any way. Rear shock absorber

damage will result in poor damping perfor-
mance. 1
2
EAS23190
DISPOSING OF A REAR SHOCK ABSORBER EAS23240
1. Gas pressure must be released before dis- CHECKING THE REAR SHOCK ABSORBER
posing of a rear shock absorber. To release ASSEMBLY
the gas pressure, drill a 2–3 mm (0.079– 1. Check:
0.118 in) hole through the rear shock absorb- • Rear shock absorber rod
er at a point 40 mm (1.57 in) from its end as Bends/damage → Replace the rear shock
shown. absorber assembly.
EWA13760 • Rear shock absorber
WARNING Gas leaks/oil leaks → Replace the rear shock
Wear eye protection to prevent eye damage absorber assembly.
from released gas or metal chips. • Spring
Damage/wear → Replace the rear shock ab-
sorber assembly.
• Bearing
• Oil seals
• Collars
• Spacer
Damage/scratches → Replace.
• Bolts
Bends/damage/wear → Replace.
EAS23260
EAS23230
CHECKING THE CONNECTING ARM AND
REMOVING THE REAR SHOCK ABSORBER
RELAY ARM
ASSEMBLY
1. Check:
EWA13120 • Connecting arm
WARNING • Relay arm
Securely support the vehicle so that there is Damage/wear → Replace.
no danger of it falling over. 2. Check:
• Bearings
4-61
• Oil seals
Damage/pitting → Replace. 4 24 4 2 6 4
3. Check:
• Collars
• Spacers
Damage/scratches → Replace. d d
b c
EAS23270
INSTALLING THE CONNECTING ARM AND A B

RELAY ARM
1. Lubricate:
• Spacers
7
• Bearings
b b
Recommended lubricant 5
Lithium-soap-based grease d d
a
2. Install:
• Bearing “1”
(to the relay arm)
• Bearings “2”
4 6 2 4 31 3 4 2 4
(to the connecting arm)
• Oil seals “3”
5. Relay arm
(to the relay arm)
6. Connecting arm
7. Rear shock absorber
(to the connecting arm)
A. Left side
Installed depth “a” B. Right side
8.0 mm (0.31 in)
3. Install:
Installed depth “b”
• Relay arm “1”
4.0 mm (0.16 in)
Installed depth “c” (to the connecting arm)
7.0 mm (0.28 in) NOTE:
Installed depth “d” Install the relay arm with its “R” mark “a” facing
0.5–1.0 mm (0.02–0.04 in) to the right and its arrow mark “b” facing upward.
a b
4. Tighten:
• Rear shock absorber assembly nut (rear
side)

nut (rear side)
T.
R.
40 Nm (4.0 m·kg, 29 ft·lb)
4-62
• Relay arm nut (relay arm and connecting

arm)
Relay arm nut (relay arm and con-

necting arm)
T.
R.
49 Nm (4.9 m·kg, 35 ft·lb)
EAS23310
INSTALLING THE REAR SHOCK

ABSORBER ASSEMBLY
1. Lubricate:
• Spacers
• Bearings
2. Install:
• Relay arm
(to the swingarm)
NOTE:
When installing the relay arm, lift up the swing-
arm.
3. Tighten:
• Rear shock absorber assembly nut (front
side)

nut (front side)
T.
R.
49 Nm (4.9 m·kg, 35 ft·lb)
• Relay arm nut (relay arm and swingarm)

swingarm)
T.
R.
40 Nm (4.0 m·kg, 29 ft·lb)
4. Adjust:
Drive chain slack

40.0–50.0 mm (1.57–1.97 in)
4-63
SWINGARM
EAS23330
SWINGARM
Removing the swingarm
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
9 Nm (0.9 m • kg, 6.5 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
LT 13
R.
9 Nm (0.9 m • kg, 6.5 ft • Ib)
T.
R.
2
7 Nm (0.7 m • kg, 5.1 ft • Ib) LT
LT
T.
R.
5 4
25 Nm (2.5 m • kg, 18 ft • Ib) 8 14
T.
LT
R.
12 3
6 LS 23
19 15 5
22 21
16 20 New
19
11 24
9 1710
LS 7
6 9
18 25
24 LS
LS
1 25 Nm (2.5 m • kg, 18 ft • Ib)

T.
R.
125 Nm (12.5 m • kg, 90 ft • lb)

T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.

Rear wheel 4-1.
Refer to “REAR SHOCK ABSORBER AS-
Rear shock absorber SEMBLY” on page 4-60.
Drive chain guard (drive sprocket side) Refer to “CHAIN DRIVE” on page 4-68.
1 Footrest cover 1
2 Drive chain guard (swingarm side) 1
3 Rear brake hose guide 1 1
4 Rear brake hose holder 1
5 Drive chain adjusting bolt/Locknut 2/2
6 Footrest bracket pinch bolt 2 Loosen.
7 Swingarm pivot shaft nut 1
8 Swingarm pivot shaft 1
9 Collar 2
10 Spacer 1
11 Spacer 1
12 Drive chain 1
4-64
SWINGARM
Removing the swingarm

7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
9 Nm (0.9 m • kg, 6.5 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
LT 13
R.
9 Nm (0.9 m • kg, 6.5 ft • Ib)
T.
R.
2
7 Nm (0.7 m • kg, 5.1 ft • Ib) LT
LT
T.
R.
5 4
25 Nm (2.5 m • kg, 18 ft • Ib) 8 14
T.
LT
R.
12 3
6 LS 23
19 15 5
22 21
16 20 New
19
11 24
9 1710
LS 7
6 9
18 25
24 LS
LS
1 25 Nm (2.5 m • kg, 18 ft • Ib)

T.
R.
125 Nm (12.5 m • kg, 90 ft • lb)

T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.

13 Rear fender 1
14 Drive chain guide 1
15 Swingarm 1
16 Spacer 1
17 Oil seal 1
18 Oil seal 1
19 Oil seal 2
20 Circlip 1
21 Bearing 1
22 Bearing 1
23 Bearing 1
24 Oil seal 2
25 Bearing 1
dure.
4-65
SWINGARM
EAS23350 EAS23360
REMOVING THE SWINGARM CHECKING THE SWINGARM

EWA13120
• Swingarm
WARNING Bends/cracks/damage → Replace.
Securely support the vehicle so that there is 2. Check:
no danger of it falling over. • Pivot shaft
Roll the pivot shaft on a flat surface.
NOTE:
Bends → Replace.
Place the vehicle on a suitable stand so that the EWA13770
rear wheel is elevated. WARNING

2. Measure: Do not attempt to straighten a bent pivot
• Swingarm side play shaft.
• Swingarm vertical movement
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the tightening torque of the pivot
shaft nut.
Swingarm pivot shaft nut

125 Nm (12.5 m·kg, 90 ft·lb)
T.
R.
b. Measure the swingarm side play “A” by mov-

ing the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers, bearings, washers, 3. Wash:
and dust covers. • Pivot shaft
Swingarm side play (at the end of • Spacer
the swingarm) • Washer
1.0 mm (0.04 in) • Bearings
• Collars
d. Check the swingarm vertical movement “B”
by moving the swingarm up and down. Recommended cleaning solvent
If swingarm vertical movement is not smooth Kerosene
or if there is binding, check the spacers, bear-
4. Check:
ings, washers, and dust covers.
• Oil seals
• Bearings
Damage/pitting → Replace.
• Collars
• Spacers
B
A EAS23380
INSTALLING THE SWINGARM

1. Lubricate:
• Bearings
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Spacer
3. Remove: • Pivot shaft
• Drive chain
Refer to “REMOVING THE DRIVE CHAIN” Recommended lubricant
on page 4-69. Lithium-soap-based grease
2. Install:
• Bearings “1”
4-66
SWINGARM

• Bearing “3”
• Oil seal “4”
Installed depth of bearing “a”

6.3 mm (0.25 in)
Installed depth of bearing “b”
5.7 mm (0.22 in)
Installed depth of oil seal “c”
0.5–1.0 mm (0.02–0.04 in)
Installed depth of oil seal “d”
0.5 mm (0.02 in)
Installed depth of bearing “e”
4.0 mm (0.16 in)
Installed depth of oil seal “f”
1.0 mm (0.04 in)
1 5 1 2
6
A B
2 d
d c
b
a
e 7
f 5
8
A B
4 3
5. Swingarm
6. Swingarm pivot shaft
7. Relay arm
8. Bolt
A. Left side
B. Right side
3. Adjust:
Drive chain slack

40.0–50.0 mm (1.57–1.97 in)
4-67
CHAIN DRIVE
EAS23400
CHAIN DRIVE
Removing the drive sprocket and drive chain
T.
T.
R.
R.
5 2
3
6
4 New
7
LT
LT
24 Nm (2.4 m • kg, 17 ft • Ib)
T.
R.
12
11 10 9 New
E
95 Nm (9.5 m • kg, 68 ft • Ib)

T.
R.
1 10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

Drain.
Clutch fluid Refer to “BLEEDING THE HYDRAULIC
1 Drive sprocket cover 1
2 Clutch pipe union bolt cap 1
3 Clutch pipe union bolt 1
4 Copper washer 2
5 Clutch pipe 1
6 Clutch release cylinder 1
7 Dowel pin 2
8 Drive chain guard (drive sprocket side) 1
9 Drive sprocket nut 1
10 Washer 1
11 Drive sprocket 1
12 Drive chain 1
dure.
4-68
CHAIN DRIVE
EAS23410
REMOVING THE DRIVE CHAIN

EWA13120
WARNING
NOTE:
rear wheel is elevated.
2. Remove: 3. Clean:
• Drive chain • Drive chain
(with the drive chain cutter) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wipe the drive chain with a clean cloth.
NOTE:
b. Put the drive chain in kerosene and remove
Only cut the drive chain if it or the swingarm is to any remaining dirt.
be replaced. c. Remove the drive chain from the kerosene
and completely dry it.
EAS23440 EC5YU1022
CHECKING THE DRIVE CHAIN CAUTION:

1. Measure: • This vehicle has a drive chain with small
• 15-link section “a” of the drive chain rubber O-rings “1” between the drive chain
Out of specification → Replace the drive side plates. Never use high-pressure water
chain. or air, steam, gasoline, certain solvents
15-link length limit (e.g., benzine), or a coarse brush to clean
239.3 mm (9.42 in) the drive chain. High-pressure methods
could force dirt or water into the drive
NOTE: chain’s internals, and solvents will deterio-
rate the O-rings. A coarse brush can also
• While measuring the 15-link section, push
damage the O-rings. Therefore, use only
down on the drive chain to increase its tension.
kerosene to clean the drive chain.
• Measure the length between drive chain roller
• Do not soak the drive chain in kerosene for
“1” and “16” as shown.
more than ten minutes, otherwise the O-
• Perform this measurement at two or three dif-
rings can be damaged.
ferent places.
2. Check:
• Drive chain
Stiffness → Clean and lubricate or replace.
4-69
CHAIN DRIVE
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Correct
4. Check: 1. Drive chain roller
• O-rings “1” 2. Drive chain sprocket
Damage → Replace the drive chain. EAS23470
• Drive chain rollers “2” CHECKING THE REAR WHEEL SPROCKET

Damage/wear → Replace the drive chain. Refer to “CHECKING AND REPLACING THE
• Drive chain side plates “3” REAR WHEEL SPROCKET” on page 4-15.
Damage/wear → Replace the drive chain.
EAS23480
Cracks → Replace the drive chain and make CHECKING THE REAR WHEEL DRIVE HUB
sure the battery breather hose is properly Refer to “CHECKING THE REAR WHEEL
routed away from the drive chain and below DRIVE HUB” on page 4-15.
the swingarm.
EAS28800
INSTALLING THE DRIVE CHAIN

1. Lubricate:
• Drive chain
Engine oil or chain lubricant
suitable for O-ring chains
2. Install:
• Drive sprocket “1”
5. Lubricate: • Washer “2”
• Drive chain • Drive sprocket nut “3” New
Recommended lubricant Drive sprocket nut

Engine oil or chain lubricant 95 Nm (9.5 m·kg, 68 ft·lb)
T.
R.
suitable for O-ring chains

NOTE:
EAS23460
• While applying the rear brake, tighten the drive
CHECKING THE DRIVE SPROCKET
sprocket nut.
1. Check:
• Install the washer “2” with its “OUT” mark “a”
• Drive sprocket
facing outward.
More than 1/4 tooth “a” wear → Replace the
• Stake the drive sprocket nut “3” at a cutout “b”
drive chain sprockets as a set.
in the drive axle.
Bent teeth → Replace the drive chain sprock-
ets as a set.
4-70
CHAIN DRIVE
1
2
b
New 3
3. Install:
• Clutch release cylinder
Refer to “INSTALLING THE CLUTCH RE-
LEASE CYLINDER” on page 5-63.
4-71
ENGINE
ENGINE REMOVAL ........................................................................................ 5-1

CHECKING THE OIL PIPES ..................................................................... 5-2
CHECKING THE OIL STRAINER ............................................................. 5-2
INSTALLING THE OIL TANK .................................................................... 5-2
REMOVING THE MUFFLER END COVERS ............................................ 5-4
INSTALLING THE MUFFLER END COVERS........................................... 5-4
REMOVING THE ENGINE ...................................................................... 5-13
INSTALLING THE ENGINE..................................................................... 5-13
CAMSHAFTS................................................................................................. 5-16
REMOVING THE ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS............................................................................ 5-21
REMOVING THE CAMSHAFTS.............................................................. 5-21
CHECKING THE CAMSHAFTS .............................................................. 5-22
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 5-24
CHECKING THE ROCKER ARM BASES ............................................... 5-24
CHECKING THE PUSH RODS ............................................................... 5-24
CHECKING THE VALVE LIFTERS AND VALVE LIFTER CASES ......... 5-25
CHECKING THE PUSH ROD COVER.................................................... 5-25
CHECKING THE DECOMPRESSION SYSTEM..................................... 5-26
CHECKING THE OIL DELIVERY PIPE................................................... 5-26
INSTALLING THE CAMSHAFTS ............................................................ 5-26
BLEEDING A VALVE LIFTER ................................................................. 5-27
INSTALLING THE VALVE LIFTERS ....................................................... 5-29
INSTALLING THE ROCKER ARMS AND PUSH RODS......................... 5-29
INSTALLING THE CYLINDER HEAD COVERS ..................................... 5-30
5
CYLINDER HEADS ....................................................................................... 5-31
REMOVING THE CYLINDER HEADS .................................................... 5-32
CHECKING THE CYLINDER HEADS..................................................... 5-32
CHECKING THE OIL PIPE ..................................................................... 5-32
INSTALLING THE CYLINDER HEADS................................................... 5-33
VALVES AND VALVE SPRINGS.................................................................. 5-34

REMOVING THE VALVES...................................................................... 5-35
CHECKING THE VALVES AND VALVE GUIDES .................................. 5-35
CHECKING THE VALVE SEATS ............................................................ 5-37
CHECKING THE VALVE SPRINGS........................................................ 5-38
INSTALLING THE VALVES .................................................................... 5-40
CYLINDERS AND PISTONS......................................................................... 5-42

REMOVING THE PISTONS .................................................................... 5-43
CHECKING THE CYLINDERS AND PISTONS ...................................... 5-43
CHECKING THE PISTON RINGS........................................................... 5-44
CHECKING THE PISTON PINS.............................................................. 5-45
INSTALLING THE PISTONS AND CYLINDERS .................................... 5-45
CLUTCH ........................................................................................................ 5-47
REMOVING THE CLUTCH ..................................................................... 5-56
REMOVING THE PRIMARY DRIVE GEAR ............................................ 5-56
CHECKING THE FRICTION PLATES..................................................... 5-56
CHECKING THE CLUTCH PLATES ....................................................... 5-57
CHECKING THE CLUTCH SPRING PLATE........................................... 5-57
CHECKING THE CLUTCH HOUSING .................................................... 5-57
CHECKING THE CLUTCH BOSS........................................................... 5-57
CHECKING THE PRESSURE PLATE .................................................... 5-57
CHECKING THE CLUTCH PUSH RODS ............................................... 5-58
CHECKING THE PRIMARY DRIVE GEAR............................................. 5-58
CHECKING THE PRIMARY DRIVEN GEAR .......................................... 5-58
INSTALLING THE CRANKSHAFT POSITION SENSOR........................ 5-58
INSTALLING THE PRIMARY DRIVE GEAR........................................... 5-58
INSTALLING THE CLUTCH.................................................................... 5-59
DISASSEMBLING THE CLUTCH MASTER CYLINDER ........................ 5-60
CHECKING THE CLUTCH MASTER CYLINDER................................... 5-61
ASSEMBLING THE CLUTCH MASTER CYLINDER .............................. 5-61
INSTALLING THE CLUTCH MASTER CYLINDER................................. 5-61
REMOVING THE CLUTCH RELEASE CYLINDER ................................ 5-62
CHECKING THE CLUTCH RELEASE CYLINDER ................................. 5-62
ASSEMBLING THE CLUTCH RELEASE CYLINDER............................. 5-63
INSTALLING THE CLUTCH RELEASE CYLINDER ............................... 5-63
SHIFT SHAFT................................................................................................ 5-65

CHECKING THE SHIFT SHAFT ............................................................. 5-66
CHECKING THE STOPPER LEVER ...................................................... 5-66
INSTALLING THE SHIFT SHAFT ........................................................... 5-66
GENERATOR AND STARTER CLUTCH...................................................... 5-67

REMOVING THE GENERATOR ............................................................. 5-69
CHECKING THE STARTER CLUTCH .................................................... 5-69
INSTALLING THE GENERATOR............................................................ 5-69
ELECTRIC STARTER ................................................................................... 5-71

CHECKING THE STARTER MOTOR ..................................................... 5-73
ASSEMBLING THE STARTER MOTOR................................................. 5-74
CRANKCASE ................................................................................................ 5-75

DISASSEMBLING THE CRANKCASE.................................................... 5-78
CHECKING THE CRANKCASE .............................................................. 5-79
CHECKING THE BEARINGS AND OIL SEAL ........................................ 5-79
CHECKING THE OIL PIPE ..................................................................... 5-79
CHECKING THE OIL PUMP DRIVE ....................................................... 5-79
INSTALLING THE BEARING RETAINER ............................................... 5-79
ASSEMBLING THE CRANKCASE.......................................................... 5-79
OIL PUMP...................................................................................................... 5-82
CHECKING THE OIL PUMP ................................................................... 5-85
CHECKING THE RELIEF VALVE ........................................................... 5-85
CHECKING THE OIL STRAINER ........................................................... 5-85
ASSEMBLING THE OIL PUMP............................................................... 5-85
INSTALLING THE OIL PUMP ................................................................. 5-86
CRANKSHAFT .............................................................................................. 5-87

REMOVING THE CONNECTING RODS ................................................ 5-88
CHECKING THE CRANKSHAFT AND CONNECTING RODS ............... 5-88
INSTALLING THE CONNECTING RODS............................................... 5-91
INSTALLING THE CRANKSHAFT ASSEMBLY...................................... 5-92
TRANSMISSION............................................................................................ 5-93
CHECKING THE SHIFT FORKS............................................................. 5-96
CHECKING THE SHIFT DRUM ASSEMBLY.......................................... 5-96
CHECKING THE TRANSMISSION ......................................................... 5-96
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE .............................. 5-97
INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY ...... 5-97
ENGINE REMOVAL
EAS23710
ENGINE REMOVAL
Removing the oil tank
13 Nm (1.3 m • kg, 9.4 ft • Ib)

13 Nm (1.3 m • kg, 9.4 ft • Ib)
T.
R.
T.
R.
13 Nm (1.3 m • kg, 9.4 ft • Ib)
T.
R.
1 2
13 Nm (1.3 m • kg, 9.4 ft • Ib)
T.
R.
LS
New LS
3
LS
New
LS 4 7
13 Nm (1.3 m • kg, 9.4 ft • Ib)

T.
R.
LS
5
New
9
35 Nm (3.5 m • kg, 25 ft • Ib) 6
T.
R.
8 (16)
New
T.
R.
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-11.
Air duct 4-1.
1 Oil tank breather hose 1 Disconnect.
2 Dipstick 1
3 Oil tank inlet pipe 1
4 Oil tank outlet pipe 1
5 Oil tank 1
6 Oil tank breather hose holder 1
7 Oil tank gasket 1
8 Oil strainer cover (oil tank) 1
9 Oil strainer (oil tank) 1
dure.
5-1
ENGINE REMOVAL
ET5YU1027
CHECKING THE OIL PIPES

1. Check:
• Oil pipes
Damage → Replace.
Obstruction → Wash and blow out with com-
pressed air.
ET5YU1028
CHECKING THE OIL STRAINER

1. Check:
• Oil strainer (oil tank)
Damage → Replace.
Contaminants → Clean with engine oil.
ET5YU1019
INSTALLING THE OIL TANK

1. Install:
• Oil tank
Oil tank bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
NOTE:
Tighten the oil tank bolts in the proper tightening
sequence as shown.
8
10 6
4 2
16
12 15
14 13
11
1
9
5
7 3
5-2
ENGINE REMOVAL
Removing the exhaust pipe
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
24 Nm (2.4 m • kg, 17 ft • Ib) LT 5
T.
R.
6 8
7
LT
LT
5
6
8
New 9
20 Nm (2.0 m • kg, 14 ft • Ib)
. T
R.
New 11
7 New
9 New 11 10
13
7 Nm (0.7 m • kg, 5.1 ft • Ib) 13
New
.
R
20 Nm (2.0 m • kg, 14 ft • Ib) 14 New

T.
R.
4
12
45 Nm (4.5 m • kg, 32 ft • Ib)
T.
R.
1
10 Nm (1.0 m • kg, 7.2 ft • Ib) 3
T.
20 Nm (2.0 m • kg, 14 ft • Ib)

R.
(3)
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)

2
.
R.
6 Nm (0.6 m • kg, 4.3 ft • Ib)

T.
R.

Seat 4-1.
1 EXUP valve pulley cover 1
2 EXUP cable 2 Disconnect.
3 O2 sensor cover 1
4 O2 sensor 1
5 Muffler end cover 2
6 Muffler end cover plate 2
7 Muffler cover 2
8 Muffler 2
9 Gasket 2
10 Front exhaust pipe 1
11 Gasket 2
12 Rear exhaust pipe 1
13 Gasket 2
14 Catalyst pipe 1
dure.
5-3
ENGINE REMOVAL
ET5YU1029
REMOVING THE MUFFLER END COVERS 1

1. Remove:
• Muffler end covers “1” a
NOTE:
Before removing a muffler end cover, turn it in
the direction of the arrow shown in the illustra-
tion.
1 1
1 1
ET5YU1030
INSTALLING THE MUFFLER END COVERS

1. Install:
• Muffler covers “1”
• Muffler end cover plates “2”
NOTE:
When installing a muffler end cover plate, be
sure to insert its hooks “a” (two locations) into
the holes in the muffler cover and align its tabs
“b” (four locations) with the grooves in the muf-
fler cover.
b
a
b
2 b
2. Install:
• Muffler end covers “1”
NOTE:
When installing a muffler end cover, align its pro-
jections “a” (four locations) with the grooves “b”
in the muffler cover, and then turn it in the direc-
tion of the arrow shown in the illustration.
5-4
ENGINE REMOVAL
Removing the EXUP servo motor and rear exhaust pipe joint
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
R.
12 10 9
11
15
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
20
19
16 17 Nm (1.7 m • kg, 12 ft • Ib)
T.
R.
22 24 17
New
18 LS
4
23 New
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
LS
2 3
13 14 LT LS 1
21 6
New 5
LS 7
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
8
13 Nm (1.3 m • kg, 9.4 ft • Ib)
24 Nm (2.4 m • kg, 17 ft • Ib) New
T.
R.
T.
R.

T.
T.
R.
R.

Air filter case/Oil catch tank/Air duct 4-1.
Throttle body/Intake manifold/Rollover valve Refer to “THROTTLE BODIES” on page 6-4.
bracket
Refer to “ISC (IDLE SPEED CONTROL)
ISC (idle speed control) unit UNIT” on page 6-11.
Shift arm Refer to “CLUTCH” on page 5-47.
Refer to “ELECTRIC STARTER” on page
Starter motor 5-71.
Refer to “GENERATOR AND STARTER
Oil pipe 2 CLUTCH” on page 5-67.
Drive sprocket Refer to “CHAIN DRIVE” on page 4-68.
Refer to “REAR SHOCK ABSORBER AS-
Rear shock absorber assembly SEMBLY” on page 4-60.
1 Rectifier/regulator coupler 1 Disconnect.
2 Stator coil assembly coupler 1 Disconnect.
3 Rectifier/regulator 1
4 Oil filter cartridge 1
5 Horn connector 2 Disconnect.
5-5
ENGINE REMOVAL
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
R.
12 10 9
11
15
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
20
19
16 17 Nm (1.7 m • kg, 12 ft • Ib)
T.
R.
22 24 17
New
18 LS
4
23 New
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
LS
2 3
13 14 LT LS 1
21 6
New 5
LS 7
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
8
13 Nm (1.3 m • kg, 9.4 ft • Ib)
24 Nm (2.4 m • kg, 17 ft • Ib) New
T.
R.
T.
R.

T.
T.
R.
R.

6 Horn 1
7 Oil pump outlet pipe 1
8 Oil pump inlet pipe 1
9 Sidestand switch coupler 1 Disconnect.
10 Shift rod 1
11 Left rider footrest assembly 1
12 Sidestand assembly 1
13 Right rider footrest assembly 1
14 Drive sprocket case assembly 1
15 Left side panel assembly 1
16 Right side panel 1
17 EXUP servo motor coupler 1 Disconnect.
18 EXUP servo motor 1
19 O2 sensor coupler 1
20 Neutral switch coupler 1 Disconnect.
21 Neutral switch 1
22 Rear exhaust pipe joint cover 1
5-6
ENGINE REMOVAL
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
R.
12 10 9
11
15
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
20
19
16 17 Nm (1.7 m • kg, 12 ft • Ib)
T.
R.
22 24 17
New
18 LS
4
23 New
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
LS
2 3
13 14 LT LS 1
21 6
New 5
LS 7
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
8
13 Nm (1.3 m • kg, 9.4 ft • Ib)
24 Nm (2.4 m • kg, 17 ft • Ib) New
T.
R.
T.
R.

T.
T.
R.
R.

23 Rear exhaust pipe joint 1
24 Gasket 1
dure.
5-7
ENGINE REMOVAL
Removing the leads

10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
9
11
8
11
10
1
2

1 Stator coil assembly lead 1
2 Horn lead 1
3 Wire harness 1
4 Decompression solenoid coupler 2 Disconnect.
5 Speed sensor coupler 1 Disconnect.
6 Starter motor connector 1
7 Starter motor lead 1
8 Crankshaft position sensor coupler 1 Disconnect.
9 Negative battery lead 1 Disconnect.
10 Engine temperature sensor coupler 1 Disconnect.
11 Spark plug cap 4
dure.
5-8
ENGINE REMOVAL
Removing the down tube

T.
T.
R.
R.
2 E 7 3
17 3
4 53 Nm (5.3 m • kg, 38 ft • Ib)
T.
R.
1
15
6
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
74 Nm (7.4 m • kg, 53 ft • lb) 15 5

.
7 Nm (0.7 m kg, 5.1 ft Ib)

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

T.
R.
LT
LT
16
94 Nm (9.4 m • kg, 68 ft • Ib)
T.
R.
13
11 18
E 14
12 55 Nm (5.5 m • kg, 40 ft • Ib)

T.
R.
8 20
19
11
10
12 9
T.
R.
T.
R.
NOTE:
Place a suitable stand under the frame and
engine.
1 Engine mounting bolt (right upper side) 1 l = 65 mm (2.56 in)

2 Engine mounting bolt (right upper side) 1 l = 80 mm (3.15 in)
3 Engine mounting bolt (left upper side) 2
4 Engine bracket bolt (right upper side) 2
5 Engine bracket bolt (left upper side) 2
6 Engine bracket (right upper side) 1
7 Engine bracket (left upper side) 1
8 Engine mounting nut (front upper side) 1
9 Engine mounting bolt (front upper side) 1
10 Engine bracket nut (front upper side) 4
11 Engine bracket bolt (front upper side) 4
12 Engine bracket (front upper side) 2
13 Down tube nut (rear side) 2
14 Down tube bolt (rear side) 2
5-9
ENGINE REMOVAL
Removing the down tube

T.
T.
R.
R.
2 E 7 3
17 3
4 53 Nm (5.3 m • kg, 38 ft • Ib)
T.
R.
1
15
6
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
74 Nm (7.4 m • kg, 53 ft • lb) 15 5

.
7 Nm (0.7 m kg, 5.1 ft Ib)

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

T.
R.
LT
LT
16
94 Nm (9.4 m • kg, 68 ft • Ib)
T.
R.
13
11 18
E 14
12 55 Nm (5.5 m • kg, 40 ft • Ib)

T.
R.
8 20
19
11
10
12 9
T.
R.
T.
R.

15 Down tube nut (front side) 2
16 Down tube spacer bolt 2 Loosen.
17 Down tube bolt (front side) 2
18 Engine mounting nut (front lower side) 1
19 Engine mounting bolt (front lower side) 1
20 Down tube 1
dure.
5-10
ENGINE REMOVAL
Removing the engine

7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
74 Nm (7.4 m • kg, 53 ft • lb) 53 Nm (5.3 m • kg, 38 ft • Ib)
T.
R.
T.
4
R.
11 13
1 12
10
14
3
E
2 6
E 8
7
74 Nm (7.4 m • kg, 53 ft • lb)
T.
R.
8 Nm (0.8 m • kg, 5.8 ft • Ib)

T.
R.
8 Nm (0.8 m • kg, 5.8 ft • Ib) 9

T.
R.
NOTE:
Place a suitable stand under the frame and
engine.
1 Engine mounting nut (rear upper side) 1

2 Engine mounting spacer bolt (rear upper side) 1 Loosen.
3 Engine mounting bolt (rear upper side) 1
4 Engine bracket nut (rear upper side) 2
5 Engine bracket bolt (rear upper side) 2
6 Engine mounting nut (rear lower side) 1
7 Engine mounting spacer bolt (rear lower side) 1 Loosen.
8 Engine mounting bolt (rear lower side) 1
9 Engine 1
10 Right side panel bracket 1
11 Cylinder-#1 right ignition coil 1
12 Cylinder-#1 left ignition coil 1
13 Ignition coil bracket 1
5-11
ENGINE REMOVAL
Removing the engine

7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
74 Nm (7.4 m • kg, 53 ft • lb) 53 Nm (5.3 m • kg, 38 ft • Ib)
T.
R.
T.
4
R.
11 13
1 12
10
14
3
E
2 6
E 8
7
74 Nm (7.4 m • kg, 53 ft • lb)
T.
R.
8 Nm (0.8 m • kg, 5.8 ft • Ib)

T.
R.
8 Nm (0.8 m • kg, 5.8 ft • Ib) 9

T.
R.

14 Engine bracket (rear upper side) 1
dure.
5-12
ENGINE REMOVAL
ET5YU1031
3. Position the engine “6” under the vehicle for
REMOVING THE ENGINE
installation.
NOTE: 4. Install:
Pass a suitable rod through the hole in the swin- • Engine “6”
garm pivot shaft and secure the rod to support • Engine mounting bolt (rear upper side) “7”
the vehicle. • Engine mounting bolt (rear lower side) “8”
• Down tube “9”
• Down tube bolts (front side) “10”
• Down tube bolts (rear side) “11”
• Down tube nut (rear side) “12”
(temporarily tighten)
• Engine mounting bolt (front lower side) “13”
NOTE:
Do not fully tighten the bolts and nuts.
5. Tighten:
• Down tube spacer bolt “2”
1. Loosen: • Engine mounting spacer bolt (rear lower side)
• Down tube spacer bolts “3”
• Engine mounting spacer bolt (rear upper • Engine mounting spacer bolt (rear upper
side) side) “1”
• Engine mounting spacer bolt (rear lower side) • Down tube nut (rear side) “12”
NOTE:
Down tube spacer bolt
Loosen the spacer bolts with the pivot shaft 8 Nm (0.8 m·kg, 5.8 ft·lb)
T.
wrench “1”.
R.

