Yamaha Xmax

2013
SERVICE MANUAL
YP400R
1SD-F8197-E0
EAS20040
YP400R 2013
SERVICE MANUAL
©2013 by MBK Industrie
First edition, April 2013
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
MBK Industrie
is expressly prohibited.
EAS5WWL025
IMPORTANT
This manual was produced by MBK Industrie. primarily for use by Yamaha dealers and their qualified
mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, any-
one who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic
understanding of mechanics and the techniques to repair these types of vehicles. Repair and mainte-
nance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit
for use.
Yamaha Motor Company, Ltd. and MBK Industrie are continually striving to improve all of its models.
Modifications and significant changes in specifications or procedures will be forwarded to all authorized
Yamaha dealers and will appear in future editions of this manual where applicable.
TIP
Designs and specifications are subject to change without notice.
EAS20081
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential person-
al injury hazards. Obey all safety messages that follow this symbol to
avoid possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could

WARNING result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid

NOTICE damage to the vehicle or other property.
TIP A TIP provides key information to make procedures easier or clearer.

EAS20090
HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
is shown at the top of each page “1”.
• Sub-section titles appear in smaller print than the section title “2”.
• To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section “3”.
• Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassembly
step “4”.
• Symbols indicate parts to be lubricated or replaced “5”.
Refer to “SYMBOLS”.
• A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts,
notes in jobs, etc “6”.
• Jobs requiring more information (such as special tools and technical data) are described sequentially
“7”.
4
5
6 7
EAS20101
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil

G
Filling fluid Molybdenum disulfide oil

M
Lubricant Brake fluid

BF
Special tool B Wheel bearing grease
Tightening torque LS Lithium-soap-based grease

T.
R.
Wear limit, clearance M Molybdenum disulfide grease
Engine speed S Silicone grease
Electrical data Apply locking agent (LOCTITE®).

LT
Engine oil New Replace the part with a new one.

E
EAS20110
TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
COOLING SYSTEM 6
FUEL SYSTEM 7
ELECTRICAL SYSTEM 8
TROUBLESHOOTING 9
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1

VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL.......................................................................................... 1-1
FEATURES...................................................................................................... 1-2
1
OUTLINE OF THE FI SYSTEM.................................................................1-2
FI SYSTEM................................................................................................1-3
INSTRUMENT FUNCTIONS............................................................................1-4
IMPORTANT INFORMATION ......................................................................... 1-8

PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-8
REPLACEMENT PARTS...........................................................................1-8
GASKETS, OIL SEALS AND O-RINGS .................................................... 1-8
LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-8
BEARINGS AND OIL SEALS .................................................................... 1-9
CIRCLIPS ..................................................................................................1-9
BASIC SERVICE INFORMATION.................................................................1-10

QUICK FASTENERS............................................................................... 1-10
ELECTRICAL SYSTEM...........................................................................1-11
SPECIAL TOOLS .......................................................................................... 1-15

IDENTIFICATION
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the frame.
EAS20150
MODEL LABEL
The model label “1” is affixed to the location
shown. This information will be needed to order
spare parts.
1-1
FEATURES
EAS20170
FEATURES
EAS37P1140
OUTLINE OF THE FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum
air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In
the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion
chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the
respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies with the engine operating
conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter
the fuel through the use of jets have been provided with various auxiliary devices, so that an optimum
air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the
engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases increase,
it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accom-
modate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place
of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by
the engine at all times by using a microprocessor that regulates the fuel injection volume according to
the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response,
better fuel economy, and reduced exhaust emissions.
3 4 5 6 7,8,9 10
1
16 15 14 13 12 11
1. Air temperature sensor 13. Ignition coil

2. Engine trouble warning light 14. Fuel pump
3. ECU (engine control unit) 15. Lean angle sensor
4. Spark plug 16. Speed sensor
5. Fuel injector
6. Coolant temperature sensor
7. Intake air pressure sensor
8. Throttle position sensor
9. ISC (idle speed control) unit
10. Intake air temperature sensor
11. Crankshaft position sensor
12. O2 sensor
1-2
FEATURES
EAS37P1141
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 246–254 kPa (2.46–2.54 kgf/cm², 35.0–36.1 psi).
Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage
opens, causing the fuel to be injected into the intake manifold only during the time the passage remains
open. Therefore, the longer the length of time the fuel injector is energized (injection duration), the
greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is
energized (injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from the
throttle position sensor, coolant temperature sensor, lean angle sensor, crankshaft position sensor, in-
take air pressure sensor, intake air temperature sensor, speed sensor and O2 sensor enable the ECU
to determine the injection duration. The injection timing is determined through the signals from the
crankshaft position sensor. As a result, the volume of fuel that is required by the engine can be supplied
at all times in accordance with the driving conditions.
7
8
2 C
6 9
3 10
A 5
4
1 11
17 12
B
16
15
14
13
1. Fuel pump 14. Intake air pressure sensor

2. Pressure regulator 15. Throttle body
3. Fuel injector 16. Intake air temperature sensor
4. Ignition coil 17. Air filter case
A. Fuel system
6. ECU (engine control unit)
B. Air system
C. Control system
9. Lean angle sensor
10. Speed sensor
11. O2 sensor
12. Catalytic converter
1-3
INSTRUMENT FUNCTIONS
EAS37P1080
• a fuel reserve tripmeter (which shows the dis-
INSTRUMENT FUNCTIONS tance traveled since the bottom segment of the
fuel meter and fuel level warning indicator
Multi-function display started flashing)
EWA12312
• a self-diagnosis device
WARNING
• a clock
Be sure to stop the vehicle before making • an ambient temperature display
any setting changes to the multi-function • an oil change indicator
display. Changing settings while riding can • a V-belt replacement indicator
distract the operator and increase the risk of
TIP
an accident.
• Be sure to turn the key to “ON” before using the
“SELECT” and “RESET” buttons.
• When the key is turned to “ON”, all of the dis-
1
play segments of the multi-function display will
2 appear one after the other and then disappear,
in order to test the electrical circuit.
3 7 • For the UK, the distance traveled is displayed
4 in miles and the temperature reading is dis-
5 played in °C.
6 • For other countries, the distance traveled is
displayed in kilometers and the temperature
1. Clock reading is displayed in °C.
2. Ambient temperature display
3. Fuel meter Odometer and tripmeter modes
4. Odometer/tripmeters/fuel reserve tripmeter Pushing the “SELECT” button switches the dis-
5. “SELECT” button play between the odometer mode “Odo” and the
6. “RESET” button tripmeter modes “Trip” in the following order:
7. Coolant temperature meter Odo → Trip 1 → Trip 2 → Odo
When approximately 2.0 L (0.53 US gal, 0.44
Imp.gal) of fuel remains in the fuel tank, the bot-
1 2 3
tom segment of the fuel meter will start flashing,
and the display will automatically change to the
fuel reserve tripmeter mode “Trip F” and start
counting the distance traveled from that point. In
that case, pushing the “SELECT” button switch-
es the display between the various tripmeter and
odometer modes in the following order:
Trip F → Trip 1 → Trip 2 → Odo → Trip F
1. V-belt replacement indicator “V-BELT”

2. Oil change indicator “OIL CHANGE”
3. Frost warning indicator “ ”
The multi-function display is equipped with the
following:
• a fuel meter
• a coolant temperature meter
• an odometer 1
• two tripmeters (which show the distance trav-
eled since they were last set to zero) 1. Fuel reserve tripmeter
1-4
To reset a tripmeter, select it by pushing the “SE- 1. Turn the key to “ON”.
LECT” button until “Trip” or “Trip F”, push the 2. Hold the “OIL CHANGE” button pushed for
“RESET” button for at least one second. If you 15 to 20 seconds.
do not reset 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).
TIP
The display cannot be changed back to “Trip F”
after pushing the “RESET” button.
1
Fuel meter
With the key in the “ON” position, the fuel meter
indicates the amount of fuel in the fuel tank. The 1. “OIL CHANGE” button
display segments of the fuel meter disappear to-
3. Release the “OIL CHANGE” button, and the
wards “E” (Empty) as the fuel level decreases.
oil change indicator will go off.
When the fuel level reaches the bottom segment
TIP
near “E”, the bottom segment will flash. Refuel
as soon as possible. If the engine oil is changed before the oil change
indicator comes on (i.e. before the periodic oil
Coolant temperature meter change interval has been reached), the indicator
With the key in the “ON” position, the coolant must be reset after the oil change for the next
temperature meter indicates the temperature of periodic oil change to be indicated at the correct
the coolant. The coolant temperature varies with time. To reset the oil change indicator before the
changes in the weather and engine load. If the periodic oil change interval has been reached,
top segment and coolant temperature “C” “H” in- follow the above procedure, but note that the in-
dicator flash, stop the vehicle and let the engine dicator will come on for 1.4 seconds after releas-
cool. ing the “OIL CHANGE” button, otherwise repeat
the procedure.
The electrical circuit of the indicator can be
checked by turning the key to “ON”
The indicator comes on for a few seconds and
then goes off.
If the indicator does not come on, check the
electrical circuit.
Refer to “SIGNALING SYSTEM” on page 8-19.
TIP
The oil change indicator may flash when the en-
ECA10021
gine is revved with the scooter on the center-
NOTICE
stand, but this does not indicate a malfunction.
Do not continue to operate the engine if it is
overheating.
V-belt replacement indicator “V-BELT”
This indicator flashes every 20000 km (12500
Oil change indicator “OIL CHANGE” mi) when the V-belt needs to be replaced.
This indicator flashes at the initial 1000 km (600
mi), then at 5000 km (3000 mi) and every 5000
km (3000 mi) thereafter to indicate that the en-
gine oil should be changed.
After changing the engine oil, reset the oil
change indicator.
To reset the oil change indicator
1-5
To reset the V-belt replacement indicator If a problem is detected in the immobilizer sys-
1. Turn the key to “ON”. tem circuits, the immobilizer system indicator
2. Remove the fuse box cover and disconnect light will flash and the multi-function display will
the V-belt replacement reset coupler “1” for indicate a fault code when the key is turned to
two to ten seconds. “ON”.
TIP
If the multi-function display indicates fault code
1
52, this could be caused by transponder interfer-
ence. If this fault code appears, try the following.
3. And then, connect the V-belt replacement re-

set coupler, the V-belt replacement indicator
will come on for 1.4 seconds. 1
And the V-belt replacement indicator will go
off.
TIP 1. Fault code display
If the V-belt is replaced before the V-belt re- 1. Use the code re-registering key to start the
placement indicator comes on (i.e. before the V- engine.
belt replacement interval has been reached), the TIP
indicator must be reset after the V-belt replace- Make sure there are no other immobilizer keys
ment for the next periodic V-belt replacement to close to the main switch, and do not keep more
be indicated at the correct time. than one immobilizer key on the same key ring!
The electrical circuit of the indicator can be Immobilizer system keys may cause signal inter-
checked by turning the key to “ON” ference, which may prevent the engine from
If the indicator does not come on, check the starting.
electrical circuit. 2. If the engine starts, turn it off, and try starting
Refer to “SIGNALING SYSTEM” on page 8-19. the engine with the standard keys.
3. If one or both of the standard keys do not start
Self-diagnosis device
the engine, re-register the standard keys.
This model is equipped with a self-diagnosis de-
If the multi-function display indicates any fault
vice for various electrical circuits.
codes, note the code number, and then check
If a problem is detected in any of those circuits,
the vehicle.
the multi-function display will indicate a fault
Refer to “IMMOBILIZER SYSTEM” on page
code.
8-69.
If the multi-function display indicates a fault
code, note the code number, and then check the
vehicle.
Refer to “FUEL INJECTION SYSTEM” on page
8-31.
ECA1SD1022
NOTICE
If the multi-function display indicates a fault
code, the vehicle should be checked as soon
as possible in order to avoid engine damage.
The self-diagnosis device also detects problems
in the immobilizer system circuits.
1-6
Clock mode
To set the clock:
1. Push the “SELECT” button and “RESET” but-
ton together for at least two seconds.
2. When the hour digits start flashing, push the
“RESET” button to set the hours.
3. Push the “SELECT” button, and the minute
digits will start flashing.
4. Push the “RESET” button to set the minutes.
5. Push the “SELECT” button and then release
it to start the clock.
Ambient temperature display
2
1
1. Ambient temperature display