(rear lower side)
Pivot shaft wrench 8 Nm (0.8 m·kg, 5.8 ft·lb)
90890-01485 Engine mounting spacer bolt
Frame mount insert wrench (rear upper side)
YM-01485 8 Nm (0.8 m·kg, 5.8 ft·lb)
Down tube nut (rear side)
55 Nm (5.5 m·kg, 40 ft·lb)
NOTE:
1 • Tighten the spacer bolts “1”, “2”, “3” to specifi-
cation with a pivot shaft wrench.
• When tightened, the spacer bolts should be flat
against the engine surface.
Pivot shaft wrench

90890-01485
EAS23720
Frame mount insert wrench
INSTALLING THE ENGINE YM-01485
1. Loosen:
6. Install:
• Engine mounting spacer bolt (rear upper
• Down tube nut (front side) “14”
side) “1”
• Down tube spacer bolts “2”
• Engine mounting nut (rear lower side) “15”
• Engine mounting spacer bolt (rear lower side)
“3”
• Engine mounting nut (rear upper side) “16”
2. Install:
• Engine bracket (rear upper side) “4”
(with the ignition coils)
• Engine bracket bolts (rear upper side) “5”
5-13
ENGINE REMOVAL
NOTE:
Engine mounting nut (front lower
Do not fully tighten the bolts and nuts. side)
T.
R.
7. Tighten: 94 Nm (9.4 m·kg, 68 ft·lb)
• Down tube nut (front side) “14” Engine bracket nut (front upper
• Engine mounting nut (rear lower side) “15” side)
• Engine mounting nut (rear upper side) “16” 53 Nm (5.3 m·kg, 38 ft·lb)
Engine mounting nut (front upper
• Engine bracket nuts (rear upper side) “17”
side)
Down tube nut (front side) 94 Nm (9.4 m·kg, 68 ft·lb)
74 Nm (7.4 m·kg, 53 ft·lb) Engine bracket bolt (left upper
T.
side)
R.
Engine mounting nut (rear lower

side) 53 Nm (5.3 m·kg, 38 ft·lb)
74 Nm (7.4 m·kg, 53 ft·lb) Engine mounting bolt (left upper
Engine mounting nut (rear upper side)
74 Nm (7.4 m·kg, 53 ft·lb) Engine bracket bolt (right upper
Engine bracket nut (rear upper side)
53 Nm (5.3 m·kg, 38 ft·lb) Engine mounting bolt (right up-
per side)
• Engine brackets (front upper side) “18”
• Engine bracket bolts (front upper side) “19”
• Engine mounting bolt (front upper side) “20”
• Engine mounting nut (front lower side) “21” 17
• Engine mounting nut (front upper side) “22”
• Engine bracket nuts (front upper side) “23” 16
(temporarily tighten) 4
• Engine bracket (left upper side) “24” 7
• Engine bracket bolts (left upper side) “25” 15
• Engine mounting bolts (left upper side) “26” 5
(temporarily tighten) 1
• Engine bracket (right upper side) “27” 3 8
• Engine bracket bolts (right upper side) “28”
• Engine mounting bolt (right upper side) “29”
• Engine mounting bolt (right upper side) “30” 6
NOTE:
Do not fully tighten the bolts and nuts.
9. Tighten:
• Engine mounting nut (front lower side) “21”
• Engine mounting nut (front upper side) “22”
• Engine bracket nuts (front upper side) “23”
• Engine bracket bolts (left upper side) “25”
• Engine mounting bolts (left upper side) “26”
• Engine bracket bolts (right upper side) “28”
• Engine mounting bolts (right upper side) “29”
and “30”
5-14
ENGINE REMOVAL
26 24
26
30 28
10
14
29
27 25
2
19 21 12
11
18
9
22 13
19
23 18 20
5-15
CAMSHAFTS
EAS23750
CAMSHAFTS
Removing the camshaft sprocket cover
18 Nm (1.8 m • kg, 13 ft • Ib)

1
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
1
New
2
4
LS
New
8 Nm (0.8 m • kg, 5.8 ft • Ib)

T.
R.
7
(6)
6 New
5
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

Engine Refer to “ENGINE REMOVAL” on page 5-1.
1 Spark plug 4
2 Timing mark accessing screw 1
3 Crankshaft end cover 1
4 Decompression solenoid cover 1
5 Camshaft sprocket cover 1
6 Camshaft sprocket cover gasket 1
7 Dowel pin 2
dure.
5-16
CAMSHAFTS
Removing cylinder head covers

10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
1 2 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
1 4 3 New
1
2 5 7 LS
4 7
New 3 6
7 6 7
LS LT
LT
7 6 5 6
6 6
6 LT 7
7 6
4
7 7 4
6
8 9
10 New
11
6
New 10
11 11
11
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

1 Tappet cover bolt 4
2 Tappet cover 2
3 O-ring 2
4 Cylinder head cover bolt 4 l = 60 mm (2.36 in)
8 Rear cylinder head cover 1
9 Front cylinder head cover 1
10 Cylinder head cover gasket 2
11 Dowel pin 4
dure.
5-17
CAMSHAFTS
Removing the push rods and rocker arms

10 Nm (1.0 m • kg, 7.2 ft • Ib)
T
20 Nm (2.0 m • kg, 14 ft • Ib)
.
R.
T.
R.
24 Nm (2.4 m • kg, 17 ft • Ib)
T.
12
R.
12 10 12 13
1 13 11 13 E
10
2
12
13
11
E
9
9
8
E 9
7 E
4
4 E
E New 3 4
5 3 New
E
6 5
E
E E

1 Rear rocker arm base assembly 1
2 Front rocker arm base assembly 1
3 Rocker arm base gasket 2
4 Dowel pin 4
5 Push rod 1 3 l = 288.5 mm (11.358 in) green painting
6 Push rod 2 1 l = 290.5 mm (11.437 in) yellow painting
7 Rear rocker arm base 1
8 Front rocker arm base 1
9 Rocker arm shaft 4
10 Rocker arm 1 2
11 Rocker arm 2 2
12 Locknut 4
13 Adjusting screw 4
dure.
5-18
CAMSHAFTS
Removing the valve lifters
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
LT
LT
E
2 New
4 E
5
LT
LT
New New
New
1
New 2
E
E 6
1
New 3
6
New 2
E 3 New
New
E E
2 New

Refer to “CYLINDERS AND PISTONS” on
Front cylinder page 5-42.
1 Push rod cover 2
2 O-ring 4
3 Seal 2
4 Rear valve lifter case 1
5 Front valve lifter case 1
6 Valve lifter 4
dure.
5-19
CAMSHAFTS
Removing the camshafts
LS
12
13 M
9
New
11 New
10
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
(6)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
14
T.
R.
12
LT
LT
M 8
3
LT
LT 2
6
7
5
4
1 30 Nm (3.0 m • kg, 22 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
52 Nm (5.2 m • kg, 37 ft • Ib)

T.
R.

1 Decompression solenoid 1
2 Long decompression push rod 1 92 mm (3.6 in)
3 Short decompression push rod 1 78 mm (3.1 in)
4 Camshaft drive gear 1
5 Straight key 1
6 Camshaft driven gear 1
7 Straight key 1
8 Front cylinder camshaft end cover 1
9 Oil delivery pipe 1
10 Camshaft cover 1
11 Camshaft cover gasket 1
12 Dowel pin 2
13 Front cylinder camshaft 1
14 Rear cylinder camshaft 1
dure.
5-20
CAMSHAFTS
EAS23790
REMOVING THE ROCKER ARMS, PUSH

RODS AND VALVE LIFTERS
1. Align:
• TDC mark “a” on the crankshaft position sen-
sor rotor
(with the pointer “b” on the clutch cover)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise.
sion stroke, align the TDC mark “a” on the
b a
EAS23830
REMOVING THE CAMSHAFTS

c. Check the camshaft drive gear mark “c” posi- 1. Loosen:
tion and camshaft driven gear mark “d” posi- • Front cylinder camshaft end cover bolts “1”
tion as shown. • Camshaft drive gear bolt “2”
If the marks are not aligned, turn the crank-
NOTE:
shaft counterclockwise 360 degrees and re-
check step (b). • Place a folded copper washer “3” between the
teeth of the camshaft drive gear and camshaft
driven gear in order to lock them.
• Do not damage the teeth of the camshaft drive
and camshaft driven gears.
d
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Remove:
• Rocker arm bases
(with the rocker arms)
3. Remove: 2. Loosen:
• Valve lifters • Camshaft driven gear nut “1”
NOTE: NOTE:
Make a note of the position of each valve lifter so • Place a folded copper washer “2” between the
that they can be installed in the correct place. teeth of the camshaft drive gear and camshaft
EC5YU1015
CAUTION: • Do not damage the teeth of the camshaft drive
and camshaft driven gears.
Do not lay the removed valve lifter on its
side.
5-21
CAMSHAFTS
EAS23860
CHECKING THE CAMSHAFTS

1. Check:
• Cam
Blue discoloration/pitting/scratches → Re-
place the camshaft.
2. Measure:
• Cam dimensions “a” and “b”
Out of specification → Replace the camshaft.
Camshaft lobe dimensions

3. Remove: Intake A
• Camshaft drive gear “1” 38.241–38.341 mm (1.5055–
• Camshaft driven gear “2” 1.5095 in) (cylinder #1)
38.243–38.343 mm (1.5056–
• Straight keys
1.5096 in) (cylinder #2)
• Front cylinder camshaft end cover Limit
NOTE: 38.141 mm (1.5016 in) (cylinder
Cover the crankcase hole with a clean rag “3” to #1)
prevent the straight keys from falling into the 38.143 mm (1.5017 in) (cylinder
crankcase. #2)
Intake B
31.950–32.050 mm (1.2579–
1.2618 in)
Limit
31.850 mm (1.2539 in)
Exhaust A
38.236–38.336 mm (1.5054–
1.5093 in)
Limit
38.136 mm (1.5014 in)
Exhaust B
31.950–32.050 mm (1.2579–
4. Remove: 1.2618 in)
• Oil delivery pipe “1” Limit
• Camshaft cover “2” 31.850 mm (1.2539 in)
(along with the camshafts)
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.
5-22
CAMSHAFTS
5. Measure:
• Crankcase hole inside diameter “a”
Out of specification → Replace the crank-
case.
Crankcase hole inside diameter

25.000–25.021 mm (0.9843–
0.9851 in)
3. Measure:
• Camshaft journal diameter (crankcase side)
“a”
Camshaft journal diameter

(crankcase side)
24.942–24.965 mm (0.9820–
0.9829 in)
6. Measure:
• Camshaft cover hole inside diameter “a”
Out of specification → Replace the camshaft
cover.
Camshaft cover hole inside diam-

eter
28.000–28.021 mm (1.1024–
1.1032 in)
4. Measure:
• Camshaft journal diameter (camshaft cover
side) “a”
Camshaft journal diameter (cam-

shaft cover side)
27.967–27.980 mm (1.1011–
1.1016 in)
7. Calculate:
• Camshaft-to-crankcase clearance
Out of specification → Replace the defective
part(s).
NOTE:
Calculate the clearance by subtracting the
crankcase side camshaft journal diameter
(crankcase side) from the crankcase hole inside
diameter.
Camshaft to crankcase clearance

0.035–0.079 mm (0.0014–0.0031
in)
5-23
CAMSHAFTS
8. Calculate: 4. Measure:
• Camshaft to camshaft cover clearance • Rocker arm shaft outside diameter “a”
Out of specification → Replace the defective Out of specification → Replace.
part(s).
NOTE:
Rocker arm shaft outside diame-
ter
Calculate the clearance by subtracting the cam- 17.976–17.991 mm (0.7077–
shaft journal diameter (camshaft cover side) 0.7083 in)
from the camshaft cover hole inside diameter.
Camshaft to camshaft cover

clearance
0.020–0.054 mm (0.0008–0.0021
in)
9. Check:
• Camshaft drive gears
• Camshaft driven gears
Chips/pitting/roughness/wear → Replace the
defective part(s).
5. Calculate:
EAS23890
• Rocker arm to rocker arm shaft clearance
CHECKING THE ROCKER ARMS AND
NOTE:
ROCKER ARM SHAFTS
The following procedure applies to all of the Calculate the clearance by subtracting the rock-
rocker arms and rocker arm shafts. er arm shaft outside diameter from the rocker
1. Check: arm inside diameter.
• Rocker arm Above 0.08 mm (0.003 in) → Replace the de-
Damage/wear → Replace. fective part(s).
2. Check:
• Rocker arm shaft Rocker-arm-to-rocker-arm-shaft
Blue discoloration/excessive wear/pitting/ clearance
scratches → Replace or check the lubrication 0.009–0.042 mm (0.0004–0.0017
system. in)
3. Measure:
EAS23900
• Rocker arm inside diameter “a” CHECKING THE ROCKER ARM BASES
Out of specification → Replace. 1. Check:
Rocker arm inside diameter • Rocker arm base
18.000–18.018 mm (0.7087– Cracks/damage → Replace.
0.7094 in) EAS23910
Limit CHECKING THE PUSH RODS
18.036 mm (0.7101 in) 1. Check:
• Push rod
• Push rod end
Bends/damage → Replace.
2. Measure:
• Push rod runout
Out of specification → Replace.
Valve push rod runout

0.3 mm (0.012 in)
5-24
CAMSHAFTS
EAS23920 4. Measure:
CHECKING THE VALVE LIFTERS AND • Valve lifter case inside diameter “a”
VALVE LIFTER CASES Out of specification → Replace.
1. Check:
• Valve lifter Valve lifter hole inside diameter
Blue discoloration/excessive wear/pitting/ (intake)
scratches → Replace and check the lubrica- 23.000–23.021 mm (0.9055–
tion system. 0.9063 in)
Valve lifter hole inside diameter
2. Check:
(exhaust)
• Valve lifter case “1” 23.000–23.021 mm (0.9055–
Damage/wear → Replace the valve lifter 0.9063 in)
case.
• Seal “2”
• O-ring “3”
Damage/wear → Replace the O-ring.
5. Calculate:
• Valve lifter-to-valve lifter case clearance
NOTE:
3. Measure:
Calculate the clearance by subtracting the valve
• Valve lifter outside diameter “a”
lifter case outside diameter.
Above 0.072 mm (0.0028 in) → Replace the
Valve lifter outside diameter (in- defective part(s).
take)
22.962–22.974 mm (0.9040– Valve-lifter-to-valve-lifter-hole
0.9045 in) clearance
Valve lifter outside diameter (ex- 0.0260–0.0590 mm (0.0010–
haust) 0.0023 in)
22.962–22.974 mm (0.9040–
0.9045 in) EAS23930
CHECKING THE PUSH ROD COVER

1. Check:
• Push rod cover
Cranks/damage → Replace.
• Seal
5-25
CAMSHAFTS
• O-ring
Damage/wear → Replace the oil seal and O-
ring as a set.
EAS23980
CHECKING THE DECOMPRESSION SYSTEM

1. Check:
• Decompression system
NOTE:
• Check the decompression system while the
decompression push rod is installed in the
camshaft. 2. Install:
• Check that the decompression pin “1” projects • Camshaft cover “1”
from the camshaft. (along with the camshafts)
• Check that the decompression push rod “2” • Camshaft oil delivery pipe “2”
moves smoothly. NOTE:
Tighten the camshaft cover bolts in stages and
in a crisscross pattern.
2. Check:
• Decompression push rods
Bends/damage → Replace. 3. Install:
EAS23990
• Front cylinder camshaft end cover “1”
CHECKING THE OIL DELIVERY PIPE NOTE:
1. Check: • Install the front cylinder camshaft end cover “1”
• Oil delivery pipe with its punch marks “a” aligned vertically.
Damage → Replace. • Finger-tighten the bolts.
pressed air.
• O-rings 1
EAS24030
INSTALLING THE CAMSHAFTS

1. Install: a
• Camshafts
(to the camshaft cover)
NOTE:
• Lubricate molybdenum disulfide oil onto the
4. Install:
camshaft journals and lobes.
• Straight keys
• Align the punch mark “a” on the rear cylinder
• Camshaft drive gear “1”
camshaft with the punch mark “b” on the front
• Camshaft driven gear “2”
cylinder camshaft.
5-26
CAMSHAFTS
NOTE:
• Cover the crankcase hole with a clean rag “3”
to prevent the straight keys from falling into the
crankcase.
• Align the punch mark “a” on the camshaft drive
gear “1” with the punch mark “b” on the cam-
shaft driven gear “2”.
• Insert a cross-headed screwdriver into one of
the holes in the outer camshaft driven gear and
rotate the gear until the teeth of both driven
gears are aligned. The teeth of both camshaft 6. Tighten:
driven gears must be aligned for installation. • Camshaft drive gear bolt “1”
• Front cylinder camshaft end cover bolts “2”
Camshaft drive gear bolt

30 Nm (3.0 m·kg, 22 ft·lb)
T.
R.
Front cylinder camshaft end cov-
er bolt
7 Nm (0.7 m·kg, 5.1 ft·lb)
LOCTITE®
NOTE:
• Place a folded copper washer “3” between the
• Do not damage the teeth of the camshaft drive
and camshaft driven gear.
• After tightening the camshaft drive gear bolt,
remove the copper washer to clean the teeth of
the camshaft drive gear and camshaft driven
gear.
5. Tighten:
• Camshaft driven gear nut “1”
Camshaft driven gear nut

52 Nm (5.2 m·kg, 37 ft·lb)
T.
R.
NOTE:
• Place a folded copper washer “2” between the
EAS24050
driven gear in order to lock them. BLEEDING A VALVE LIFTER
• Do not damage the teeth of the camshaft drive A valve lifter must be bled in the following cases.
and camshaft driven gear. • When installing a new valve lifter
• After tightening the camshaft driven gear nut, • When the valve lifter leaks oil
remove the copper washer to clean the teeth of 1. Bleed:
the camshaft drive gear and camshaft driven • Valve lifter
gear. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill a container with kerosene and place the
valve lifter into the container as shown.
5-27
CAMSHAFTS
Pump the plunger side of the valve lifter with

a press a number of times to let in kerosene.
ECA14630
CAUTION:
• Do not pump the valve lifter excessively.
• Kerosene is highly flammable.
1. Kerosene
2. Valve lifter
b. Install the valve lifter into the engine.
ECA14650
CAUTION:
1. Piston #1 TDC punch mark
Be sure to install the valve lifter in its appro- 2. Cylinder-#2 intake valve at its highest point
priate position. 3. Cylinder-#1 exhaust valve at its highest point
c. Start the engine and warm it up. 4. Cylinder-#1 intake valve at its highest point
d. Stop the engine. 5. Cylinder-#2 exhaust valve at its highest point
e. Remove the camshaft sprocket cover. h. Rotate the crankshaft until the mark (on the
f. Rotate the camshaft until the punch mark “1” camshaft driven gear) for the valve lifter to be
on the camshaft driven gear aligns with the bled aligns with the camshaft drive gear as
punch mark on the camshaft drive gear as shown.
shown. This is the condition in which piston Example:
#1 is at top dead center (TDC). For bleeding the cylinder-#2 intake valve lift-
NOTE: er, align mark “2” as shown.
The crankshaft can be rotated smoothly when
the spark plugs are removed.
EWA12880
WARNING
Be careful since the engine is hot.
g. With piston #1 at TDC, count the indicated
number of gear teeth and place marks “2”
through “5” on the camshaft driven gear as
shown. When these marks align between the
centers of the camshaft drive and driven
gears, the corresponding valve lifter is at its
highest point.
5-28
CAMSHAFTS
EAS24070
INSTALLING THE ROCKER ARMS AND

PUSH RODS
The following procedure applies to both cylin-
ders.
1. Install:
• Rocker arms “1”
• Rocker arm shafts “2”
(onto rocker arm base)
NOTE:
The thread hole “a” of the rocker arm shaft must
face to the outside.
1. Piston #1 TDC punch mark

2. Cylinder-#2 intake valve at its highest point 2. Install:
i. Leave the camshaft drive and driven gears • Rocker arm base
aligned for five minutes to allow the valve lift- (with rocker arms)
er to bleed. • Push rods
j. If necessary, repeat steps (h) and (i) to bleed ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
other valve lifters. a. Put the rocker arm base on the cylinder head.
b. Install the push rods.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
NOTE:
EAS24060
INSTALLING THE VALVE LIFTERS • Be sure to correctly install the push rods be-
1. Install: tween the rocker arms and valve lifters as
• Front valve lifter case shown. The illustration is viewed from the right
• Rear valve lifter case side of the vehicle.
• Valve lifters • The lengths of push rod 1 and push rod 2 are
NOTE: different. Therefore, be sure to install them in
the proper position.
• Install the valve lifter in the correct place.
• Lubricate the push rod end balls with engine
• After installing the valve lifters, fill the tops of
oil.
them with engine oil.
5-29
CAMSHAFTS
NOTE:
Apply locking agent (LOCTITE®) to the threads
of the bolt “3”.
Cylinder head cover bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
Bolts “3”, “4”: l = 40 mm (1.57 in)
Bolts “5”: l = 50 mm (1.97 in)
Bolt with washer “6”: l = 50 mm (1.97 in)
A. Rear cylinder Bolts “7”: l = 60 mm (2.36 in)
B. Front cylinder 7 5
1. Intake side rocker arm 4
2. Exhaust side rocker arm
3. Intake valve lifter
LT 3
4. Exhaust valve lifter
5. Push rod 1 l = 288.5 mm (11.358 in)
1
6. Push rod 2 l = 290.5 mm (11.437 in)
c. Install the rocker arm base bolts (M6) “1”, “2” 4
and the rocker arm base bolts (M8) “3”. 5 7
NOTE:
Tighten the rocker arm base bolts in stages and 5 6 7
in a crisscross pattern.
Rocker arm base bolt (M6) 4

10 Nm (1.0 m·kg, 7.2 ft·lb)
3
T.
R.
LT
Rocker arm base bolt (M8)
24 Nm (2.4 m·kg, 17 ft·lb) 2
4
Bolts “1”: l = 36 mm (1.42 in) 7 5
6
Bolts “2”: l = 40 mm (1.57 in)
2. Install:
• Tappet covers “1”
NOTE:
Install the tappet covers with their “UP” marks “a”
facing each other.
Tappet cover bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
1 a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24080 UP
INSTALLING THE CYLINDER HEAD

COVERS
The following procedure applies to both cylin-
ders.
1. Install: UP
• Front cylinder head cover “1”

• Rear cylinder head cover “2” 1 a
5-30
CYLINDER HEADS
EAS24110
CYLINDER HEADS
Removing the cylinder heads
45 Nm (4.5 m • kg, 32 ft • Ib)

T.
R.
39 Nm (3.9 m • kg, 28 ft • Ib)

T.
R.
E
21 Nm (2.1 m • kg, 15 ft • Ib)
7
T.
R.
4 New
E
E
New 4
New 9
3
10
6
5 New
8
New
2 New 9
1
18 Nm (1.8 m • kg, 13 ft • Ib)
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib) 10

T.
R.
10

Cylinder head covers/Rocker arms Refer to “CAMSHAFTS” on page 5-16.
1 Front exhaust pipe joint 1
2 Front exhaust pipe joint gasket 1
3 Oil pipe 1 1 From crankcase to cylinder heads.
4 Copper washer 4
5 Copper washer 2
6 Engine temperature sensor 1
7 Rear cylinder head 1
8 Front cylinder head 1
9 Cylinder head gasket 2
10 Dowel pin 4
dure.
5-31
CYLINDER HEADS
EAS24140
REMOVING THE CYLINDER HEADS

1. Remove:
• Cylinder head nuts
NOTE:
• Loosen the nuts in the proper sequence as
shown.
• Loosen each nut 1/2 of a turn at a time. After all
of the nuts are fully loosened, remove them.
2. Check:
• Cylinder head
3. Measure:
• Cylinder head warpage
Out of specification → Resurface the cylinder
head.
Warpage limit
B 0.03 mm (0.0012 in)
3
6 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge and a thickness gauge
2 1 across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder
5 head as follows.
4
d. Place a 400–600 grit wet sandpaper on the
surface plate and resurface the cylinder head
using a figure-eight sanding pattern.
A. Front cylinder NOTE:
B. Rear cylinder To ensure an even surface, rotate the cylinder
EAS24170 head several times.
CHECKING THE CYLINDER HEADS
The following procedure applies to all of the cyl-
inder heads.
1. Eliminate:
• Combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damag-
ing or scratching:
• Spark plug bore threads
• Valve seats
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24220
CHECKING THE OIL PIPE

1. Check:
• Oil pipe
Damage → Replace.
pressed air.
5-32
CYLINDER HEADS
EAS24250
INSTALLING THE CYLINDER HEADS

1. Tighten:
• Cylinder head nuts (M12) “1”–“4”
Cylinder head nut (M12)

45 Nm (4.5 m·kg, 32 ft·lb)
T.
R.
• Cylinder head nuts (M10) “5”, “6”
Cylinder head nut (M10)

39 Nm (3.9 m·kg, 28 ft·lb)
T.
R.
NOTE:
• Lubricate the cylinder head nuts with engine
oil.
• Tighten the cylinder head nuts in the proper
tightening sequence as shown and torque
them in two stages.
B
4
1
5 6
3 2
A. Front cylinder
B. Rear cylinder
5-33
VALVES AND VALVE SPRINGS
EAS24270

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

The following procedure applies to both cyl-
inders.
Cylinder heads Refer to “CYLINDER HEADS” on page 5-31.
1 Valve cotter 8
2 Upper spring seat 4
3 Outer valve spring 4
4 Inner valve spring 4
5 Intake valve 2
6 Exhaust valve 2
7 Valve stem seal 4
8 Lower spring seat 4
9 Valve guide 4
dure.
5-34
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 5-37. • 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 GUIDES
NOTE: The following procedure applies to all of the
Remove the valve cotters by compressing the valves and valve guides.
valve springs with the valve spring compressor 1. Measure:
set “1”. • 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 stem diameter “b”
5-35
Valve-stem-to-valve-guide clear-
ance (intake)
0.010–0.037 mm (0.0004–0.0015
in)
Limit
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear-
ance (exhaust)
0.025–0.052 mm (0.0010–0.0020
in)
Limit
b. Install the new valve guide with the valve
0.100 mm (0.0039 in)
guide installer “2” and valve guide remover
“1”.
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.
2. Replace:
• Valve guide
NOTE:
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder NOTE:
head to 100 °C (212 °F) in an oven.
After replacing the valve guide, reface the valve
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ seat.
a. Remove the valve guide with the valve guide
remover “1”.
5-36
• If the valve is removed or replaced, always re-

Valve guide remover (ø6) place the oil seal.
90890-04064
Valve guide remover (6.0 mm)
YM-04064-A Valve stem runout
Valve guide installer (ø6) 0.010 mm (0.0004 in)
90890-04065
Valve guide installer (6.0 mm)
YM-04065-A
Valve guide reamer (ø6)
90890-04066
Valve guide reamer (6.0 mm)
YM-04066
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
EAS24300
4. Check: CHECKING THE VALVE SEATS
• Valve face The following procedure applies to all of the
Pitting/wear → Grind the valve face. valves and valve seats.
• Valve stem end 1. Eliminate:
Mushroom shape or diameter larger than the • Carbon deposits
body of the valve stem → Replace the valve. (from the valve face and valve seat)
5. Measure: 2. Check:
• Valve margin thickness D “a” • Valve seat
Out of specification → Replace the valve. Pitting/wear → Replace the cylinder head.
Valve margin thickness D (intake) 3. Measure:
0.70–1.30 mm (0.0276–0.0512 in) • Valve seat width C “a”
Limit Out of specification → Replace the cylinder
0.4 mm (0.02 in) head.
Valve margin thickness D (ex-
haust) Valve seat width C (intake)
0.70–1.30 mm (0.0276–0.0512 in) 0.90–1.10 mm (0.0354–0.0433 in)
Limit Limit
0.4 mm (0.02 in) 2.0 mm (0.08 in)
Valve seat width C (exhaust)
0.90–1.10 mm (0.0354–0.0433 in)
Limit
2.0 mm (0.08 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.
5-37
d. Turn the valve until the valve face and valve

seat are evenly polished, then clean off all of
the lapping compound.
NOTE:
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth be-
tween your hands.
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
b. Install the valve into the cylinder head. clean off all of the lapping compound from the
c. Press the valve through the valve guide and valve face and valve seat.
onto the valve seat to make a clear impres- g. Apply Mechanic’s blueing dye (Dykem) “b”
sion. onto the valve face.
d. Measure the valve seat width.
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been re-
moved.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Lap:
• Valve face
• Valve seat
NOTE:
h. Install the valve into the cylinder head.
After replacing the cylinder head or replacing the
i. Press the valve through the valve guide and
valve and valve guide, the valve seat and valve
onto the valve seat to make a clear impres-
face should be lapped.
sion.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ j. Measure the valve seat width “c” again. If the
a. Apply a coarse lapping compound “a” to the valve seat width is out of specification, reface
valve face. and lap the valve seat.
ECA13790
CAUTION:
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24310
CHECKING THE VALVE SPRINGS

valve springs.
b. Apply molybdenum disulfide oil onto the 1. Measure:
valve stem. • Valve spring free length “a”
c. Install the valve into the cylinder head. Out of specification → Replace the valve
spring.
5-38
Inner spring Inner spring

Free length (intake) Installed compression spring
38.26 mm (1.51 in) force (intake)
Limit 63.00–73.00 N (14.16–16.41 lb)
36.26 mm (1.43 in) (6.42–7.44 kgf)
Free length (exhaust) Installed compression spring
38.26 mm (1.51 in) force (exhaust)
Limit 63.00–73.00 N (14.16–16.41 lb)
36.26 mm (1.43 in) (6.42–7.44 kgf)
Outer spring Installed length (intake)
43.25 mm (1.70 in) Installed length (exhaust)
Limit 29.00 mm (1.14 in)
41.26 mm (1.62 in) Outer spring
Free length (exhaust) Installed compression spring
43.25 mm (1.70 in) force (intake)
Limit 139.00–161.00 N (31.25–36.19 lb)
41.26 mm (1.62 in) (14.17–16.42 kgf)
Installed compression spring
force (exhaust)
139.00–161.00 N (31.25–36.19 lb)
(14.17–16.42 kgf)
Installed length (intake)
31.00 mm (1.22 in)
Installed length (exhaust)
31.00 mm (1.22 in)
2. Measure:
• Compressed valve spring force “a”
spring.
b. Installed length
3. Measure:
• Valve spring tilt “a”
spring.
Inner spring
Spring tilt (intake)
2.5°/1.7 mm (2.5°/0.067 in)
Spring tilt (exhaust)
2.5°/1.7 mm (2.5°/0.067 in)
Outer spring
Spring tilt (intake)
2.5°/1.9 mm (2.5°/0.075 in)
Spring tilt (exhaust)
2.5°/1.9 mm (2.5°/0.075 in)
5-39
• Upper spring seat “7”

(into the cylinder head)
NOTE:
Install the valve springs with the larger pitch “a”
facing up.
EAS24340
INSTALLING THE VALVES

valves and related components.
1. Deburr:
• Valve stem end
(with an oil stone)
b. Smaller pitch
2. Lubricate:
• Valve stem “1” 4. Install:
• Valve stem seal “2” • Valve cotters
(with the recommended lubricant) NOTE:
Install the valve cotters by compressing the
Recommended lubricant valve springs with the valve spring compressor
Molybdenum disulfide oil set “1”.
Valve spring compressor

90890-04019
YM-04019
3. Install:
• Valve guide “1”
• Lower spring seat “2”
• Valve stem seal “3”
• Valve “4”
• Inner valve spring “5”
• Outer valve spring “6”
5-40
5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
ECA13800
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.
5-41
CYLINDERS AND PISTONS
EAS24360

Removing the cylinders and pistons
2
8
New 3
9 8
9
10 10
E
4
E
E 5 New 7
5 New
6 5 New
1
6
5 7
New
New 3
4

Cylinder head Refer to “CYLINDER HEADS” on page 5-31.
1 Front cylinder 1
2 Rear cylinder 1
3 Cylinder gasket 2
4 Dowel pin 4
5 Piston pin clip 4
6 Piston pin 2
7 Piston 2
8 Top ring 2
9 2nd ring 2
10 Oil ring 2
dure.
5-42
EAS24380
• 2nd ring
REMOVING THE PISTONS
• Oil ring
The following procedure applies to all of the pis-
tons. 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 clip, cover the
crankcase opening with a clean rag to prevent
the piston pin clip from falling into the crank-
case.
• For reference during installation, put an identi- EAS24410
fication mark on each piston crown. CHECKING THE CYLINDERS AND PISTONS
• Before removing the piston pin, deburr the pis- The following procedure applies to all of the cyl-
ton pin clip’s groove and the piston’s pin bore inders and pistons.
area. If both areas are deburred and the piston 1. Check:
pin is still difficult to remove, remove it with the • Piston wall
piston pin puller set “4”. • 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.
Cylinder
Bore
97.000–97.010 mm (3.8189–
3.8193 in)
Taper limit
0.050 mm (0.0020 in)
Out of round limit
0.050 mm (0.0020 in)
“C” = maximum of D1–D6

“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
5-43
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
Top ring
rings as a set.
Ring side clearance
c. Measure piston skirt diameter D “a” with the 0.030–0.080 mm (0.0012–
micrometer. 0.0032 in)
Limit
Piston 0.120 mm (0.0047 in)
Diameter D 2nd ring
96.960–96.975 mm (3.8173– Ring side clearance
3.8179 in) 0.030–0.070 mm (0.0012–
0.0028 in)
Limit
0.120 mm (0.0047 in)
b. 10 mm (0.39 in) from the bottom edge of the

piston
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
0.025–0.050 mm (0.0010–0.0020
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. 10 mm (0.39 in)
5-44
3. Measure:
• Piston ring end gap
Out of specification → Replace the piston
ring.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings.
Piston ring
Top ring 3. Measure:
End gap (installed) • Piston pin bore diameter “b”
0.30–0.50 mm (0.0118–0.0197 Out of specification → Replace the piston.
in)
Limit Piston pin bore inside diameter
0.70 mm (0.0276 in) 22.004–22.015 mm (0.8663–
2nd ring 0.8667 in)
End gap (installed) Limit
0.30–0.45 mm (0.0118–0.0177 22.045 mm (0.8679 in)
in)
Limit
0.80 mm (0.0315 in)
Oil ring
End gap (installed)
0.20–0.70 mm (0.0079–0.0276
in)
EAS24440
CHECKING THE PISTON PINS

ton pins.
1. Check: 4. Calculate:
• Piston pin • Piston-pin-to-piston-pin-bore clearance
Blue discoloration/grooves → Replace the Out of specification → Replace the piston pin
piston pin and then check the lubrication sys- and piston as a set.
tem.
• Piston-pin-to-piston-pin-bore clearance =
2. Measure: Piston pin bore diameter “b” -
• Piston pin outside diameter “a” Piston pin outside diameter “a”
Out of specification → Replace the piston pin.
Piston pin outside diameter Piston-pin-to-piston-pin-bore

21.991–22.000 mm (0.8658– clearance
0.8661 in) 0.004–0.024 mm (0.0002–0.0009
Limit in)
21.971 mm (0.8650 in) Limit
0.074 mm (0.0029 in)
EAS24460
INSTALLING THE PISTONS AND

CYLINDERS
tons and cylinders.
1. Install:
• Top ring “1”
• 2nd ring “2”
5-45
• Lower oil ring rail “3”

A
• Upper oil ring rail “4” 90 ˚
• Oil ring expander “5” d.e b
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up. 90 ˚
a.c
45 ˚
a. Top ring
b. Upper oil ring rail
c. Oil ring expander
d. Lower oil ring rail
e. 2nd ring
A. forward
2. Install: 5. Install:
• Piston “1” • Cylinder “1”
• Piston pin “2” NOTE:
• Piston pin clips “3” New • While compressing the piston rings with one
NOTE: hand, install the cylinder with the other hand.
• Apply engine oil onto the piston pin.
• Make sure the arrow mark “a” on the piston fac-
es towards the front of the vehicle. 1
• Before installing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the clip from falling into the crankcase.
• Reinstall each piston into its original cylinder
(numbering order starting from the left: #1 to
#2).
3. Lubricate:
• Piston
• Piston rings
• Cylinder
(with the recommended lubricant)
Engine oil
4. Offset:
• Piston ring end gaps
5-46
CLUTCH
EAS25060
CLUTCH
Removing the clutch cover
1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
6
2
6
(5)
New 5
(10)
4 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

Drain.
page 3-11.
Battery box/Air duct 4-1.
Oil tank/Shift rod Refer to “ENGINE REMOVAL” on page 5-1.
1 Crankshaft position sensor coupler 1 Disconnect.
2 Shift arm 1
3 Oil tank bracket 1
4 Clutch cover 1
5 Clutch cover gasket 1
6 Dowel pin 2
dure.
5-47
CLUTCH
Removing the crankshaft position sensor
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
LT
LT
LT
LT
3
3
3
LT
LT
LT
2
New 1
LS

1 Oil seal 1
2 Bearing 1
3 Crankshaft position sensor lead holder 3
4 Crankshaft position sensor 1
dure.
5-48
CLUTCH
Removing the clutch
LS
25
24 23 22
19 New
18
21 17
E
16
15 125 Nm (12.5 m • kg, 90 ft • lb)
20 14
T.
R.
13
29 12 11
10 9 New
New
8
28
27 26
6
LT 5
E
100 Nm (10.0 m • kg, 72 ft • lb)
7
T.
New
R.
(6)
LS
4
3
2 1
E 8 Nm (0.8 m kg, 5.8 ft • Ib)
•
T.
R.

1 Clutch spring plate retainer 1
2 Clutch spring plate 1
3 Clutch spring plate seat 1
4 Pressure plate 1
5 Short clutch push rod 1
6 Friction plate 1 9
7 Clutch plate 8
8 Conical spring washer 1
9 Wire circlip 1
10 Clutch plate 1
11 Friction plate 2 1
12 Clutch damper spring 1
13 Clutch damper spring seat 1
14 Clutch boss 1
15 Thrust washer 1 1
16 Bearing 1
17 Clutch housing 1
5-49
CLUTCH
Removing the clutch
LS
25
24 23 22
19 New
18
21 17
E
16
15 125 Nm (12.5 m • kg, 90 ft • lb)
20 14
T.
R.
13
29 12 11
10 9 New
New
8
28
27 26
6
LT 5
E
100 Nm (10.0 m • kg, 72 ft • lb)
7
T.
New
R.
(6)
LS
4
3
2 1
E 8 Nm (0.8 m kg, 5.8 ft • Ib)
•
T.
R.

18 Washer 1
19 Circlip 1
20 Oil pump drive gear 1
21 Dowel pin 1
22 Collar 1
23 Thrust washer 2 1
24 Ball 1
25 Long clutch push rod 1
26 Spacer 1
27 Crankshaft position sensor rotor 1
28 Primary drive gear 1
29 Straight key 1
dure.
5-50
CLUTCH
Removing the clutch master cylinder
14 Nm (1.4 m • kg, 10 ft • Ib)

T.
R.
1
12
T.
T.
R.
R.
10 New 2 6
∗
9 3
4
11
13
5
∗ 8

Drain.
CLUTCH SYSTEM” on page 3-14.
1 Left rearview mirror 1
2 Clutch master cylinder reservoir cap 1
Clutch master cylinder reservoir diaphragm
3 1
holder
4 Clutch master cylinder reservoir diaphragm 1
5 Clutch lever 1
6 Bushing 1
7 Clutch switch coupler 1 Disconnect.
8 Clutch switch 1
9 Clutch hose union bolt 1
10 Copper washer 2
11 Clutch hose 1
12 Clutch master cylinder holder 1
5-51
CLUTCH
Removing the clutch master cylinder
14 Nm (1.4 m • kg, 10 ft • Ib)

T.
R.
1
12
T.
T.
R.
R.
10 New 2 6
∗
9 3
4
11
13
5
∗ 8

13 Clutch master cylinder 1
dure.
5-52
CLUTCH
Disassembling the clutch master cylinder
2 New

1 Clutch master cylinder push rod 1
2 Clutch master cylinder kit 1
3 Clutch master cylinder body 1
cedure.
5-53
CLUTCH
Removing the clutch release cylinder
5
1
2
10 Nm (1.0 m • kg, 7.2 ft • Ib) New 3 26 Nm (2.6 m • kg, 19 ft • Ib)
T.
T.
R.
R.

Drain.
1 Clutch pipe union bolt cap 1
2 Clutch pipe union bolt 1
3 Copper washer 2
4 Clutch pipe 1
5 Clutch release cylinder 1
6 Dowel pin 2
dure.
5-54
CLUTCH
Disassembling the clutch release cylinder
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.
R.
LS
New 4
2
LS

1 Boots 1
2 Clutch release cylinder piston 1
3 Clutch release cylinder spring 1
4 Clutch release cylinder piston seal 1
5 Bleed screw 1
cedure.
5-55
CLUTCH
EAS25080
REMOVING THE CLUTCH Sheave holder

1. Loosen: 90890-01701
• Clutch boss nut “1” Primary clutch holder
NOTE: YS-01880-A
While holding the clutch boss “2” with the univer-
sal clutch holder “3”, loosen the clutch boss nut.
Universal clutch holder

90890-04086
YM-91042
2
1
3
3
2. Remove:
• Clutch boss nut “1”
• Washer “2” 2
• Clutch boss assembly “3”
NOTE: EAS25100
There is a built-in damper between the clutch CHECKING THE FRICTION PLATES
boss and the clutch plate. It is not necessary to The following procedure applies to all of the fric-
remove the wire circlip “4” and disassemble the tion plates.
built-in damper unless there is serious clutch 1. Check:
chattering. • Friction plate
Damage/wear → Replace the friction plates
as a set.
3 2. Measure:
• Friction plate thickness
Out of specification → Replace the friction
4 plates as a set.
2 NOTE:
1 Measure the friction plate at four places.
Friction plate thickness

2.92–3.08 mm (0.115–0.121 in)
EAS25090
Wear limit
REMOVING THE PRIMARY DRIVE GEAR 2.82 mm (0.1110 in)
1. Remove:
• Primary drive gear bolt “1”
NOTE:
While holding the generator rotor “2” with the
sheave holder “3”, loosen the primary drive gear
bolt.
5-56
CLUTCH
EAS25150
CHECKING THE CLUTCH HOUSING

1. Check:
• Clutch housing dogs
Damage/pitting/wear → Deburr the clutch
housing dogs or replace the clutch housing.
NOTE:
Pitting on the clutch housing dogs will cause er-
ratic clutch operation.
EAS25110
CHECKING THE CLUTCH PLATES

clutch plates.
1. Check:
• Clutch plate
Damage → Replace the clutch plates as a
set.
2. Measure:
• Clutch plate warpage
(with a surface plate and thickness gauge “1”) 2. Check:
Out of specification → Replace the clutch • Bearing
plates as a set. Damage/wear → Replace the bearing and
clutch housing.
Thickness gauge
EAS25160
90890-03079
Narrow gauge set CHECKING THE CLUTCH BOSS
YM-34483 1. Check:
• Clutch boss splines
Damage/pitting/wear → Replace the clutch
Clutch plate thickness boss.
1.90–2.10 mm (0.075–0.083 in) NOTE:
Warpage limit
0.20 mm (0.0079 in) Pitting on the clutch boss splines will cause er-
ratic clutch operation.
EAS25130
CHECKING THE CLUTCH SPRING PLATE EAS25170
1. Check: CHECKING THE PRESSURE PLATE

• Clutch plate spring 1. Check:
Damage → Replace. • Pressure plate
2. Check: Cracks/damage → Replace.
• Clutch plate spring seat • Bearing
Damage → Replace. Damage/wear → Replace.
5-57
CLUTCH
EAS25190
CHECKING THE CLUTCH PUSH RODS Yamaha bond No. 1215

1. Check: 90890-85505
• O-ring (Three Bond No.1215®)
• Short clutch push rod
• Long clutch push rod
• Ball
Cracks/damage/wear → Replace the defec-
tive part(s).
2. Measure:
• Long clutch push rod bending limit
Out of specification → Replace the defective
part(s).
Long clutch push rod bending

limit
0.15 mm (0.0059 in) EAS25230
INSTALLING THE PRIMARY DRIVE GEAR

EAS25200 1. Install:
CHECKING THE PRIMARY DRIVE GEAR • Straight key “1”
1. Check: • Primary drive gear “2”
• Primary drive gear • Crankshaft position sensor rotor “3”
Damage/wear → Replace the primary drive • Spacer “4”
and primary driven gears as a set. • Primary drive gear bolt “5”
Excessive noise during operation → Replace
the primary drive and primary driven gears as Primary drive gear bolt
a set. 100 Nm (10.0 m·kg, 72 ft·lb)
T.
R.
EAS25210
LOCTITE®
CHECKING THE PRIMARY DRIVEN GEAR EC5YU1014
1. Check: CAUTION:
• Primary driven gear “1”
The timing marks on the crankshaft position
Damage/wear → Replace the primary drive
sensor rotor must face outside.
and primary driven gears as a set.
Excessive noise during operation → Replace NOTE:
the primary drive and primary driven gears as While holding the generator rotor “6” with the
a set. sheave holder “7”, tighten the primary drive gear
bolt.
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
EAS24540
INSTALLING THE CRANKSHAFT POSITION

SENSOR
1. Apply:
• Sealant
(onto the crankshaft position sensor lead
grommet)
5-58
CLUTCH
3. Install:
• Clutch boss “1”
• Conical spring washer “2”
• Clutch boss nut “3” New
Clutch boss nut

125 Nm (12.5 m·kg, 90 ft·lb)
T.
R.
NOTE:
• Lubricate the clutch boss nut threads and con-
ical spring washer mating surfaces with engine
oil.
• Install the washer “2” with the “OUT” mark “a”
facing out.
• While holding the clutch boss with the univer-
7 sal clutch holder “4”, tighten the clutch boss
nut.
• Stake the clutch boss nut “3” at a cutout “b” in
the main axle.
6
Universal clutch holder
EAS25260 90890-04086
INSTALLING THE CLUTCH YM-91042
1. Install:
• Clutch housing 2
• Thrust washer 1
NOTE: New 3
• Lubricate the clutch housing bearings with en- a
gine oil.
• Make sure that the primary driven gear teeth b
and primary drive gear teeth mesh correctly.
• Make sure that the oil pump drive gear teeth
and oil pump driven gear teeth mesh correctly. 4
2. Install:
4. Lubricate:
• Clutch boss assembly “1”
• Friction plates
NOTE: • Clutch plates
• If the wire circlip “2” has been removed, care- (with the recommended lubricant)
fully install a new one.
• Install the clutch damper spring “3” with the Recommended lubricant
“OUTSIDE” mark facing out. Engine oil
5. Install:
1 • Friction plates
• Clutch plates
NOTE:
• First, install a friction plate and then alternate
between a clutch plate and a friction plate.
• Install the last friction plate “1” offset from the
3 other friction plates “2”, making sure to align a
New 2 projection on the friction plate with the punch
mark “a” on the clutch housing.
5-59
CLUTCH
EAS25280
DISASSEMBLING THE CLUTCH MASTER

a
CYLINDER
ECA13840
2 CAUTION:
1
• Clutch components rarely require disas-
sembly.
• Therefore, always follow these preventive
measures:
• Never disassemble clutch components un-
6. Install: • If any connection on the hydraulic clutch
• Clutch spring plate “1” system is disconnected, the entire clutch
• Clutch spring plate retainer “2” system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
Clutch spring plate retainer bolt sembly.
8 Nm (0.8 m·kg, 5.8 ft·lb) • Never use solvents on internal clutch com-
T.
R.
ponents.
NOTE: • Use only clean or new clutch fluid for clean-
Tighten the clutch spring bolts in stages and in a ing clutch components.
crisscross pattern. • Clutch fluid may damage painted surfaces
up any spilt fluid immediately.
• Avoid clutch fluid coming into contact with
1 the eyes as it can cause serious injury.
• First aid for clutch fluid entering the eyes:
• Flush with water for 15 minutes and get im-
mediate medical attention.
2 NOTE:
Before disassembling the clutch master cylinder,
drain the clutch fluid from the entire clutch sys-
7. Install: tem.
• Shift arm “1” 1. Remove:
Shift arm bolt • Clutch hose union bolt “1”
10 Nm (1.0 m·kg, 7.2 ft·lb) • Copper washers “2”
T.
• Clutch hose “3”

R.
NOTE: NOTE:
Install the shift arm “1” with its punch mark “a” To collect any remaining clutch fluid, place a
aligned with the notch “b” in end of the shift shaft. container under the master cylinder and the end
of the clutch hose.
1
2
b 1
3
5-60
CLUTCH
EAS25290 EAS25310
CHECKING THE CLUTCH MASTER INSTALLING THE CLUTCH MASTER

CYLINDER CYLINDER
Recommended clutch component replace- 1. Install:
ment schedule • Clutch master cylinder “1”
• Clutch master cylinder holder “2”
Piston seals Every two years
Clutch hose Every four years Clutch master cylinder holder
bolt
T.
R.
Every two years and 14 Nm (1.4 m·kg, 10 ft·lb)
Clutch fluid whenever the clutch
is disassembled NOTE:
1. Check: • The clutch master cylinder holder should be in-
• Clutch master cylinder body stalled with the punch mark “a” forward.
Cracks/damage → Replace the clutch mas- • Align the end of the clutch master cylinder
ter cylinder. holder with the punch mark “b” on the handle-
• Clutch fluid delivery passage bar.
(clutch master cylinder body) • First, tighten the front bolt, then the rear bolt.
2. Check: a
• Clutch master cylinder
• Clutch master cylinder kit 1
Rust/scratches/wear → Replace the clutch
master cylinder and clutch master cylinder kit
as a set.
3. Check:
• Clutch master cylinder reservoir 2
Cracks/damage → Replace. b
• Clutch master cylinder reservoir diaphragm
Damage/wear → Replace. 2. Install:
4. Check: • Copper washers “1” New
• Clutch hose • Clutch hose “2”
Cracks/damage/wear → Replace. • Clutch hose union bolt “3”
EAS25300
Clutch hose union bolt
ASSEMBLING THE CLUTCH MASTER
30 Nm (3.0 m·kg, 22 ft·lb)
T.
CYLINDER
R.
EWA13340
EWA5YU8001
WARNING WARNING
• Before installation, all internal clutch com- Proper clutch hose routing is essential to in-
ponents must be cleaned and lubricated sure safe vehicle operation. Refer to “CABLE
with clean or new clutch fluid. ROUTING” on page 2-41.
• Never use solvents on internal clutch com-
ECA5YU8001
ponents as they will cause the piston seals CAUTION:
to swell and distort.
• Whenever a clutch master cylinder is disas- When installing the clutch hose onto the
sembled, replace the piston seals. clutch master cylinder, make sure the clutch
pipe “a” touches the projection “b” as
shown.
Recommended clutch fluid
Brake fluid DOT4 NOTE:
Turn the handlebar to the left and to the right to
make sure the clutch hose does not touch other
parts (e.g., wire harness, cables, leads). Correct
if necessary.
5-61
CLUTCH
UPPER
a
1 New LOWER
a
2
3. Fill: 6. Check:
• Clutch master cylinder reservoir • Clutch lever operation
(with the specified amount of the recom- Soft or spongy feeling → Bleed the clutch
mended clutch fluid) system.
Recommended clutch fluid CLUTCH SYSTEM” on page 3-14.
Brake fluid DOT4
ET5YU1020
EWA13370 REMOVING THE CLUTCH RELEASE
WARNING CYLINDER
• Use only the designated clutch fluid. Other 1. Remove:
clutch fluids may cause the rubber seals to • Clutch pipe union bolt “1”
deteriorate, causing leakage and poor • Copper washers “2”
clutch performance. • Clutch pipe “3”
• Refill with the same type of clutch fluid that NOTE:
is already in the system. Mixing clutch flu- Put the end of the clutch pipe into a container
ids may result in a harmful chemical reac- and pump out the clutch fluid carefully.
not enter the clutch fluid reservoir. Water
3
the clutch fluid and could cause vapor lock.
ECA13420
CAUTION: 1
plastic parts. Therefore, always clean up any
spilt clutch fluid immediately. 2
NOTE:
EAS25330
In order to ensure a correct reading of the clutch CHECKING THE CLUTCH RELEASE
fluid level, make sure the top of the reservoir is CYLINDER
horizontal.
Recommended clutch component replace-
4. Bleed: ment schedule
• Clutch system Piston seals Every two years
CLUTCH SYSTEM” on page 3-14. Clutch hose Every four years
5. Check: Every two years and
• Clutch fluid level Clutch fluid whenever the clutch
Below the minimum level mark “a” → Add the is disassembled
recommended clutch fluid to the proper level.
Refer to “CHECKING THE CLUTCH FLUID
5-62
CLUTCH
1. Check:
• Clutch release cylinder body a
Cracks/damage → Replace the clutch re-
lease cylinder. 2
2. Check:
• Clutch release cylinder
b
• Clutch release cylinder piston
Rust/scratches/wear → Replace the clutch 3
release cylinder and clutch release cylinder 1 New
piston as a set.
EAS25340 2. Fill:
ASSEMBLING THE CLUTCH RELEASE • Clutch master cylinder reservoir
CYLINDER (with the specified amount of the recom-
EW5YU1007
mended clutch fluid)
WARNING
• Before installation, all internal clutch com- Recommended clutch fluid
ponents must be cleaned and lubricated Brake fluid DOT4
with clean or new clutch fluid.
EWA13370
• Never use solvents on internal clutch com-
WARNING
ponents as they will cause the piston seal
to swell and distort. • Use only the designated clutch fluid. Other
• Whenever a clutch release cylinder is dis- clutch fluids may cause the rubber seals to
assembled, replace the piston seal. deteriorate, causing leakage and poor
clutch performance.
• Refill with the same type of clutch fluid that
Recommended clutch fluid
Brake fluid DOT4 is already in the system. Mixing clutch flu-
ids may result in a harmful chemical reac-
EAS25350
INSTALLING THE CLUTCH RELEASE • When refilling, be careful that water does
CYLINDER not enter the clutch fluid reservoir. Water
1. Check: will significantly lower the boiling point of
• Copper washers “1” New the clutch fluid and could cause vapor lock.
• Clutch pipe “2” ECA13420
• Clutch pipe union bolt “3” CAUTION:

Clutch pipe union bolt plastic parts. Therefore, always clean up any
26 Nm (2.6 m·kg, 19 ft·lb) spilt clutch fluid immediately.
T.
R.
EW5YU1010
NOTE:
WARNING
In order to ensure a correct reading of the clutch
Proper clutch hose routing is essential to in- fluid level, make sure that the top of the reservoir
sure safe vehicle operation. Refer to “CABLE is horizontal.
ROUTING” on page 2-41.
3. Bleed:
EC5YU1007
CAUTION:
• Clutch system
When installing the clutch pipe onto the CLUTCH SYSTEM” on page 3-14.
clutch release cylinder, make sure the pipe 4. Check:
“a” touches the projection “b”. • Clutch fluid level
recommended clutch fluid to the proper level.
Refer to “CHECKING THE CLUTCH FLUID
5-63
CLUTCH
UPPER
a
LOWER
5. Check:
• Clutch lever operation
Soft or spongy feeling → Bleed the clutch
system.
5-64
SHIFT SHAFT
EAS25410
SHIFT SHAFT
Removing the shift shaft and stopper lever
LS
3
New 2
5 6
7
4
LT LT

T.
R.
T.
R.

Clutch housing Refer to “CLUTCH” on page 5-47.
1 Shift shaft 1
2 Circlip 2
3 Shift shaft spring 1
4 Shift shaft spring stopper 1
5 Washer 1
6 Stopper lever 1
7 Stopper lever spring 1
dure.
5-65
SHIFT SHAFT
EAS25420
• Hook the end of the shift shaft spring onto the
CHECKING THE SHIFT SHAFT
shift shaft spring stopper “3”.
1. Check:
• Shift shaft
Bends/damage/wear → Replace.
• Shift shaft spring
EAS25430
CHECKING THE STOPPER LEVER

1. Check:
• Stopper lever
Bends/damage → Replace.
Roller turns roughly → Replace the stopper
lever.
• Stopper lever spring
EAS25450
INSTALLING THE SHIFT SHAFT

1. Install:
• Stopper lever “1”
• Stopper lever bolt “2”
• Stopper lever spring “3”
Stopper lever bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
LOCTITE®
NOTE:
• Hook the ends of the stopper lever spring onto
the stopper lever and the crankcase boss “4”.
• Install the stopper lever spring as shown in the
illustration.
• Mesh the stopper lever with the shift drum seg-
ment assembly.
2. Install:
• Shift shaft spring “1”
• Circlips
• Shift shaft “2”
NOTE:
• Lubricate the oil seal lips with lithium-soap-
based grease.
5-66
GENERATOR AND STARTER CLUTCH
EAS24480

Removing the stator coil assembly
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

T.
R.
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib) LT
T.
R.
LS
New
6
7
3
New
6 LT
LT
LS 8 1
2
5 New
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
New
(9) 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

Drain.
page 3-11.
Oil tank/Front exhaust pipe Refer to “ENGINE REMOVAL” on page 5-1.
1 Stator coil assembly coupler 1 Disconnect.
2 Rectifier/regulator 1
3 Oil pipe 2 1 From oil pump to generator cover.
4 Generator cover 1
5 Generator cover gasket 1
6 Dowel pin 2
7 Stator coil assembly lead holder 1
8 Stator coil assembly 1
dure.
5-67
Removing the generator rotor
1
4
E
2
80 Nm (8.0 m • kg, 58 ft • Ib) E

.
T
R.

1 Starter clutch idle gear shaft #2 1
2 Starter clutch idle gear shaft #1 1
3 Starter clutch idle gear #2 1
4 Starter clutch idle gear #1 1
5 Generator rotor 1
6 Woodruff key 1
7 Starter clutch gear 1
dure.
5-68
EAS24490
2. Check:
REMOVING THE GENERATOR
• Starter clutch gear’s contacting surfaces
1. Remove:
Damage/pitting/wear → Replace the starter
• Generator rotor bolt “1”
clutch gear.
• Washer
3. Check:
NOTE: • Starter clutch operation
While holding the generator rotor “2” with the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
sheave holder “3”, loosen the generator rotor a. Install the starter clutch gear “1” onto the gen-
bolt. erator rotor “2” and hold the generator rotor.
b. When turning the starter clutch gear clock-
Sheave holder wise “A”, the starter clutch and the starter
90890-01701 clutch gear should engage, otherwise the
Primary clutch holder starter clutch is faulty and must be replaced.
YS-01880-A c. When turning the starter clutch gear counter-
clockwise “B”, it should turn freely, otherwise
the starter clutch is faulty and must be re-
placed.
1 2
2. Remove:
• Generator rotor “1”
(with the rotor puller “2”) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Woodruff key EAS24510
INSTALLING THE GENERATOR

Rotor puller 1. Install:
90890-01080
• Woodruff key
Stator rotor puller
YM-01080-A • Generator rotor “1”
• Washer
NOTE:
• Clean the tapered portion of the crankshaft and
the generator rotor hub.
• When installing the rotor, make sure the woo-
druff key is properly seated in the key way of
the crankshaft.
• Lubricate the generator rotor bolt threads and
washer mating surfaces with engine oil.
EAS24570
CHECKING THE STARTER CLUTCH

1. Check:
• Starter clutch idle gears
• Starter clutch gear
Burrs/chips/roughness/wear → Replace the
defective part(s).
5-69
2. Tighten:
Generator rotor bolt

80 Nm (8.0 m·kg, 58 ft·lb)
T.
R.
NOTE:
Tighten the generator rotor bolt “1” while holding
the generator rotor “2” with a sheave holder “3”.
Sheave holder
90890-01701
YS-01880-A
1 2
3. Apply:
• Sealant
(onto the stator coil assembly lead grommet)
Yamaha bond No. 1215

90890-85505
5-70
ELECTRIC STARTER
EAS24780
ELECTRIC STARTER
Removing the starter motor

Oil tank Refer to “ENGINE REMOVAL” on page 5-1.
1 Starter motor lead 1 Disconnect.
2 Starter motor assembly 1
dure.
5-71
ELECTRIC STARTER
Disassembling the starter motor
LS
LS
New 1
2
New
3 New 5 4
New 6
12 New
New
13
14 9
8
10
11
New 12
7

1 Circlip 1
2 Starter motor gear 1
3 Starter motor rear cover 1
4 Bearing 1
5 Oil seal 1
6 Circlip 1
7 Starter motor front cover 1
8 Brush 2
9 Brush holder (along with the brushes) 1
10 Brush seat (along with the brushes) 1
11 Bearing 1
12 Gasket 2
13 Armature assembly 1
14 Starter motor yoke 1
cedure.
5-72
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.
0.0081–0.0099 Ω at 20°C (68°F)
Limit Insulation resistance “2”
27.5 mm (1.08 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.
1.50 mm (0.06 in)
Limit
NOTE: 5.00 mm (0.20 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. 7.36–11.04 N (26.49–39.74 oz)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
(750–1126 gf)
a. Measure the armature assembly resistances
with the pocket tester.
5-73
ELECTRIC STARTER
3. Install:
• Starter motor yoke “1”
• Starter motor front cover “2”
• Starter motor rear cover “3”
NOTE:
Align the match mark “a” on the starter motor
yoke with the match mark “b” on the starter mo-
tor rear cover.
a b
7. Check:
• Gear teeth
Damage/wear → Replace the gear.
8. Check:
• Bearing
• Oil seal
Damage/wear → Replace the defective 3
part(s). 2 1
EAS24800
ASSEMBLING THE STARTER MOTOR

1. Install:
• Brush seat “1”
NOTE:
Align the slot “a” on the brush seat with the tab
“b” in the starter motor front cover.
2. Install:
• Starter motor yoke “1”
NOTE:
Align the tab “a” on the brush holder with the slot
“b” in the starter motor yoke.
1 b
5-74
CRANKCASE
EAS25540
CRANKCASE
Separating the crankcase

Engine Refer to “ENGINE REMOVAL” on page 5-1.
Camshafts Refer to “CAMSHAFTS” on page 5-16.
Refer to “CYLINDERS AND PISTONS” on
Pistons page 5-42.
Shift shaft Refer to “SHIFT SHAFT” on page 5-65.
Refer to “GENERATOR AND STARTER
Generator rotor CLUTCH” on page 5-67.
1 Speed sensor 1
2 Oil filter cartridge bracket 1
3 Generator shaft end cover 1
4 Oil delivery pipe 2 1
5 Oil pump driven gear stopper 1
6 Oil pump driven gear 1
7 Left crankcase 1
8 Dowel pin 2
9 Joint pipe 1
5-75
CRANKCASE
Separating the crankcase

10 Right crankcase 1
dure.
5-76
CRANKCASE
Removing the oil baffle plate and bearings

Oil pump Refer to “OIL PUMP” on page 5-82.
Crankshaft Refer to “CRANKSHAFT” on page 5-87.
Transmission Refer to “TRANSMISSION” on page 5-93.
1 Oil baffle plate 1
2 Bearing retainer 1
3 Bearing retainer 1
4 Oil seal 1
5 Bearing 4
dure.
5-77
CRANKCASE
EAS25570
• M6 × 75 mm bolts: “14”, “15”
DISASSEMBLING THE CRANKCASE
• M6 × 60 mm bolts: “4”–“7”
NOTE: • M6 × 40 mm bolts: “8”, “10”–“12”, “16”–“20”
Loosen the generator shaft bolt before removing
the generator rotor.
1. Loosen:
• Generator shaft bolt “1”
NOTE:
While the holding the generator rotor “2” with the
primary sheave holder “3”, loosen the generator
shaft bolt.
Sheave holder
90890-01701
YS-01880-A
A. Right crankcase
B. Left crankcase
3. Turn:
• Shift drum segment
NOTE:
Turn the shift drum segment “1” to the position
shown in the illustration. In this position, the shift
drum segment’s teeth will not contact the crank-
case during crankcase separation.
2. Remove:
• Crankcase bolts
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. 4. Remove:
• Loosen the bolts in decreasing numerical order • Left crankcase
(refer to the numbers in the illustration). EC5YU1016
• The numbers embossed on the crankcase in- CAUTION:

dicate the crankcase tightening sequence. • First check that the shift drum segment’s
• M8 × 100 mm bolts: “1”, “2” teeth then remove the left crankcase.
• M8 × 80 mm bolt: “3” • Tap on one side of the crankcase with a
• M6 × 105 mm bolt: “21” soft-face hammer. Tap only on reinforced
• M6 × 85 mm bolt: “9”, “13” portions of the crankcase, not on the crank-
5-78
CRANKCASE
case mating surfaces. Work slowly and NOTE:

carefully and make sure the crankcase • Install the bearing retainer “1” with its “OUT”
halves separate evenly. mark “a” facing outward.
• Apply locking agent (LOCTITE®) to the threads
of the bearing retainer bolt.
T
OU
EAS25580
CHECKING THE CRANKCASE

1. Thoroughly wash the crankcase halves in a
mild solvent. EAS25690
2. Thoroughly clean all the gasket surfaces and ASSEMBLING THE CRANKCASE
crankcase mating surfaces. 1. Apply:
3. Check: • Sealant
• Crankcase (onto the crankcase mating surfaces)
Cracks/damage → Replace. Yamaha bond No. 1215
• Oil delivery passages 90890-85505
ET5YU1022
CHECKING THE BEARINGS AND OIL SEAL NOTE:

1. Check: Do not allow any sealant to come into contact
• Bearings with the oil gallery.
Clean and lubricate the bearings, then rotate
the inner race with your finger. 2. Install:
Rough movement → Replace. • Dowel pins “1”
• Oil seal • Joint pipe “2”
EAS25590
CHECKING THE OIL PIPE

1. Check:
• Oil pipe
Damage → Replace.
pressed air.
EAS25610
CHECKING THE OIL PUMP DRIVE

• Oil pump drive gear • Left crankcase
• Oil pump driven gear (onto the right crankcase)
Chips/pitting/roughness/wear → Replace the NOTE:
defective part(s). • Turn the shift drum segment “1” to the position
shown in the illustration. In this position, the
ET5YU1023
INSTALLING THE BEARING RETAINER shift drum segment’s teeth will not contact the
1. Install: crankcase during crankcase installation.
• Bearing retainer “1”
5-79
CRANKCASE
• Tap lightly on the left crankcase with a soft-

face hammer.
4. Install:
• Crankcase bolts (M8)
• Crankcase bolts (M6)
Crankcase bolt (M8)