2. Frost warning indicator “ ”
This display shows the ambient temperature
from –9 °C to 50 °C in 1 °C increments. The tem-
perature displayed may vary from the ambient
temperature.
The frost warning indicator “ ” will flash when
the temperature is below 4 °C.
TIP
• If the ambient temperature falls below –9 °C, a
lower temperature than –9 °C will not be dis-
played.
• If the ambient temperature climbs above 50 °C,
a higher temperature than 50 °C will not be dis-
played.
• The accuracy of the temperature reading may
be affected when riding slowly (approximately
under 20 km/h (12.5 mi/h)) or when stopped at
traffic signals, railroad crossings, etc.
1-7
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 1-15.
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
After removal, replace all lock washers/plates
4. During disassembly, clean all of the parts and “1” and cotter pins. After the bolt or nut has been
place them in trays in the order of disassem- tightened to specification, bend the lock tabs
bly. This will speed up assembly and allow for along a flat of the bolt or nut.
the correct installation of all parts.
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.
1-8
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
NOTICE
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.
1-9
BASIC SERVICE INFORMATION
EAS30380

EAS30390
QUICK FASTENERS
Rivet type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, push its pin with a
screwdriver, then pull the fastener out. Screw type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, loosen the screw
with a screwdriver, then pull the fastener out.
2. Install:
• Quick fastener
TIP
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
the fastener into the part to be secured and push 2. Install:
the pin in with a screwdriver. Make sure that the • Quick fastener
pin is flush with the fastener’s head.
TIP
To install the quick fastener, insert the fastener
into the part to be secured and tighten the screw.
1-10
ECA16760
EAS30402
NOTICE
ELECTRICAL SYSTEM
Be sure to connect the battery leads to the
Electrical parts handling correct battery terminals. Reversing the bat-
ECA16600 tery lead connections could damage the
NOTICE electrical components.
Never disconnect a battery lead while the en-
gine is running; otherwise, the electrical
components could be damaged.
ECA16771
NOTICE
When connecting the battery leads to the
ECA16751 battery, be sure to connect the positive bat-
NOTICE tery lead first, then the negative battery lead.
When disconnecting the battery leads from If the negative battery lead is connected first
the battery, be sure to disconnect the nega- and a tool or similar item contacts the vehi-
tive battery lead first, then the positive bat- cle while the positive battery lead is being
tery lead. If the positive battery lead is connected, a spark could be generated,
disconnected first and a tool or similar item which is extremely dangerous.
contacts the vehicle, a spark could be gener-
ated, which is extremely dangerous.
ECA16610
NOTICE
Turn the main switch to “OFF” before dis-
TIP
connecting or connecting an electrical com-
If a battery lead is difficult to disconnect due to ponent.
rust on the battery terminal, remove the rust us-
ing hot water.
1-11
ECA16620
NOTICE Checking the electrical system

Handle electrical components with special TIP
care, and do not subject them to strong Before checking the electrical system, make
shocks. sure that the battery voltage is at least 12 V.
ECA16630 ECA14371
NOTICE NOTICE
Electrical components are very sensitive to Never insert the tester probes into the cou-
and can be damaged by static electricity. pler terminal slots. Always insert the probes
Therefore, never touch the terminals and be from the opposite end “a” of the coupler, tak-
sure to keep the contacts clean. ing care not to loosen or damage the leads.
ECA16640
TIP NOTICE
When resetting the ECU by turning the main
For waterproof couplers, never insert the
switch to “OFF”, be sure to wait approximately 5
tester probes directly into the coupler. When
seconds before turning the main switch back to
performing any checks using a waterproof
“ON”.
coupler, use the specified test harness or a
suitable commercially available test har-
ness.
1-12
2. Check:
Checking the connections • Lead
Check the leads, couplers, and connectors for • Coupler
stains, rust, moisture, etc. • Connector
1. Disconnect: Moisture → Dry with an air blower.
• Lead Rust/stains → Connect and disconnect sev-
• Coupler eral times.
• Connector
ECA16780
NOTICE
• When disconnecting a coupler, release the
coupler lock, hold both sections of the cou-
pler securely, and then disconnect the cou-
pler.
• There are many types of coupler locks;
therefore, be sure to check the type of cou-
pler lock before disconnecting the coupler.
3. Connect:
• Lead
• Coupler
• Connector
TIP
• When connecting a coupler or connector, push
both sections of the coupler or connector to-
gether until they are connected securely.
• Make sure all connections are tight.
ECA16790
NOTICE
When disconnecting a connector, do not pull
the leads. Hold both sections of the connec-
tor securely, and then disconnect the con-
nector.
1-13
TIP
The resistance values shown were obtained at
the standard measuring temperature of 20 °C
(68 °F). If the measuring temperature is not 20
°C (68 °F), the specified measuring conditions
will be shown.
Intake air temperature sensor re-

sistance
5.40–6.60 kΩ at 0 °C (32 °F)
4. Check: 290–390 Ω at 80 °C (176 °F)
• Continuity
(with the pocket tester)
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
TIP
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
5. Check:
• Resistance
Pocket tester
90890-03112
YU-03112-C
1-14
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.
TIP
• For U.S.A. and Canada, use part numbers starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part numbers starting with “90890-”.
Reference
Tool name/Tool No. Illustration
pages
Pocket tester 1-14, 8-83,
90890-03112 8-84, 8-85,
Analog pocket tester 8-89, 8-90,
YU-03112-C 8-91, 8-92,
8-93, 8-94,
8-95, 8-96,
8-97, 8-98,
8-99, 8-100
Valve lapper 3-6
90890-04101
Valve lapping tool
YM-A8998
FI diagnostic tool 3-9, 8-34

90890-03182
YU-03182
Steering nut wrench 3-16, 4-61

90890-01403
Exhaust flange nut wrench
YU-A9472
Damper rod holder 4-54, 4-56

90890-01294
Damping rod holder set
YM-01300
YM-01300
1-15
SPECIAL TOOLS
Reference
pages
T-handle 4-54, 4-56
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
Fork seal driver weight 4-56

90890-01367
Replacement hammer
YM-A9409-7
YM-A9409-7/YM-A5142-4
Fork seal driver attachment (ø38) 4-56

90890-01372
Replacement 38 mm
YM-A5142-1
Compression gauge 5-1

90890-03081
Engine compression tester
YU-33223
Yamaha bond No. 1215 5-14, 5-46,

90890-85505 5-57
(Three Bond No.1215®)
Valve spring compressor 5-20, 5-25

90890-04019
YM-04019
Valve spring compressor attachment 5-20, 5-25

90890-01243
Valve spring compressor adapter (26 mm)
YM-01253-1
Valve guide remover (ø5) 5-22

90890-04097
Valve guide remover (5.0 mm)
YM-04097
1-16
SPECIAL TOOLS
Reference
pages
Valve guide installer (ø5) 5-22
90890-04098
Valve guide installer (5.0 mm)
YM-04098
Valve guide reamer (ø5) 5-22

90890-04099
Valve guide reamer (5.0 mm)
YM-04099
Piston pin puller set 5-28

90890-01304
Piston pin puller
YU-01304
YU-01304
Rotor holding tool 5-35, 5-39,

90890-01235 5-40
Universal magneto & rotor holder
YU-01235
Sheave holder 5-35, 5-40,

90890-01701 5-44, 5-45,
Primary clutch holder 5-46
YS-01880-A
Locknut wrench 5-35, 5-39

90890-01348
YM-01348
1-17
SPECIAL TOOLS
Reference
pages
Sheave spring compressor 5-36, 5-39
90890-04134
YM-04134
Sheave fixed block 5-36, 5-39

90890-04135
Sheave fixed bracket
YM-04135
Oil seal guide (ø41) 5-38

90890-01396
Flywheel puller 5-44

90890-01362
Heavy duty puller
YU-33270-B
Flywheel puller attachment 5-44

90890-04155
Digital circuit tester 5-52, 8-93,

90890-03174 8-97
Model 88 Multimeter with tachometer
YU-A1927
1-18
SPECIAL TOOLS
Reference
pages
Plane bearing installer 5-60, 5-62
90890-04146
Radiator cap tester 6-2

90890-01325
Mityvac cooling system tester kit
YU-24460-A
YU-24460-A
Radiator cap tester adapter 6-2

90890-01352
Pressure tester adapter
YU-33984
YU-33984
Middle driven shaft bearing driver 6-8

90890-04058
Middle drive bearing installer 40 & 50 mm
YM-04058
Mechanical seal installer 6-8

90890-04145 ø30
ø10
Pressure gauge 7-3

90890-03153
YU-03153
1-19
SPECIAL TOOLS
Reference
pages
Fuel pressure adapter 7-3
90890-03181
YM-03181
Ignition checker 8-92

90890-06754
Oppama pet-4000 spark checker
YM-34487
Test harness- lean angle sensor (6P) 8-93

90890-03209
YU-03209
Test harness- speed sensor (3P) 8-95

90890-03208
YU-03208
Test harness- TPS 5RU (3P) 8-97

90890-03230
Test harness- TPS (3P) 8-97

90890-03204
YU-03204
1-20
SPECIAL TOOLS
1-21
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................2-2
CHASSIS SPECIFICATIONS ..........................................................................2-9
ELECTRICAL SPECIFICATIONS .................................................................2-12
TIGHTENING TORQUES .............................................................................. 2-15

2
GENERAL TIGHTENING TORQUE SPECIFICATIONS......................... 2-15
ENGINE TIGHTENING TORQUES......................................................... 2-16
CHASSIS TIGHTENING TORQUES.......................................................2-19
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-23

ENGINE................................................................................................... 2-23
CHASSIS.................................................................................................2-25
COOLING SYSTEM DIAGRAMS .................................................................. 2-27
CABLE ROUTING ......................................................................................... 2-31

GENERAL SPECIFICATIONS
EAS20280
GENERAL SPECIFICATIONS
Model
Model 1SD1
Dimensions
Overall length 2190 mm (86.2 in)
Overall width 780 mm (30.7 in)
Overall height 1385 mm (54.5 in)
Seat height 785 mm (30.9 in)
Wheelbase 1565 mm (61.6 in)
Ground clearance 103 mm (4.06 in)
Minimum turning radius 2500 mm (98.4 in)
Weight
Curb weight 211 kg (465 lb)
Maximum load 199 kg (439 lb)
2-1
ENGINE SPECIFICATIONS
EAS20291
Engine
Engine type Liquid cooled 4-stroke, DOHC
Displacement 395 cm³
Cylinder arrangement Single cylinder
Bore × stroke 83.0 × 73.0 mm (3.27 × 2.87 in)
Compression ratio 10.60 : 1
Standard compression pressure (at sea level) 1400 kPa/500 r/min (14.0 kgf/cm²/500 r/min,
199.1 psi/500 r/min)
Minimum-maximum 1100–1650 kPa (11.0–16.5 kgf/cm², 156.5–
234.7 psi)
Starting system Electric starter
Fuel
Recommended fuel Premium unleaded gasoline (Gasohol (E10)
acceptable)
Fuel tank capacity 14.8 L (3.91 US gal, 3.26 Imp.gal)
Fuel reserve amount 2.0 L (0.53 US gal, 0.44 Imp.gal)
Engine oil
Lubrication system Wet sump
Recommended brand YAMALUBE
Type SAE 10W-30, 10W-40, 10W-50, 15W-40, 20W-
40 or 20W-50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Engine oil quantity
Without oil filter element replacement 1.50 L (1.59 US qt, 1.32 Imp.qt)
With oil filter element replacement 1.70 L (1.80 US qt, 1.50 Imp.qt)
Final transmission oil