24 Nm (2.4 m·kg, 17 ft·lb)
T.
R.
Crankcase bolt (M6)

10 Nm (1.0 m·kg, 7.2 ft·lb)
A. Right crankcase
NOTE: B. Left crankcase
• Lubricate the bolt threads with engine oil. 5. Apply:
• Tighten each bolt 1/4 of a turn at a time, in stag- • Engine oil
es and in a crisscross pattern. (onto the crankshaft pins bearings and oil de-
• Tighten the bolts in numerical order (refer to livery holes)
the numbers in the illustration). 6. Check:
• M8 × 100 mm bolts: “1”, “2” • Crankshaft and transmission operation
• M8 × 80 mm bolt: “3” Rough movement → Repair.
• M6 × 105 mm bolt: “21” 7. Install:
• M6 × 85 mm bolts: “9”, “13” • Generator shaft bolt “1”
• M6 × 75 mm bolts: “14”, “15”
Generator shaft bolt
• M6 × 60 mm bolts: “4”–“7”
28 Nm (2.8 m·kg, 20 ft·lb)
• M6 × 40 mm bolts: “8”, “10”–“12”, “16”–“20”
T.
R.
NOTE:
While the holding the generator rotor “2” with the
primary sheave holder “3”, tighten the generator
shaft bolt.
Sheave holder
90890-01701
YS-01880-A
5-80
CRANKCASE
5-81
OIL PUMP
EAS24910
OIL PUMP
Removing the oil pump

Separate.
Crankcase Refer to “CRANKCASE” on page 5-75.
1 Oil strainer (crankcase) 1
2 Oil pump assembly 1
dure.
5-82
OIL PUMP
Disassembling the oil pump

1 Spring retainer 1
2 Spring 1
3 Relief valve 1
4 Oil pump housing cover 1 1
5 Pin 2
6 Spring 1
7 Collar 1
8 Ball 1
9 Oil pump outer rotor 1 1
10 Oil pump inner rotor 1 1
11 Pin 1
12 Oil pump housing cover 2 1
13 Pin 2
14 Oil pump shaft 1
15 Pin 1
16 Oil pump inner rotor 2 1
17 Oil pump outer rotor 2 1
5-83
OIL PUMP
Disassembling the oil pump

18 Oil seal 2
19 Oil pump housing 1
cedure.
5-84
OIL PUMP
EAS24960
3. Check:
CHECKING THE OIL PUMP
• Oil pump operation
1. Check:
Rough movement → Repeat steps (1) and
• Oil pump housing
(2) or replace the defective part(s).
• Oil pump housing cover
Cracks/damage/wear → Replace the defec-
tive part(s).
2. Measure:
• Inner-rotor-to-outer-rotor-tip clearance “a”
• Outer-rotor-to-oil-pump-housing clearance
“b”
• Oil-pump-housing-to-inner-rotor-and-outer-
rotor clearance “c”
Out of specification → Replace the oil pump.
Inner-rotor-to-outer-rotor-tip EAS24970
clearance CHECKING THE RELIEF VALVE
Less than 0.12 mm (0.0047 in) 1. Check:
Limit • Relief valve body
0.20 mm (0.0079 in) • Relief valve
Outer-rotor-to-oil-pump-housing
• Spring
clearance
0.09–0.15 mm (0.0035–0.0059 in) Damage/wear → Replace the defective
Limit part(s).
0.220 mm (0.0087 in) 2. Check:
Oil-pump-housing-to-inner-and- • Ball
outer-rotor clearance • Collar
0.03–0.08 mm (0.0012–0.0032 in) • Spring
Limit • Oil seal
0.150 mm (0.0059 in) Damage/wear → Replace the defective
part(s).
EAS24990
CHECKING THE OIL STRAINER

1. Check:
• Oil strainer (crankcase)
Damage → Replace.
Contaminants → Clean with solvent.
EAS25000
ASSEMBLING THE OIL PUMP

1. Lubricate:
• Inner rotor
• Outer rotor
• Oil pump shaft
Engine oil
2. Install:
• Oil pump housing “1”
• Oil seal “2” New
• Oil pump outer rotor 2 “3”
1. Inner rotor • Oil pump inner rotor 2 “4”
2. Outer rotor • Pin “5”
3. Oil pump housing
5-85
OIL PUMP
• Oil pump shaft “6” 3. Check:

• Pins “7” • Oil pump operation
• Oil pump housing cover 2 “8” Refer to “CHECKING THE OIL PUMP” on
page 5-85.
Oil pump housing cover 2 screw
2 Nm (0.2 m·kg, 1.4 ft·lb) EAS25020
T.
INSTALLING THE OIL PUMP

R.
• Pin “9” 1. Install:

• Oil pump inner rotor 1 “10” • Oil pump “1”
• Oil pump outer rotor 1 “11”
Oil pump bolt
• Ball “12”
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
• Collar “13”
R.
• Spring “14” ECA13890
• Pins “15” CAUTION:

• Oil pump housing cover 1 “16” After tightening the bolts, make sure the oil
pump turns smoothly.
Oil pump housing cover 1 screw
2 Nm (0.2 m·kg, 1.4 ft·lb)
T.
R.
• Relief valve “17”

• Spring “18”
• Spring retainer “19”
Spring retainer bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
NOTE:
When installing the inner rotor, align the pin in
the oil pump shaft with the groove in the inner ro-
tor.
5-86
CRANKSHAFT
EAS25960
CRANKSHAFT
Removing the crankshaft

Separate.
1 Crankshaft 1
2 Generator shaft 1
3 Connecting rod cap 2
4 Big end lower bearing 2
5 Connecting rod 2
6 Big end upper bearing 2
dure.
5-87
CRANKSHAFT
EAS26010
REMOVING THE CONNECTING RODS

The following procedure applies to all of the con-
necting rods.
1. Remove:
• Connecting rod caps “1”
• Connecting rod
• Big end bearings
NOTE:
Identify the position of each big end bearing so
that it can be reinstalled in its original place.
3. Measure:
• Crankshaft-pin-to-big-end-bearing clearance
Out of specification → Replace the big end
bearings.
Journal oil clearance (using plas-

tigauge®)
0.030–0.062 mm (0.0012–0.0024
in)

connecting rods.
EAS26090 ECA13930
CHECKING THE CRANKSHAFT AND CAUTION:

CONNECTING RODS Do not interchange the big end bearings and
1. Measure: connecting rods. To obtain the correct
• Crankshaft runout crankshaft-pin-to-big-end-bearing clear-
Out of specification → Replace the crank- ance and prevent engine damage, the big
shaft. end bearings must be installed in their origi-
nal positions.
Runout limit C
0.040 mm (0.0016 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the big end bearings, crankshaft pins,
and the inside of the connecting rod halves.
b. Install the big end upper bearing into the con-
necting rod and the big end lower bearing into
the connecting rod cap.
NOTE:
Align the projections “a” on the big end bearings
with the notches “b” in the connecting rod and
connecting rod cap.
2. Check:
• Crankshaft journal surfaces
• Crankshaft pin surfaces
• Bearing surfaces
Scratches/wear → Replace the crankshaft.
• Generator shaft drive gear “1”
Damage/wear → Replace the crankshaft.
5-88
CRANKSHAFT
c. Put a piece of Plastigauge® “1” on the crank- g. Put a mark “1” on the connecting rod bolts “2”
shaft pin. and the connecting rod cap “3”.
d. Assemble the connecting rod halves. h. Tighten the connecting rod bolts further to
NOTE:
reach the specified angle 120°–150°.
• Do not move the connecting rod or crankshaft Connecting rod bolt (final)
until the clearance measurement has been Specified angle 120°–150°
T.
R.
completed.
• Lubricate the bolts threads and nut seats with
molybdenum disulfide grease.
• Make sure the projection “c” on the connecting
rod faces towards the left side of the crank-
shaft.
• Make sure the characters “d” on both the con-
necting rod and connecting rod cap are
aligned.
EWA12900
WARNING
When the bolts are tightened more than the
specified angle, do not loosen the bolt and
then retighten it.
Replace the bolt with a new one and perform
the procedure again.
EC5YU1008
CAUTION:
e. Tighten the connecting rod bolts.
EWA12890 • Do not use a torque wrench to tighten the
WARNING bolt to the specified angle.
• Replace the connecting rod bolts with new • Tighten the bolt until it is the specified an-
ones. gle.
• Clean the connecting rod bolts. i. Remove the connecting rod and big end
NOTE:
bearings.
Refer to “REMOVING THE CONNECTING
The tightening procedure of the connecting rod
RODS” on page 5-88.
bolts is angle controlled, therefore tighten the
bolts using the following procedure. j. Measure the compressed Plastigauge® width
“e” on the crankshaft pin.
f. Tighten the connecting rod bolts to the spec- If the crankshaft-pin-to-big-end-bearing
ified torque. clearance is out of specification, select re-
placement big end bearings.
Connecting rod bolt (1st)
15 Nm (1.5 m·kg, 11 ft·lb)
T.
R.
5-89
CRANKSHAFT
For example, if the connecting rod “P1” and

the crankshaft web “P” numbers are “5” and
“2” respectively, then the bearing size for “P1”
is:
“P1” (connecting rod) - “P” (crankshaft)
=
5 - 2 = 3 (brown)
Bearing color code

1.Blue 2.Black 3.Brown 4.Green
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5.Yellow
4. Select:
• Big end bearings (“P1”–“P2”) 5. Measure:
NOTE: • Crankshaft journal diameter “a”
• The numbers “a” stamped into the crankshaft
shaft.
web and the numbers “b” on the connecting
rods are used to determine the replacement NOTE:
big end bearing sizes. Measure the diameter of each crankshaft journal
• “P1”–“P2” refer to the bearings shown in the at two places.
crankshaft illustration.
Crankshaft journal diameter
49.968–49.980 mm (1.9672–
1.9677 in)
P1 P2
a 6. Measure:
• Crankshaft journal bearing inside diameter
“a”
case assembly.
NOTE:
Measure the inside diameter of each crankshaft
journal bearing at two places.
Crankshaft journal bearing inside

diameter
50.010–50.030 mm (1.9689–
1.9697 in)
5-90
CRANKSHAFT
EAS26150
INSTALLING THE CONNECTING RODS

1. Lubricate:
• Bolt threads
• Nut seats
Molybdenum disulfide grease
2. Lubricate:
4. Tighten:
• Crankshaft pins
• Connecting rod bolts “1”
• Connecting rod inner surface
Engine oil
3. Install:
• Connecting rods
• Connecting rod caps
(onto the crankshaft pins)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
NOTE: EWA12890
WARNING
• Align the projections “a” on the big end bear-
ings with the notches “b” in the connecting rods • Replace the connecting rod bolts with new
and connecting rod caps. ones.
• Be sure to reinstall each big end bearing in its • Clean the connecting rod bolts.
original place. NOTE:
• Make sure the projections “c” on the connect-
The tightening procedure of the connecting rod
ing rods face towards the left side of the crank-
bolts is angle controlled, therefore tighten the
shaft.
bolts using the following procedure.
• Make sure the characters “d” on both the con-
necting rod and connecting rod cap are a. Tighten the connecting rod bolts to the spec-
aligned. ified torque.
Connecting rod bolt (1st)

15 Nm (1.5 m·kg, 11 ft·lb)
T.
R.
b. Put a mark “1” on the connecting rod bolts “2”

and the connecting rod cap “3”.
5-91
CRANKSHAFT
NOTE:
• Make sure that the generator shaft drive gear
teeth and generator shaft driven gear teeth
mesh correctly.
• Align the right connecting rod with the front cyl-
inder sleeve hole.
c. Tighten the connecting rod bolts further to

reach the specified angle 120°–150°.
Connecting rod bolt (final)

Specified angle 120°–150°
T.
R.
EWA12900
WARNING
When the bolts are tightened more than the
specified angle, do not loosen the bolt and
then retighten it.
Replace the bolt with a new one and perform
the procedure again.
EC5YU1008
CAUTION:
• Do not use a torque wrench to tighten the
bolt to the specified angle.
• Tighten the bolt until it is the specified an-
gle.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS26210
INSTALLING THE CRANKSHAFT

ASSEMBLY
1. Install:
• Crankshaft assembly
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.
5-92
TRANSMISSION
EAS26240
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks

Separate.
1 Shift fork guide bar 2
2 Shift drum assembly 1
3 Shift fork-L 1
4 Shift fork-R 1
5 Shift fork-C 1
6 Drive axle assembly 1
7 Main axle assembly 1
8 Spacer 1
dure.
5-93
TRANSMISSION
Disassembling the main axle assembly

1 Circlip 1
2 Washer 1
3 5th pinion gear 1
4 Collar 1
5 Washer 1
6 2nd/3rd pinion gear 1
7 Circlip 1
8 Washer 1
9 4th pinion gear 1
10 Collar 1
11 Main axle/1st pinion gear 1
cedure.
5-94
TRANSMISSION
Disassembling the drive axle assembly

1 5th wheel gear 1
2 Circlip 1
3 Washer 1
4 2nd wheel gear 1
5 Collar 1
6 Circlip 1
7 Washer 1
8 1st wheel gear 1
9 Collar 1
10 Washer 1
11 4th wheel gear 1
12 Circlip 1
13 Washer 1
14 3rd wheel gear 1
15 Collar 1
16 Drive axle 1
cedure.
5-95
TRANSMISSION
EAS26260
CHECKING THE SHIFT FORKS

The following procedure applies to all of the shift
forks.
1. Check:
• Shift fork cam follower “1”
• Shift fork pawl “2”
Bends/damage/scoring/wear → Replace the
shift fork.
EAS26300
CHECKING THE TRANSMISSION

1. Measure:
• Main axle runout
(with a centering device and dial gauge “1”)
Out of specification → Replace the main axle.
Main axle runout limit

0.08 mm (0.0032 in)
2. Check:
• Shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends → Replace.
EWA12840
WARNING
Do not attempt to straighten a bent shift fork
guide bar.
3. Check:
• Shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift forks 2. Measure:
and shift fork guide bar as a set. • Drive axle runout
EAS26270
(with a centering device and dial gauge “1”)
CHECKING THE SHIFT DRUM ASSEMBLY Out of specification → Replace the drive axle.
1. Check:
Drive axle runout limit
• Shift drum groove
0.08 mm (0.0032 in)
Damage/scratches/wear → Replace the shift
drum assembly.
• Shift drum segment “1”
Damage/wear → Replace the shift drum as-
sembly.
• Shift drum bearing “2”
Damage/pitting → Replace the shift drum as-
sembly.
3. Check:
• Transmission gears
Blue discoloration/pitting/wear → Replace
the defective gear(s).
5-96
TRANSMISSION
• Transmission gear dogs EAS26320
INSTALLING THE SHIFT FORKS AND SHIFT

Cracks/damage/rounded edges → Replace
DRUM ASSEMBLY
the defective gear(s).
1. Install:
4. Check:
• Shift fork-R “1”
• Transmission gear engagement
• Shift fork-C “2”
(each pinion gear to its respective wheel
• Shift fork-L “3”
gear)
• Shift drum assembly “4”
Incorrect → Reassemble the transmission
• Shift fork guide bars “5”
axle assemblies.
5. Check: NOTE:
• Transmission gear movement The embossed marks on the shift forks should
Rough movement → Replace the defective face towards the right side of the engine and be
part(s). in the following sequence: “R”, “C”, “L”.
6. Check:
• Circlips
Bends/damage/looseness → Replace.
ET5YU1024
ASSEMBLING THE MAIN AXLE AND DRIVE

AXLE
1. Install:
• Washer “1”
• Circlip “2” New
NOTE:
• Be sure the circlip sharp-edged corner “a” is 2. Check:
positioned opposite side to the toothed washer • Transmission
and gear. Rough movement → Repair.
• Install the circlip so that both ends “b” rest on NOTE:
the sides of a spline “c” with both axles aligned. Oil each gear, shaft, and bearing thoroughly.
1 2
2 New
5-97
FUEL SYSTEM
FUEL TANK..................................................................................................... 6-1

REMOVING THE FUEL TANK .................................................................. 6-2
REMOVING THE FUEL PUMP ................................................................. 6-2
CHECKING THE FUEL PUMP BODY....................................................... 6-2
CHECKING THE FUEL PUMP OPERATION............................................ 6-2
INSTALLING THE FUEL PUMP................................................................ 6-2
INSTALLING THE FUEL TANK................................................................. 6-2
THROTTLE BODIES ....................................................................................... 6-4

CHECKING THE INJECTORS .................................................................. 6-9
CHECKING THE THROTTLE BODIES..................................................... 6-9
CHECKING THE ROLLOVER VALVES.................................................... 6-9
CHECKING THE PRESSURE REGULATOR ........................................... 6-9
CHECKING THE PRESSURE REGULATOR OPERATION ..................... 6-9
ADJUSTING THE THROTTLE POSITION SENSOR.............................. 6-10
INSTALLING THE FUEL PIPE ................................................................ 6-10
ISC (IDLE SPEED CONTROL) UNIT ............................................................ 6-11

CHECKING THE ISC (IDLE SPEED CONTROL) SYSTEM ................... 6-13
6
FUEL TANK
EAS26620
FUEL TANK
Removing the fuel tank and fuel pump
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
1 8
9 New
4 5 6
3 (6)
2
7
4 Nm (0.4 m • kg, 2.9 ft • Ib)
T.
R.

Seat 4-1.
1 Fuel tank cover 1
2 Fuel pump coupler 1 Disconnect.
3 Fuel sender coupler 1 Disconnect.
4 Fuel tank overflow hose 1 Disconnect.
5 Fuel tank breather hose 1 Disconnect.
6 Fuel hose 1 Disconnect.
7 Fuel return hose 1 Disconnect.
8 Fuel tank 1
9 Fuel pump 1
dure.
6-1
FUEL TANK
EAS26630 EAS26670
REMOVING THE FUEL TANK CHECKING THE FUEL PUMP BODY

1. Extract the fuel in the fuel tank through the 1. Check:
fuel tank cap with a pump. • Fuel pump body
2. Disconnect: Obstruction → Clean.
• Fuel hose Cracks/damage → Replace fuel pump as-
• Fuel return hose sembly.
EC5YU1029
2. Check:
CAUTION: • Diaphragms and gaskets
Although the fuel has been removed from Tears/fatigue/cracks → Replace fuel pump
the fuel tank be careful when removing the assembly.
fuel hoses, since there may be fuel remain-
EAS26690
ing in them.
CHECKING THE FUEL PUMP OPERATION
NOTE: 1. Check:
• To remove the fuel hose from the fuel pump, • Fuel pump operation
slide the fuel hose connector cover “1” on the Refer to “CHECKING THE FUEL PUMP” on
end of the hose in the direction of the arrow page 7-105.
shown, press the two buttons “2” on the sides EAS26710
of the connector, and then remove the hose. INSTALLING THE FUEL PUMP
• Remove the fuel hose manually without using 1. Tighten:
any tools. • Fuel pump
• Before removing the hoses, place a few rags in
the area under where they will be removed. Fuel pump bolt
4 Nm (0.4 m·kg, 2.9 ft·lb)
T.
R.
NOTE:
• Do not damage the installation surfaces of the
fuel tank when installing the fuel pump.
• Always use a new fuel pump gasket.
• Install the fuel pump as shown in the illustra-
tion.
1 2 • Align the projection “a” on the fuel pump with
the slot in the fuel pump bracket.
• Tighten the fuel pump bolts in the proper tight-
3. Remove: ening sequence as shown.
• Fuel tank
NOTE:
Do not set the fuel tank down on the installation 4 6
surface of the fuel pump. Be sure to lean the fuel
tank against a wall or the like.
FWD 1 2
EAS26640
REMOVING THE FUEL PUMP

1. Remove: 3 5
• Fuel pump a
ECA14720
CAUTION: ET5YU1025
• Do not drop the fuel pump or give it a INSTALLING THE FUEL TANK
strong shock. 1. Connect:
• Do not touch the base section of the fuel • Fuel return hose
sender. • Fuel hose
6-2
FUEL TANK
EC5YU1017
CAUTION:
When installing the fuel hose and the fuel re-
turn hose, make sure that they are securely
connected, and that the fuel hose connector
cover on the fuel hose is in the correct posi-
tion, otherwise the fuel hose will not be prop-
erly installed.
NOTE:
• Install the fuel hose securely onto the fuel
pump until a distinct “click” is heard.
• To install the fuel hose onto the fuel pump,
slide the fuel hose connector cover “1” on the
end of the hose in the direction of the arrow
shown.
6-3
THROTTLE BODIES
EAS26970
THROTTLE BODIES
Removing the pressure regulator and rollover valves
7 Nm (0.7 m • kg, 5.1 ft • Ib) 5
T.
R.
6
3 7
4
2
5
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
15
12 1
9 12 10
14
13
11
9 Nm (0.9 m • kg, 6.5 ft • Ib)

12
T.
R.
12

Air duct 4-1.
1 Pressure regulator cover 1
Fuel hose (intake manifold assembly to pres-
2 1 Disconnect.
sure regulator)
3 Pressure regulator 1
4 Fuel return hose 1
5 Fuel pipe holder 2
6 Fuel return hose (fuel return pipe to fuel pump) 1
7 Fuel return pipe 1
8 Fuel tank breather hose 1
9 Fuel tank overflow hose 1
10 Fuel tank breather/overflow hose holder 1
11 Fuel tank breather/overflow hose 1
12 Rollover valve hose 4
13 Rollover valve 1 1
6-4
THROTTLE BODIES
Removing the pressure regulator and rollover valves
7 Nm (0.7 m • kg, 5.1 ft • Ib) 5
T.
R.
6
3 7
4
2
5
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
15
12 1
9 12 10
14
13
11
9 Nm (0.9 m • kg, 6.5 ft • Ib)

12
T.
R.
12

14 Rollover valve 2 1
15 Rollover valve bracket 1
dure.
6-5
THROTTLE BODIES
Removing the throttle bodies

5
4 Nm (0.4 m • kg, 2.9 ft • Ib)

LS 7
T.
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib)
T.
R.
6 6
4 Nm (0.4 m • kg, 2.9 ft • Ib)
T.
R.
2
3

Seat/Air filter case 4-1.
1 Throttle position sensor coupler 1 Disconnect.
2 Cylinder-#1 intake air pressure sensor hose 1 Disconnect.
3 Cylinder-#2 intake air pressure sensor hose 1 Disconnect.
Intake solenoid vacuum hose (one-way valve to
4 1 Disconnect.
throttle body)
5 Throttle cable 2 Disconnect.
6 Throttle body joint clamp screw 2 Loosen.
EC5YU1030
CAUTION:
7 Throttle body 1
The throttle body should not be disas-
sembled.
8 Throttle position sensor 1

dure.
6-6
THROTTLE BODIES
Removing the intake manifolds

10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
3
(2) (2)
2
4
8 New
New 8
5
7
1

1 Fuel hose 1
Fuel hose (intake manifold assembly to pres-
2 1
sure regulator)
Cylinder-#2 ISC (idle speed control) unit outlet
3 1
hose
4 1
hose
5 Intake manifold assembly 1
6 Cylinder-#2 injector coupler 1 Disconnect.
7 Cylinder-#1 injector coupler 1 Disconnect.
8 Gasket 2
dure.
6-7
THROTTLE BODIES
Removing the injectors
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
R.
New
New
T.
R.
5 Nm (0.5 m • kg, 3.6 ft • Ib)
1
2
New
5 4
New New
New
5
New
4
New
5 Nm (0.5 m • kg, 3.6 ft • Ib)

T.
R.

1 Fuel pipe 1
2 Injector joint 1 1
3 Injector joint 2 1
4 Injector 2
5 Intake manifold 2
dure.
6-8
THROTTLE BODIES
EAS26980 EAS27010
CHECKING THE INJECTORS CHECKING THE PRESSURE REGULATOR

1. Check: OPERATION
• Injectors 1. Check:
Damage → Replace. • Pressure regulator operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EAS26990
a. Remove the pressure regulator cover.
CHECKING THE THROTTLE BODIES
Refer to “THROTTLE BODIES” on page 6-4.
1. Check:
b. Disconnect the fuel hose “1” from the pres-
• Throttle bodies
sure regulator “2”.
Cracks/damage → Replace the throttle bod-
c. Connect the fuel pressure adapter “3” be-
ies as a set.
tween the fuel hose “1” and pressure regula-
2. Check:
tor “2”.
• Fuel passages
d. Connect the pressure gauge “4” to the fuel
Obstructions → Clean.
pressure adapter “3”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the throttle bodies in a petroleum- e. Connect the vacuum/pressure pump gauge
based solvent. set “5” to the pressure regulator.
Do not use any caustic carburetor cleaning
Vacuum/pressure pump gauge
solution. set
b. Blow out all of the passages with compressed 90890-06756
air. Mityvac brake bleeding tool
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ YS-42423
ET5YU1014 Pressure gauge
CHECKING THE ROLLOVER VALVES 90890-03153
1. Check: YU-03153
• Rollover valve 1 “1” Fuel pressure adapter
• Rollover valve 2 “2” 90890-03176
Damage/faulty → Replace. YM-03176
NOTE:
• Check that air flows smoothly only in the direc- 2
• The rollover valves must be in an upright posi-
tion when checking the airflow. 1
1
2
4
2
EAS27000
CHECKING THE PRESSURE REGULATOR

1. Check: 1 3 5
• Pressure regulator
Damage → Replace.
f. Start the engine.
g. Measure the fuel pressure.
6-9
THROTTLE BODIES
Fuel pressure
392 kPa (3.92 kg/cm², 55.7 psi) 3
h. Use the vacuum/pressure pump gauge set to

adjust the fuel pressure in relation to the vac- 2 3
uum pressure as described below.
NOTE:
1
The vacuum pressure should not exceed 100
kPa (760 mm Hg).
• Increase the vacuum pressure → ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

Fuel pressure is decreased ET5YU1016
• Decrease the vacuum pressure → INSTALLING THE FUEL PIPE
Fuel pressure is increased 1. Install:
• Fuel pipe “1”
Faulty → Replace the pressure regulator.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Fuel pipe bolt
EAS27030 30 Nm (3.0 m·kg, 22 ft·lb)
T.
R.
ADJUSTING THE THROTTLE POSITION
SENSOR NOTE:
1. Check: Install the fuel pipe “1” so that it contacts the pro-
• Throttle position sensor jections “a” on the injector joints.
Refer to “CHECKING THE THROTTLE PO-
SITION SENSOR” on page 7-104.
2. Adjust:
• Throttle position sensor angle
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the throttle position sensor coupler a
to the throttle position sensor.
b. Connect the digital circuit tester to the throttle
position sensor coupler.
1
• Positive tester probe
yellow terminal “1”
• Negative tester probe
black terminal “2”
Digital circuit tester

90890-03174
Model 88 Multimeter with ta-
chometer
YU-A1927
c. Measure the throttle position sensor voltage.

d. Adjust the throttle position sensor angle so
that the voltage is within the specified range.
Output voltage (at idle)

0.63–0.73 V
e. After adjusting the throttle position sensor an-

gle, tighten the throttle position sensor
screws “3”.
6-10
ISC (IDLE SPEED CONTROL) UNIT
ET5YU1012

Removing the ISC (idle speed control) unit and intake solenoid
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
13
12
7 4
8 5
15
11
14 6
3
9
10 2
16 1

T.
R.
T.
R.

Air filter case 4-1.
1 ISC (idle speed control) unit cover 1
2 Surge tank 1
3 Surge tank hose 1
Intake solenoid vacuum hose (one-way valve to
4 1 Disconnect.
throttle body)
5 One-way valve 1
Intake solenoid vacuum hose (intake solenoid to
6 1
one-way valve)
Intake solenoid vacuum hose (air filter case
7 1
valve to intake solenoid)
8 Intake solenoid coupler 1 Disconnect.
9 Intake solenoid 1
10 Intake solenoid holder 1
11 Intake solenoid bracket 1
6-11
Removing the ISC (idle speed control) unit and intake solenoid
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
13
12
7 4
8 5
15
11
14 6
3
9
10 2
16 1

T.
R.
T.
R.

12 ISC (idle speed control) unit coupler 1 Disconnect.
13 1 Disconnect.
hose
14 1 Disconnect.
hose
15 ISC (idle speed control) unit inlet hose 1
16 ISC (idle speed control) unit 1
dure.
6-12
ET5YU1015
CHECKING THE ISC (IDLE SPEED

CONTROL) SYSTEM
1. Check:
• Hoses
Loose connections → Connect properly.
2. Check:
• Surge tank
3. Check:
• One-way valve
Cracks/damage/faulty → Replace.
NOTE:
Check that air flows smoothly only in the direc-
4. Check:
• Intake solenoid
Damage → Replace.
6-13
ELECTRICAL SYSTEM
IGNITION SYSTEM ......................................................................................... 7-1

CIRCUIT DIAGRAM .................................................................................. 7-1
TROUBLESHOOTING .............................................................................. 7-3
ELECTRIC STARTING SYSTEM .................................................................... 7-5

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

CIRCUIT DIAGRAM ................................................................................ 7-11
TROUBLESHOOTING ............................................................................ 7-13
LIGHTING SYSTEM ...................................................................................... 7-15

CIRCUIT DIAGRAM ................................................................................ 7-15
SIGNALING SYSTEM ................................................................................... 7-19

CIRCUIT DIAGRAM ................................................................................ 7-19
FUEL INJECTION SYSTEM.......................................................................... 7-25

CIRCUIT DIAGRAM ................................................................................ 7-25
ECU SELF-DIAGNOSTIC FUNCTION.................................................... 7-27
SELF-DIAGNOSTIC FUNCTION TABLE ................................................ 7-28
TROUBLESHOOTING METHOD............................................................ 7-31
DIAGNOSTIC MODE .............................................................................. 7-31
TROUBLESHOOTING DETAILS ............................................................ 7-39
FUEL PUMP SYSTEM................................................................................... 7-67

CIRCUIT DIAGRAM ................................................................................ 7-67
7
MUFFLER COOLING SYSTEM .................................................................... 7-71
CIRCUIT DIAGRAM ................................................................................ 7-71
IMMOBILIZER SYSTEM................................................................................ 7-75

CIRCUIT DIAGRAM ................................................................................ 7-75
GENERAL INFORMATION ..................................................................... 7-77
PART REPLACEMENT AND KEY CODE REGISTRATION
REQUIREMENTS................................................................................... 7-77
SELF-DIAGNOSIS FAULT CODE INDICATION..................................... 7-81
ELECTRICAL COMPONENTS...................................................................... 7-85
CHECKING THE SWITCHES ................................................................. 7-89
CHECKING THE BULBS AND BULB SOCKETS ................................... 7-92
CHECKING THE FUSES ........................................................................ 7-93
CHECKING AND CHARGING THE BATTERY....................................... 7-94
CHECKING THE RELAYS ...................................................................... 7-96
CHECKING THE TURN SIGNAL/HAZARD RELAY................................ 7-97
CHECKING THE RELAY UNIT (DIODE) ................................................ 7-98
CHECKING THE SPARK PLUG CAPS................................................... 7-99
CHECKING THE IGNITION COILS......................................................... 7-99
CHECKING THE IGNITION SPARK GAP.............................................7-100
CHECKING THE CRANKSHAFT POSITION SENSOR........................7-101
CHECKING THE LEAN ANGLE CUT-OFF SWITCH............................7-101
CHECKING THE STATOR COIL ..........................................................7-101
CHECKING THE RECTIFIER/REGULATOR ........................................7-102
CHECKING THE HORN........................................................................7-102
CHECKING THE ENGINE TEMPERATURE SENSOR ........................7-103
CHECKING THE FUEL SENDER .........................................................7-103
CHECKING THE SPEED SENSOR ...................................................... 7-104
CHECKING THE THROTTLE POSITION SENSOR .............................7-104
CHECKING THE FUEL PUMP..............................................................7-105
CHECKING THE EXUP SERVO MOTOR.............................................7-105
CHECKING THE DECOMPRESSION SOLENOID...............................7-106
CHECKING THE INTAKE AIR PRESSURE SENSORS .......................7-106
CHECKING THE AIR TEMPERATURE SENSOR ................................7-107
CHECKING THE INTAKE SOLENOID..................................................7-107
CHECKING THE MUFFLER COOLING FAN MOTOR .........................7-108
CHECKING THE MUFFLER COOLING FAN TEMPERATURE
SENSOR ..............................................................................................7-108
EAS27110
EAS27090
B/R
L Sb/W R
Sb/W B/R L R/L L/R