Type YAMALUBE 10W-40 or SAE 10W-30 type SE
motor oil
Quantity 0.25 L (0.26 US qt, 0.22 Imp.qt)
Oil filter
Oil filter type Paper
Oil pump
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance Less than 0.150 mm (0.0059 in)
Limit 0.23 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing clearance 0.010–0.034 mm (0.0005–0.0013 in)
Limit 0.104 mm (0.0041 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.040–0.096 mm (0.0016–0.0038 in)
Limit 0.166 mm (0.0065 in)
Cooling system
Radiator capacity (including all routes) 1.38 L (1.46 US qt, 1.21 Imp.qt)
Radiator capacity 1.07 L (1.13 US qt, 0.94 Imp.qt)
2-2
Coolant reservoir capacity (up to the maximum level

mark) 0.31 L (0.33 US qt, 0.27 Imp.qt)
Radiator cap opening pressure 110.0–140.0 kPa (1.10–1.40 kgf/cm², 15.6–19.9
psi)
Thermostat
Valve opening temperature 70.5–73.5 °C (158.9–164.3 °F)
Valve full open temperature 85.0 °C (185.0 °F)
Valve lift (full open) 3.0 mm (0.12 in)
Radiator core
Width 244.0 mm (9.61 in)
Height 164.0 mm (6.46 in)
Depth 24.0 mm (0.94 in)
Water pump
Water pump type Single suction centrifugal pump
Spark plug(s)
Manufacturer/model NGK/CR7E
Spark plug gap 0.7–0.8 mm (0.028–0.031 in)
Cylinder head
Combustion chamber volume 30.30–31.10 cm³ (1.85–1.90 cu.in)
Warpage limit 0.05 mm (0.0020 in)
Camshaft
Drive system Chain drive (right)
Camshaft cap inside diameter 24.500–24.521 mm (0.9646–0.9654 in)
Camshaft journal diameter 24.459–24.472 mm (0.9630–0.9635 in)
Camshaft-journal-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in)
Limit 0.080 mm (0.0032 in)
Camshaft lobe dimensions
Intake A 34.350–34.450 mm (1.3524–1.3563 in)
Limit 34.250 mm (1.3484 in)
Intake B 24.950–25.050 mm (0.9823–0.9862 in)
Limit 24.850 mm (0.9783 in)
Exhaust A 33.450–33.550 mm (1.3169–1.3209 in)
Limit 33.350 mm (1.3130 in)
Exhaust B 24.950–25.050 mm (0.9823–0.9862 in)
Limit 24.850 mm (0.9783 in)
AA
B
B
2-3
Camshaft runout limit 0.030 mm (0.0012 in)
Timing chain
Tensioning system Automatic
Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.15–0.20 mm (0.0059–0.0079 in)
Exhaust 0.25–0.30 mm (0.0098–0.0118 in)
Valve dimensions
Valve head diameter A (intake) 30.90–31.10 mm (1.2165–1.2244 in)
Valve head diameter A (exhaust) 27.90–28.10 mm (1.0984–1.1063 in)
A
Valve face width B (intake) 1.838–2.687 mm (0.0724–0.1058 in)
Valve face width B (exhaust) 1.697–2.828 mm (0.0668–0.1113 in)
Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in)

Limit 1.6 mm (0.06 in)
Valve seat width C (exhaust) 1.00–1.20 mm (0.0394–0.0472 in)
Valve margin thickness D (intake) 1.15–1.45 mm (0.0453–0.0571 in)

Valve margin thickness D (exhaust) 1.15–1.45 mm (0.0453–0.0571 in)
Valve stem diameter (intake) 4.975–4.990 mm (0.1959–0.1965 in)

Limit 4.945 mm (0.1947 in)
Valve stem diameter (exhaust) 4.960–4.975 mm (0.1953–0.1959 in)
Limit 4.930 mm (0.1941 in)
Valve guide inside diameter (intake) 5.000–5.012 mm (0.1969–0.1973 in)
Limit 5.050 mm (0.1988 in)
Valve guide inside diameter (exhaust) 5.000–5.012 mm (0.1969–0.1973 in)
Limit 5.050 mm (0.1988 in)
Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in)
2-4
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)
Valve stem runout 0.010 mm (0.0004 in)
Valve spring
Free length (intake) 46.45 mm (1.83 in)
Limit 44.13 mm (1.74 in)
Free length (exhaust) 46.45 mm (1.83 in)
Limit 44.13 mm (1.74 in)
Installed length (intake) 35.10 mm (1.38 in)
Installed length (exhaust) 35.10 mm (1.38 in)
Spring rate K1 (intake) 15.21 N/mm (1.55 kgf/mm, 86.85 lbf/in)
Spring rate K2 (intake) 19.84 N/mm (2.02 kgf/mm, 113.29 lbf/in)
Spring rate K1 (exhaust) 15.21 N/mm (1.55 kgf/mm, 86.85 lbf/in)
Spring rate K2 (exhaust) 19.84 N/mm (2.02 kgf/mm, 113.29 lbf/in)
Installed compression spring force (intake) 160.50–184.70 N (16.37–18.83 kgf, 36.08–
41.52 lbf)
Installed compression spring force (exhaust) 160.50–184.70 N (16.37–18.83 kgf, 36.08–
41.52 lbf)
Spring tilt (intake) 2.0 mm (0.08 in)
Spring tilt (exhaust) 2.0 mm (0.08 in)
Winding direction (intake) Counterclockwise

Winding direction (exhaust) Counterclockwise
Valve lifter
Valve lifter outside diameter (intake) 27.976–28.000 mm (1.1014–1.1024 in)
Limit 27.951 mm (1.1004 in)
Valve lifter outside diameter (exhaust) 27.976–28.000 mm (1.1014–1.1024 in)
Limit 27.951 mm (1.1004 in)
Cylinder
Bore 83.000–83.010 mm (3.2677–3.2681 in)
Warp limit 0.05 mm (0.0020 in)
Piston
Piston-to-cylinder clearance 0.060–0.075 mm (0.0024–0.0030 in)
Limit 0.15 mm (0.0059 in)
Diameter D 82.930–82.945 mm (3.2650–3.2655 in)
2-5
Height H 5.0 mm (0.20 in)
H
D
Offset 0.50 mm (0.0197 in)

Offset direction Intake side
Piston pin bore inside diameter 20.004–20.015 mm (0.7876–0.7880 in)
Limit 20.045 mm (0.7892 in)
Piston pin outside diameter 19.991–20.000 mm (0.7870–0.7874 in)
Limit 19.971 mm (0.7862 in)
Piston-pin-to-piston-pin-bore clearance 0.004–0.024 mm (0.0002–0.0009 in)
Piston ring
Top ring
Ring type Barrel
Dimensions (B × T) 1.00 × 2.70 mm (0.04 × 0.11 in)
B
T
End gap (installed) 0.20–0.35 mm (0.0079–0.0138 in)

Limit 0.50 mm (0.0197 in)
Ring side clearance 0.030–0.070 mm (0.0012–0.0028 in)
Limit 0.100 mm (0.0039 in)
2nd ring
Ring type Taper
B
T

Limit 0.80 mm (0.0315 in)
Limit 0.100 mm (0.0039 in)
Oil ring
B
T

Crankshaft
Width A 63.95–64.00 mm (2.518–2.520 in)
Runout limit C 0.030 mm (0.0012 in)
2-6
Big end side clearance D 0.350–0.850 mm (0.0138–0.0335 in)

Big end radial clearance E 0.010–0.024 mm (0.0004–0.0009 in)
C C
E
D
A
Journal oil clearance 0.030–0.077 mm (0.0012–0.0030 in)

Crankshaft journal diameter 35.008–35.017 mm (1.3783–1.3786 in)
Clutch
Clutch type Dry, centrifugal automatic
Automatic centrifugal clutch

Clutch shoe thickness 4.0 mm (0.16 in)
Clutch shoe spring free length 33.0 mm (1.30 in)
Clutch housing inside diameter 160.0 mm (6.30 in)
Limit 160.5 mm (6.32 in)
Compression spring free length 127.0 mm (5.00 in)
Limit 111.5 mm (4.39 in)
Weight outside diameter 25.0 mm (0.98 in)
Limit 24.5 mm (0.96 in)
Clutch-in revolution 1900–2500 r/min
Clutch-stall revolution 4000–5000 r/min
V-belt
V-belt width 30 mm (1.18 in)
Limit 27 mm (1.06 in)
Transmission
Transmission type V-belt automatic
Primary reduction ratio 1.000
Final drive Gear
Secondary reduction ratio 6.643 (31/14 × 42/14)
Operation Centrifugal automatic type
Gear ratio 2.384–0.763 :1
Air filter
Air filter element Oil-coated paper element
Air filter oil grade Yamaha foam air filter oil or other quality foam
air filter oil
Fuel pump
Pump type Electrical
Maximum consumption amperage 1.9 A
Output pressure 246–254 kPa (2.46–2.54 kgf/cm², 35.0–36.1 psi)
2-7
Fuel injector
Model/quantity 1100–87H90/1
Resistance 12.0 Ω
Throttle body
Type/quantity EFI 5RUG/1
ID mark 5RUG 20
Throttle position sensor

Output voltage (at idle) 0.40–0.90 V
Fuel injection sensor

Crankshaft position sensor resistance 228–342 Ω
Intake air pressure sensor output voltage 3.57–3.71 V
Intake air temperature sensor resistance 2.21–2.69 kΩ
Coolant temperature sensor resistance 2.32–2.59 kΩ at 20 °C (68 °F)
310–326 Ω at 80 °C (176 °F)
Idling condition
Engine idling speed 1400–1600 r/min
Intake vacuum 35.0–41.0 kPa (263–308 mmHg, 10.3–12.1
inHg)
Water temperature 80.0–90.0 °C (176.00–194.00 °F)
Oil temperature 70.0–80.0 °C (158.00–176.00 °F)
Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)
Air induction system

Solenoid resistance 18–22 Ω
2-8
CHASSIS SPECIFICATIONS
EAS20300
Chassis
Frame type Underbone
Caster angle 28.00°
Trail 102 mm (4.0 in)
Front wheel
Wheel type Cast wheel
Rim size 15 × MT3.50
Rim material Aluminum
Wheel travel 110.0 mm (4.33 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Wheel axle bending limit 0.25 mm (0.01 in)
Rear wheel
Wheel type Cast wheel
Rim size 13 × MT4.00
Rim material Aluminum
Wheel travel 92.0 mm (3.62 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 120/70–15M/C 56S
Manufacturer/model MICHELIN/CITY GRIP
Manufacturer/model SAVA/DIAMONDS MC28
Wear limit (front) 1.6 mm (0.06 in)
Rear tire
Type Tubeless
Size 150/70–13M/C 64S
Manufacturer/model MICHELIN/CITY GRIP
Manufacturer/model SAVA/DIAMONDS MC28
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 220 kPa (2.20 kgf/cm², 32 psi)
Rear 250 kPa (2.50 kgf/cm², 36 psi)
Loading condition 90–199 kg (198–439 lb)
Front 220 kPa (2.20 kgf/cm², 32 psi)
Rear 250 kPa (2.50 kgf/cm², 36 psi)
Front brake
Type Dual disc brake
Operation Right hand operation
Front disc brake
Disc outside diameter × thickness 267.0 × 4.0 mm (10.51 × 0.16 in)
Brake disc thickness limit 3.5 mm (0.14 in)
2-9
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 15.87 mm (0.62 in)
Caliper cylinder inside diameter 27.00 mm (1.06 in)
Specified brake fluid DOT 4
Rear brake
Type Single disc brake
Operation Left hand operation
Rear disc brake
Disc outside diameter × thickness 267.0 × 5.0 mm (10.51 × 0.20 in)
Brake disc thickness limit 4.5 mm (0.18 in)
Brake disc deflection limit 0.15 mm (0.0059 in)
Brake pad lining thickness (inner) 6.5 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 (1.06 in)
Specified brake fluid DOT 4
Steering
Steering bearing type Angular and taper roller bearing
Center to lock angle (left) 42.0°
Center to lock angle (right) 42.0°
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 110.0 mm (4.33 in)
Fork spring free length 303.1 mm (11.93 in)
Limit 297.0 mm (11.69 in)
Fork spring installed length 285.1 mm (11.22 in)
Spring rate K1 12.00 N/mm (1.22 kgf/mm, 68.52 lbf/in)
Spring stroke K1 0.0–77.0 mm (0.00–3.03 in)
Inner tube outer diameter 35.0 mm (1.38 in)
Inner tube bending limit 0.2 mm (0.01 in)
Optional spring available No
Recommended oil Fork oil 10W or equivalent
Quantity 130.0 cm³ (4.40 US oz, 4.59 Imp.oz)
Level 110.0 mm (4.33 in)
Rear suspension
Type Unit swing
Spring/shock absorber type Coil spring/oil damper
Rear shock absorber assembly travel 110.0 mm (4.33 in)
Spring free length 279.5 mm (11.00 in)
Limit 273.9 mm (10.78 in)
2-10
Spring installed length 263.5 mm (10.37 in)

Optional spring available No
Spring preload adjusting positions
Minimum (soft) 1
Standard 2
Maximum (hard) 4
Swingarm
Swingarm end free play limit (radial) 1.0 mm (0.04 in)
Swingarm end free play limit (axial) 1.0 mm (0.04 in)
2-11
ELECTRICAL SPECIFICATIONS
EAS20310
Voltage
System voltage 12 V
Ignition system
Ignition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 5.0°/1500 r/min
Engine control unit

Model/manufacturer 1SD1/YAMAHA MOTOR ELECTRONICS
Ignition coil
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
Standard output 14.0 V, 27.5 A at 5000 r/min
Stator coil resistance 0.232–0.348 Ω
Rectifier/regulator
Regulator type Semi conductor-short circuit
Regulated voltage (DC) 14.1–14.9 V
Rectifier capacity (DC) 35.0 A
Battery
Model GT9B-4
Voltage, capacity 12 V, 8.0 Ah
Specific gravity 1.330
Manufacturer GS YUASA
Ten hour rate charging current 0.80 A
Headlight
Bulb type Halogen bulb
Bulb voltage, wattage × quantity

Headlight 12 V, 55.0 W × 2
Auxiliary light LED
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
Meter lighting 12 V, 2.0 W × 3
Indicator light
Turn signal indicator light 12 V, 1.4 W × 2
2-12
High beam indicator light 12 V, 1.4 W × 1

Engine trouble warning light 12 V, 1.4 W × 1
Immobilizer system indicator light LED
Electric starting system

System type Constant mesh
Starter motor
Power output 0.65 kW
Armature coil resistance 0.0100–0.0140 Ω
Brush overall length 9.0 mm (0.35 in)
Limit 3.00 mm (0.12 in)
Brush spring force 7.75 N (790 gf, 27.90 oz)
Commutator diameter 24.0 mm (0.94 in)
Limit 22.4 mm (0.88 in)
Mica undercut (depth) 1.00 mm (0.04 in)
Starter relay
Amperage 180.0 A
Coil resistance 4.18–4.62 Ω
Horn
Horn type Plane
Quantity 1 pc
Maximum amperage 3.0 A
Turn signal/hazard relay

Relay type Full transistor
Built-in, self-canceling device No
Fuel sender unit

Sender unit resistance (full) 10.0–12.0 Ω
Sender unit resistance (empty) 137.0–143.0 Ω
Starting circuit cut-off relay

Radiator fan
Running rpm 4500 r/min
Fuses
Main fuse 30.0 A
Headlight fuse 20.0 A
Signaling system fuse 10.0 A
Ignition fuse 10.0 A
Radiator fan motor fuse 7.5 A
Turn signal/hazard fuse 10.0 A
ECU fuse 10.0 A
Backup fuse 10.0 A
Spare fuse 7.5 A
Spare fuse 10.0 A
Spare fuse 20.0 A
2-13
Spare fuse 30.0 A
2-14
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·kgf ft·lbf
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
2-15
TIGHTENING TORQUES
EAS20340
ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Camshaft cap bolt M6 8 10 Nm (1.0 m·kgf, 7.2 ft·lbf) E
Cylinder head plug M12 2 28 Nm (2.8 m·kgf, 20 ft·lbf) LT
Exhaust pipe stud bolt M8 2 13 Nm (1.3 m·kgf, 9.4 ft·lbf)

Spark plug M10 1 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Cylinder head timing chain cavity
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
bolt
Cylinder head and cylinder nut M10 2 40 Nm (4.0 m·kgf, 29 ft·lbf) E
Cylinder head cap nut M10 2 52 Nm (5.2 m·kgf, 38 ft·lbf) E
Cylinder head cover bolt M6 9 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Cylinder head cover bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil check bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Generator rotor nut M18 1 130 Nm (13 m·kgf, 94 ft·lbf) E
Camshaft sprocket M7 4 20 Nm (2.0 m·kgf, 14 ft·lbf)

Timing chain guide M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Timing chain tensioner assembly M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Timing chain tensioner cap bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Water pump cover M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Joint bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Thermostat cover M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Radiator filler neck M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Radiator pipe M6 2 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Radiator bracket bolt M6 2 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Radiator fan screw M4 4 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Coolant reservoir bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Heat exchanger M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Heat exchanger cover M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Coolant drain bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Coolant bleed screw M5 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Oil pump cover M3 1 1.0 Nm (0.10 m·kgf, 0.72 ft·lbf)
Oil pump bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Oil strainer cover M35 1 32 Nm (3.2 m·kgf, 23 ft·lbf)
Oil filter element cover M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Throttle body hose clamp M4 1 2.8 Nm (0.28 m·kgf, 2.0 ft·lbf)
Intake manifold M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Throttle body joint M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Fuel injector M6 1 12 Nm (1.2 m·kgf, 8.7 ft·lbf) LT
2-16
TIGHTENING TORQUES
Thread
size
Fuel hose holder bolt M5 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf) LT
Intake air pressure sensor M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Air filter case cap (left/right) M5 6 0.8 Nm (0.08 m·kgf, 0.60 ft·lbf)
Throttle body clamp screw M4 1 2.8 Nm (0.28 m·kgf, 2.0 ft·lbf)
Air filter case cover M5 11 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Air filter case M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Air filter joint clamp screw M4 1 2.8 Nm (0.28 m·kgf, 2.0 ft·lbf)
Muffler joint M8 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Muffler protector M6 2 8 Nm (0.8 m·kgf, 5.8 ft·lbf) LT
Muffler end cap M6 5 8 Nm (0.8 m·kgf, 5.8 ft·lbf) LT
Muffler end cap stay M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Exhaust pipe protector M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Exhaust pipe nut M8 2 20 Nm (2.0 m·kgf, 14 ft·lbf)

Air induction pipe and cylinder
M6 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
head
Air induction pipe stay M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Air induction assembly M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Muffler bolt M10 3 53 Nm (5.3 m·kgf, 38 ft·lbf) LT
V-belt case air duct M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf) LT
Left crankcase and right crank-

M6 7 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
case
M8 5 16 Nm (1.6 m·kgf, 12 ft·lbf)
case
M8 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
case
Cylinder stud bolt M10 4 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Final transmission oil drain bolt M8 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Bearing plate M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Transmission case cover and left

M8 7 16 Nm (1.6 m·kgf, 12 ft·lbf)
crankcase
V-belt case cover and left crank-
M8 1 22 Nm (2.2 m·kgf, 16 ft·lbf)
case
V-belt case cover and left crank-
M6 9 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
case
V-belt case air filter cover M6 4 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
V-belt case air filter element M6 4 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
V-belt case cover M6 6 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
V-belt case cover mole M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Generator rotor inner bracket M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf) LT
Generator cover M6 11 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
2-17
TIGHTENING TORQUES
Thread
size
Primary fixed sheave nut M18 1 83 Nm (8.3 m·kgf, 60 ft·lbf)
Timing mark accessing screw M16 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Engine oil drain bolt M12 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Secondary sheave nut M14 1 60 Nm (6.0 m·kgf, 43 ft·lbf)
Starter clutch M8 6 30 Nm (3.0 m·kgf, 22 ft·lbf) LT
Clutch carrier nut M36 1 90 Nm (9.0 m·kgf, 65 ft·lbf)

Stator coil M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Crankshaft position sensor M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Starter motor M6 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf)

Starter motor lead nut M6 1 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Starter motor terminal nut M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Starter motor bolt M5 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Coolant temperature sensor M12 1 18 Nm (1.8 m·kgf, 13 ft·lbf)
O2 sensor M18 1 45 Nm (4.5 m·kgf, 33 ft·lbf)
Camshaft cap tightening sequence
6 4 2 8
7 1 3 5
Cylinder head tightening sequence

6 5
4 1
2 3
2-18
TIGHTENING TORQUES
EAS20350
CHASSIS TIGHTENING TORQUES

Thread
size
Engine bracket and engine nut M12 1 65 Nm (6.5 m·kgf, 47 ft·lbf) LS
Engine bracket (center) bolt M10 4 56 Nm (5.6 m·kgf, 41 ft·lbf) LT
Engine bracket and frame nut M12 4 59 Nm (5.9 m·kgf, 43 ft·lbf)

Fuel tank bolt M6 3 14 Nm (1.4 m·kgf, 10 ft·lbf)
Fuel tank bracket bolt M6 4 13 Nm (1.3 m·kgf, 9.4 ft·lbf) LT
Fuel pump nut M6 6 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Seat bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Seat hinge bolt M6 2 9 Nm (0.9 m·kgf, 6.5 ft·lbf) LS
Seat damper pivot M8 1 23 Nm (2.3 m·kgf, 17 ft·lbf)

Storage box bolt M6 5 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Grab bar bolt M8 4 23 Nm (2.3 m·kgf, 17 ft·lbf)
Rear lower cover bolt M6 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Rear lower cover screw M5 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Center panel screw M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Center panel bolt M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Right center panel cover bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear panel and frame bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tail/brake light assembly screw M5 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Tail/brake light assembly screw M5 1 2.3 Nm (0.23 m·kgf, 1.7 ft·lbf)
Mudguard and frame bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Frame and mudguard bolt M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)

License plate light nut M5 2 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Rear reflector nut M5 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Front cowling bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front cowling and headlight as-
M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
sembly screw
Leg shield and front cowling M5 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Battery bracket bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Headlight assembly bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Windshield screw M5 6 0.4 Nm (0.04 m·kgf, 0.29 ft·lbf)
Windshield bracket bolt M8 3 23 Nm (2.3 m·kgf, 17 ft·lbf)
Radiator cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Bottom cover and radiator brack-

M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
et bolt
Relay holder bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Main switch cover screw M5 2 2.3 Nm (0.23 m·kgf, 1.7 ft·lbf)

Fuse box cover screw M5 1 2.3 Nm (0.23 m·kgf, 1.7 ft·lbf)
2-19
TIGHTENING TORQUES
Thread
size
Coolant reservoir cover screw M5 1 2.3 Nm (0.23 m·kgf, 1.7 ft·lbf)
Leg shield bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Footrest board bolt M6 6 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Sidestand nut M10 1 56 Nm (5.6 m·kgf, 41 ft·lbf) LT
Sidestand switch nut M5 2 8 Nm (0.8 m·kgf, 5.8 ft·lbf)

Front fender bolt M6 4 9 Nm (0.9 m·kgf, 6.5 ft·lbf) LT
Front wheel axle M16 1 59 Nm (5.9 m·kgf, 43 ft·lbf) LS
Front wheel axle pinch bolt M8 1 23 Nm (2.3 m·kgf, 17 ft·lbf)

Front brake disc bolt M6 10 12 Nm (1.2 m·kgf, 8.7 ft·lbf) LT
Rear wheel axle nut M14 1 135 Nm (13.5 m·kgf, 98 ft·lbf)

Rear brake disc bolt M8 3 23 Nm (2.3 m·kgf, 17 ft·lbf) LT
Front brake caliper bolt M10 4 40 Nm (4.0 m·kgf, 29 ft·lbf) LT
Front brake hose union bolt M10 3 23 Nm (2.3 m·kgf, 17 ft·lbf)

Front brake hose holder bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Front brake hose holder screw M5 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Front brake caliper bleed screw M7 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Front brake pad pin cap M8 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Front brake pad pin M8 1 18 Nm (1.8 m·kgf, 13 ft·lbf)
Rear brake caliper bolt M10 2 40 Nm (4.0 m·kgf, 29 ft·lbf)
Rear brake hose union bolt M10 2 23 Nm (2.3 m·kgf, 17 ft·lbf)
Rear brake hose holder bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear brake caliper bleed screw M7 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Rear brake caliper retaining bolt M10 2 40 Nm (4.0 m·kgf, 29 ft·lbf)
Upper handlebar holder bolt M8 4 23 Nm (2.3 m·kgf, 17 ft·lbf)
Front and rear brake master cyl-
M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
inder holder bolt
Front and rear brake master cyl-
M6 8 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
inder reservoir cap screw
Front and rear brake lever nut M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Handlebar switch screw M5 4 2.3 Nm (0.23 m·kgf, 1.7 ft·lbf)
Grip end M16 2 26 Nm (2.6 m·kgf, 19 ft·lbf)
Throttle cable and handlebar
M5 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
switch screw
Throttle cable and throttle body
M5 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
screw
Steering stem nut M20 1 120 Nm (12 m·kgf, 87 ft·lbf)
Upper ring nut M25 1 75 Nm (7.5 m·kgf, 54 ft·lbf)
Lower ring nut M25 1 See TIP
Lower bracket pinch bolt M8 4 23 Nm (2.3 m·kgf, 17 ft·lbf)
2-20
TIGHTENING TORQUES
Thread
size
Cap bolt M29 2 70 Nm (7.0 m·kgf, 51 ft·lbf)
Damper rod bolt M10 2 30 Nm (3.0 m·kgf, 22 ft·lbf) LT
Swingarm bolt M10 2 See TIP