L/G L/Y Sb B/Y L/W1 R
L/G
O B/R O O B/R O
L/R
L/W1 Sb L/Y R/L
B/Y
WIRE HARNESS SUB-WIRE-HARNESS1

Br/W P/Y W/R L Br/Y Gy/G L/Y W/B R/L R/W R/B B/Br P/L B/L R/G B/Y
L/G Y/G Br P/W L/R L/W W/Y G/R Gy1 R/B B/Br Y/L Y Br/L W/G
CIRCUIT DIAGRAM
Sb
B B2 R/G R/G B2 B Br/B R/W
Y/L Lg R/W R/W Lg Y/L B
B Sb Gy/W B/R B3 Br/B Gy G/Y O Gy/R
R/L G Lg B/G B3 G Y/B O Gy/B
B B
B G B (BLUE)
B B2 R/W R/G Br/B Br/B R/W
Gy G G Gy
Lg Y/L
B B W W B
IGNITION SYSTEM
R/L B B B/R
B L/G (BLACK) (BLACK)
(DARK GREEN)
B B (BLUE) Gy/B Gy/B
Gy/R
B
B R R R/G B/R C
B R/W
L/Y Gy/R Gy/R
B R Gy1
Gy1
B/R Ch Dg Dg Ch
B B B (BLACK) A
B B B B B
(BLACK) B/R
B/L
Gy1 B/L B Gy L W/Y W L L B/R
R B/L B W/Y W/Y O O A O WIRE HARNESS SUB-WIRE-HARNESS3
R R/W L O O A O O
B/L
R Br/R B B B B B/L
L Y B Y Y D Y Y R/G R/G
Br/R L L D L L P/L P/L D
L (BLACK) W/G W/G
ON R R
L/W Br/L Br/L B/R
OFF R
Br/L B/L Br/Y Br/Y
O L Y Y L
B R/W R/B
B Br/Y B/L W/G R/B R/G Br Br
B/L B B R/B
Br/L R/B P/L
Br/L B/L P/W L P/W (BLACK) (BLACK)
R B B
Br/R B L P/W
Br/L (BLACK) B/G B/G WIRE HARNESS SUB-WIRE-HARNESS2
B B P/Y
B/R B/R
B/L
B/L P/Y L P/Y B/L Br/W Br/W L
L L W/R B/L
Br W/R W/R B/G B/R
(BLACK) Br/W B/L B/L
(BLACK)
R R R (BLACK) R/B Y/L
R R/B
B1 B2 B Br Br D Br
G/R G/R G G G/R B/L
R Br/W Gy/R
G/Y Gy/G
B2 B1 Br B
R/L Gy/W
L/R Lg Lg B B Gy/R Lg
L (BLACK) W/B B/L (BLACK)
R R/B (BLACK)
B2 Y/G Y/G Gy
L Y/G B/L
7-1
B1 B/L B/Y G
BB4 Y/B
BB3
BB2 B/Br B3 Gy B Gy Gy W
BB1 B/Br B3
W Gy
B B (DARK GRAY)
B B
G B G G G W
BB3 BB2 W G
BB4 BB1 Br/R Br/G R Gy/R
Gy/R
(GRAY)
W B W
Br/L Br
Br/L R/W
Br/G
Br Gy/G B/L
Br/L R/Y Gy/W

R/Y R/Y Sb/W
Br/W R/L
R/Y Br/G B
Br/W G/L B B
R/W Y/L
L/W1 R/Y Y/B W L
R/B B/R W/B R/W
Br/W (BLACK) R/G
Br/W G/L Y/B G
L L/Y Gy/W R/L B
R/B G/Y B/Y Br/W Gy/G B/L
R/Y G/L B
L (BLACK)
G/Y
L Br Y L/W1 R/W R/W L/W B
B/R W/B Br B B/Y R/B
(BLUE) B
B B (BLUE)
L L B B Lg
B R/Y Br/W L/B Y Dg Dg Y G/L Br/W R/Y
(BLACK) (BLACK) (BROWN) Y Br (BLACK) P B B/Y G B Ch Ch L/Y G B B/Y B
Y Y
B Br Y
Y G Dg Ch B
(BROWN)
Ch
Dg
L L Y
Dg Ch L
C C
L Y Y L
Dg Ch
B B
Ch Dg
Y/L R/G
L/R Y G Dg Y L Dg
Ch G B Lg
L B B G/R R/W Sb Ch
(BLACK)
(GRAY) (GRAY)
Y B G B Ch Dg Dg Ch R/G Y/L Dg L Y
B B B B Lg B G Ch Sb/W R/W
(GRAY) (BLACK) (BLACK) (GRAY) (BLACK)
B Y G
B L/R B
B Ch B Dg B Dg B Ch
B B B B
G Y B B B
(GRAY) (BLACK) (BLACK) (GRAY)
B L/R C C
B B
IGNITION SYSTEM
IGNITION SYSTEM
3. Main switch
4. Battery
8. Main fuse
10.ECU fuse
13.Relay unit
14.Starting circuit cut-off relay
16.Neutral switch
19.Sidestand switch
20.Crankshaft position sensor
24.Lean angle cut-off switch
29.ECU (electronic control unit)
32.Spark plug
33.Cylinder-#2 right ignition coil
34.Cylinder-#2 left ignition coil
56.Clutch switch
73.Engine stop switch
81.Ignition fuse
7-2
IGNITION SYSTEM
EAS27150
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
NOTE:
• Before troubleshooting, remove the following part(s):
1. Seat
2. Fuel tank
3. Air filter case
4. Battery box
5. Engine
1. Check the fuses. NG →

(Main, ignition, and ECU)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 7-93.
OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 7-94.
OK ↓
3. Check the spark plugs. NG →
Refer to “CHECKING THE SPARK Re-gap or replace the spark plug(s).
PLUGS” on page 3-8.
OK ↓
4. Check the ignition spark gap. OK →
Refer to “CHECKING THE IGNI- Ignition system is OK.
TION SPARK GAP” on page 7-100.
NG ↓
5. Check the spark plug caps. NG →
Refer to “CHECKING THE SPARK Replace the spark plug cap(s).
PLUG CAPS” on page 7-99.
OK ↓
6. Check the ignition coils. NG →
Refer to “CHECKING THE IGNI- Replace the ignition coil(s).
TION COILS” on page 7-99.
OK ↓
7. Check the crankshaft position sen- NG →
sor.
Refer to “CHECKING THE CRANK- Replace the crankshaft position sensor.
SHAFT POSITION SENSOR” on
page 7-101.
OK ↓
7-3
IGNITION SYSTEM
8. Check the main switch. NG →

Refer to “CHECKING THE Replace the main switch/immobilizer unit.
SWITCHES” on page 7-89.
OK ↓
9. Check the engine stop switch. NG →
Refer to “CHECKING THE Replace the right handlebar switch.
OK ↓
10.Check the neutral switch. NG →
Refer to “CHECKING THE Replace the neutral switch.
OK ↓
11.Check the sidestand switch. NG →
Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
12.Check the clutch switch. NG →
Refer to “CHECKING THE Replace the clutch switch.
OK ↓
13.Check the relay unit (starting circuit NG →
cut-off relay).
Replace the relay unit.
Refer to “CHECKING THE RE-
LAYS” on page 7-96.
OK ↓
14.Check the relay unit (diode). NG →
Refer to “CHECKING THE RELAY Replace the relay unit.
UNIT (DIODE)” on page 7-98.
OK ↓
15.Check the lean angle cut-off switch. NG →
Refer to “CHECKING THE LEAN
Replace the lean angle cut-off switch.
ANGLE CUT-OFF SWITCH” on
page 7-101.
OK ↓
16.Check the entire ignition system NG →
wiring. Properly connect or repair the ignition sys-
Refer to “CIRCUIT DIAGRAM” on tem wiring.
page 7-1.
OK ↓
Replace the ECU.
7-4
EAS27170
EAS27160
B/R
L Sb/W R
Sb/W B/R L R/L L/R

L/G
O B/R O O B/R O
L/R
L/W1 Sb L/Y R/L
B/Y

CIRCUIT DIAGRAM
Sb
B B
B G B (BLUE)
Gy G G Gy
Lg Y/L
B B W W B
R/L B B B/R
(DARK GREEN)
B
B R R R/G B/R C
B R/W
L/Y Gy/R Gy/R
B R Gy1
Gy1
B/R Ch Dg Dg Ch
B B B (BLACK) A
B B B B B
(BLACK) B/R
Gy1 B/L B Gy B/L B/R
L W/Y W L L
R O O A O
B/L B W/Y WIRE HARNESS SUB-WIRE-HARNESS3
R R/W L W/Y O A O
O O
B/L
R Br/R B B B B B/L
L (BLACK) W/G W/G
ON R R
L/W Br/L Br/L B/R
OFF R
Br/L B/L Br/Y Br/Y
O L Y Y L
B R/W R/B
B/L B B R/B
Br/L R/B P/L
R B B
ELECTRIC STARTING SYSTEM
Br/R B L P/W
B B P/Y
B/R B/R
B/L
L L W/R B/L
Br W/R W/R B/G B/R
(BLACK)
R R/B
B1 B2 B Br Br D Br
G/R G/R G G G/R B/L
R Br/W Gy/R
G/Y Gy/G
B2 B1 Br B
R/L Gy/W
R R/B (BLACK)
B2 Y/G Y/G Gy
L Y/G B/L
7-5
B1 B/L B/Y G
BB4 Y/B
BB3
BB1 B/Br B3
W Gy
B B (DARK GRAY)
B B
G B G G W
BB3 BB2 W G
(GRAY)
W B W
Br/L Br
Br/L R/W
Br/G
Br Gy/G B/L
Br/L R/Y Gy/W

R/Y R/Y Sb/W
Br/W R/L
R/Y Br/G B
Br/W G/L B B
R/W Y/L
L/W1 R/Y Y/B W L
R/B B/R W/B R/W
Br/W (BLACK) R/G
Br/W G/L Y/B G
L L/Y Gy/W R/L B
R/Y G/L B
L (BLACK)
G/Y
(BLUE) B
B B (BLUE)
L L B B Lg
Y Y
B Br Y
Y G Dg Ch B
(BROWN)
Ch
Dg
L L Y
Dg Ch L
C C
L Y Y L
Dg Ch
B B
Ch Dg
Y/L R/G
L/R Y G Dg Y L Dg
Ch G B Lg
L B B G/R R/W Sb Ch
(BLACK)
(GRAY) (GRAY)
B Y G
B L/R B
B Ch B Dg B Dg B Ch
B B B B
G Y B B B
B L/R C C
B B
3. Main switch
4. Battery
6. Starter relay
7. Starter motor
8. Main fuse
10.ECU fuse
13.Relay unit
14.Starting circuit cut-off relay
16.Neutral switch
19.Sidestand switch
38.Decompression solenoid
56.Clutch switch
70.Auto decompression fuse
74.Start switch
81.Ignition fuse
7-6
EAS27180
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the engine stop switch is set to “ ” and the main switch is turned “ON” (both switch circuits are
closed), the starter motor can only operate if at least one of the following conditions is met:
• The transmission is in neutral (the neutral switch circuit is closed).
• The clutch lever is pulled to the handlebar (the clutch switch circuit is closed) and the sidestand is up
(the sidestand switch circuit is closed).
The starting circuit cut-off relay prevents the starter motor from operating when neither of these condi-
tions has been met. In this instance, the starting circuit cut-off relay stays open so current cannot reach
the starter motor. When at least one of the above conditions has been met, the starting circuit cut-off
relay is closed and the engine can be started by pushing the start switch “ ”.
13
12
4
15 14
11
6
7
7
a
8 7
9 10
b
16 17
7-7
a. WHEN THE TRANSMISSION IS IN

NEUTRAL
b. WHEN THE SIDESTAND IS UP AND THE
CLUTCH LEVER IS PULLED TO THE
HANDLEBAR
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
5. Engine stop switch
6. Relay unit (starting circuit cut-off relay)
7. Relay unit (diode)
8. Clutch switch
9. Sidestand switch
10. Neutral switch
11. Start switch
12. Starter relay
13. Starter motor
14. ECU fuse
15. Auto decompression fuse
16. Decompression solenoid
7-8
EAS27190
TROUBLESHOOTING
The starter motor fails to turn.
NOTE:
1. Seat
2. Fuel tank
3. Air filter case
4. Oil tank

(Main, ignition, auto decompres-
sion, and ECU) Replace the fuse(s).
ES” on page 7-93.
OK ↓
page 7-94.
OK ↓
3. Check the starter motor. NG →
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-73.
OK ↓
4. Check the relay unit (starting circuit NG →
cut-off relay).
OK ↓
5. Check the relay unit (diode). NG →
Refer to “CHECKING THE RELAY Replace the relay unit.
UNIT (DIODE)” on page 7-98.
OK ↓
6. Check the starter relay. NG →
Refer to “CHECKING THE RE- Replace the starter relay.
OK ↓
OK ↓
7-9

OK ↓
9. Check the neutral switch. NG →
OK ↓
10.Check the sidestand switch. NG →
Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
11.Check the clutch switch. NG →
Refer to “CHECKING THE Replace the clutch switch.
OK ↓
12.Check the start switch. NG →
OK ↓
13.Check the decompression sole- NG →
noid.
Refer to “CHECKING THE DE- Replace the decompression solenoid.
COMPRESSION SOLENOID” on
page 7-106.
OK ↓
14.Check the entire starting system NG →
wiring. Properly connect or repair the starting sys-
page 7-5.
OK ↓
The starting system circuit is OK.
7-10
EAS27210
EAS27200
B/R
L Sb/W R
Sb/W B/R L R/L L/R

L/G
L/R
L/W1 Sb L/Y R/L
B/Y
CIRCUIT DIAGRAM
Sb L/G
B B2 R/G R/G B2 B
Y/L Lg R/W R/W Lg Y/L
B Sb
R/L G
CHARGING SYSTEM
B B
B G B (BLUE)
B B2 R/W R/G
Lg Y/L
B R/L B B
B L/G
(DARK GREEN)
B B (BLUE)
B
B R R R/G
B
B R
Gy1
B B B (BLACK)
B
(BLACK)
Gy1 B/L B Gy B/L
L W/Y W L L
R
B/L B W/Y
R R/W L
B/L
R Br/R B
7-11
B B B
L Y B Y Y D Y
Br/R L L D L
L (BLACK)
ON R R
OFF R
Br/L B/L Br/Y
B R/W
B Br/Y B/L B B
B/L
R B B
Br/R B L
Br/L (BLACK)
B B
B/L
B/L P/Y L P/Y B/L Br/W
L
(BLACK) Br/W B/L
R R R (BLACK)
R
B1 B2 B Br Br D Br
R Br/W
B2 B1 Br B
L (BLACK)
R R/B
B2 Y/G
L Y/G B/L
B1 B/L
BB4
BB3
BB2
BB1
B B
B B
BB3 BB2
Br/L Br
CHARGING SYSTEM
CHARGING SYSTEM
1. AC magneto
4. Battery
8. Main fuse
7-12
CHARGING SYSTEM
EAS27220
TROUBLESHOOTING
The battery is not being charged.
NOTE:
1. Seat
1. Check the fuse. NG →

(Main)
Replace the fuse.
ES” on page 7-93.
OK ↓
page 7-94.
OK ↓
3. Check the stator coil. NG →
Refer to “CHECKING THE STATOR Replace the stator assembly.
COIL” on page 7-101.
OK ↓
4. Check the rectifier/regulator. NG →
Refer to “CHECKING THE RECTI-
Replace the rectifier/regulator.
FIER/REGULATOR” on page
7-102.
OK ↓
5. Check the entire charging system NG →
wiring. Properly connect or repair the charging
Refer to “CIRCUIT DIAGRAM” on system wiring.
page 7-11.
OK ↓
This circuit is OK.
7-13
CHARGING SYSTEM
7-14
EAS27250
EAS27240
B/R
L Sb/W R
Sb/W B/R L R/L L/R

L/G
O B/R O O B/R O
L/R
L/W1 Sb L/Y R/L
B/Y

CIRCUIT DIAGRAM
Sb
B B
B G B (BLUE)
Gy G G Gy
Lg Y/L
B B W W B
R/L B B B/R
(DARK GREEN)
LIGHTING SYSTEM

B
B R R R/G B/R C
B R/W
L/Y Gy/R Gy/R
B R Gy1
Gy1
B/R Ch Dg Dg Ch
B B B (BLACK) A
B B B B B
(BLACK) B/R
L W/Y W L L
R O O A O
R R/W L W/Y O A O
O O
B/L
R Br/R B B B B B/L
L (BLACK) W/G W/G
ON R R
L/W Br/L Br/L B/R
OFF R
Br/L B/L Br/Y Br/Y
O L Y Y L
B R/W R/B
B W/G R/B R/G Br Br
B/L Br/Y B/L B B R/B
Br/L R/B P/L
R B B
Br/R B L P/W
B B P/Y
B/R B/R
B/L
L L W/R B/L
Br W/R W/R B/G B/R
(BLACK)
R R/B
B1 B2 B Br Br D Br
G/R G/R G G G/R B/L
R Br/W Gy/R
G/Y Gy/G
B2 B1 Br B
R/L Gy/W
R R/B (BLACK)
B2 Y/G Y/G Gy
L Y/G B/L
B1 B/L B/Y G
7-15
BB4 Y/B
BB3
BB1 B/Br B3
W Gy
B B (DARK GRAY)
B B
G B G G W
BB3 BB2 W G
(GRAY)
W B W
Br/L Br
Br/L R/W
Br/G
Br Gy/G B/L
Br/L R/Y Gy/W

R/Y R/Y Sb/W
Br/W R/L
R/Y Br/G B
Br/W G/L B B
R/W Y/L
L/W1 R/Y Y/B W L
R/B B/R W/B R/W
Br/W (BLACK) R/G
Br/W G/L Y/B G
L L/Y Gy/W R/L B
R/Y G/L B
L (BLACK)
G/Y
(BLUE) B
B B (BLUE)
L L B B Lg
Y Y
B Br Y
Y G Dg Ch B
(BROWN)
Ch
Dg
L L Y
Dg Ch L
C C
L Y Y L
Dg Ch
B B
Ch Dg
Y/L R/G
L/R Y G Dg Y L Dg
Ch G B Lg
L B B G/R R/W Sb Ch
(BLACK)
(GRAY) (GRAY)
B Y G
B L/R B
B Ch B Dg B Dg B Ch
B B B B
G Y B B B
B L/R C C
B B
LIGHTING SYSTEM
LIGHTING SYSTEM
3. Main switch
4. Battery
8. Main fuse
10.ECU fuse
47.High beam indicator light
50.Meter light
54.Headlight relay
57.Pass switch
58.Dimmer switch
67.Auxiliary light
68.Headlight (high beam)
69.Headlight (low beam)
75.Tail/brake light
76.License plate light
80.Headlight fuse
82.Signaling system fuse
83.Parking lighting fuse
7-16
LIGHTING SYSTEM
EAS27260
TROUBLESHOOTING
Any of the following fail to light: headlight (high beam), headlight (low beam), high beam indicator light,
taillight, license plate light, auxiliary light or meter light.
NOTE:
1. Seat
2. Fuel tank
3. Air filter case
4. Headlight assembly
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
7-92.
OK ↓
(Main, headlight, signaling system,
parking lighting, and ECU) Replace the fuse(s).
ES” on page 7-93.
OK ↓
page 7-94.
OK ↓
OK ↓
5. Check the dimmer switch. NG →
Refer to “CHECKING THE Replace the left handlebar switch.
OK ↓
6. Check the pass switch. NG →
OK ↓
7. Check the headlight relay. NG →
Refer to “CHECKING THE RE- Replace the headlight relay.
OK ↓
7-17
LIGHTING SYSTEM
8. Check the entire lighting system NG →

wiring. Properly connect or repair the lighting sys-
page 7-15.
OK ↓
This circuit is OK.
7-18
EAS27280
EAS27270
L Sb/W B/RR
Sb/W B/R L R/L L/R

L/G
O B/R O O B/R O
L/R
L/W1 Sb L/Y R/L
B/Y

CIRCUIT DIAGRAM
Sb
R/L G
B B Lg B/G B3 G Y/B O Gy/B
B G B (BLUE)
Gy G G Gy
Lg Y/L
B B W W B
R/L B B B/R
(DARK GREEN)
SIGNALING SYSTEM
B
B R R R/G B/R C
B R/W
L/Y Gy/R Gy/R
B R Gy1
Gy1
B/R Ch Dg Dg Ch
B B B (BLACK) A
B B B B B
(BLACK) B/R
B/L
Gy1 B/L B Gy L W/Y W L L B/R
R B/L O O A O
B W/Y W/Y WIRE HARNESS SUB-WIRE-HARNESS3
R R/W L O O A O O
B/L
R Br/R B B B B B/L
L (BLACK) W/G W/G
ON R R
L/W Br/L Br/L B/R
OFF R
Br/L B/L Br/Y Br/Y
O L Y Y L
B R/W R/B
B W/G R/B R/G Br Br
Br/L R/B P/L
R B B
Br/R B L P/W
B B P/Y
B/R B/R
B/L
L L W/R B/L
Br W/R W/R B/G B/R
(BLACK)
R R/B
B1 B2 B Br Br D Br
G/R G/R G G G/R B/L
R Br/W Gy/R
G/Y Gy/G
B2 B1 Br B
R/L Gy/W
R R/B (BLACK)
B2 Y/G Y/G Gy
L Y/G B/L
B1 B/L B/Y G
7-19
BB4 Y/B
BB3
BB1 B/Br B3
W Gy
B B (DARK GRAY)
B B
G B G G W
BB3 BB2 W G
(GRAY)
W B W
Br/L Br
Br/L R/W
Br/G
Br Gy/G B/L
Br/L R/Y Gy/W

R/Y R/Y Sb/W
Br/W R/L
R/Y Br/G B
Br/W G/L B B
R/W Y/L
L/W1 R/Y Y/B W L
R/B B/R W/B R/W
Br/W (BLACK) R/G
Br/W G/L Y/B G
L L/Y Gy/W R/L B
R/Y G/L B
L (BLACK)
G/Y
(BLUE) B
B B (BLUE)
L L B B Lg
Y Y
B Br Y
Y G Dg Ch B
(BROWN)
Ch
Dg
L L Y
Dg Ch L
C C
L Y Y L
Dg Ch
B B
Ch Dg
Y/L R/G
L/R Y G Dg Y L Dg
Ch G B Lg
L B B G/R R/W Sb Ch
(BLACK)
(GRAY) (GRAY)
B Y G
B L/R B
B Ch B Dg B Dg B Ch
B B B B
G Y B B B
B L/R C C
B B
SIGNALING SYSTEM
SIGNALING SYSTEM
3. Main switch
4. Battery
8. Main fuse
10.ECU fuse
12.Backup fuse (odometer, clock and immobilizer
system)
13.Relay unit
16.Neutral switch
18.Fuel sender
25.Speed sensor
42.Fuel level warning light
43.Neutral indicator light
44.Multi-function meter
45.Engine trouble warning light
48.Left turn signal indicator light
49.Right turn signal indicator light
52.Horn
53.Turn signal/hazard relay
59.Hazard switch
60.Turn signal switch
61.Horn switch
62.Front left turn signal light
63.Front right turn signal light
64.Rear right turn signal light
65.Rear left turn signal light
72.Front brake light switch
75.Tail/brake light
77.Rear brake light switch
81.Ignition fuse
82.Signaling system fuse
83.Parking lighting fuse
7-20
SIGNALING SYSTEM
EAS27290
TROUBLESHOOTING
• Any of the following fail to light: turn signal light, brake light or indicator light.
• The horn fails to sound.
• The speedometer fails to operate.
NOTE:
1. Seat
2. Fuel tank
3. Air filter case
4. Headlight assembly

(Main, ignition, signaling system,
parking lighting, and ECU) Replace the fuse(s).
ES” on page 7-93.
OK ↓
page 7-94.
OK ↓
OK ↓
4. Check the entire signaling system NG →
wiring. Properly connect or repair the signaling
page 7-19.
OK ↓
Check the condition of each of the sig-
naling system’s circuits. Refer to
“Checking the signaling system”.
Checking the signaling system

The horn fails to sound.
1. Check the horn switch. NG →
OK ↓
2. Check the horn. NG →
Refer to “CHECKING THE HORN” Replace the horn.
on page 7-102.
OK ↓
7-21
SIGNALING SYSTEM

page 7-19.
OK ↓
This circuit is OK.
The tail/brake light fails to come on.

1. Check the front brake light switch. NG →
Refer to “CHECKING THE Replace the front brake light switch.
OK ↓
2. Check the rear brake light switch. NG →
Refer to “CHECKING THE Replace the rear brake light switch.
OK ↓
page 7-19.
OK ↓
This circuit is OK.
The turn signal light, turn signal indicator light or both fail to blink.
1. Check the turn signal light bulbs NG →
and sockets.
Replace the turn signal light bulb, socket or
Refer to “CHECKING THE BULBS
both.
AND BULB SOCKETS” on page
7-92.
OK ↓
2. Check the turn signal switch. NG →
OK ↓
3. Check the hazard switch. NG →
OK ↓
4. Check the turn signal/hazard relay. NG →
Refer to “CHECKING THE TURN
Replace the turn signal/hazard relay.
SIGNAL/HAZARD RELAY” on page
7-97.
OK ↓
7-22
SIGNALING SYSTEM

page 7-19.
OK ↓
This circuit is OK.
The neutral indicator light fails to come on.

1. Check the neutral switch. NG →
OK ↓
page 7-19.
OK ↓
This circuit is OK.
The fuel level warning light fails to come on.

1. Check the fuel sender. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump assembly.
SENDER” on page 7-103.
OK ↓
page 7-19.
OK ↓
This circuit is OK.
The speedometer fails to operate.

1. Check the speed sensor. NG →
Refer to “CHECKING THE SPEED Replace the speed sensor.
SENSOR” on page 7-104.
OK ↓
page 7-19.
OK ↓
Replace the meter assembly.
7-23
SIGNALING SYSTEM
7-24
EAS27340
EAS27330
B/R
L Sb/W R
Sb/W B/R L R/L L/R

A
L/G
O B/R O O B/R O
L/R
L/W1 Sb L/Y R/L
B/Y

Y/G Br P/W L/R L/W W/Y G/R Gy1 R/B B/Br Y/L Y Br/L W/G
L/G
CIRCUIT DIAGRAM
Sb
Sb Gy/W B/R B3 Br/B Gy G/Y O Gy/R
B
B B
B G B (BLUE)
Gy G G Gy
Lg Y/L
B B W W B
R/L B B B/R
(DARK GREEN)
B
B R R R/G B/R C
B R/W
L/Y Gy/R Gy/R
B R Gy1
Gy1
B/R Ch Dg Dg Ch
B B B (BLACK) A
B B B B B
(BLACK) B/R
L W/Y W L L
R O O A O
R R/W L W/Y O A O
O O
B/L
FUEL INJECTION SYSTEM
R Br/R B B B B B/L
L (BLACK) W/G W/G
ON R R
L/W Br/L Br/L B/R
OFF R
Br/L B/L Br/Y Br/Y
O L Y Y L
B R/W R/B
B W/G R/B R/G Br Br
Br/L R/B P/L
B/L P/W L P/W (BLACK) (BLACK)
Br/L R B B
Br/R B L P/W
B B P/Y
B/R B/R
B/L
L L W/R B/L
Br W/R W/R B/G B/R
(BLACK)
R R/B
B1 B2 B Br Br D Br
G/R G/R G G G/R B/L
R Br/W Gy/R
G/Y Gy/G
B2 B1 Br B
R/L Gy/W
R R/B (BLACK)
B2 Y/G Y/G Gy
L Y/G B/L
B1 B/L B/Y G
7-25
BB4 Y/B
BB3
BB1 B/Br B3
W Gy
B B (DARK GRAY)
B B
G B G G W
BB3 BB2 W G
(GRAY)
W B W
Br/L Br
Br/L R/W
Br/G
Br Gy/G B/L
Br/L R/Y Gy/W

R/Y R/Y Sb/W
Br/W R/L
R/Y Br/G B
Br/W G/L B B
R/W Y/L
L/W1 R/Y Y/B W L
R/B B/R W/B R/W
Br/W (BLACK) R/G
Br/W G/L Y/B G
L L/Y Gy/W R/L B
R/Y G/L B
L (BLACK)
G/Y
(BLUE) B
B B (BLUE)
L L B B Lg
Y Y
B Br Y
Y G Dg Ch B
(BROWN)
Ch
Dg
L L Y
Dg Ch L
C C
L Y Y L
Dg Ch
B B
Ch Dg
Y/L R/G
L/R Y G Dg Y L Dg
Ch G B Lg
L B B G/R R/W Sb Ch
(BLACK)
(GRAY) (GRAY)
B Y G
B L/R B
B Ch B Dg B Dg B Ch
B B B B
G Y B B B
B L/R C C
B B
3. Main switch
4. Battery
5. Fuel injection system fuse
8. Main fuse
10.ECU fuse
15.Fuel pump relay
16.Neutral switch
17.Fuel pump
19.Sidestand switch
20.Crankshaft position sensor
21.Throttle position sensor
22.Cylinder-#1 intake air pressure sensor
23.Cylinder-#2 intake air pressure sensor
24.Lean angle cut-off switch
25.Speed sensor
26.Muffler cooling fan temperature sensor
27.Air temperature sensor
28.Engine temperature sensor
30.ISC (idle speed control) unit
31.Intake solenoid
32.Spark plug
37.EXUP servo motor
38.Decompression solenoid
39.Injector #1
40.Injector #2
45.Engine trouble warning light
51.O2 sensor
70.Auto decompression fuse
81.Ignition fuse
7-26
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 odometer/tripme-
ter/fuel reserve tripmeter LCD. Once a fault code has been displayed, it remains stored in the memory
of the ECU until it is deleted.
Engine trouble warning light indication and fuel injection system operation
Warning light indica- Fuel injection opera-
ECU operation Vehicle operation
tion tion
Warning provided
when unable to start Operation stopped Cannot be operated
Flashing* engine
Fault code No. 63 de-
Operates Can be operated
tected
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 cut-off switch
12: Crankshaft position sensor 41:
(open or short-circuit)
Blue/yellow ECU lead ECU internal malfunction
19: 50:
(broken or disconnected) (memory check error)
Lean angle cut-off switch
30:
(latch up detected)
Checking the engine trouble warning light bulb

The engine trouble warning light comes on for 1.4 seconds after the main switch has been turned to
“ON” and it comes on while the start switch is being pushed. If the warning light does not come on under
these conditions, the warning light bulb may be defective.
7-27
a b
c d c
a. Main switch “OFF” d. Engine trouble warning light on for 1.4

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.
Cylinder-#1 intake air Cylinder-#1 intake air pressure
13 pressure sensor sensor: open or short circuit de- Able Able
(open or short circuit) tected.
14 pressure sensor sensor: hose system malfunction Able Able
(hose line) (clogged or detached hose).
Throttle position sen-
Throttle position sensor: open or
15 sor Able Able
short circuit detected.
(open or short circuit)
EXUP servo motor
EXUP servo motor circuit: open or
17 circuit Able Able
EXUP servo motor
18 EXUP servo motor is stuck. Able Able
(lock)
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.
Air temperature sen-
Air temperature sensor: open or
22 sor Able Able
7-28
Able / un-
Fault Able / un-
drive
No normal signal is received from
24 O2 sensor Able Able
the O2 sensor.
25 pressure sensor sensor: open or short circuit de- Able Able
26 pressure sensor sensor: hose system malfunction Able Able
(hose system) (clogged or detached hose).
Engine temperature
Engine temperature sensor: open
28 sensor Able Able
or short circuit detected.
Decompression sole- Decompression solenoid (ther-
29 noid (thermistor) mistor): open or short circuit de- Able Able
Lean angle cut-off
30 switch The vehicle has overturned. Unable Unable
(latch up detected)
Able Able
(depending (depending
Cylinder-#1 left or Malfunction detected in the prima-
on the on the
33 right ignition coil ry wire of the cylinder-#1 left or
number of number of
(faulty ignition) right ignition coil.
faulty cylin- faulty cylin-
ders) ders)
Able Able
Cylinder-#2 left igni- Malfunction detected in the prima-
on the on the
34 tion coil ry wire of the cylinder-#2 left igni-
number of number of
(faulty ignition) tion coil.
ders) ders)
Able Able
Cylinder-#1 left or Malfunction detected in the prima-
on the on the
35 right ignition coil ry wire of the cylinder-#1 left or
number of number of
(faulty ignition) right ignition coil.
ders) ders)
Able Able
Cylinder-#2 right igni- Malfunction detected in the prima-
on the on the
36 tion coil ry wire of the cylinder-#2 right igni-
number of number of
(faulty ignition) tion coil.
ders) ders)
ISC valve (stuck fully Engine speed is high when the en-
37 Able Able
open) gine is idling.
Decompression sole- Decompression solenoid: open or
38 Able Able
noid short circuit detected.
Lean angle cut-off
Lean angle cut-off switch: open or
41 switch Unable Unable
7-29
Able / un-
Fault Able / un-
drive
No normal signals are received
Speed sensor
from the speed sensor.
42 Able Able
Open or short circuit is detected in
Neutral switch
the neutral switch.
The ECU is unable to monitor the
Fuel system voltage battery voltage
43 Able Able
(monitoring voltage) (an open or short circuit in the line
to the ECU).
Error in writing the Error is detected while reading or
44 amount of CO adjust- writing on EEPROM (CO adjust- Able Able
ment on EEPROM ment value).
Vehicle system power
Power supply to the fuel injection
46 supply Able Able
system is not normal.
(Monitoring voltage)
Faulty ECU memory. (When this
ECU internal malfunc-
malfunction is detected in the
50 tion Unable Unable
ECU, the fault code number might
(memory check error)
not appear on the meter.)
Muffler cooling fan Muffler cooling fan temperature
62 temperature sensor sensor: open or short circuit de- Able Able
Muffler cooling fan Engine trouble warning light is
temperature sensor flashing. (Abnormally high temper-
63 Able Able
(ambient temperature ature is detected by muffler cool-
abnormally high) ing fan temperature sensor.)
Communication error with the meter

Able / un-
Fault Able / un-
drive
No signals are received from the
Er-1 tion Unable Unable
ECU.
(output signal error)
No signals are received from the
ECU within the specified duration.
Data from the ECU cannot be re-
ceived correctly.
Non-registered data has been re-
ceived from the meter.
(input signal error)
7-30
EAS27400
4. Turn 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 fault codes are displayed, repeat steps (1) to
• Fault code number (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 meter.
(Diagnostic code No. 62)”.
b. Identify the faulty system with the fault code.
Refer to “Self-Diagnostic Function table”. NOTE:
c. Identify the probable cause of the malfunc- Turning the main switch to “OFF” will not erase
tion. Refer to “Diagnostic code table”. the malfunction history.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check and repair the probable cause of mal- The engine operation is not normal but the
function. engine trouble warning light does not come
Fault code No. No fault code No. on.
1. Check the operation of following sensors and
Check and repair. Check and repair. actuators in the Diagnostic mode. Refer to
Refer to “TROUBLE- Refer to “Self-Diag- “Sensor operation table” and “Actuator oper-
SHOOTING DE- nostic Function ta- ation table”.
TAILS” on page 7-39. ble”.
Monitor the opera- 01: Throttle position sensor (throttle angle)
tion of the sensors 30: Cylinder-#1 left ignition coil
and actuators in the 31: Cylinder-#2 left ignition coil
diagnostic mode. Re- 32: Cylinder-#1 right ignition coil
fer to “Sensor opera- 33: Cylinder-#2 right ignition coil
tion table” and 36: Injector #1
“Actuator operation 37: Injector #2
table”.
If a malfunction is detected in the sensors or
3. Perform ECU reinstatement action. actuators, repair or replace all faulty parts.
Refer to “Reinstatement method” of table in If no malfunction is detected in the sensors
“TROUBLESHOOTING DETAILS”. and actuators, check and repair inner parts of
the engine.
EAS27420
DIAGNOSTIC MODE
Setting the diagnostic mode
1. Turn the main switch to “OFF” and set the engine stop switch to “ ”.
2. Disconnect the wire harness coupler from the fuel pump.
3. Press and hold the “RESET” button, turn the main switch to “ON”, and continue to press the button
for 8 seconds or more.
“RESET” “SELECT”
7-31
NOTE:
• All displays on the meter disappear except the clock and odometer/trip meter/fuel reserve trip meter
displays.
• “dIAG” appears on the odometer/trip meter/fuel reserve trip meter LCD.
4. Press the “SELECT” button to select the diagnostic mode “dIAG”.
5. After selecting “dIAG”, simultaneously press the “SELECT” and “RESET” buttons for 2 seconds or
more to activate the diagnostic mode. The diagnostic code number “d01” appears on the clock LCD.
6. Set the engine stop switch to “ ”.
7. Select the diagnostic code number corresponding to the fault code number by pressing the “SE-
LECT” and “RESET” buttons.
NOTE:
• To decrease the selected diagnostic code number, press the “RESET” button. Press the “RESET”
button for 1 second or longer to automatically decrease the diagnostic code numbers.
• To increase the selected diagnostic code number, press the “SELECT” button. Press the “SELECT”
button for 1 second or longer to automatically increase the diagnostic code numbers.
“d70 d01” “d01 d70”
8. Verify the operation of the sensor or actuator.