Rear shock absorber assembly
M10 2 32 Nm (3.2 m·kgf, 23 ft·lbf)
nut (upper side)
M8 2 29 Nm (2.9 m·kgf, 21 ft·lbf)
bolt (lower side)
Ignition coil bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Ignition coil bracket bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
ECU (engine control unit) bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Lean angle sensor bolt M4 2 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Rectifier/regulator bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Main switch bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Immobilizer screw M5 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Battery terminal bolt M5 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Starter relay bracket bolt M6 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Starter relay terminal nut M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Horn bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
TIP
Ring nut
1. Tighten the lower ring nut 38 Nm (3.8 m·kgf, 27 ft·lbf) with a torque wrench and the steering nut
wrench, and then loosen the nut 1/4 turn.
2. Tighten the lower ring nut 22 Nm (2.2 m·kgf, 16 ft·lbf) with a torque wrench and the steering nut
wrench.
3. Install the rubber washer and the center ring nut.
4. Finger tighten the center ring nut, align the slots of both ring nuts, and then install the lock washer.
5. Hold the lower and center ring nuts, and then tighten the upper ring nut 75 Nm (7.5 m·kgf, 54 ft·lbf)
with a torque wrench and the steering nut wrench.
TIP
Swingarm mounting bolt
1. Temporarily install the rear wheel axle nut “1”.
2. Temporarily install the swingarm mounting bolt (upper side) “2”, then the swingarm mounting bolt
(lower side) “3”.
3. Tighten the rear wheel axle nut to 135 Nm (13.5 m·kgf, 98 ft·lbf).
4. Tighten the swingarm mounting bolt (upper side), then the swingarm mounting bolt (lower side) to
44 Nm (4.4 m·kgf, 32 ft·lbf).
2-21
TIGHTENING TORQUES
Swingarm tightening sequence:
1
3
2-22
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20360

EAS20370
ENGINE
Lubrication point Lubricant
Oil seal lips LS
O-rings LS
Bearings E
Cylinder head nut and washer E
Camshaft cap bolt E
Cylinder sleeve and O-ring Baby powder

Crankshaft pin E
Connecting rod big end thrust surface E
Balancer drive gear inner surface E
Crankshaft thrust surface E
Crankshaft journals E
Generator rotor nut and washer E
Piston and piston rings E
Piston pin E
Connecting rod small end E
Balancer impeller shaft end E
Balancer weight gear assembly E
Camshaft lobes and camshaft journals M
Valve stems (intake and exhaust) M
Valve stem seals (intake and exhaust) M
Valve stem ends (intake and exhaust) M
Valve lifter outer surface (intake and exhaust) E
Decompression exhaust camshaft, pin and spring lever part E
Impeller shaft E
Oil pump assembly E
Oil pump shafts E
O-ring and gasket (fuel injector assembly) E
Primary sheave collar Shell BT grease 3®

Primary sheave O-ring Shell BT grease 3®
Primary drive gear Shell BT grease 3®
Secondary sheave O-ring Shell BT grease 3®
Crankcase holder, union collar outer surface LS
Crankcase plain bearing outer surface E
Impeller shaft bearing LS
2-23

Starter clutch idle gear E
Starter clutch idle gear and shaft E
Starter clutch gear thrust surface E
Starter clutch gear E
Main axle thrust surfaces E
Main axle serration E or LS
Drive axle LS
Drive axle serration 1st wheel gear E
Drive axle bearing LS
Cylinder head straight screw plug LT
Yamaha bond No.

Semi circular plug 1215 (Three Bond
No. 1215®)
Water pump cover breather pipe LT
Yamaha bond No.

Crankcase mating surface 1215 (Three Bond
No. 1215®)
Crankcase cover breather pipe LT
Yamaha bond No.

Generator rotor cover (grommet mating surface) 1215 (Three Bond
No. 1215®)
Yamaha bond No.
Left crankcase cover and cover stay 1207B (Three Bond
No. 1207B®)
2-24
EAS20380
CHASSIS
Drive axle LS
Engine mounting bolt LS
Rear wheel axle nut LS
Swingarm oil seal lips LS
Steering bearings (upper and lower) LS
Seat hinge spacer and bolt LS
Seat lock sliding parts LS
Front wheel oil seal lip and front wheel axle LS
Speed sensor oil seal lip LS
Brake lever pivoting point and metal-to-metal moving parts S
Rear brake caliper retaining bolt S
Throttle cable end LS
Throttle grip inner surface and throttle cables LS
Handlebar grip inner surface Rubber adhesive

Sidestand pivoting point and metal-to-metal moving parts LS
Sidestand spring hook metal-to-metal moving parts LS
Centerstand shaft pivoting point and metal-to-metal moving parts LS
Centerstand spring hook metal-to-metal moving parts LS
Passenger footrest pivoting point LS
2-25
2-26
COOLING SYSTEM DIAGRAMS
EAS20420
1
4
2
8 7
4
3
1
8 9
2-27
1. Coolant reservoir overflow hose

2. Coolant reservoir hose
3. Coolant reservoir
4. Radiator cap
5. Radiator filler hose
6. Radiator
7. Radiator inlet hose
8. Radiator pipes
9. Radiator outlet hose
2-28
11
7 8
6
10
13
12
2
2-29
1. Radiator pipes
2. Heat exchanger outlet hose
3. Heat exchanger
4. Water pump outlet hose
5. Water pump cover
6. Water pump inlet hose
7. Thermostat inlet hose
8. Air bleed hose
9. Thermostat outlet hose
10. Thermostat
11. Thermostat cover
12. Water jacket inlet pipe
13. Heat exchanger
2-30
CABLE ROUTING
EAS20430
CABLE ROUTING
Frame (front view)
A 6
13
8
12
12
11
10
2-31
CABLE ROUTING
1. Fuse box
2. Battery
3. Positive battery lead
4. Negative battery lead
5. Starter relay
6. Left front turn signal light lead
7. Seat lock cable
8. Front brake hose
9. Horn
10. Fuel tank overflow hose
11. Wire harness
12. Speed sensor lead
13. Right front turn signal light lead
A. Route the front brake hose in front of the rear
brake hose.
2-32
CABLE ROUTING
Front brake (left side view)
1
C A
4 2 3
2-33
CABLE ROUTING
1. Front brake hose

2. Speed sensor lead
3. Front brake caliper
4. Speed sensor
A. Fasten the front brake hose with the holder on the
front fender.
B. Fasten the grommets on the speed sensor lead
with the holders.
C. Fasten the speed sensor lead to the front brake
hose with the holders. Align the holders with the
paint marks on the speed sensor lead.
2-34
CABLE ROUTING
Rear brake (right side view)
3
2
A 1
2-35
CABLE ROUTING
1. Rear brake hose

2. Rear brake caliper
3. Rear shock absorber assembly
A. Fasten the rear brake hose with the brake hose
holder.
2-36
CABLE ROUTING
Steering head (right side view)
1 2 3 16
15
14
13
12 5
7 6
11 9
9 4
4
4
9
10
2-37
CABLE ROUTING
1. Throttle cable
2. Front brake hose
3. Fuse box
4. Wire harness
5. Headlight lead
6. Starting circuit cut-off relay
7. Headlight relay
8. Radiator fan motor relay
9. Radiator fan motor lead
10. Radiator hose
11. Rectifier/regulator
12. Rear brake hose
13. Turn signal/hazard relay
14. Main switch
15. Right handlebar switch lead
16. Left handlebar switch lead
A. Route the handlebar switch leads to the inside of
the meter cover, and then fasten the leads with a
plastic locking tie.
2-38
CABLE ROUTING
Engine (right side view)
5
2
1
3
4 B
6
5
5
2-39
CABLE ROUTING
1. License plate light lead

2. Right tail/brake light lead
3. Seat lock cable
4. Right rear turn signal light lead
5. Wire harness
6. Rear brake hose
A. Fasten the grommets on the rear brake hose with
the holders.
B. Do not cut off the end of a plastic locking tie.
2-40
CABLE ROUTING
Steering head (left side view)
4 5
7 3
20 21 1 2
19
A 23
18 22
B
6
10
7
17 7
8 9
14
7
8 11
8
15
16
14
14 8
7
9 14
13 12
8
14
2-41
CABLE ROUTING

2. Rear brake hose
3. Throttle cable
5. Front brake hose
6. Main switch
7. Wire harness
8. Seat lock cable
9. Throttle cable
11. Horn
13. Fuel tank overflow hose
14. Starter motor lead
15. Left front turn signal light lead
16. Air temperature sensor
17. Headlight lead
18. Left auxiliary light lead
19. Negative battery lead
20. Ground lead
21. Starter relay
23. Connector housing
A. Front
B. Position the connector housing at the location
shown between the frame tubes.
2-42
CABLE ROUTING
Engine (left side view)
4
2 5
6
3
1 2 A
7 10 9
2-43
CABLE ROUTING
1. Rear brake hose

2. Seat lock cable
3. Wire harness
4. Left rear turn signal light lead
5. Left tail/brake light lead
8. Ground lead
9. Ignition coil
10. Throttle cable
A. Route the throttle cables through the guide.
2-44
CABLE ROUTING
Steering head (top view)
1 7
2 3 4 5 6 7 8 9 10
17 16 15 14 13 12 11
16
14
14
18
18
2-45
CABLE ROUTING
1. Front right turn signal light

3. Headlight relay
6. Fuse box
7. Wire harness
8. Front brake hose
10. Rear brake hose
11. Fuel hose
12. Fuel pump lead
15. Seat lock cable
16. Throttle cable
17. Front left turn signal light
18. Sidestand switch lead
2-46
CABLE ROUTING
Engine (top view)
1 2
5
4
7
8 5
11 10
7
12 9
13
4 6
3 7
2-47
CABLE ROUTING
1. Wire harness
2. Rear brake hose
3. Right rear turn signal light lead
4. Right tail/brake light lead
6. Left tail/brake light lead
7. Left rear turn signal light lead
8. Seat lock cable
9. Throttle body
10. Ground lead
12. Thermostat inlet hose
13. O2 sensor lead
2-48
CABLE ROUTING
2-49
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE ............................................................................3-1

INTRODUCTION .......................................................................................3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM ...................................................................................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART .......................3-1
CHECKING THE FUEL LINE .................................................................... 3-4
CHECKING THE SPARK PLUG ............................................................... 3-4
ADJUSTING THE VALVE CLEARANCE .................................................. 3-4
CHECKING THE THROTTLE BODY JOINT AND INTAKE MANIFOLD...3-7
CHECKING THE CRANKCASE BREATHER HOSE ................................3-7
CHECKING THE EXHAUST SYSTEM......................................................3-8
ADJUSTING THE EXHAUST GAS VOLUME ...........................................3-9
CHECKING THE AIR INDUCTION SYSTEM............................................3-9
REPLACING THE AIR FILTER ELEMENT ............................................. 3-10
CLEANING THE V-BELT CASE AIR FILTER ELEMENT .......................3-10
CHECKING THE BRAKE OPERATION .................................................. 3-11
3
CHECKING THE BRAKE FLUID LEVEL................................................. 3-11
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-12
CHECKING THE FRONT BRAKE PADS ................................................ 3-12
CHECKING THE REAR BRAKE PADS .................................................. 3-13
CHECKING THE FRONT BRAKE HOSES ............................................. 3-13
CHECKING THE REAR BRAKE HOSE .................................................. 3-13
CHECKING THE WHEELS ..................................................................... 3-13
CHECKING THE TIRES..........................................................................3-13
CHECKING THE WHEEL BEARINGS ....................................................3-15
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-15
CHECKING THE CHASSIS FASTENERS .............................................. 3-17
LUBRICATING THE LEVERS .................................................................3-17
CHECKING THE SIDESTAND................................................................3-17
LUBRICATING THE SIDESTAND........................................................... 3-17
CHECKING THE CENTERSTAND ......................................................... 3-17
LUBRICATING THE CENTERSTAND ....................................................3-17
CHECKING THE SIDESTAND SWITCH................................................. 3-17
CHECKING THE FRONT FORK ............................................................. 3-17
CHECKING THE REAR SUSPENSION.................................................. 3-17
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES .............. 3-18
CHECKING THE ENGINE OIL LEVEL....................................................3-18
CHANGING THE ENGINE OIL ...............................................................3-19
CHECKING THE COOLANT LEVEL.......................................................3-20
CHECKING THE COOLING SYSTEM ....................................................3-21
CHANGING THE COOLANT................................................................... 3-21
CHANGING THE FINAL TRANSMISSION OIL....................................... 3-23
REPLACING THE V-BELT ...................................................................... 3-24
CHECKING THE BRAKE LIGHT SWITCHES.........................................3-24
CHECKING AND LUBRICATING THE CABLES .................................... 3-24
LUBRICATING THE REAR SUSPENSION............................................. 3-24
CHECKING THE THROTTLE GRIP OPERATION .................................3-24
CHECKING THE SWITCHES, LIGHTS AND SIGNALS ......................... 3-25
ADJUSTING THE HEADLIGHT BEAM ...................................................3-25
REPLACING THE HEADLIGHT BULB....................................................3-25
PERIODIC MAINTENANCE
EAS20450
EAS20460
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a long-
er service life and reduce the need for costly overhaul work. This information applies to vehicles already
in service as well as to new vehicles that are being prepared for sale. All service technicians should be
familiar with this entire chapter.
EAU46910
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

TIP
• The annual checks must be performed every year, except if a kilometer-based maintenance,
or for the UK, a mileage-based maintenance, is performed instead.
• From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
ODOMETER READING
CHECK OR MAINTENANCE ANNUAL
NO. ITEM JOB CHECK
1000 km 10000 km 20000 km 30000 km 40000 km
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
• Check fuel hoses for cracks or

1 * Fuel line damage. √ √ √ √ √
• Check condition. √ √
2 Spark plug • Clean and regap.
• Replace. √ √
3 * Valves • Check valve clearance. Every 40000 km (24000 mi)

• Adjust.
4 * Fuel injection • Check engine idle speed. √ √ √ √ √ √
5 * Muffler and ex- • Check the screw clamp(s) for √ √ √ √ √

haust pipe looseness.
• Check the air cut-off valve,
Air induction sys- reed valve, and hose for dam-
6 * age. √ √ √ √ √
tem • Replace any damaged parts if
necessary.
EAU1770F
GENERAL MAINTENANCE AND LUBRICATION CHART

TIP
• The annual checks must be performed every year, except if a kilometer-based maintenance,
or for the UK, a mileage-based maintenance, is performed instead.
• From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE ANNUAL
JOB 1000 km 10000 km 20000 km 30000 km 40000 km CHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
1 Air filter elements • Replace. √ √

V-belt case air fil-
2 ter element • Clean. √ √ √ √ √
• Check operation, fluid level √ √ √ √ √ √

3 * Front brake and vehicle for fluid leakage.
• Replace brake pads. Whenever worn to the limit
3-1
ODOMETER READING
CHECK OR MAINTENANCE ANNUAL
NO. ITEM
JOB 1000 km 10000 km 20000 km 30000 km 40000 km CHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
• Check operation, fluid level

√ √ √ √ √ √
4 * Rear brake and vehicle for fluid leakage.
• Replace brake pads. Whenever worn to the limit
• Check for cracks or damage.
• Check for correct routing and √ √ √ √ √
5 * Brake hoses clamping.
• Replace. Every 4 years
6 * Brake fluid • Replace. Every 2 years
7 * Wheels • Check runout and for damage. √ √ √ √
• Check tread depth and for
damage.
8 * Tires • Replace if necessary. √ √ √ √ √
• Check air pressure.
• Correct if necessary.
• Check bearing for looseness
9 * Wheel bearings √ √ √ √
or damage.
• Check bearing play and steer-
ing for roughness. √ √ √ √ √
10 * Steering bearings
• Lubricate with lithium-soap- Every 20000 km (12000 mi)
based grease.
• Make sure that all nuts, bolts
11 * Chassis fasteners and screws are properly tight- √ √ √ √ √
ened.
Front brake lever
12 • Lubricate with silicone grease. √ √ √ √ √
pivot shaft
Rear brake lever
13 pivot shaft • Lubricate with silicone grease. √ √ √ √ √
Sidestand, center- • Check operation.

14 • Lubricate with lithium-soap- √ √ √ √ √
stand based grease.
15 * Sidestand switch • Check operation. √ √ √ √ √ √
• Check operation and for oil
16 * Front fork leakage. √ √ √ √
17 * Shock absorber • Check operation and shock √ √ √ √

assemblies absorbers for oil leakage.
• Change. √ When the oil change indicator flashes
18 Engine oil • Check oil level and vehicle for Every 5000 km (3000 mi) √
oil leakage.
Engine oil filter el-
19 • Replace. √ √ √
ement
• Check coolant level and vehi-
cle for coolant leakage. √ √ √ √ √
20 * Cooling system
• Change coolant. Every 3 years
Final transmis- • Check vehicle for oil leakage. √ √ √

21 sion oil • Change. √ √ √ √ √ √
22 * V-belt • Replace. When the V-belt replacement indicator flashes [every 20000 km (12500
mi)]
Front and rear
23 * • Check operation. √ √ √ √ √ √
brake switches
Moving parts and
24 cables • Lubricate. √ √ √ √ √
• Check operation.
• Check throttle grip free play,
25 * Throttle grip and adjust if necessary. √ √ √ √ √
• Lubricate cable and grip hous-
ing.
26 * Lights, signals • Check operation. √ √ √ √ √ √

and switches • Adjust headlight beam.
3-2
EAU34491
TIP
• Engine air filters and V-belt air filter
• This model’s engine air filters are equipped with disposable oil-coated paper elements, which must
not be cleaned with compressed air to avoid damaging them.
• The engine air filter elements need to be replaced and the V-belt air filter element needs to be ser-
viced more frequently when riding in unusually wet or dusty areas.
• Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-3
EAS21030
CHECKING THE FUEL LINE

1. Remove:
• Storage box
Refer to “GENERAL CHASSIS” on page 4-1.
2. Check:
• Fuel hose “1”
Cracks/damage → Replace.
Loose connections → Connect properly.
5. Clean:
• Spark plug
(with a spark plug cleaner or wire brush)
6. Measure:
• Spark plug gap “a”
1 (with a wire thickness gauge)
Out of specification → Regap.
Spark plug gap

3. Install: 0.7–0.8 mm (0.028–0.031 in)
• Storage box
EAS20690
CHECKING THE SPARK PLUG

1. Remove:
• Storage box
• Spark plug cap
2. Remove:
• Spark plug
ECA13330
NOTICE 7. Install:
Before removing the spark plug, blow away • Spark plug
any dirt accumulated in the spark plug well
Spark plug
with compressed air to prevent it from falling 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
T.
into the cylinder.

R.
3. Check: TIP
• Spark plug type Before installing the spark plug, clean the spark
Incorrect → Change. plug and gasket surface.
Manufacturer/model 8. Install:
NGK/CR7E • Spark plug cap
• Storage box
4. Check: Refer to “GENERAL CHASSIS” on page 4-1.
• Electrode “1”
Damage/wear → Replace the spark plug.
EAS20510
ADJUSTING THE VALVE CLEARANCE

• Insulator “2” The following procedure applies to all of the
Abnormal color → Replace the spark plug. valves.
Normal color is medium-to-light tan.
TIP
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
3-4
• When the valve clearance is to be measured or

adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
1. Remove:
• Storage box
• V-belt case cover mole
• Left air filter case cover
• V-belt case air filter cover “1”
• V-belt case air filter element
TIP
• TDC on the compression stroke can be found
when the camshaft lobes are turned away from
1 each other.
• In order to be sure that the piston is at TDC, the
match marks “c” on the intake camshaft
sprocket and the match marks “d” on the ex-
haust camshaft sprocket must align with the
cylinder head mating surface as shown in the
illustration.
2. Remove:
• Timing mark accessing screw
• Spark plug
• Rubber sheet
• Cylinder head cover
• Cylinder head cover gasket
Refer to “CAMSHAFTS” on page 5-7.
3. Measure: c d
• Valve clearance
Out of specification → Adjust.
Valve clearance (cold) c. Measure the valve clearance with a thickness

Intake gauge “1”.
0.15–0.20 mm (0.0059–0.0079 in)
Exhaust
0.25–0.30 mm (0.0098–0.0118 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise by
turning the primary sheave nut.
b. When the piston is at TDC on the compres-
sion stroke, align the mark “a” on the genera- 1
tor rotor with the mark “b” on the generator
cover.
TIP
If the valve clearance is incorrect, record the
measured reading.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Remove:
• Intake camshaft
• Exhaust camshaft
3-5
TIP b. Calculate the difference between the speci-

• Refer to “CAMSHAFTS” on page 5-7. fied valve clearance and the measured valve
• When removing the timing chain and cam- clearance.
shafts, fasten the timing chain with a wire to re- Example:
trieve it if it falls into the crankcase. Specified valve clearance = 0.15–0.20 mm
(0.0059–0.0079 in)
5. Adjust: Measured valve clearance = 0.23 mm
• Valve clearance (0.0091 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 0.23 mm (0.0091 in) - 0.20 mm (0.0079 in) =
a. Remove the valve lifter “1” and the valve pad
0.03 mm (0.001 in)
“2” with a valve lapper “3”.
c. Check the thickness of the current valve pad.
TIP
The thickness “a” of each valve pad is marked in
hundredths of millimeters on the side that touch-
es the valve lifter.
Example:
If the valve pad is marked “155”, the pad
thickness is 1.55 mm (0.061 in).
Valve lapper
90890-04101
Valve lapping tool
YM-A8998
TIP
• Cover the timing chain opening with a rag to
prevent the valve pad from falling into the d. Calculate the sum of the values obtained in
crankcase. steps (b) and (c) to determine the required
• Make a note of the position of each valve lifter valve pad thickness and the valve pad num-
“1” and valve pad “2” so that they can be in- ber.
stalled in the correct place. Example:
1.55 mm (0.061 in) + 0.03 mm (0.001 in) =
1.58 mm (0.062 in)
The valve pad number is 158.
e. Round off the valve pad number according to
the following table, and then select the suit-
able valve pad.
3-6
Last digit Rounded value • Align the camshaft sprocket marks with the
edge of the cylinder head.
0, 1, 2 0 • Turn the crankshaft counterclockwise several
3, 4, 5, 6 5 full turns to seat the parts.
7, 8, 9 10 h. Measure the valve clearance again.
i. If the valve clearance is still out of specifica-
TIP tion, repeat all of the valve clearance adjust-
Refer to the following table for the available ment steps until the specified clearance is
valve pads. obtained.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Valve pad range No. 120–240
6. Install:
1.20–2.40 mm • All removed parts
Valve pad thickness
(0.0472–0.0945 in)
TIP
25 thicknesses in For installation, reverse the removal procedure.
Available valve pads 0.05 mm (0.002 in)
increments EAS21020
CHECKING THE THROTTLE BODY JOINT

Example:
AND INTAKE MANIFOLD
Valve pad number = 158
1. Remove:
Rounded value = 160
• Storage box
New valve pad number = 160
f. Install the new valve pad “1” and the valve lift-
2. Check:
er “2”.
• Throttle body joint “1”
• Intake manifold “2”
1
2
1
2
TIP
• Lubricate the valve pad with molybdenum dis-
ulfide grease. 3. Install:
• Lubricate the valve lifter with engine oil. • Storage box
• The valve lifter must turn smoothly when rotat- Refer to “GENERAL CHASSIS” on page 4-1.
ed by hand.
• Install the valve lifter and the valve pad in the EAS21070
correct place. CHECKING THE CRANKCASE BREATHER

HOSE
g. Install the exhaust and intake camshafts, tim- 1. Remove:
ing chain and the camshaft cap. • Storage box
Camshaft cap bolt 2. Check:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
• Crankcase breather hose “1”