• Sensor operation
The data representing the operating conditions of the sensor appears on the odometer/trip meter/fu-
el reserve trip meter LCD.
• Actuator operation
Set the engine stop switch to “ ” to operate the actuator.
NOTE:
If the engine stop switch is set to “ ”, set it to “ ”, and then set it to “ ” again.
9. Turn the main switch to “OFF” to cancel the diagnostic mode.
Diagnostic code table

Fault
Diagnostic
code Symptom Probable cause of malfunction
code No.
No.
• Open or short circuit in wire harness.
No normal signals are re- • Defective crankshaft position sensor.
12 ceived from the crankshaft • Malfunction in pickup rotor. —
position sensor. • Malfunction in ECU.
• Improperly installed sensor.
Cylinder-#1 intake air pres-
• Defective cylinder-#1 intake air pressure
13 sure sensor: open or short 03
sensor.
circuit detected.
• Malfunction in ECU.
7-32
Fault
Diagnostic
code No.
No.
• Cylinder-#1 intake air pressure sensor hose
sure sensor: hose system
14 is detached, clogged, kinked, or pinched. 03
malfunction (clogged or de-
tached hose).
• Open or short circuit in wire sub lead.
Throttle position sensor: • Open or short circuit in wire harness.
15 open or short circuit detect- • Defective throttle position sensor. 01
ed. • Malfunction in ECU.
• Improperly installed throttle position sensor.
EXUP servo motor circuit: • Open or short circuit in wire harness.
17 open or short circuit detect- • Defective EXUP servo motor (potentiome- 53
ed. ter circuit).
18 EXUP servo motor is stuck. • Stuck EXUP servo motor (mechanism). 53
• Stuck EXUP servo motor (motor).
A break or disconnection of
• Open circuit in wire harness (ECU coupler).
19 the blue/yellow lead of the 20
ECU is detected.
Air temperature sensor:
• Defective air temperature sensor.
22 open or short circuit detect- 05
ed.
• Improperly installed air temperature sensor.
No normal signal is re- • Defective O2 sensor.
24 ceived from the O2 sensor. —
• Defective cylinder-#2 intake air pressure
25 sure sensor: open or short 04
sensor.
circuit detected.
• Cylinder-#2 intake air pressure sensor hose
sure sensor: hose system
26 is detached, clogged, kinked, or pinched. 04
malfunction (clogged or de-
tached hose).
Engine temperature sen- • Open or short circuit in wire harness.
28 sor: open or short circuit • Defective engine temperature sensor. 11
detected. • Malfunction in ECU.
Decompression solenoid • Defective decompression solenoid (ther-
29 (thermistor): open or short mistor). 55
circuit detected. • Malfunction in ECU.
The vehicle has over- • Overturned.
30 08
turned. • Malfunction in ECU.
7-33
Fault
Diagnostic
code No.
No.
Malfunction detected in the
• Malfunction in cylinder-#1 left or right igni-
primary wire of the cylin- 30
33 tion coil.
der-#1 left or right ignition 32
coil.
• Malfunction in a component of ignition cut-
off circuit system.
Malfunction detected in the • Malfunction in cylinder-#2 left ignition coil.
34 primary wire of the cylin- • Malfunction in ECU. 31
der-#2 left ignition coil. • Malfunction in a component of ignition cut-
off circuit system.
Malfunction detected in the
• Malfunction in cylinder-#1 left or right igni-
primary wire of the cylin- 30
35 tion coil.
der-#1 left or right ignition 32
coil.
• Malfunction in a component of ignition cut-
off circuit system.
Malfunction detected in the • Malfunction in cylinder-#2 right ignition coil.
36 primary wire of the cylin- • Malfunction in ECU. 33
der-#2 right ignition coil. • Malfunction in a component of ignition cut-
off circuit system.
• 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 hose or coupler. (High en-
Engine speed is high when
37 gine idle speed is detected with the ISC 54
the engine is idling.
valve stuck fully open even though signals
for the valve to close are continuously being
transmitted by the ECU.)
• ECU fuse is blown.
Decompression solenoid:
• Defective decompression solenoid.
38 open or short circuit detect- 55
ed.
Lean angle cut-off switch: • Open or short circuit in wire harness.
41 open or short circuit detect- • Defective lean angle cut-off switch. 08
ed. • Malfunction in ECU.
• Open circuit in wire harness.
• Defective speed sensor.
No normal signals are re-
• Malfunction in vehicle speed sensor detect-
ceived from the speed sen-
ed. 07
42 sor.
• Defective neutral switch. 21
Open circuit is detected in
• Malfunction in the engine side of the neutral
the neutral switch.
switch.
7-34
Fault
Diagnostic
code No.
No.
The ECU is unable to moni-
tor the battery voltage (an • Open or short circuit in wire harness.
43 09
open or short circuit in the • Malfunction in ECU.
line to the ECU).
Error is detected while
• Malfunction in ECU. (The CO adjustment
reading or writing on EE-
44 value is not properly written on or read from 60
PROM (CO adjustment val-
the internal memory).
ue).
Power supply to the fuel in-
Malfunction in the charging system. Refer to
46 jection system is not nor- —
“CHARGING SYSTEM” on page 7-11.
mal.
Faulty ECU memory.
(When this malfunction is • Malfunction in ECU. (The program and data
50 detected in the ECU, the are not properly written on or read from the —
fault code number might internal memory.)
not appear on the meter.)
Muffler cooling fan temper- • Defective muffler cooling fan temperature
62 ature sensor: open or short sensor. 12
circuit detected. • Malfunction in ECU.
• Muffler cover fan fuse or ECU fuse is blown.
• Defective muffler cooling fan temperature
Engine trouble warning sensor or muffler cooling fan motor relay
light is flashing. (Abnormal- • Positions of muffler cooling fan temperature
63 ly high temperature is de- sensor and its surrounding parts changed 63
tected by muffler cooling due to deformed parts near sensor
fan temperature sensor.) • Muffler cooling fan temperature sensor de-
tected a temperature of 120 °C (248 °F) or
higher.
• Malfunction in meter.
No signals are received
Er-1 • Malfunction in ECU. —
from the ECU.
• Defective wire connection of the ECU cou-
pler.
No signals are received • Improper connection in wire harness.
Er-2 from the ECU within the • Malfunction in meter. —
specified duration. • Malfunction in ECU.
• Improper connection in wire harness.
Data from the ECU cannot
Er-3 • Malfunction in meter. —
be received correctly.
Non-registered data has • Improper connection in wire harness.
Er-4 been received from the • Malfunction in meter. —
meter. • Malfunction in ECU.
7-35
Sensor operation table

Diag-
nostic
Item Meter display Checking method
code
No.
01 Throttle angle
• Fully closed position 15–20 Check with throttle fully
closed.
• Fully opened position 95–100 Check with throttle fully
open.
03 Pressure difference Displays the cylinder-#1 in- Set the engine stop switch
(atmospheric pressure and take air pressure. to “ ”, then operate the
cylinder-#1 intake air pres- throttle while pushing the
sure) start switch “ ”. (If the dis-
play value changes, the
performance is OK.)
04 Pressure difference Displays the cylinder-#2 in- Set the engine stop switch
(atmospheric pressure and take air pressure. to “ ”, then operate the
cylinder-#2 intake air pres- throttle while pushing the
sure) start switch “ ”. (If the dis-
play value changes, the
performance is OK.)
05 Air temperature Displays the air temperature. Compare the actually mea-
sured air temperature with
the meter display value.
07 Vehicle speed pulse 0–999 Check that the number in-
creases when the rear
wheel is rotated. The num-
ber is cumulative and does
not reset each time the
wheel is stopped.
08 Lean angle cut-off switch Remove the lean angle cut-
• Upright 0.4–1.4 off switch and incline it
more than 65 degrees.
• Overturned 3.7–4.4
09 Fuel system voltage Set the engine stop switch
(battery voltage) Approximately 12.0 to “ ”, and then compare
with the actually measured
battery voltage. (If the bat-
tery voltage is lower, per-
form recharging.)
11 Engine temperature Displays the engine tempera- Compare the actually mea-
ture. sured engine temperature
with the meter display val-
ue.
12 Muffler cooling fan temper- Displays the muffler cooling Compare the actually mea-
ature fan temperature. sured muffler cooling fan
temperature with the meter
display value.
7-36
Diag-
nostic
Item Meter display Checking method
code
No.
20 Sidestand switch Set ON/OFF the Sidestand
• Stand retracted ON switch. (with the transmis-
sion in gear.)
• Stand extended OFF
21 Neutral switch Shift the transmission.
• Neutral ON
• In gear OFF
53 EXUP servo motor Displays the operating angle. —
Engine trouble warning light
comes on twice: once when
the EXUP valve is closing
and once when it is opening.
60 EEPROM fault code dis- —
play
• No history 00
• History exists 01 or 02 (Cylinder fault code)
• (If both cylinders are defec-
tive, the display alternates
every two seconds.)
61 Malfunction history code —
display
• No history 00
• History exists Fault codes 12-63
• (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 28 fault codes To erase the history, set the
engine stop switch to “ ”.
63 Stopping the flashing of the 00 To stop the flashing of the
engine trouble warning light engine trouble warning
(erasing the muffler cool- light, set the engine stop
ing fan temperature sensor switch to “ ”.
fault code)
70 Control number 0–255 —
7-37
Actuator operation table

Diag-
nostic
Item Actuation Checking method
code
No.
Actuates the cylinder-#1 left
or right ignition coil five times Check the spark five times.
Cylinder-#1 left or right ig-
30 at one-second intervals. • Connect an ignition
nition coil
Illuminates the engine trou- checker.
ble warning light.
ignition coil five times at one- Check the spark five times.
31 Cylinder-#2 left ignition coil second intervals. • Connect an ignition
ble warning light.
or right ignition coil five times Check the spark five times.
Cylinder-#1 left or right ig-
32 at one-second intervals. • Connect an ignition
nition coil
ble warning light.
Actuates the cylinder-#2 right
ignition coil five times at one- Check the spark five times.
Cylinder-#2 right ignition
33 second intervals. • Connect an ignition
coil
ble warning light.
Actuates the injector #1 five
times at one-second inter-
Check the operating sound
36 Injector #1 vals.
of the injector #1 five times.
Illuminates the engine trou-
ble warning light.
Actuates the injector #2 five
times at one-second inter-
37 Injector #2 vals.
of the injector #2 five times.
ble warning light.
Actuates the intake solenoid
five times at one-second in- Check the operating sound
49 Intake solenoid tervals. of the intake solenoid five
Illuminates the engine trou- times.
ble warning light.
Actuates the fuel pump relay
five times at one-second in-
tervals.
ble warning light.
50 Fuel pump relay of the fuel pump relay five
(The engine trouble warning
times.
light is OFF when the relay is
ON, and the engine trouble
warning light is ON when the
relay is OFF).
7-38
Diag-
nostic
Item Actuation Checking method
code
No.
Actuates the muffler cooling
fan motor relay for five cycles
Muffler cooling fan motor of five seconds. (ON 2 sec-
51 of the muffler cooling fan
relay onds, OFF 3 seconds)
motor relay five times.
ble warning light.
Actuates the headlight relay
for five cycles of five sec-
onds. (ON 2 seconds, OFF 3
52 Headlight relay of the headlight relay five
seconds)
times.
ble warning light.
Actuates and fully closes the
ISC valve, then opens it to
the standby opening position
when the engine is started.
The ISC unit vibrates when
54 ISC valve This operation takes approxi-
the ISC valve operates.
mately 12 seconds until it is
completed.
ble warning light.
Actuates the decompression
solenoid for five cycles of five
seconds. (ON 2 seconds, Check the operating sound
OFF 3 seconds) of the decompression sole-
Illuminates the engine trou- noid five times.
ble warning light. NOTE:
55 Decompression solenoid
NOTE: Disconnect the starter mo-
Be sure to push the start tor lead before performing
switch, otherwise the above this procedure.
mentioned operation will not
be possible.
EAS27460
TROUBLESHOOTING DETAILS
This section describes the measures per fault code number displayed on the meter. 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 has been completed, reset the meter display ac-
cording to the reinstatement method.
Fault code No.:
Code number displayed on the meter when the engine failed to work normally. Refer to “Self-Diagnostic
Function table”.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOSTIC
MODE” on page 7-31.
7-39
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. Cranking the
tion sensor. engine.
2 Connections • Check the coupler for any pins
• Crankshaft position sensor coupler that may be pulled out.
• Main 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.
(gray–gray)
(black/blue–black/blue)
4 Defective crankshaft position sensor. • Replace if defective.
Refer to “CHECKING THE
CRANKSHAFT POSITION
SENSOR” on page 7-101.
7-40
Fault code No. 13 Symptom Cylinder-#1 intake air pressure sensor: open or short cir-
cuit detected.
Diagnostic code No. 03 Cylinder-#1 intake air pressure sensor
cause method
1 Connections • Check the coupler for any pins Turning the
• Cylinder-#1 intake air pressure sen- that may be pulled out. main switch to
sor coupler • Check the locking condition of “ON”.
• Main wire harness ECU coupler the coupler.
curely.
• Between cylinder-#1 intake air
pressure sensor coupler and
ECU coupler
(pink/white–pink/white)
(blue–blue)
3 Defective cylinder-#1 intake air pres- • Execute the diagnostic mode.
sure sensor. (Code No.03)
• Replace if defective.
Refer to “CHECKING THE IN-
TAKE AIR PRESSURE SEN-
SORS” on page 7-106.
7-41
Fault code No. 14 Symptom Cylinder-#1 intake air pressure sensor: hose system mal-
function (clogged or detached hose).
cause method
1 Cylinder-#1 intake air pressure sensor • Check the cylinder-#1 intake air Starting the en-
hose pressure sensor hose condition. gine and oper-
• Repair or replace the sensor ating it at idle.
hose.
2 Cylinder-#1 intake air pressure sensor • Check and repair the connec-
malfunction at intermediate electrical tion.
potential. • Replace it if there is a malfunc-
tion.
• Cylinder-#1 intake air pressure sen- that may be pulled out.
sor coupler • Check the locking condition of
curely.
7-42
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- Turning the
sensor. ing. main switch to
• Check that the sensor is in- “ON”.
stalled in the specified position.
• Throttle position sensor coupler that may be pulled out.
• Sub-wire harness 2 coupler the coupler.
curely.
3 Open or short circuit in wire harness • Repair or replace if there is an
and/or sub lead. open or short circuit.
• Between throttle position sen-
sor coupler and ECU coupler
(blue–blue)
(yellow–yellow)
(back–black)
4 Throttle position sensor lead wire • Check for open circuit and re-
open circuit output voltage check. place the throttle position sen-
sor.
(black–yellow)
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-
SOR” on page 7-104.
7-43
Fault code No. 17 Symptom EXUP servo motor circuit: open or short circuit detected.
Diagnostic code No. 53 EXUP servo motor
cause method
• EXUP servo motor coupler that may be pulled out. main switch to
• Main wire harness ECU coupler • Check the locking condition of “ON”.
the coupler.
curely.
• Between servo motor coupler
and ECU coupler
(blue–blue)
(white/red–white/red)
3 Defective EXUP servo motor (potenti- • Execute the diagnostic mode.
ometer circuit). (Code No.53)
EXUP SERVO MOTOR” on
page 7-105.
Fault code No. 18 Symptom EXUP servo motor is stuck.

Diagnostic code No. 53 EXUP servo motor
cause method
• EXUP servo motor coupler that may be pulled out. main switch to
the coupler. It takes 120
• If there is a malfunction, repair it seconds at the
and connect the coupler se- maximum be-
curely. fore the origi-
2 Open or short circuit in wire harness. • Repair or replace if there is an nal state
open or short circuit. returns.
• Between the EXUP servo motor
coupler and the ECU coupler.
(black/green–black/green)
(black/red–black/red)
3 Defective EXUP servo motor. • Execute the diagnostic mode.
(Code No.53)
EXUP SERVO MOTOR” on
page 7-105.
4 Defective EXUP valve, pulley, cables. Replace if defective.
7-44
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. If the transmis-
• Main wire harness ECU coupler (Code No.20) sion is in gear,
• Check the coupler for any pins retracting the
that may be pulled out. sidestand.
• Check the locking condition of If the transmis-
the coupler. sion is in neu-
• If there is a malfunction, repair it tral,
and connect the coupler se- reconnecting
curely. the wiring.
• Between ECU and blue/yellow
lead
3 Defective sidestand switch. • Replace if defective.
Fault code No. 22 Symptom Air temperature sensor: open or short circuit detected.
Diagnostic code No. 05 Air temperature sensor
cause method
1 Installed condition of air temperature Check for looseness or pinching. Turning the
sensor. main switch to
2 Connections • Check the coupler for any pins “ON”.
• Air temperature sensor coupler that may be pulled out.
the coupler.
curely.
• Between air temperature sen-
sor coupler and ECU coupler
(brown/white–brown/white)
4 Defective air temperature sensor. • Execute the diagnostic mode.
(Code No.05)
Refer to “CHECKING THE AIR
TEMPERATURE SENSOR” on
page 7-107.
7-45
Fault code No. 24 Symptom No normal signal is received from the O2 sensor.

cause method
1 Installed state of O2 sensor. Check for looseness or pinching. Starting the en-
gine and oper-
2 Connections • Check the coupler for any pins ating it at idle.
• O2 sensor coupler that may be pulled out.
the coupler.
curely.
• Between O2 sensor coupler and
ECU coupler.
(gray/white–gray/white)
(red/blue–red/blue)
(gray/green–gray/green)
4 Check fuel pressure. • Refer to “THROTTLE BODIES”
on page 6-4.
5 Defective O2 sensor. • Replace if defective.
7-46
Fault code No. 25 Symptom Cylinder-#2 intake air pressure sensor: open or short cir-
cuit detected.
cause method
• Cylinder-#2 intake air pressure sen- that may be pulled out. main switch to
sor coupler • Check the locking condition of “ON”.
curely.
• Between cylinder-#2 intake air
pressure sensor coupler and
ECU coupler
(pink/yellow–pink/yellow)
(blue–blue)
7-47
Fault code No. 26 Symptom Cylinder-#2 intake air pressure sensor: hose system mal-
function (clogged or detached hose).
cause method
1 Cylinder-#2 intake air pressure sensor • Check the cylinder-#2 intake air Starting the en-
hose pressure sensor hose condition. gine and oper-
• Repair or replace the sensor ating it at idle.
hose.
2 Cylinder-#2 intake air pressure sensor • Check and repair the connec-
malfunction at intermediate electrical tion.
potential. • Replace it if there is a malfunc-
tion.
• Cylinder-#2 intake air pressure sen- that may be pulled out.
curely.
7-48
Fault code No. 28 Symptom Engine temperature sensor: open or short circuit detect-
ed.
Diagnostic code No. 11 Engine temperature sensor
cause method
1 Installed state of engine temperature Check for looseness or pinching. Turning the
sensor. main switch to
• Engine temperature sensor coupler that may be pulled out.
• Sub-wire harness 2 coupler the coupler.
curely.
• Between engine temperature
sensor coupler and ECU cou-
pler
(brown–brown)
(black–black)
4 Defective engine temperature sensor. • Execute the diagnostic mode.
(Code No.11)
Refer to “CHECKING THE EN-
GINE TEMPERATURE SEN-
SOR” on page 7-103.
7-49
Fault code No. 29 Symptom Decompression solenoid (thermistor): open or short cir-
cuit detected.
Diagnostic code No. 55 Decompression solenoid
cause method
1 Installed state of decompression sole- Check for looseness or pinching. Turning the
noid. main switch to
• Decompression solenoid (ther- that may be pulled out.
mistor) coupler • Check the locking condition of
curely.
• Between decompression sole-
noid (thermistor) coupler and
ECU coupler
(green/red–green/red)
4 Defective decompression solenoid • Execute the diagnostic mode.
(thermistor). (Code No.55)
Refer to “CHECKING THE DE-
COMPRESSION SOLENOID”
on page 7-106.
Fault code No. 30 Symptom The vehicle has overturned.

Diagnostic code No. 08 Lean angle cut-off switch
cause method
1 The vehicle has overturned. Raise the vehicle upright. Turning the
2 Installed condition of the lean angle Check for looseness or pinching. main switch to
cut-off switch. “ON” (however,
the engine can-
3 Connections • Check the coupler for any pins not be restarted
• Lean angle cut-off switch coupler that may be pulled out. unless the main
• Main wire harness ECU coupler • Check the locking condition of switch is first
the coupler. turned “OFF”).
curely.
4 Defective lean angle cut-off switch. • Execute the diagnostic mode.
(Code No.08)
LEAN ANGLE CUT-OFF
SWITCH” on page 7-101.
7-50
Fault code No. 33 Symptom Malfunction detected in the primary wire of the cylinder-#1
left or right ignition coil.
Diagnostic code No. 30, 32 Cylinder-#1 left or right ignition coil
cause method
1 Connections • Check the connector and cou- Starting the en-
• Cylinder-#1 left or right ignition coil pler for any pins that may be gine and oper-
connector (primary coil side) pulled out. ating it at idle.
• Sub-wire harness 1 coupler the connector and coupler.
curely.
• Between cylinder-#1 left or right
ignition coil connector and ECU
coupler/main wire harness.
(black/red–blue/red)
(orange–orange)
3 Defective cylinder-#1 left or right igni- • Execute the diagnostic mode.
tion coil. (Code No.30 or 32)
• Test the primary and secondary
coils for continuity.
Refer to “CHECKING THE IG-
NITION COILS” on page 7-99.
7-51
left ignition coil.
Diagnostic code No. 31 Cylinder-#2 left ignition coil
cause method
• Cylinder-#2 left ignition coil connec- pler for any pins that may be gine and oper-
tor (primary coil side) pulled out. ating it at idle.
the connector and coupler.
curely.
• Between cylinder-#2 left ignition
coil connector and ECU cou-
pler/main wire harness.
(gray/red–gray/red)
3 Defective cylinder-#2 left ignition coil. • Execute the diagnostic mode.
(Code No.31)
7-52
left or right ignition coil.
Diagnostic code No. 30, 32 Cylinder-#1 left or right ignition coil
cause method
• Cylinder-#1 left or right ignition coil pler for any pins that may be gine and oper-
connector (primary coil side) pulled out. ating it at idle.
• Sub-wire harness 1 coupler the connector and coupler.
curely.
• Between cylinder-#1 left or right
ignition coil connector and ECU
(orange–orange)
3 Defective cylinder-#1 left or right igni- • Execute the diagnostic mode.
tion coil. (Code No.30 or 32)
7-53
right ignition coil.
Diagnostic code No. 33 Cylinder-#2 right ignition coil
cause method
• Cylinder-#2 right ignition coil con- pler for any pins that may be gine and oper-
nector (primary coil side) pulled out. ating it at idle.
the connector and coupler.
curely.
• Between cylinder-#2 right igni-
tion coil connector and ECU
(gray/black–gray/black)
3 Defective cylinder-#2 right ignition • Execute the diagnostic mode.
coil. (Code No.33)
7-54
Fault code No. 37 Symptom Engine speed is high when the engine is idling.
Diagnostic code No. 54 ISC valve
cause method
1 ECU fuse is blown. • Check the ECU fuse. ISC valve re-
Refer to “CHECKING THE turns to its orig-
FUSES” on page 7-93. inal position by
2 Throttle valve does not fully close. • Check the throttle body. turning the
Refer to “THROTTLE BODIES” main switch to
on page 6-4. “ON” and back
• Check the throttle cables. to “OFF”.
Refer to “ADJUSTING THE Reinstated if
THROTTLE CABLE FREE the engine idle
PLAY” on page 3-7. speed is within
specification af-
3 ISC valve is stuck fully open due to • Check that the ISC unit hose is ter starting the
disconnected ISC unit hose or cou- not disconnected. engine.
pler. (High engine idle speed is de- • Check that the ISC unit coupler
tected with the ISC valve stuck fully is not disconnected.
open even though signals for the valve • The ISC valve is stuck fully
to close are continuously being trans- open if it does not operate when
mitted by the ECU.) the main switch is turned “OFF”.
(Touch the ISC unit with your
hand and check if it is vibrating
to confirm if the ISC valve is op-
erating.)
4 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.
7-55
Fault code No. 38 Symptom Decompression solenoid: open or short circuit detected.
Diagnostic code No. 55 Decompression solenoid
cause method
1 Installed state of decompression sole- Check for looseness or pinching. Turning the
noid. main switch to
• Decompression solenoid coupler that may be pulled out.
the coupler.
curely.
noid coupler and ECU coupler
(light green–light green)
noid coupler and auto decom-
pression fuse
(gray/red–gray/red)
4 Defective decompression solenoid. • Execute the diagnostic mode.
(Code No.55)
Refer to “CHECKING THE DE-
COMPRESSION SOLENOID”
on page 7-106.
7-56
Fault code No. 41 Symptom Lean angle cut-off switch: open or short circuit detected.
Diagnostic code No. 08 Lean angle cut-off switch
cause method
• Lean angle cut-off switch coupler that may be pulled out. main switch to
the coupler.
curely.
2 Open or short circuit in lead wire. • Repair or replace if there is an
• Between lean angle cut-off
switch coupler and ECU cou-
pler.
(blue–blue)
(yellow/green–yellow/green)
3 Defective lean angle cut-off switch. • Execute the diagnostic mode.
(Code No.08)
LEAN ANGLE CUT-OFF
SWITCH” on page 7-101.
7-57
Fault code No. 42 Symptom A. No normal signals are received from the speed sensor.
B. Open circuit is detected in the neutral switch.
Diagnostic code No. A 07 Speed sensor
B 21 Neutral switch
cause method
A-1 Connections • Check the coupler for any pins Starting the en-
• Speed sensor coupler that may be pulled out. gine, and acti-
• Main wire harness ECU coupler • Check the locking condition of vating the
the coupler. vehicle speed
• If there is a malfunction, repair it sensor by oper-
and connect the coupler se- ating the vehi-
curely. cle at 20 to 30
A-2 Open or short circuit in speed sensor • Repair or replace if there is an km/h.
lead. open or short circuit.
• Between speed sensor coupler
and ECU coupler.
(blue–blue)
(white/yellow–white/yellow)
A-3 Gear for detecting vehicle speed has • Replace if defective.
broken. Refer to “TRANSMISSION” on
page 5-93.
A-4 Defective speed sensor. • Execute the diagnostic mode.
(Code No.07)
SPEED SENSOR” on page
7-104.
7-58
Fault code No. 42 Symptom A. No normal signals are received from the speed sensor.
B. Open circuit is detected in the neutral switch.
Diagnostic code No. A 07 Speed sensor
B 21 Neutral switch
cause method
B-1 Connections • Check the coupler for any pins Starting the en-
• Neutral switch coupler that may be pulled out. gine, and acti-
• Main wire harness ECU coupler • Check the locking condition of vating the
the coupler. vehicle speed
• If there is a malfunction, repair it sensor by oper-
and connect the coupler se- ating the vehi-
curely. cle at 20 to 30
B-2 Open circuit in neutral switch lead. • Repair or replace if there is an km/h.
open circuit.
• Between neutral switch coupler
and fuel pump relay coupler.
(sky blue–sky blue)
• Between fuel pump relay cou-
pler and ECU coupler.
(blue/yellow–blue/yellow)
B-3 Faulty shift drum (neutral detection ar- • Replace if defective.
ea). Refer to “TRANSMISSION” on
page 5-93.
B-4 Defective neutral switch. • Execute the diagnostic mode.
(Code No.21)
7-59
Fault code No. 43 Symptom The ECU is unable to monitor the battery voltage (an open
or short circuit in the line to the ECU).
Diagnostic code No. 09 Fuel system voltage
cause method
1 Connections • Check the coupler for any pins Starting the en-
• Relay unit coupler (fuel pump relay) that may be pulled out. gine and oper-
• Main wire harness ECU coupler • Check the locking condition of ating it at idle.
the coupler.
curely.
2 Open or short circuit in the wire har- • Repair or replace if there is an
ness. open or short circuit.
pler and ECU coupler.
(blue/red–blue/red)
(red/blue–red/blue)
pler and battery terminal.
(red–red)
pler and engine stop switch
coupler.
(black/red–black/red)
3 Malfunction or open circuit in fuel • Execute the diagnostic mode.
pump relay. (Code No. 09)
• If there is no malfunction with
the fuel pump relay, replace the
ECU.
Fault code No. 44 Symptom Error is detected while reading or writing on EEPROM (CO
adjustment value).
Diagnostic code No. 60 EEPROM improper cylinder indication
cause method
1 Malfunction in ECU. • Execute the diagnostic mode. Turning the
(Code No. 60) main switch to
1. Check the faulty cylinder. (If “ON”.
multiple cylinders are defec-
tive, the number of the faulty
cylinders appears alternate-
ly at 2-second intervals.)
• Replace ECU if defective.
7-60
Fault code No. 46 Symptom Power supply to the fuel injection system is not normal.
cause method
1 Connections • Check the coupler for any pins Starting the en-
• Main wire harness ECU coupler that may be pulled out. gine and oper-
• Check the locking condition of ating it at idle.
the coupler.
curely.
2 Faulty battery. • Replace or change the battery
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 7-94.
3 Malfunction in rectifier/regulator • Replace if defective.
Refer to “CHARGING SYS-
TEM” on page 7-11.
• Between battery and main
switch
(red–red)
• Between main switch and igni-
tion fuse
(brown/blue–brown/blue)
• Between ignition fuse and ECU
(red/white–red/white)
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
meter.)
cause method
1 Malfunction in ECU. Replace the ECU. Turning the
NOTE: main switch to
Do not perform this procedure “ON”.
with the main switch turned to
“ON”.
7-61
Fault code No. 62 Symptom Muffler cooling fan temperature sensor: open or short cir-
cuit detected.
Diagnostic code No. 12 Muffler cooling fan temperature sensor
cause method
1 Installed condition of muffler cooling Check for looseness or pinching. Turning the
fan temperature sensor. main switch to
• Muffler cooling fan temperature sen- that may be pulled out.
curely.
• Between muffler cooling fan
temperature sensor coupler and
ECU coupler.
(brown/yellow–brown/yellow)
4 Defective muffler cooling fan tempera- • Execute the diagnostic mode.
ture sensor. (Code No.12)
MUFFLER COOLING FAN
page 7-108.
7-62
Fault code No. 63 Symptom Engine trouble warning light is flashing. (Abnormally high
temperature is detected by muffler cooling fan tempera-
ture sensor.)
Diagnostic code No. 12 Muffler cooling fan temperature sensor
51 Muffler cooling fan motor relay
63 Stopping the flashing of the engine trouble warning light
(erasing the muffler cooling fan temperature sensor fault
code)
cause method
1 Muffler cover fan fuse or ECU fuse is • Check the muffler cover fan Turning the
blown. fuse and ECU fuse. main switch to
Refer to “CHECKING THE “ON”.
FUSES” on page 7-93. Execute the di-
2 Defective muffler cooling fan tempera- • Execute the diagnostic mode. agnostic mode.
ture sensor or motor relay (Code No.12 and 51) (Code No.63)
MUFFLER COOLING FAN
page 7-108 and “CHECKING
THE RELAYS” on page 7-96.
3 • Positions of muffler cooling fan tem- • Check that the parts near the
perature sensor and its surrounding muffler cooling fan temperature
parts changed due to deformed sensor are not deformed and
parts near sensor that the sensor and its sur-
• Muffler cooling fan temperature sen- rounding parts are in their cor-
sor detected a temperature of 120 rect positions. Repair or replace
°C (248 °F) or higher. if necessary.
Fault code No. Er-1 Symptom No signals are received from the ECU.
cause method
• Main wire harness ECU coupler that may be pulled out. main switch to
• Main wire harness meter assembly • Check the locking condition of “ON”.
coupler the coupler.
curely.
• Between meter assembly cou-
pler and ECU coupler
(yellow/blue–yellow/blue)
3 Malfunction in meter assembly. Replace the meter assembly.
4 Malfunction in ECU. Replace the ECU.
7-63
Fault code No. Er-2 Symptom No signals are received from the ECU within the specified
duration.
cause method
curely.
Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly.
cause method
curely.
7-64
Fault code No. Er-4 Symptom Non-registered data has been received from the meter.
cause method
curely.
7-65
7-66
EAS27560
EAS27550
B/R
L Sb/W R
Sb/W B/R L R/L L/R