R.
• Transmission breather hose “2”

TIP
• Refer to “CAMSHAFTS” on page 5-7. Loose connections → Connect properly.
• Lubricate the camshaft lobes and camshaft
journals.
• First, install the exhaust camshaft.
3-7
ECA13450
• Bottom cover
NOTICE Refer to “GENERAL CHASSIS” on page 4-1.
Make sure the crankcase breather hose is 2. Check:
routed correctly. • Exhaust pipe “1”
3. Remove: • Muffler “2”
• Catch tank “3” Cracks/damage → Replace.
• Gaskets “3”, “4”
Exhaust gas leaks → Replace.
3. Check:
3 Tightening torque
• Exhaust pipe nuts “5”
• Exhaust pipe and muffler bolt “6”
• Muffler bolts “7”
• O2 sensor “8”
1
Exhaust pipe nut
20 Nm (2.0 m·kgf, 14 ft·lbf)
T.
R.
Exhaust pipe and muffler bolt
20 Nm (2.0 m·kgf, 14 ft·lbf)
Muffler bolt
53 Nm (5.3 m·kgf, 38 ft·lbf)
2 O2 sensor
45 Nm (4.5 m·kgf, 33 ft·lbf)
4. Clean:
• Catch tank 8
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 3
a. Thoroughly flush out the catch tank with
clean water.
b. Hold the catch tank upside down to allow the
1
water to drain out. 4
5
c. Repeat the flushing steps until the excess
water is clear and free of debris.
d. Place the catch tank in an upright position to 2
6
allow any remaining water to drain out of the
lower drain tube.
e. Keep the catch tank upright to allow it to dry
sufficiently.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install: 7
• Catch tank
6. Install:
4. Install:
• Storage box
• Bottom cover
• Right center panel cover
EAS21080 Refer to “GENERAL CHASSIS” on page 4-1.
CHECKING THE EXHAUST SYSTEM
1. Remove:
• Right center panel cover
3-8
EAS20600
6. Press the “UP” button to select the CO adjust-
ADJUSTING THE EXHAUST GAS VOLUME
ment mode “CO” or the diagnostic mode “DI-
TIP AG”.
Be sure to set the CO density level to standard, 7. After selecting “CO”, press the “MODE” but-
and then adjust the exhaust gas volume. ton.
1. Remove: 8. Check that “C1” appears on the LCD of the FI
• Battery cover diagnostic tool, and then press the “MODE”
Refer to “GENERAL CHASSIS” on page 4-1. button.
2. Turn the main switch to “OFF”. 9. Start the engine.
ECA37P1015
3. Disconnect: NOTICE
• Self-diagnosis signal coupler
Perform the adjustment after the battery has
4. Connect:
been sufficiently charged.
• FI diagnostic tool “1”
FI diagnostic tool
90890-03182
YU-03182 FI Diagnostic Tool
1550rpm
C1 : -10
1
10.Change the CO adjustment volume by press-
ing the “UP” and “DOWN” buttons.
TIP
The CO adjustment volume and engine idling
5. While pressing the “MODE” button “1”, turn speed appears on the LCD of the FI diagnostic
the main switch to “ON”. tool.
TIP • To decrease the CO adjustment volume, press
the “DOWN” button.
• “DIAG” appears on the LCD “2” of the FI diag-
• To increase the CO adjustment volume, press
nostic tool.
the “UP” button.
• “POWER” LED (Green) “3” comes on.
11.Release the “DOWN” and “UP” buttons to ex-
ecute the selection.
3 12.Set the main switch to “OFF” to cancel the
FI Diagnostic Tool mode.
2 13.Disconnect:
DIAG • FI diagnostic tool
14.Connect:
1 • Self-diagnosis signal coupler
15.Install:
• Fuse box cover
EAS1SD1003
CHECKING THE AIR INDUCTION SYSTEM

Refer to “CHECKING THE AIR INDUCTION
SYSTEM” on page 7-14.
3-9
EAS20960
REPLACING THE AIR FILTER ELEMENT

1. Remove:
• Left air filter case cover “1”
• Right air filter case cover “2” 2
• Air filter elements
3. Install:
• Air filter elements
• Air filter case covers
ECA1SD1002
NOTICE
Never operate the engine without the air filter
element installed. Unfiltered air will cause
rapid wear of engine parts and may damage
the engine. Operating the engine without the
air filter element will also affect throttle body
2 turning, leading to poor engine performance
and possible overheating.
TIP
When installing the air filter element into the air
filter case cover, make sure that the sealing sur-
2. Check: faces are aligned to prevent any air leaks.
• Left air filter element “1”
EAS20980
• Right air filter element “2” CLEANING THE V-BELT CASE AIR FILTER
Damage → Replace. ELEMENT
TIP 1. Remove:
• Replace the air filter element every 20000 km • V-belt case cover mole
(12000 mi) of operation. • Left air filter case cover
• The air filter needs more frequent service if you • V-belt case air filter cover “1”
are riding in unusually wet or dusty areas. • V-belt case air filter element
• Do not clean by blowing the compression air.
2. Clean:
• V-belt case air filter element “1”
Blow compressed air onto the outer surface
of the V-belt case air filter element.
3-10
2. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the
1 specified brake fluid to the proper level.
Specified brake fluid

DOT 4
A
a
3. Check:
Damage → Replace.
ECA13440
NOTICE
Since the V-belt case air filter element is a
dry type, do not let grease or water contact it.
4. Install:
• V-belt case air filter element B
• V-belt case air filter cover
a
V-belt case air filter cover screw
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
T.
R.
5. Install:
• Left air filter case cover
• V-belt case cover mole
EAS30921
CHECKING THE BRAKE OPERATION A. Front brake

1. Check: B. Rear brake
• Brake operation
Brake not working properly → Check the
EWA1SD1001
WARNING
brake system.
Refer to “FRONT BRAKE” on page 4-25 and • Use only the designated brake fluid. Other
“REAR BRAKE” on page 4-37. brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
TIP
brake performance.
Drive on the road, operate the front and rear • Refill with the same type of brake fluid that
brakes separately and check to see if the brakes is already in the system. Mixing brake fluids
are operating properly. may result in a harmful chemical reaction,
leading to poor brake performance.
EAS21240
• When refilling, be careful that water does
CHECKING THE BRAKE FLUID LEVEL
not enter the brake master cylinder reser-
1. Stand the vehicle on a level surface.
voir. Water will significantly lower the boil-
TIP
ing point of the brake fluid and could cause
• Place the vehicle on the centerstand. vapor lock.
• Make sure the vehicle is upright. ECA13540
• In order to ensure a correct reading of the NOTICE
brake fluid level, make sure the top of the brake
Brake fluid may damage painted surfaces
fluid reservoir is horizontal.
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
3-11
EAS21350
BLEEDING THE HYDRAULIC BRAKE B 2

SYSTEM
EWA1SD1002
1
WARNING
Bleed the hydraulic brake system whenever:
• the system is disassembled.
• a brake hose is loosened, disconnected or
replaced.
• the brake fluid level is very low.
• the brake operation is faulty.
TIP A. Front brake caliper
• Be careful not to spill any brake fluid or allow B. Rear brake caliper
the brake master cylinder reservoir to overflow. d. Place the other end of the hose into a con-
• When bleeding the hydraulic brake system, tainer.
make sure there is always enough brake fluid e. Slowly apply the brake several times.
before applying the brake. Ignoring this pre- f. Fully pull the brake lever and hold it in posi-
caution could allow air to enter the hydraulic tion.
brake system, considerably lengthening the g. Loosen the bleed screw.
bleeding procedure.
TIP
• If bleeding is difficult, it may be necessary to let
Loosening the bleed screw will release the pres-
the brake fluid settle for a few hours. Repeat
the bleeding procedure when the tiny bubbles sure and cause the brake lever to contact the
throttle grip.
in the hose have disappeared.
h. Tighten the bleed screw and then release the
1. Bleed:
brake lever.
• Hydraulic brake system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
i. Repeat steps (e) to (h) until all of the air bub-
a. Fill the brake master cylinder reservoir to the bles have disappeared from the brake fluid in
proper level with the recommended brake flu- the plastic hose.
id. j. Tighten the bleed screw to specification.
b. Install the diaphragm (brake master cylinder
Brake caliper bleed screw
reservoir).
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
T.
c. Connect a clear plastic hose “1” tightly to the

R.
bleed screw “2”. k. Fill the brake master cylinder reservoir to the
A
proper level with the specified brake fluid.
1 Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-11.
EWA13110
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2 EAS21250
CHECKING THE FRONT BRAKE PADS

The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check:
• Front brake pad
Wear indicator grooves “a” almost disap-
peared → Replace the brake pads as a set.
Refer to “FRONT BRAKE” on page 4-25.
3-12
3. Hold the vehicle upright and apply the front

brake several times.
4. Check:
• Brake hose
Brake fluid leakage → Replace the damaged
a a hose.
Refer to “FRONT BRAKE” on page 4-25.
EAS21290
CHECKING THE REAR BRAKE HOSE

1. Check:
EAS21260
• Brake hose “1”
CHECKING THE REAR BRAKE PADS Cracks/damage/wear → Replace.
brake pads. 1
1. Operate the brake.
2. Check:
• Rear brake pad
Wear indicator grooves “a” almost disap-
peared → Replace the brake pads as a set.
Refer to “REAR BRAKE” on page 4-37.
2. Check:
• Brake hose holder
Loose → Tighten the holder bolt.
3. Hold the vehicle upright and apply the rear
a a brake several times.
4. Check:
• Brake hose
Brake fluid leakage → Replace the damaged
EAS21280 hose.
CHECKING THE FRONT BRAKE HOSES Refer to “REAR BRAKE” on page 4-37.
1. Check:
EAS21670
• Brake hoses “1”
CHECKING THE WHEELS
Cracks/damage/wear → Replace.
The following procedure applies to born of the
wheels.
1. Check:
1 • Wheel
Damage/out-of-round → Replace.
EWA13260
WARNING
Never attempt to make any repairs to the
wheel.
TIP
After a tire or wheel has been changed or re-
2. Check:
placed, always balance the wheel.
• Brake hose holders
Loose → Tighten the holder bolt.
EAS21660
CHECKING THE TIRES

The following procedure applies to both of the
tires.
3-13
1. Check:
• Tire pressure
Out of specification → Regulate.
1. Tire tread depth

2. Side wall
3. Wear indicator
EWA13180
WARNING
Wear limit (front)
• The tire pressure should only be checked
1.6 mm (0.06 in)
and regulated when the tire temperature Wear limit (rear)
equals the ambient air temperature. 1.6 mm (0.06 in)
• The tire pressure and the suspension must
be adjusted according to the total weight EWA14080
(including cargo, rider, passenger and ac- WARNING

cessories) and the anticipated riding • Do not use a tubeless tire on a wheel de-
speed. signed only for tube tires to avoid tire fail-
• Operation of an overloaded vehicle could ure and personal injury from sudden
cause tire damage, an accident or an injury. deflation.
NEVER OVERLOAD THE VEHICLE. • When using a tube tire, be sure to install the
correct tube.
Tire air pressure (measured on • Always replace a new tube tire and a new
cold tires) tube as a set.
Loading condition • To avoid pinching the tube, make sure the
0–90 kg (0–198 lb) wheel rim band and tube are centered in the
Front wheel groove.
220 kPa (2.20 kgf/cm², 32 psi) • Patching a punctured tube is not recom-
Rear mended. If it is absolutely necessary to do
250 kPa (2.50 kgf/cm², 36 psi) so, use great care and replace the tube as
Loading condition
soon as possible with a good quality re-
90–199 kg (198–439 lb)
Front placement.
220 kPa (2.20 kgf/cm², 32 psi)
Rear
250 kPa (2.50 kgf/cm², 36 psi)
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- A. Tire
place the tire immediately. B. Wheel
2. Check:
Tube wheel Tube tire only
• Tire surfaces
Damage/wear → Replace the tire. Tubeless wheel Tube or tubeless tire
3-14
EWA1SD1003
WARNING
A
After extensive tests, the tires listed below 2
have been approved by Yamaha Motor Co., 90˚
Ltd. for this model. The front and rear tires 1
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.
A. Forward
Front tire
Size TIP
120/70–15M/C 56S
Manufacturer/model For tires with a direction of rotation mark “3”:
MICHELIN/CITY GRIP Install the tire with the mark pointing in the direc-
Manufacturer/model tion of wheel rotation.
SAVA/DIAMONDS MC28
Rear tire
Size
150/70–13M/C 64S
Manufacturer/model
MICHELIN/CITY GRIP
Manufacturer/model
SAVA/DIAMONDS MC28
EWA1SD1016
WARNING EAS1SD1004
• New tires have a relatively low grip on the CHECKING THE WHEEL BEARINGS
road surface until they have been slightly The following procedure applies to all of the
worn. Therefore, approximately 100 km wheel bearings.
should be traveled at normal speed before 1. Check:
any high-speed riding is done. • Wheel bearings
• After the rear tire has been repaired or re- Refer to “CHECKING THE FRONT WHEEL”
placed, be sure to tighten the tire air valve on page 4-19 and “CHECKING THE REAR
stem nut “1” and locknut “2” to specifica- WHEEL” on page 4-24.
tion. EAS21520
CHECKING AND ADJUSTING THE

Valve stem STEERING HEAD
Valve stem nut 1. Stand the vehicle on a level surface.
T.
R.
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) EWA13120
Valve stem locknut WARNING