L/G
L/R
L/W1 Sb R/L
L/Y
B/Y
CIRCUIT DIAGRAM
Sb
B B2 R/G R/G B2 B
R/L G
B G B (BLUE)
B B2 R/W R/G Br/B
Lg Y/L
B R/L B B
B L/G
(DARK GREEN)
B B (BLUE) Gy/B
FUEL PUMP SYSTEM
B
B R R R/G
B R/W
L/Y Gy/R
B R Gy1
Gy1
B/R
B B B (BLACK) A
B
(BLACK) B/R
Gy1 B/L B Gy B/L
L W/Y W L L
R O O A O
B/L B W/Y W/Y
R R/W L O O A O
B/L
R Br/R B B B B B/L
Br/R L L D L L P/L P/L
L (BLACK) W/G W/G
ON R R
L/W Br/L Br/L
OFF R
Br/L B/L Br/Y Br/Y
B R/W R/B
B W/G R/B R/G
Br/L R/B P/L
Br/L P/W (BLACK) (BLACK)
R B B B/L P/W L
Br/R B L P/W
Br/L B/G B/G
B B (BLACK) P/Y
B/R B/R
B/L
L Br W/R W/R
7-67
R R/B
B1 B2 B Br Br D Br
G/R G/R
R Br/W Gy/R
G/Y Gy/G
B2 B1 Br B
R/L Gy/W
L/R Lg Lg
L (BLACK) W/B B/L
R R/B
B2 Y/G Y/G Gy
L Y/G B/L
B1 B/L B/Y G
BB4 Y/B
BB3
BB2 B/Br B3 Gy B
BB1 B/Br B3
B B
B B
G B G
BB3 BB2
W B
Br/L Br
Br/L R/W
Br/G
Br Gy/G B/L
Br/L R/Y Gy/W

R/Y R/Y R/L
Br/W
R/Y Br/G B
Br/W G/L B B
R/W
L/W1 R/Y Y/B W L
R/B B/R W/B R/W
Br/W (BLACK) R/G
Br/W G/L Y/B G
L L/Y Gy/W R/L
R/Y G/L B
L (BLACK)
G/Y
(BLUE) B
B B (BLUE)
L L B B Lg
Y Y
B Br Y
Y G Dg Ch B
(BROWN)
Ch
Dg
L L Y
Dg Ch L
FUEL PUMP SYSTEM
C C
FUEL PUMP SYSTEM
3. Main switch
4. Battery
8. Main fuse
10.ECU fuse
15.Fuel pump relay
17.Fuel pump
81.Ignition fuse
7-68
FUEL PUMP SYSTEM
EAS27570
TROUBLESHOOTING
If the fuel pump fails to operate.
NOTE:
1. Seat
2. Fuel tank
3. Air filter case

(Main, ignition, fuel injection sys-
tem, and ECU) Replace the fuse(s).
ES” on page 7-93.
OK ↓
page 7-94.
OK ↓
OK ↓
OK ↓
5. Check the relay unit (fuel pump re- NG →
lay).
OK ↓
6. Check the fuel pump. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump.
PUMP” on page 7-105.
OK ↓
7. Check the entire fuel pump system NG →
wiring. Properly connect or repair the fuel pump
page 7-67.
OK ↓
Replace the ECU.
7-69
FUEL PUMP SYSTEM
7-70
B/R
L Sb/W R
ET5YU1003
Sb/W B/R L R/L L/R ET5YU1002
L/G
L/R
L/W1 Sb L/Y R/L
B/Y
Sb
B B2 R/G R/G B2 B
R/L G
CIRCUIT DIAGRAM
Lg B/G B3 G Y/B O Gy/B

B B
B G B (BLUE)
B B2 R/W R/G Br/B
Lg Y/L
B R/L B B
B L/G
(DARK GREEN)
B B (BLUE) Gy/B
B
B R R R/G
B R/W
L/Y Gy/R
B R Gy1
Gy1
B B B (BLACK)
B
(BLACK)
Gy1 B/L B Gy B/L
L W/Y W L L
R O O A O
B/L B W/Y W/Y
R R/W L O O A O
B/L
R Br/R B B B B B/L
Y
MUFFLER COOLING SYSTEM
L Y B Y D Y Y R/G R/G
Br/R L L D L L P/L P/L
L (BLACK) W/G W/G
ON R R
L/W Br/L Br/L
OFF R
Br/L B/L Br/Y Br/Y
B R/W R/B
B W/G R/B R/G
Br/L R/B P/L
R B B
Br/R B L P/W
Br/L (BLACK) B/G
B B P/Y
B/R
B/L
B/L P/Y L P/Y B/L Br/W Br/W
L Br W/R
(BLACK) Br/W B/L
7-71
R R/B
B1 B2 B Br Br D Br
G/R
R Br/W
G/Y Gy/G
B2 B1 Br B
R/L Gy/W
L/R Lg
L (BLACK) W/B
R R/B
B2 Y/G Y/G Gy
L Y/G B/L
B1 B/L B/Y G
BB4 Y/B
BB3
BB2 B/Br B3
BB1 B/Br B3
B B
B B
BB3 BB2
Br/L Br
Br/L R/W
Br/G
Br Gy/G
Br/L R/Y
R/Y R/Y R/L
Br/W
R/Y Br/G B
Br/W G/L B B
R/W
L/W1 R/Y Y/B W L
R/B B/R W/B
Br/W (BLACK)
Br/W G/L Y/B
L L/Y Gy/W R/L
R/Y G/L B
L (BLACK)
G/Y
(BLUE) B
B B (BLUE)
L L B B B R/Y Br/W L/B Y Dg Dg Y G/L Br/W R/Y
Y
B Br Y
Y G Dg Ch B
(BROWN)
4. Battery
8. Main fuse
9. Muffler cover fan fuse
10.ECU fuse
26.Muffler cooling fan temperature sensor
78.Muffler cooling fan motor
79.Muffler cooling fan motor relay
7-72
ET5YU1004
TROUBLESHOOTING
The muffler cooling fan motor fails to turn.
NOTE:
1. Seat

(Main, muffler cover fan, and ECU)
ES” on page 7-93.
OK ↓
page 7-94.
OK ↓
3. Check the muffler cooling fan mo- NG →
tor.
Refer to “CHECKING THE MUF- Replace the muffler cooling fan motor.
FLER COOLING FAN MOTOR” on
page 7-108.
OK ↓
4. Check the muffler cooling fan motor NG →
relay. Replace the muffler cooling fan motor re-
Refer to “CHECKING THE RE- lay.
OK ↓
5. Check the muffler cooling fan tem- NG →
perature sensor.
Replace the muffler cooling fan tempera-
Refer to “CHECKING THE MUF-
ture sensor.
FLER COOLING FAN TEMPERA-
TURE SENSOR” on page 7-108.
OK ↓
6. Check the entire muffler cooling NG →
system wiring. Properly connect or repair the muffler cool-
Refer to “CIRCUIT DIAGRAM” on ing system wiring.
page 7-71.
OK ↓
Replace the ECU.
7-73
7-74
EAS27650
EAS27640
B/R
L Sb/W R
Sb/W B/R L R/L L/R

L/G
O B/R O O B/R O
L/R
L/W1 Sb L/Y R/L
B/Y

Sb
CIRCUIT DIAGRAM

R/L G
B G B (BLUE)
Gy G G Gy
Lg Y/L
B B W W B
R/L B B B/R
(DARK GREEN)
B
B R R R/G B/R C
B R/W
L/Y Gy/R Gy/R
B R Gy1
Gy1
B/R Ch Dg Dg Ch
B B B (BLACK) A
B B B B B
IMMOBILIZER SYSTEM
(BLACK) B/R
L W/Y W L L
R O O A O
R R/W L W/Y O A O
O O
B/L
R Br/R B B B B B/L
L (BLACK) W/G W/G
ON R R
L/W Br/L Br/L B/R
OFF R
Br/L B/L Br/Y Br/Y
O L Y Y L
B R/W R/B
B W/G R/B R/G Br Br
Br/L R/B P/L
Br/L B/L P/W L P/W (BLACK)
R B B (BLACK)
Br/R B L P/W
Br/L B/G B/G WIRE HARNESS SUB-WIRE-HARNESS2
B B (BLACK) P/Y
B/R B/R
B/L
L L W/R B/L
Br W/R W/R B/G B/R
(BLACK)
R R/B
B1 B2 B Br Br D Br
G/R G/R G G G/R B/L
R Br/W Gy/R
G/Y Gy/G
B2 B1 Br B
R/L Gy/W
R R/B (BLACK)
B2 Y/G Y/G Gy
L Y/G B/L
B1 B/L B/Y G
BB4 Y/B
BB3
7-75
BB1 B/Br B3
W Gy
B B (DARK GRAY)
B B
G B G G W
BB3 BB2 W G
(GRAY)
W B W
Br/L Br
Br/L R/W
Br/G
Br Gy/G B/L
Br/L R/Y Gy/W

R/Y R/Y Sb/W
Br/W R/L
R/Y Br/G B
Br/W G/L B B
R/W Y/L
L/W1 R/Y Y/B W L
R/B B/R W/B R/W
Br/W (BLACK) R/G
Br/W G/L Y/B G
L L/Y Gy/W R/L B
R/Y G/L B
L (BLACK)
G/Y
(BLUE) B
B B (BLUE)
L L B B Lg
Y Y
B Br Y
Y G Dg Ch B
(BROWN)
Ch
Dg
L L Y
Dg Ch L
C C
L Y Y L
Dg Ch
B B
Ch Dg
Y/L R/G
L/R Y G Dg Y L Dg
Ch G B Lg
L B B G/R R/W Sb Ch
(BLACK)
(GRAY) (GRAY)
B Y G
B L/R B
B Ch B Dg B Dg B Ch
B B B B
G Y B B B
B L/R C C
B B
IMMOBILIZER SYSTEM
IMMOBILIZER SYSTEM
3. Main switch
4. Battery
8. Main fuse
10.ECU fuse
11.Immobilizer unit
12.Backup fuse (odometer, clock and immobilizer
system)
46.Immobilizer system indicator light
81.Ignition fuse
7-76
IMMOBILIZER SYSTEM
EAS27670
GENERAL INFORMATION
This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the
standard keys. This system consists of the following:
• a code re-registering key (with a red bow)
• two standard keys (with a black bow) that can be re-registered with new codes
• a transponder (installed in the red key bow)
• an immobilizer unit
• the ECU
• an immobilizer system indicator light
The key with the red bow is used to register codes in each standard key. Do not use the key with the
red bow for driving. It should only be used for re-registering new codes in the standard keys. The im-
mobilizer system cannot be operated with a new key until the key registered with a code. If you lose the
code re-registering key, the ECU and main switch (equipped with the immobilizer unit) need to be re-
placed.
Therefore, always use a standard key for driving. (See caution below.)
NOTE:
Each standard key is registered during production, therefore re-registering at purchase is not neces-
sary.
EC5YU1026
CAUTION:
• DO NOT LOSE THE CODE RE-REGISTERING KEY! If the code re-registering key is lost, regis-
tering new codes in the standard keys is impossible. The standard keys can still be used to
start the vehicle. However, if code re-registering is required (e.g., if a new standard key is made
or all keys are lost) the entire immobilizer system must be replaced. Therefore, it is highly rec-
ommended to use either standard key for driving, and to keep the code re-registering key in a
safe place.
• Do not submerse the keys in water.
• Do not expose the keys to excessively high temperatures.
• Do not place the keys close to magnets (this includes, but is not limited to, products such as
speakers, etc.).
• Do not place heavy items on the keys.
• Do not grind the keys or alter their shape.
• Do not disassemble the key bows.
• Do not put two keys of any immobilizer system on the same key ring.
• Keep the standard keys as well as other immobilizer system keys away from the code re-reg-
istering key.
• Keep other immobilizer system keys away from the main switch as they may cause signal in-
terference.
EAS27690
PART REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS

In the course of use, you may encounter the following cases where replacement of parts and registra-
tion of code re-registering/standard keys are required.
NOTE:
Each standard key is registered during production, therefore re-registering at purchase is not neces-
sary.
7-77
IMMOBILIZER SYSTEM
Parts to be replaced
Main switch/immo-
bilizer unit Accesso- Key registration re-
Standard quirement
ECU ry lock*
Main Immobiliz- key
and key
switch er unit
Standard key is lost √ New standard key
All keys have been Code re-registering
lost (including code √ √ √ √ key and standard
re-registering key) keys
Code re-registering
ECU is defective √ key and standard
keys
Code re-registering
Immobilizer unit is
√ key and standard
defective
keys
Code re-registering
Main switch is defec-
√ √ √ √ key and standard
tive
keys
Accessory lock* is
√ Not required
defective
* Accessory locks mean the seat lock and fuel tank cap.
Code re-registering key registration:

When the immobilizer unit or ECU is replaced, the code re-registering key must be registered to the
unit.
To register a code re-registering key:
1. Turn the main switch to “ON” with the code re-registering key.
NOTE:
Check that the immobilizer system indicator light comes on for one second, then goes off. When the
immobilizer system indicator light goes off, the code re-registering key has been registered.
2. Check that the engine can be started.
3. Register the standard key, following the instructions in the section below.
Standby mode:
To enable the immobilizer system, turn the ignition key to “OFF”. 30 seconds later, the indicator light
will start flashing continuously in the standby flashing mode pattern for up to 24 hours. After that time,
the indicator light will stop flashing, but the immobilizer system is still enabled.
7-78
IMMOBILIZER SYSTEM
Standby mode
a. Main switch “ON” e. Standby mode on

b. Main switch “OFF” f. Standby mode off
c. LED on
d. LED off
Standard key registration:

Standard key registration is required when a standard key is lost and needs to be replaced, or when
the code re-registering key is re-registered after the immobilizer unit or ECU are replaced.
NOTE:
Do not start the engine with a standard key that has not been registered. If the main switch is turned
“ON” with a standard key that has not been registered, the immobilizer system indicator light flashes to
indicate fault code “52”. (Refer to “SELF-DIAGNOSIS FAULT CODE INDICATION” on page 7-81.)
1. Check that the immobilizer system indicator light signals the standby mode.
2. Using the code re-registering key, turn the main switch to “ON”, then “OFF”, and then remove the
key within 5 seconds.
3. Insert the first standard key to be registered into the main switch, then turn the key to “ON” within 5
seconds to activate the key registration mode.
NOTE:
The existing standard key code is erased from the memory when the key registration mode is activated.
When the key registration mode is activated, the immobilizer system indicator light flashes rapidly.
4. While the indicator light is flashing, turn the main switch to “OFF”, remove the key, and within 5 sec-
onds, insert the second standard key to be registered into the main switch.
NOTE:
If the immobilizer system indicator light stops flashing 5 seconds after the first standard key is regis-
tered, the registration mode is deactivated. If this occurs, the second standard key cannot be registered,
and steps 2 to 4 need to be repeated to register both standard keys.
5. Turn the main switch to “ON”.
NOTE:
When the indicator light goes off, the registration is complete.
6. Check that the engine can be started with the two registered standard keys.
7-79
IMMOBILIZER SYSTEM
Standard key registration
a. Main switch “ON” B. Immobilizer system indicator light stops

b. Main switch “OFF” flashing when the registration of the second
standard key is complete.
c. LED on
d. LED off
e. Less than 5.0 s
f. Code re-registering key
g. First standard key
h. Second standard key
i. Registration mode
A. Registration of the second standard key is
complete.
Voiding the standard key code:

If a standard key has been lost, it is possible to disable its use by re-registering the remaining standard
key. Standard key registration erases the stored standard key code from the memory, thus disabling
the lost standard key. To re-register, refer to “Standard key registration”.
Standard key code voiding method
a. Main switch “ON”

b. Main switch “OFF”
c. LED on
d. LED off
e. Less than 5.0 s
f. Code re-registering key
g. Remaining standard key
h. Registration mode
A. If the immobilizer system indicator light stops
flashing 5 seconds after the first standard key
is registered, the second standard key cannot
be registered.
7-80
IMMOBILIZER SYSTEM
EAS27700
TROUBLESHOOTING
When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor
flashes.
(Main, ignition, backup, and ECU)
ES” on page 7-93.
OK ↓
page 7-94.
OK ↓
OK ↓
4. Check the entire immobilizer sys- NG →
tem wiring. Properly connect or repair the immobilizer
page 7-75.
OK ↓
• Check the condition of the each im-
mobilizer system circuits.
• Refer to “SELF-DIAGNOSIS FAULT
CODE INDICATION” on page 7-81.
EAS27720
SELF-DIAGNOSIS FAULT CODE INDICATION

When a system malfunction occurs, the fault code number is signaled by the immobilizer system indi-
cator light.
Fault
Part Symptom Cause Action
code
51 IMMOBILIZER Code cannot be 1. Radio wave interfer- 1. Keep magnets,
UNIT transmitted be- ence caused by ob- metal objects,
tween the key and jects around the keys and other immo-
the immobilizer unit. and antenna. bilizer system
2. Immobilizer unit mal- keys away from
function. the keys and an-
3. Key malfunction. tennas.
2. Replace the
main switch/im-
mobilizer unit.
3. Replace the key.
7-81
IMMOBILIZER SYSTEM
Fault
Part Symptom Cause Action
code
52 IMMOBILIZER Codes between the 1. Signal received from 1. Place the immo-
UNIT key and immobilizer other transponder bilizer unit at
unit do not match. (failed to recognize least 50 mm
code after ten con- away from the
secutive attempts). transponder of
2. Signal received from other vehicles.
unregistered stan- 2. Register the
dard key. standard key.
53 IMMOBILIZER Codes cannot be Noise interference or 1. Check the wire
UNIT transmitted be- disconnected lead/ca- harness and
tween the ECU and ble. connector.
the immobilizer unit. 1. Interference due to 2. Replace the
radio wave noise. main switch/im-
2. Disconnected com- mobilizer unit.
munication harness. 3. Replace the
3. Immobilizer unit mal- ECU.
function.
4. ECU malfunction.
54 IMMOBILIZER Codes transmitted Noise interference or 1. Register the
UNIT between the ECU disconnected lead/ca- code re-register-
and the immobilizer ble. ing key.
unit do not match. 1. Interference due to 2. Check the wire
radio wave noise. harness and
2. Disconnected com- connector.
munication harness. 3. Replace the
3. Immobilizer unit mal- main switch/im-
function. mobilizer unit.
4. ECU failure. 4. Replace the
(The ECU or immobi- ECU.
lizer unit was re-
placed with a used
unit from another ve-
hicle.)
55 IMMOBILIZER Key code registra- Same standard key was
UNIT tion malfunction. attempted to be regis- Register another
tered two consecutive standard key.
times.
56 ECU Unidentified code is Noise interference or 1. Check the wire
received. disconnected lead/ca- harness and
ble. connector.
2. Replace the
main switch/im-
mobilizer unit.
3. Replace the
ECU.
Immobilizer system indicator light fault code indication

Units of 10: Cycles of on for 1 second and off for 1.5 seconds.
Units of 1: Cycles of on for 0.5 second and off for 0.5 second.
Example: fault code 52
7-82
IMMOBILIZER SYSTEM
a. Light on
b. Light off
7-83
IMMOBILIZER SYSTEM
7-84
ELECTRICAL COMPONENTS
EAS27970
4 5
3
1 7
8
15
14
10
12
13 11
7-85

3. Cylinder-#2 right ignition coil
5. Intake solenoid
6. Cylinder-#1 right ignition coil
8. Muffler cooling fan temperature sensor
9. Muffler cooling fan motor
10. Speed sensor
11. Rear brake light switch
12. Neutral switch
13. Decompression solenoid
15. Horn
7-86
4 6
5
3 7
9
2
10
11
18
12
13
17
14
16 15
7-87

3. Immobilizer unit
5. Main fuse
6. Fuse box
7. Muffler cooling fan motor relay
9. Headlight relay
10. Relay unit
11. Turn signal/hazard relay
13. Starter relay
14. Lean angle cut-off switch
15. Battery
16. EXUP servo motor
17. Crankshaft position sensor
7-88
EAS27980
CHECKING THE SWITCHES
1 R/W L/W B 5
B
B B/Y R/B
(BLUE)
B
2 R/W R/B
4 B
Br/R
R Br/L Br/R
ON
B B 3 L/W B/Y OFF R
Br/L
11 R/Y Br/W L/B Y Dg 7 6

B B
P B B/Y G B Ch
B B B B
B
(BROWN) (BLUE)
B
8 Dg Br/W Ch
(BLACK)
9 Dg Br/W Ch
12 R/Y Y
13 Y L/B G 10 P B/Y
7-89
1. Front brake light switch

2. Engine stop switch
3. Start switch
4. Main switch
5. Neutral switch
6. Sidestand switch
7. Rear brake light switch
8. Hazard switch
9. Turn signal switch
10. Horn switch
11. Clutch switch
12. Pass switch
13. Dimmer switch
7-90
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 indication
by “ ”. There is continuity between red, brown/blue, and brown/red when the switch is set to
“ON” and between red and brown/red when the switch is set to “ ”.
b
R Br/L Br/R
ON
a OFF
P
R
Br/R
Br/L
7-91
EAS27990
Checking the condition of the bulbs
CHECKING THE BULBS AND BULB
SOCKETS
bulbs.
NOTE: 1. Remove:
Do not check any of the lights that use LEDs. • Bulb
EW5YU1009
Check each bulb and bulb socket for damage or WARNING
wear, proper connections, and also for continuity
Since headlight bulbs get extremely hot,
between the terminals.
Damage/wear → Repair or replace the bulb,
away from them until they have cooled
bulb socket or both.
down.
Improperly connected → Properly connect.
No continuity → Repair or replace the bulb, bulb EC5YU1020
CAUTION:
socket or both.
• Be sure to hold the socket firmly when re-
Types of bulbs moving the bulb. Never pull the lead, other-
The bulbs used on this vehicle are shown in the wise it may be pulled out of the terminal in
following illustration. the coupler.
• Bulbs “a” and “b” are used for the headlights • Avoid touching the glass part of a headlight
and usually use a bulb holder that must be de- bulb to keep it free from oil, otherwise the
tached before removing the bulb. The majority transparency of the glass, the life of the
of these types of bulbs can be removed from bulb, and the luminous flux will be adverse-
their respective socket by turning them coun- ly affected. If a headlight bulb gets soiled,
terclockwise. thoroughly clean it with a cloth moistened
• Bulbs “c” are used for turn signal and tail/brake with alcohol or lacquer thinner.
lights and can be removed from the socket by 2. Check:
pushing and turning the bulb counterclockwise. • Bulb (for continuity)
• Bulbs “d” and “e” are used for meter and indi- (with the pocket tester)
cator lights and can be removed from their re- No continuity → Replace.
spective socket by carefully pulling them out.
Pocket tester
90890-03112
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-92
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. Turn 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 50 A 1
same manner as described in the bulb section; Ignition 25 A 1
however, note the following. Headlight 15 A 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Fuel injection system 15 A 1
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the re- Muffler cover fan 15 A 1
spective leads of the bulb socket. Auto decompression 15 A 1
c. Check the bulb socket for continuity. If any of Signaling system 10 A 1
the readings indicate no continuity, replace
the bulb socket. Parking lighting 10 A 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ECU 10 A 1
EAS28000 Backup (odometer,
CHECKING THE FUSES clock and immobilizer 10 A 1
The following procedure applies to all of the fus- system)
es. Spare 25 A 1
EC5YU1013
CAUTION: Spare 15 A 1
To avoid a short circuit, always turn the main Spare 10 A 1
switch to “OFF” when checking or replacing
EWA13310
a fuse. WARNING
1. Remove: Never use a fuse with an amperage rating
• Seat other than that specified. Improvising or us-
• Lead holder ing a fuse with the wrong amperage rating
Refer to “GENERAL CHASSIS” on page 4-1. may cause extensive damage to the electri-
2. Check: cal system, cause the lighting and ignition
• Fuse systems to malfunction and could possibly
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ cause a fire.
a. Connect the pocket tester to the fuse and
check the continuity. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-93
4. Install: NOTE:
• Lead holder Since MF batteries are sealed, it is not possible
• Seat to check the charge state of the battery by mea-
Refer to “GENERAL CHASSIS” on page 4-1. suring the specific gravity of the electrolyte.
EAS28030 Therefore, the charge of the battery has to be
CHECKING AND CHARGING THE BATTERY checked by measuring the voltage at the battery
EWA13290
terminals.
WARNING
Batteries generate explosive hydrogen gas 1. Remove:
and contain electrolyte which is made of poi- • Seat
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)
ECA13640
working near batteries. CAUTION:
• Charge batteries in a well-ventilated area.
First, disconnect the negative battery lead
• Keep batteries away from fire, sparks or
“1”, and then positive battery lead “2”.
open flames (e.g., welding equipment,
lighted cigarettes).
• DO NOT SMOKE when charging or han- 2
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: 1
EXTERNAL
• Skin — Wash with water. 3. Remove:
• Eyes — Flush with water for 15 minutes and • Battery band
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.
ECA13660
• Positive tester probe →
CAUTION: positive battery terminal
• This is a sealed battery. Never remove the • Negative tester probe →
sealing caps because the balance between negative battery terminal
cells will not be maintained and battery per-
formance will deteriorate. NOTE:
• Charging time, charging amperage and • The charge state of an MF battery can be
charging voltage for an MF battery are dif- checked by measuring its open-circuit voltage
ferent from those of conventional batteries. (i.e., the voltage when the positive battery ter-
The MF battery should be charged as ex- minal is disconnected).
plained in the charging method illustra- • No charging is necessary when the open-cir-
tions. If the battery is overcharged, the cuit voltage equals or exceeds 12.8 V.
electrolyte level will drop considerably. b. Check the charge of the battery, as shown in
Therefore, take special care when charging the charts and the following example.
the battery.
7-94
Example ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Open-circuit voltage = 12.0 V Charging method using a variable-current
Charging time = 6.5 hours (voltage) charger
Charge of the battery = 20–30% a. Measure the open-circuit voltage prior to
charging.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ NOTE:
5. Charge: Voltage should be measured 30 minutes after
• Battery the engine is stopped.
(refer to the appropriate charging method)
EWA13300 b. Connect a charger and ammeter to the bat-
WARNING tery and start charging.
Do not quick charge a battery. NOTE:
ECA13670 Set the charging voltage at 16–17 V. If the set-
CAUTION: ting is lower, charging will be insufficient. If too
• Never remove the MF battery sealing caps. high, the battery will be over-charged.
• Do not use a high-rate battery charger c. Make sure that the current is higher than the
since it forces a high-amperage current standard charging current written on the bat-
into the battery quickly and can cause battery.
tery overheating and battery plate damage.
NOTE:
• If it is impossible to regulate the charging
current on the battery charger, be careful If the current is lower than the standard charging
not to overcharge the battery. current written on the battery, set the charging
• When charging a battery, be sure to remove voltage adjust dial at 20–24 V and monitor the
it from the vehicle. (If charging has to be amperage for 3–5 minutes to check the battery.
done with the battery mounted on the vehi- • Standard charging current is reached
cle, disconnect the negative battery lead Battery is good.
from the battery terminal.) • Standard charging current is not reached
• To reduce the chance of sparks, do not Replace the battery.
plug in the battery charger until the battery
charger leads are connected to the battery. d. Adjust the voltage so that the current is at the
• Before removing the battery charger lead standard charging level.
clips from the battery terminals, be sure to e. Set the time according to the charging time
turn off the battery charger. suitable for the open-circuit voltage.
• Make sure the battery charger lead clips are Refer to “Battery condition checking steps”.
in full contact with the battery terminal and f. If charging requires more than 5 hours, it is
that they are not shorted. A corroded bat- advisable to check the charging current after
tery charger lead clip may generate heat in a lapse of 5 hours. If there is any change in
the contact area and a weak clip spring may the amperage, readjust the voltage to obtain
cause sparks. the standard charging current.
• If the battery becomes hot to the touch at g. Measure the battery open-circuit voltage after
any time during the charging process, dis- leaving the battery unused for more than 30
connect the battery charger and let the bat- minutes.
tery cool before reconnecting it. Hot 12.8 V or more --- Charging is complete.
batteries can explode! 12.7 V or less --- Recharging is required.
• As shown in the following illustration, the Under 12.0 V --- Replace the battery.
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 Charging method using a constant volt-
measuring the open-circuit voltage. age charger
a. Measure the open-circuit voltage prior to
charging.
7-95
NOTE: 9. Lubricate:
Voltage should be measured 30 minutes after • Battery terminals
the engine is stopped.
b. Connect a charger and ammeter to the bat- Dielectric grease
tery and start charging.
c. Make sure that the current is higher than the 10.Install:
standard charging current written on the bat- • Seat
tery. Refer to “GENERAL CHASSIS” on page 4-1.
NOTE: EAS28040
If the current is lower than the standard charging CHECKING THE RELAYS
current written on the battery, this type of battery Check each switch for continuity with the pocket
charger cannot charge the MF battery. A vari- tester. If the continuity reading is incorrect, re-
able voltage charger is recommended. place the relay.
d. Charge the battery until the battery’s charg- Pocket tester

ing voltage is 15 V. 90890-03112
NOTE: Analog pocket tester
YU-03112-C
Set the charging time at 20 hours (maximum).
e. Measure the battery open-circuit voltage after 1. Disconnect the relay from the wire harness.
leaving the battery unused for more than 30 2. Connect the pocket tester (Ω × 1) and battery
minutes. (12 V) to the relay terminal as shown.
12.8 V or more --- Charging is complete. Check the relay operation.
12.7 V or less --- Recharging is required. Out of specification → Replace.
Under 12.0 V --- Replace the battery.
Starter relay
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3
6. Install:
• Battery R
• Battery band
7. Connect: R
• Battery leads R/W L

(to the battery terminals) B
ECA13630
2 1
CAUTION:
4
First, connect the positive battery lead “1”,
and then the negative battery lead “2”.
1. Positive battery terminal
2. Negative battery terminal
1 3. Positive tester probe
4. Negative tester probe
Result
Continuity
(between “3” and “4”)
8. Check:
• Battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
7-96
Relay unit (starting circuit cut-off relay) Headlight relay

3
1 3 2 4 4 +
+
2 1
Y/B R/Y
Sb/W B/R L R/L L/R
G/L
L/G L/Y Sb B/Y L/W R
R/Y
1. Positive battery terminal 1. Positive battery terminal

2. Negative battery terminal 2. Negative battery terminal
3. Positive tester probe 3. Positive tester probe
4. Negative tester probe 4. Negative tester probe
Result Result
Continuity Continuity
(between “3” and “4”) (between “3” and “4”)
Relay unit (fuel pump relay) Muffler cooling fan motor relay
3
1 4 3 2 4 +
+
2 1
G/Y R/B
Sb/W B/R L R/L L/R
L
Br/W
1. Positive battery terminal 1. Positive battery terminal

2. Negative battery terminal 2. Negative battery terminal
3. Positive tester probe 3. Positive tester probe
4. Negative tester probe 4. Negative tester probe
Result Result
Continuity Continuity
(between “3” and “4”) (between “3” and “4”)
ET5YU1021
CHECKING THE TURN SIGNAL/HAZARD

RELAY
1. Check:
• Turn signal/hazard relay input voltage
Out of specification → The wiring circuit from
the main switch to the turn signal/hazard re-
lay coupler is faulty and must be repaired.
Turn signal/hazard relay input

voltage
DC 12 V
7-97
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the
turn signal/hazard relay terminal as shown.
Pocket tester
90890-03112
YU-03112-C

brown/green “1”
• Negative tester probe → b. Turn the main switch to “ON”.
ground c. Measure the turn signal/hazard relay output
voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28050
CHECKING THE RELAY UNIT (DIODE)

1. Check:
• Relay unit (diode)
Pocket tester
90890-03112
b. Turn the main switch to “ON”. YU-03112-C
c. Measure the turn signal/hazard relay input
voltage. NOTE:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ The pocket tester and the analog pocket tester
2. Check: readings are shown in the following table.
• Turn signal/hazard relay output voltage
Turn signal/hazard relay output

voltage
DC 12 V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the
turn signal/hazard relay terminal as shown.
Pocket tester
90890-03112
YU-03112-C

brown/white “1”
• Negative tester probe →
ground
7-98
b. Connect the pocket tester (Ω × 1) to the relay

Continuity unit terminal as shown.
Positive tester probe → sky blue c. Check the relay unit (diode) for continuity.
“1” d. Check the relay unit (diode) for no continuity.
Negative tester probe →
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
black/yellow “2”
No continuity EAS28070
Positive tester probe → CHECKING THE SPARK PLUG CAPS

black/yellow “2” The following procedure applies to all of the
Negative tester probe → sky spark plug caps.
blue “1” 1. Check:
Continuity • Spark plug cap resistance
Positive tester probe → sky blue Out of specification → Replace.
“1”
Negative tester probe → Resistance
blue/yellow “3” 10.0 kΩ
No continuity
Positive tester probe → ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
blue/yellow “3” a. Remove the spark plug cap from the spark
Negative tester probe → sky plug lead.
blue “1” b. Connect the pocket tester (Ω × 1k) to the
Continuity spark plug cap as shown.
Positive tester probe → sky blue
“1” Pocket tester
Negative tester probe → sky 90890-03112
blue/white “4” Analog pocket tester
No continuity YU-03112-C
Positive tester probe → sky
blue/white “4”
Negative tester probe → sky
blue “1”
Continuity
Positive tester probe →
blue/green “5”
Negative tester probe →
blue/yellow “3”
No continuity
Positive tester probe →
blue/yellow “3”
Negative tester probe → c. Measure the spark plug cap resistance.
blue/green “5”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28100
CHECKING THE IGNITION COILS

3 1 The following procedure applies to all of the igni-
tion coils.
5 1. Check:
• Primary coil resistance
4 2 Out of specification → Replace.
Sb/W B/R L R/L L/R
Primary coil resistance
2.16–2.64 Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the relay unit coupler from the a. Disconnect the ignition coil connectors from
wire harness. the ignition coil terminals.
7-99
b. Connect the pocket tester (Ω × 1) to the igni-

tion coil as shown.
Pocket tester
90890-03112
YU-03112-C

black/red “1”
orange or gray/red or gray/black “2” c. Measure the secondary coil resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET5YU1032
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
7-3.
Minimum ignition spark gap

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

black/red “1”
spark plug lead “2”
2. Spark plug cap

c. Turn the main switch to “ON” and engine stop
switch to “ ”.
d. Measure the ignition spark gap “a”.
7-100
e. Crank the engine by pushing the start switch

“ ” and gradually increase the spark gap un- Lean angle cut-off switch output
til a misfire occurs. voltage
Less than 65°: 0.4–1.4 V
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
More than 65°: 3.7–4.4 V
EAS28120
CHECKING THE CRANKSHAFT POSITION ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

SENSOR a. Connect the lean angle cut-off switch coupler
1. Disconnect: to the lean angle cut-off switch.
• Crankshaft position sensor coupler b. Connect the pocket tester (DC 20 V) to the
(from the wire harness) lean angle cut-off switch coupler as shown.
2. Check:
• Crankshaft position sensor resistance Pocket tester
Out of specification → Replace the crank- 90890-03112
shaft position sensor. Analog pocket tester
YU-03112-C
Crankshaft position sensor resis-
tance • Positive tester probe →
248–372 Ω/gray-black yellow/green “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ black/blue “2”
a. Connect the pocket tester (Ω × 100) to the
crankshaft position sensor coupler as shown.
Pocket tester
90890-03112
YU-03112-C

gray “1”
black “2”
c. Turn the lean angle cut-off switch to 65°.
d. Measure the lean angle cut-off switch output
voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28150
CHECKING THE STATOR COIL

1. Disconnect:
B Gy
• Stator coil coupler
(from the wire harness)
2 1 2. Check:
• Stator coil resistance
b. Measure the crankshaft position sensor re- Out of specification → Replace the stator as-
sistance. sembly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Stator coil resistance
EAS28130
0.128–0.192 Ω
CHECKING THE LEAN ANGLE CUT-OFF
SWITCH ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1. Remove: a. Connect the pocket tester (Ω × 1) to the stator
• Lean angle cut-off switch coil coupler as shown.
2. Check:
• Lean angle cut-off switch output voltage
7-101

Pocket tester red “1”
90890-03112 • Negative tester probe →
Analog pocket tester black “2”
YU-03112-C

black “1”
black “2”
• Positive tester probe → B B B R B

black “1”
• Negative tester probe → 2
1
black “3”
• Positive tester probe → c. Start the engine and let it run at approximate-
black “2” ly 5000 r/min.
• Negative tester probe → d. Measure the charging voltage.
black “3”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28180
CHECKING THE HORN

1. Check:
• Horn resistance
Coil resistance
B B B
1.01–1.11 Ω at 20 °C (68 °F)
1 2 3 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the horn leads from the horn ter-
b. Measure the stator coil resistance. minals.
b. Connect the pocket tester (Ω × 1) to the horn
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
terminals.
EAS28170
CHECKING THE RECTIFIER/REGULATOR Pocket tester

1. Check: 90890-03112
• Charging voltage Analog pocket tester
Out of specification → Replace the rectifi- YU-03112-C
er/regulator.
Charging voltage horn terminal “1”
14 V at 5000 r/min • Negative tester probe →
horn terminal “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the engine tachometer to the cylinder-#1
left spark plug lead or right spark plug lead.
b. Connect the pocket tester (DC 20 V) to the 1
rectifier/regulator coupler as shown.
Pocket tester
90890-03112
Analog pocket tester 2
YU-03112-C
7-102
c. Measure the horn resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check: 3
• Horn sound 1
Faulty sound → Adjust or replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a battery (12 V) to the horn.
b. Turn the adjusting screw in direction “a” or “b” 2
until the horn sound is obtained.
b. Immerse the engine temperature sensor “1”

a b in a container filled with water “2”.
NOTE:
Make sure that the engine temperature sensor
terminals do not get wet.
c. Place a thermometer “3” in the water.
d. Slowly heat the water, then let it cool down to
the specified temperature.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
e. Measure the engine temperature sensor re-
EAS28210
sistance.
CHECKING THE ENGINE TEMPERATURE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
SENSOR 3. Install:
1. Remove: • Engine temperature sensor
• Engine temperature sensor
(from the front cylinder head) Engine temperature sensor
EWA14140 20 Nm (2.0 m·kg, 14 ft·lb)
T.
R.
WARNING
EAS28230
• Handle the engine temperature sensor with
CHECKING THE FUEL SENDER
special care.
1. Disconnect:
• Never subject the engine temperature sen-
• Fuel pump coupler
sor to strong shocks. If the engine temper-
• Fuel sender coupler
ature sensor is dropped, replace it.
(from the wire harness)
2. Check: 2. Remove:
• Engine temperature sensor resistance • Fuel tank
Out of specification → Replace. 3. Remove:
• Fuel pump
Engine temperature sensor resis- (from the fuel tank)
tance 4. Check:
0.90–1.10 kΩ at 100 °C (212 °F)
• Fuel sender resistance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Out of specification → Replace the fuel pump
a. Connect the pocket tester (Ω × 1k) to the en- assembly.
gine temperature sensor terminal as shown.
Fuel sender resistance
Pocket tester 1.35–1.65 kΩ at 25 °C (77 °F)
90890-03112
Analog pocket tester ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
YU-03112-C a. Connect the pocket tester (Ω × 1k) to the fuel
sender terminal as shown.
7-103
Pocket tester
90890-03112 1
YU-03112-C
W L L W/Y
• Positive tester probe → B B/ L
green “1”
black “2” 2
b. Turn the main switch to “ON”.

c. Elevate the rear wheel and slowly rotate it.
d. Measure the voltage of white/yellow and
black/blue. With each full rotation of the rear
wheel, the voltage reading should cycle from
0.6 V to 4.8 V to 0.6 V to 4.8 V.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28300
CHECKING THE THROTTLE POSITION

SENSOR
b. Measure the fuel sender resistance. 1. Remove:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Throttle position sensor
EAS28240
(from the throttle body)
CHECKING THE SPEED SENSOR 2. Check:
1. Check: • Throttle position sensor maximum resistance
• Speed sensor output voltage Out of specification → Replace the throttle
Out of specification → Replace. position sensor.
Output voltage reading cycle Resistance

0.6 V to 4.8 V to 0.6 V to 4.8 V 4.0–6.0 kΩ/blue-black
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the a. Connect the pocket tester (Ω × 1k) to the
speed sensor coupler (wire harness side) as throttle position sensor terminal as shown.
shown.
Pocket tester
Pocket tester 90890-03112
90890-03112 Analog pocket tester
Analog pocket tester YU-03112-C
YU-03112-C
• Positive tester probe → blue “1”
white/yellow “1” • Negative tester probe →
• Negative tester probe → black “2”
black/blue “2”
7-104
d. Connect the battery (DC 12 V) to the fuel

2 1 pump terminal as shown.
• Positive battery lead →
red/blue “3”
• Negative battery lead →
black “4”
B Y L
b. Measure the throttle position sensor maxi-

mum resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Throttle position sensor
NOTE:
When installing the throttle position sensor, ad-
just its angle properly. Refer to “ADJUSTING B
G
THE THROTTLE POSITION SENSOR” on page

6-10.
3 2
EAS28350 R/L
B
CHECKING THE FUEL PUMP 4
EWA13850
WARNING
Gasoline is extremely flammable and under
1
certain circumstances there can be a danger
of an explosion or fire. Be extremely careful e. Check the fuel pump operation.
and note the following points:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Stop the engine before refueling.
EAS28360
• Do not smoke, and keep away from open
CHECKING THE EXUP SERVO MOTOR
flames, sparks, or any other source of fire.
1. Check:
• If you do accidentally spill gasoline, wipe it
• EXUP servo motor operation
up immediately with dry rags.
• If gasoline touches the engine when it is
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
hot, a fire may occur. Therefore, make sure a. Disconnect the EXUP cables from the EXUP
the engine is completely cool before per- servo motor pulley.
forming the following test. b. Disconnect the EXUP servo motor coupler
1. Disconnect: from the EXUP servo motor.
• Fuel pump coupler c. Connect the battery leads to the EXUP servo
• Fuel sender coupler motor terminal as shown.
(from the wire harness) For counterclockwise rotation “a”
2. Remove: • Positive battery lead →
• Fuel tank black/green “1”
3. Check: • Negative battery lead →
• Fuel pump operation black/red “2”
Faulty/rough movement → Replace. For clockwise rotation “b”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Positive battery lead →
a. Insert a plug “1” into the fuel return hose end. black/red “2”
b. Fill the fuel tank. • Negative battery lead →
c. Put the end of the fuel hose “2” into an open black/green “1”
container.
7-105
1 2
a L W/R B/L
B/G B/R
d. Check that the EXUP servo motor pulley ro- c. Measure the decompression solenoid (ther-
tates several times in directions “a” and “b”. mistor) resistance.
EC5YU1023
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CAUTION:
2. Check:
To prevent damaging the EXUP servo motor, • Decompression solenoid resistance
perform this test within a few seconds of Out of specification → Replace.
connecting the battery.
Decompression solenoid resis-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
tance
EAS28400
0.96–1.44 Ω at 20 °C (68 °F)
CHECKING THE DECOMPRESSION
SOLENOID ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1. Check: a. Connect the pocket tester (Ω × 1) to the de-
• Decompression solenoid (thermistor) resis- compression solenoid coupler as shown.
tance
Out of specification → Replace. Pocket tester
90890-03112
Decompression solenoid (ther- Analog pocket tester
mistor) resistance YU-03112-C
56–84 Ω at 25 °C (77 °F)
NOTE: black “1”
The resistance value for the thermistor changes • Negative tester probe →
when the temperature changes; therefore, mea- black “2”
sure the decompression solenoid (thermistor)
resistance at the specified temperature.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the decompression solenoid cou-
plers from the wire harness.
b. Connect the pocket tester (Ω × 10) to the de-
compression solenoid coupler as shown.
Pocket tester
90890-03112
YU-03112-C b. Measure the decompression solenoid resis-
tance.
• Positive tester probe → ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
green “1” EAS28410
• Negative tester probe → CHECKING THE INTAKE AIR PRESSURE
green “2” SENSORS
The following procedure applies to both of the in-
take air pressure sensors.
7-106
1. Check:
• Intake air pressure sensor output voltage Air temperature sensor resis-
Out of specification → Replace. tance
290–390 Ω at 80 °C (176 °F)
Intake air pressure sensor output
voltage ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3.75–4.25 V a. Connect the pocket tester (Ω × 100) to the air
temperature sensor terminal as shown.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the in- Pocket tester
take air pressure sensor coupler as shown. 90890-03112
Pocket tester YU-03112-C
90890-03112
YU-03112-C
3
• Positive tester probe → 1
pink/white “1” or pink/yellow
black/blue “2”
2
2 1
b. Immerse the air temperature sensor “1” in a
container filled with water “2”.
B/L P/W L NOTE:
Make sure that the air temperature sensor termi-
nals do not get wet.
c. Place a thermometer “3” in the water.
d. Slowly heat the water, then let it cool down to
b. Turn the main switch to “ON”. the specified temperature.
c. Measure the intake air pressure sensor out- e. Measure the air temperature sensor resis-
put voltage. tance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET5YU1007 ET5YU1008
CHECKING THE AIR TEMPERATURE CHECKING THE INTAKE SOLENOID
SENSOR 1. Check:
1. Remove: • Intake solenoid resistance
• Air temperature sensor Out of specification → Replace.
EW5YU1002
WARNING Intake solenoid resistance

• Handle the air temperature sensor with 42–48 Ω at 20 °C (68 °F)
special care.
• Never subject the air temperature sensor to ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the intake solenoid coupler from
strong shocks. If the air temperature sen-
the intake solenoid.
sor is dropped, replace it.
b. Connect the pocket tester (Ω × 10) to the in-
2. Check: take solenoid terminal as shown.
• Air temperature sensor resistance
Out of specification → Replace. Pocket tester
90890-03112
YU-03112-C
7-107
EW5YU1003
• Positive tester probe
WARNING
brown/black “1”
• Negative tester probe • Handle the muffler cooling fan temperature
red/white “2” sensor with special care.
• Never subject the intake muffler cooling fan
temperature sensor to strong shocks. If the
1 intake muffler cooling fan temperature sen-
2
sor is dropped, replace it.
Br/B R/W
2. Check:
• Muffler cooling fan temperature sensor resis-
tance
Muffler cooling fan temperature

sensor resistance
c. Measure the intake solenoid resistance. 1.82–2.24 kΩ at 75 °C (167 °F)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
ET5YU1005 a. Connect the pocket tester (Ω × 1k) to the muf-
CHECKING THE MUFFLER COOLING FAN fler cooling fan temperature sensor terminal
MOTOR as shown.
1. Check:
• Muffler cooling fan motor Pocket tester
Faulty/rough movement → Replace. 90890-03112
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Analog pocket tester
a. Disconnect the muffler cooling fan motor cou- YU-03112-C
pler from the wire harness.
b. Connect the battery (DC 12 V) as shown. • Positive tester probe →
• Positive tester probe → black “1”
blue “1” • Negative tester probe →
• Negative tester probe → black “2”
black “2”
5
B B
1 3
2
b. Immerse the muffler cooling fan temperature

c. Check the muffler cooling fan motor move- sensor “3” in a container filled with water “4”.
ment. NOTE:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Make sure that the muffler cooling fan tempera-
ET5YU1006 ture sensor terminals do not get wet.
CHECKING THE MUFFLER COOLING FAN
TEMPERATURE SENSOR c. Place a thermometer “5” in the water.
1. Remove: d. Slowly heat the water, then let it cool down to
• Muffler cooling fan temperature sensor the specified temperature.
e. Measure the muffler cooling fan temperature
sensor resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-108
3. Install:
• Muffler cooling fan temperature sensor
7-109
TROUBLESHOOTING
TROUBLESHOOTING..................................................................................... 8-1
GENERAL INFORMATION ....................................................................... 8-1
STARTING FAILURES.............................................................................. 8-1
INCORRECT ENGINE IDLING SPEED .................................................... 8-1
POOR MEDIUM AND HIGH-SPEED PERFORMANCE ........................... 8-2
FAULTY GEAR SHIFTING........................................................................ 8-2
SHIFT PEDAL DOES NOT MOVE ............................................................ 8-2
JUMPS OUT OF GEAR............................................................................. 8-2
FAULTY CLUTCH ..................................................................................... 8-2
OVERHEATING ........................................................................................ 8-3
POOR BRAKING PERFORMANCE.......................................................... 8-3
FAULTY FRONT FORK LEGS.................................................................. 8-3
UNSTABLE HANDLING ............................................................................ 8-3
FAULTY LIGHTING OR SIGNALING SYSTEM ........................................ 8-3
8
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(s)
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
EAS28470
• Worn or damaged insulator
STARTING FAILURES • Faulty spark plug cap
4. Ignition coil(s)
Engine • Cracked or broken ignition coil body
1. Cylinder(s) and cylinder head(s) • 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 • Faulty engine stop switch
• Incorrect valve timing • Broken or shorted wiring
• Faulty valve spring • Faulty neutral switch
• Seized valve • Faulty start switch
2. Piston(s) and piston ring(s) • Faulty sidestand switch
• Improperly installed piston ring • Faulty clutch switch
• Damaged, worn or fatigued piston ring • Improperly grounded circuit
• Seized piston ring • Loose connections
• Seized or damaged piston 7. Starting system
3. Air filter • Faulty starter motor
• Improperly installed air filter • Faulty starter relay
• Clogged air filter element • Faulty starting circuit cut-off relay
4. Crankcase and crankshaft • Faulty starter clutch
• Improperly assembled crankcase EAS28490
• Seized crankshaft INCORRECT ENGINE IDLING SPEED
Fuel system Engine

1. Fuel tank 1. Cylinder(s) and cylinder head(s)
• Empty fuel tank • Incorrect valve clearance
• Clogged fuel tank drain hose • Damaged valve train components
• Clogged rollover valve 2. Air filter
• Clogged rollover valve hose • Clogged air filter element
• Deteriorated or contaminated fuel
2. Fuel pump Fuel system
• Faulty fuel pump 1. Throttle body(-ies)
• Faulty fuel pump relay • Damaged or loose throttle body joint
3. Throttle body(-ies) • Improperly synchronized throttle bodies
• Deteriorated or contaminated fuel • Improper throttle cable free play
• Sucked-in air • Flooded throttle body
8-1
TROUBLESHOOTING
Electrical system EAS28550
JUMPS OUT OF GEAR

1. Battery
• Discharged battery
Shift shaft
• Faulty battery
• Incorrect shift pedal position
2. Spark plug(s)
• Improperly returned stopper lever
• Incorrect spark plug gap
• Incorrect spark plug heat range Shift forks
• Fouled spark plug • Worn shift fork
• Worn or damaged electrode
• Worn or damaged insulator Shift drum
• Faulty spark plug cap • Incorrect axial play
3. Ignition coil(s) • Worn shift drum groove
• Broken or shorted primary or secondary coils
• Faulty spark plug lead Transmission
• Cracked or broken ignition coil • Worn gear dog
4. Ignition system
• Faulty ECU EAS28570
FAULTY CLUTCH
• Faulty crankshaft position sensor
• Broken generator rotor woodruff key
Clutch slips
EAS28510 1. Clutch
POOR MEDIUM AND HIGH-SPEED • Improperly assembled clutch
PERFORMANCE • Improperly assembled clutch master cylinder
Refer to “STARTING FAILURES” on page 8-1. • Improperly assembled clutch release cylinder
• Incorrect clutch fluid level
Engine • Damaged clutch hose
1. Air filter • Loose or fatigued clutch spring
• Clogged air filter element • Loose union bolt
• Worn friction plate
Fuel system • Worn clutch plate
1. Fuel pump • Damaged clutch release cylinder
• Faulty fuel pump 2. Engine oil
EAS28530 • Incorrect oil level
FAULTY GEAR SHIFTING • Incorrect oil viscosity (low)
• Deteriorated oil
Shifting is difficult
Refer to “Clutch drags”. Clutch drags
1. Clutch
EAS28540
SHIFT PEDAL DOES NOT MOVE • Air in hydraulic clutch system

• Unevenly tensioned clutch springs
Shift shaft • Warped pressure plate
• Improperly adjusted shift rod • Bent clutch plate
• Bent shift shaft • Swollen friction plate
• Bent clutch push rod
Shift drum and shift forks • Damaged clutch boss
• Foreign object in a shift drum groove • Burnt primary driven gear bushing
• Seized shift fork • Damaged clutch release cylinder
• Bent shift fork guide bar • Match marks not aligned
2. Engine oil
Transmission • Incorrect oil level
• Seized transmission gear • Incorrect oil viscosity (high)
• Foreign object between transmission gears • Deteriorated oil
• Improperly assembled transmission
8-2
TROUBLESHOOTING
EAS28590
Malfunction
OVERHEATING
• Bent or damaged inner tube
• Bent or damaged outer tube
Engine
• Damaged fork spring
1. Cylinder head(s) and piston(s)
• Worn or damaged outer tube bushing
• Heavy carbon buildup
• Bent or damaged damper rod
2. Engine oil
• Incorrect oil viscosity
• Incorrect oil level
• Incorrect oil level
• Incorrect oil viscosity
• Inferior oil quality EAS28670
UNSTABLE HANDLING
Fuel system 1. Handlebar
1. Throttle body(-ies) • Bent or improperly installed handlebar
• Faulty throttle body(-ies) 2. Steering head components
• Damaged or loose throttle body joint • Improperly installed upper bracket
2. Air filter • Improperly installed lower bracket
• Clogged air filter element (improperly tightened ring nut)
• Bent steering stem
Chassis • Damaged ball bearing or bearing race
1. Brake(s) 3. Front fork leg(s)
• Dragging brake • Uneven oil levels (both front fork legs)
• Unevenly tensioned fork spring (both front
Electrical system fork legs)
1. Spark plug(s) • Broken fork spring
• Incorrect spark plug gap • Bent or damaged inner tube
• Incorrect spark plug heat range • Bent or damaged outer tube
2. Ignition system 4. Swingarm
• Faulty ECU • Worn bearing or bushing
EAS28620
• Bent or damaged swingarm
POOR BRAKING PERFORMANCE 5. Rear shock absorber assembly
• Worn brake pad • Faulty rear shock absorber spring
• Worn brake disc • Leaking oil or gas
• Air in hydraulic brake system 6. Tire(s)
• Leaking brake fluid • Uneven tire pressures (front and rear)
• Faulty brake caliper kit • Incorrect tire pressure
• Faulty brake caliper seal • Uneven tire wear
• Loose union bolt 7. Wheel(s)
• Damaged brake hose • Incorrect wheel balance
• Oil or grease on the brake disc • Deformed cast wheel
• Oil or grease on the brake pad • Damaged wheel bearing
• Incorrect brake fluid level • Bent or loose wheel axle
• Excessive wheel runout
EAS28660
8. Frame
FAULTY FRONT FORK LEGS
• Bent frame
• Damaged steering head pipe
Leaking oil
• Improperly installed bearing race
• Bent, damaged or rusty inner tube
• Cracked or damaged outer tube EAS28710
• Improperly installed oil seal FAULTY LIGHTING OR SIGNALING SYSTEM

• Damaged oil seal lip
• Incorrect oil level (high) Headlight does not come on
• Cracked or damaged cap bolt O-ring • Wrong headlight bulb
• Too many electrical accessories
• Hard charging
• Incorrect connection
8-3
TROUBLESHOOTING
• Improperly grounded circuit • Faulty horn switch

• Poor contacts (main or light switch) • Faulty battery
• Burnt-out headlight bulb • Blown, damaged or incorrect fuse
• Faulty wire harness
Headlight bulb burnt out
• Wrong headlight bulb
• Faulty battery
• Faulty rectifier/regulator
• Improperly grounded circuit
• Faulty main switch
• Faulty light switch
• Headlight bulb life expired
Tail/brake light does not come on

• Wrong tail/brake light LED
• Too many electrical accessories
• Burnt-out tail/brake light LED
Tail/brake light LED burnt out

• Wrong tail/brake light LED
• Faulty battery
• Incorrectly adjusted rear brake light switch
• Tail/brake light LED life expired
Turn signal does not come on

• Faulty turn signal switch
• Faulty turn signal/hazard relay
• Burnt-out turn signal bulb
• Damaged or faulty wire harness
• Improperly grounded circuit
• Faulty battery
• Blown, damaged or incorrect fuse
Turn signal flashes slowly

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

Turn signal flashes quickly

• Incorrect turn signal bulb
Horn does not sound

• Improperly adjusted horn
• Damaged or faulty horn
8-4
EAS28740
53. Turn signal/hazard relay Gy/B Gray/Black
WIRING DIAGRAM 54. Headlight relay Gy/G Gray/Green
MT01(T–W) 2005–2007 55. Left handlebar switch Gy/R Gray/Red
1. AC magneto 56. Clutch switch Gy/W Gray/White
2. Rectifier/regulator 57. Pass switch L/B Blue/Black
3. Main switch 58. Dimmer switch L/G Blue/Green
4. Battery 59. Hazard switch L/R Blue/Red
60. Turn signal switch L/W Blue/White
L/Y Blue/Yellow
6. Starter relay 61. Horn switch
P/L Pink/Blue
7. Starter motor 62. Front left turn signal light P/W Pink/White
8. Main fuse 63. Front right turn signal light P/Y Pink/Yellow
9. Muffler cover fan fuse 64. Rear right turn signal light R/B Red/Black
10. ECU fuse 65. Rear left turn signal light R/G Red/Green
11. Immobilizer unit 66. Headlight assembly R/L Red/Blue
12. Backup fuse (odometer, clock 67. Auxiliary light R/W Red/White
and immobilizer system) 68. Headlight (high beam) R/Y Red/Yellow
13. Relay unit 69. Headlight (low beam) Sb/W Sky blue/White
14. Starting circuit cut-off relay 70. Auto decompression fuse W/B White/Black
71. Right handlebar switch W/G White/Green
15. Fuel pump relay
W/R White/Red
16. Neutral switch 72. Front brake light switch
W/Y White/Yellow
17. Fuel pump 73. Engine stop switch Y/B Yellow/Black
18. Fuel sender 74. Start switch Y/G Yellow/Green
19. Sidestand switch 75. Tail/brake light Y/L Yellow/Blue
20. Crankshaft position sensor 76. License plate light
21. Throttle position sensor 77. Rear brake light switch
22. Cylinder-#1 intake air pressure 78. Muffler cooling fan motor
sensor 79. Muffler cooling fan motor relay
23. Cylinder-#2 intake air pressure 80. Headlight fuse
sensor 81. Ignition fuse
24. Lean angle cut-off switch 82. Signaling system fuse
25. Speed sensor 83. Parking lighting fuse
26. Muffler cooling fan temperature 84. Anti-theft alarm (OPTION)
sensor
EAS28750
COLOR CODE
29. ECU (electronic control unit) B Black
Br Brown
Ch Chocolate
31. Intake solenoid Dg Dark green
32. Spark plug G Green
33. Cylinder-#2 right ignition coil Gy Gray
34. Cylinder-#2 left ignition coil L Blue
35. Cylinder-#1 left ignition coil Lg Light green
36. Cylinder-#1 right ignition coil O Orange
37. EXUP servo motor P Pink
38. Decompression solenoid R Red
39. Injector #1 Sb Sky blue
40. Injector #2 W White
Y Yellow
41. Meter assembly
B/Br Black/Brown
42. Fuel level warning light B/G Black/Green
43. Neutral indicator light B/L Black/Blue
44. Multi-function meter B/R Black/Red
45. Engine trouble warning light B/Y Black/Yellow
46. Immobilizer system indicator Br/B Brown/Black
light Br/G Brown/Green
47. High beam indicator light Br/L Brown/Blue
48. Left turn signal indicator light Br/R Brown/Red
49. Right turn signal indicator light Br/W Brown/White
Br/Y Brown/Yellow
50. Meter light
G/L Green/Blue
51. O2 sensor G/R Green/Red
52. Horn G/Y Green/Yellow
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
MT01(T–W) 2005–2007 MT01(T–W) 2005–2007 MT01(T–W) 2005–2007 MT01(T–W) 2005–2007 MT01(T–W) 2005–2007
WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO
B/R
L Sb/W R
Sb/W B/R L R/L L/R

L/G
O B/R O O B/R O
L/R
L/W1 Sb L/Y R/L
B/Y

Sb
B B
B G B (BLUE)
Gy G G Gy
Lg Y/L
B B W W B
R/L B B B/R
(DARK GREEN)
B
B R R R/G B/R C
B R/W
L/Y Gy/R Gy/R
B R Gy1
Gy1
B/R Ch Dg Dg Ch
B B B (BLACK) A
B B B B B
(BLACK) B/R
L W/Y W L L
R O O A O
R R/W L W/Y O A O
O O
B/L
R Br/R B B B B B/L
L (BLACK) W/G W/G
ON R R
L/W Br/L Br/L B/R
OFF R
Br/L B/L Br/Y Br/Y
O L Y Y L
B R/W R/B
B/L B B R/B
Br/L R/B P/L
R B B
Br/R B L P/W
B B P/Y
B/R B/R
B/L
L L W/R B/L
Br W/R W/R B/G B/R
(BLACK) B/L
Br/W B/L
(BLACK)
R R/B
B1 B2 B Br Br D Br
G/R G/R G G G/R B/L
R Br/W Gy/R
G/Y Gy/G
B2 B1 Br B
R/L Gy/W
R R/B (BLACK)
B2 Y/G Y/G Gy
L Y/G B/L
B1 B/L B/Y G
BB4 Y/B
BB3
BB1 B/Br B3
W Gy
B B (DARK GRAY)
B B
G B G G W
BB3 BB2 W G
(GRAY)
W B W
Br/L Br
Br/L R/W
Br/G
Br Gy/G B/L
Br/L R/Y Gy/W

R/Y R/Y Sb/W
Br/W R/L
R/Y Br/G B
Br/W G/L B B
R/W Y/L
L/W1 R/Y Y/B W L
R/B B/R W/B R/W
Br/W (BLACK) R/G
Br/W G/L Y/B G
L L/Y Gy/W R/L B
R/Y G/L B
L (BLACK)
G/Y
(BLUE) B
B B (BLUE)
L L B B Lg
Y Y
B Br Y
Y G Dg Ch B
(BROWN)
Ch
Dg
L L Y
Dg Ch L
C C
L Y Y L
Dg Ch
B B
Ch Dg
Y/L R/G
L/R Y G Dg Y L Dg
Ch G B Lg
L B B G/R R/W Sb Ch
(BLACK)
(GRAY) (GRAY)
B Y G
B L/R B
B Ch B Dg B Dg B Ch
B B B B
G Y B B B
B L/R C C
B B

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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

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

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

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

VEHICLE IDENTIFICATION NUMBER

OUTLINE OF THE FI SYSTEM

1. Pressure regulator 13. Intake air pressure sensor

To set the clock: If the multi-function display indicates an error

3. Push the “SELECT” button, and the minute CAUTION:

1. Odometer/Tripmeter/Fuel reserve tripmeter

Brightness control mode

PREPARATION FOR REMOVAL AND

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS

CHECKING THE CONNECTIONS Pocket tester

Locknut wrench 3-5

Tappet adjusting tool 3-5

Vacuum gauge 3-6

Compression gauge 3-10

Oil filter wrench 3-12

Steering nut wrench 3-26, 4-58

Vacuum/pressure pump gauge set 4-5, 6-9

Fork spring compressor 4-49, 4-54

Rod holder 4-49, 4-54

Damper rod holder 4-50, 4-51

Rod puller 4-53, 4-54

Rod puller attachment (M10) 4-53, 4-54

Ring nut wrench 4-58

Pivot shaft wrench 5-13

Valve spring compressor 5-35, 5-40

Valve guide installer (ø6) 5-37

Valve guide reamer (ø6) 5-37

Piston pin puller set 5-43

Universal clutch holder 5-56, 5-59

Sheave holder 5-56, 5-58,

Rotor puller 5-69

Pressure gauge 6-9

Fuel pressure adapter 6-9

Digital circuit tester 6-10

Ignition checker 7-100

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 .................................... 2-27

LUBRICATION SYSTEM CHART AND DIAGRAMS.................................... 2-31

CABLE ROUTING ......................................................................................... 2-41

Spark plug (s)

Rocker arm/rocker arm shaft

Valve, valve seat, valve guide

Valve face width B (intake) 1.300–2.300 mm (0.0512–0.0906 in)