3.0 Nm (0.30 m·kgf, 2.2 ft·lbf) Securely support the vehicle so that there is
no danger of it falling over.
TIP
Place the vehicle on a suitable stand so that the
front wheel is elevated.
2. Check:
• Steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
3-15
Binding/looseness → Adjust the steering

head. Lower ring nut (final tightening
3. Remove: torque)
T.
R.
• Lower handlebar holder 22 Nm (2.2 m·kgf, 16 ft·lbf)
Refer to “STEERING HEAD” on page 4-59. EWA13140
4. Adjust: WARNING
• Steering head Do not overtighten the lower ring nut.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the upper ring nut “1”, the lock wash- d. Check the steering head for looseness or
er “2”, the center ring nut “3” and the rubber binding by turning the front fork all the way in
washer. both directions. If any binding is felt, remove
the lower bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” on page 4-59.
e. Install the rubber washer.
f. Install the center ring nut.
g. Finger tighten the center ring nut, then align
the slots of both ring nuts. If necessary, hold
the lower ring nut and tighten the center ring
nut until their slots are aligned.
h. Install the lock washer “2”.
b. Loosen the lower ring nut “4” and then tighten TIP
it to specification with a steering nut wrench Make sure the lock washer tabs “a” sit correctly
“5”. in the ring nut slots “b”.
TIP
Set the torque wrench at a right angle to the
steering nut wrench.
Steering nut wrench

90890-01403
YU-A9472
Lower ring nut (initial tightening

torque) i. Hold the lower and center ring nuts with a
T.
R.
38 Nm (3.8 m·kgf, 27 ft·lbf) steering nut wrench and tighten the upper
ring nut with a another steering nut wrench.
Steering nut wrench

90890-01403
YU-A9472
Upper ring nut

75 Nm (7.5 m·kgf, 54 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c. Loosen the lower ring nut “4” 1/4 of a turn, 5. Install:

and then tighten it to specification with a • Lower handlebar holder
steering nut wrench “5”. Refer to “STEERING HEAD” on page 4-59.
3-16
EAS1SD1006 EAS21530
CHECKING THE CHASSIS FASTENERS CHECKING THE FRONT FORK

Make sure that all nuts, bolts, and screws are 1. Stand the vehicle on a level surface.
properly tightened. EWA13120
Refer to “CHASSIS TIGHTENING TORQUES” WARNING

on page 2-19. Securely support the vehicle so that there is
EAS21700
LUBRICATING THE LEVERS 2. Check:

Lubricate the pivoting point and metal-to-metal • Inner tube
moving parts of the levers. Damage/scratches → Replace.
• Oil seal
Recommended lubricant Oil leakage → Replace.
Silicone grease 3. Hold the vehicle upright and apply the front
brake.
EAS1SD1007
CHECKING THE SIDESTAND 4. Check:

1. Check: • Front fork operation
• Sidestand operation Push down hard on the handlebar several
Check that the sidestand moves smoothly. times and check if the front fork rebounds
Rough movement → Repair or replace. smoothly.
Rough movement → Repair.
EAS21720 Refer to “FRONT FORK” on page 4-52.
LUBRICATING THE SIDESTAND
Lubricate the pivoting point, metal-to-metal mov-
ing parts, and spring contact point of the side-
stand.
Recommended lubricant
Lithium-soap-based grease
EAS1SD1008
CHECKING THE CENTERSTAND

1. Check:
• Centerstand operation
EAS1SD1010
Check that the centerstand moves smoothly.
CHECKING THE REAR SUSPENSION
Rough movement → Repair or replace.
EWA13120
EAS21730
LUBRICATING THE CENTERSTAND WARNING

Lubricate the pivoting point, metal-to-metal mov- Securely support the vehicle so that there is
ing parts, and spring contact points of the center- no danger of it falling over.
stand. 2. Check:
Recommended lubricant • Rear shock absorber assembly
Lithium-soap-based grease Oil leaks → Replace the rear shock absorber
assembly.
EAS1SD1009 Refer to “CHECKING THE REAR SHOCK
CHECKING THE SIDESTAND SWITCH ABSORBER ASSEMBLY” on page 4-64.
Refer to “CHECKING THE SWITCHES” on 3. Check:
page 8-81. • Rear shock absorber assembly operation
• Rear suspension link pivots
Push down seat on the vehicle several times
and check if the rear shock absorber assem-
bly rebounds smoothly.
Rough movement → Repair.
3-17
Refer to “REAR SHOCK ABSORBER AS-

SEMBLIES AND SWINGARM” on page Spring preload adjusting positions
4-63. Minimum (soft)
1
EAS21630 Standard
ADJUSTING THE REAR SHOCK ABSORBER 2
ASSEMBLIES Maximum (hard)
The following procedure applies to both of the 4
rear shock absorber assemblies.
EWA13170
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
WARNING
EAS20730
• Securely support the motorcycle so that CHECKING THE ENGINE OIL LEVEL
there is no danger of it falling over. 1. Stand the vehicle on a level surface.
• Always adjust both rear shock absorber as- TIP
semblies evenly. Uneven adjustment can • Place the vehicle on the centerstand.
result in poor handling and loss of stability. • Make sure the vehicle is upright.
2. Start the engine, warm it up for several min-
Spring preload
ECA13590 utes, and then turn it off.
NOTICE 3. Check:
Never go beyond the maximum or minimum • Engine oil level
adjustment positions. Remove the engine oil filler cap “1” the en-
gine oil level should be between the minimum
1. Adjust: level mark “a” and maximum level mark “b”.
• Spring preload Below the minimum level mark → Add the
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ recommended engine oil to the proper level.
a. Turn the spring preload adjusting ring “1” in
direction “a” or “b”.
b. Align the desired position on the spring seat 1
with the stopper “2”.
TIP
Adjust the spring preload with the special
wrench “3” included in the owner’s tool kit.
b
Direction “a” a
Spring preload is increased (suspen-
sion is harder).
Direction “b” TIP
Spring preload is decreased (suspen- • Before checking the engine oil level, wait a few
sion is softer). minutes until the oil has settled.
• Do not screw the dipstick in when inspecting
the oil level.
3
4
3
1
2
Recommended brand
YAMALUBE
Type
2 SAE 10W-30, 10W-40, 10W-50,
15W-40, 20W-40 or 20W-50
1 Recommended engine oil grade
b API service SG type or higher,
a JASO standard MA
3-18
5. Drain:
-20 -10 0 10 20 30 40 50 ˚C
• Engine oil
SAE 10W-30 (completely from the crankcase)
SAE 10W-40 6. If the oil filter element is also to be replaced,
perform the following procedure.
SAE 10W-50
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
SAE 15W-40 a. Remove the oil filter element cover “1” and oil
SAE 20W-40 filter element “2”.
SAE 20W-50
ECA1SD1003
NOTICE
Do not allow foreign materials to enter the
crankcase.
utes, and then turn it off.
5. Check the engine oil level again. 1
EAS20810
CHANGING THE ENGINE OIL b. Check the O-ring “3” and replace it if it is
1. Remove: cracked or damaged.
• Storage box
3. Place a container under the engine oil drain
bolt.
4. Remove:
• Engine oil filler cap “1” 1 3 2 3
• Engine oil drain bolt “2”
(along with the gasket)
c. Install the new oil filter element and the oil fil-
ter element cover.
Oil filter element cover bolt

1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. If the oil strainer is also to be cleaned, per-
form the following procedure.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the oil strainer cover “1” and oil
strainer “2”.
b. Install new O-ring “3”. New
3-19
2 1
3 New
1
1
c. Install the oil strainer cover. b. Start the engine and keep it idling until engine
oil starts to seep from the oil check bolt. If no
Oil strainer cover engine oil comes out after one minute, turn
32 Nm (3.2 m·kgf, 23 ft·lbf) the engine off so that it will not seize.
T.
R.
c. Check the engine oil passages, the oil filter

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ cartridge and the oil pump for damage or
8. Install: leakage. Refer to “OIL PUMP” on page 5-47.
• Engine oil drain bolt d. Start the engine after solving the problem(s)
(along with the gasket New ) and check the engine oil pressure again.
e. Tighten the oil check bolt to specification.
Engine oil drain bolt
20 Nm (2.0 m·kgf, 14 ft·lbf) Oil check bolt
T.
R.
10 Nm (1.0 m·kgf, 7.2 ft·lbf)

T.
R.
9. Fill:
• Crankcase ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
(with the specified amount of the recom- 15.Reset the maintenance counter for the en-
mended engine oil) gine oil.
Refer to “INSTRUMENT FUNCTIONS” on
Engine oil capacity page 1-4.
Without oil filter element replace- 16.Install:
ment
• Storage box
1.50 L (1.59 US qt, 1.32 Imp.qt)
With oil filter element replace- Refer to “GENERAL CHASSIS” on page 4-1.
ment EAS21110
1.70 L (1.80 US qt, 1.50 Imp.qt) CHECKING THE COOLANT LEVEL

10.Install: TIP
• Engine oil filler cap
• Place the vehicle on the centerstand.
11.Start the engine, warm it up for several min-
• Make sure the vehicle is upright.
12.Check: 2. Remove:
• Engine • Coolant reservoir cover
(for engine oil leaks) Refer to “GENERAL CHASSIS” on page 4-1.
13.Check: 3. Check:
• Engine oil level • Coolant level
Refer to “CHECKING THE ENGINE OIL The coolant level should be between the min-
LEVEL” on page 3-18. imum level mark “a” and maximum level mark
14.Check: “b”.
• Engine oil pressure Below the minimum level mark → Add the
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ recommended coolant to the proper level.
a. Slightly loosen the oil check bolt “1”.
3-20
2
b
a
3 6
1
ECA13470
NOTICE
• Adding water instead of coolant lowers the
4
antifreeze content of the coolant. If water is
used instead of coolant check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may 5
be used.
3. Install:
• Footrest board
5. Check:
• Front cowling
• Coolant level
TIP
Before checking the coolant level, wait a few EAS21130
CHANGING THE COOLANT

minutes until the coolant has settled.
1. Remove:
6. Install: • Front cowling
• Coolant reservoir cover • Storage box
Refer to “GENERAL CHASSIS” on page 4-1. Refer to “GENERAL CHASSIS” on page 4-1.
EAS21120
• Coolant reservoir hose “1”
CHECKING THE COOLING SYSTEM
1. Remove:
• Front cowling
• Footrest board
2. Check: 1
• Radiator “1”
• Radiator inlet hose “2”
• Radiator outlet hose “3”
• Radiator filler hose
• Oil cooler outlet hose 2. Drain:
• Water pump inlet hose “4” • Coolant
• Water pump outlet hose “5” (from the coolant reservoir)
• Thermostat inlet hose “6” 3. Remove:
• Thermostat outlet hose • Radiator cap “1”
Cracks/tears → Replace.
Refer to “RADIATOR” on page 6-1 and
“THERMOSTAT” on page 6-4.
3-21
EWA13030
9. Install:
WARNING • Coolant drain bolt (engine)
A hot radiator is under pressure. Therefore, (along with copper washer)
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may Coolant drain bolt
be blown out, which could cause serious in- 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
jury. When the engine has cooled, open the
radiator cap as follows: 10.Fill:
Place a thick rag or a towel over the radiator • Cooling system
cap and slowly turn the radiator cap counter- (with the specified amount of the recom-
clockwise toward the detent to allow any re- mended coolant)
sidual pressure to escape. When the hissing
Recommended antifreeze
sound has stopped, press down on the radi- High-quality ethylene glycol anti-
ator cap and turn it counterclockwise to re- freeze containing corrosion in-
move. hibitors for aluminum engines
4. Remove: Mixing ratio
• Coolant drain bolt (engine) “1” 1:1 (antifreeze:water)
Radiator capacity (including all
(along with the copper washer)
routes)
1.38 L (1.46 US qt, 1.21 Imp.qt)
1 Coolant reservoir capacity (up
to the maximum level mark)
0.31 L (0.33 US qt, 0.27 Imp.qt)
Handling notes for coolant

Coolant is potentially harmful and should be
handled with special care.
EWA13040
WARNING
• If coolant splashes in your eyes, thorough-
5. Drain:
ly wash them with water and consult a doc-
• Coolant
tor.
(from the engine and radiator)
• If coolant splashes on your clothes, quickly
6. Check:
wash it away with water and then with soap
• Copper washer (coolant drain bolt)
and water.
7. Connect:
• If coolant is swallowed, induce vomiting
• Coolant reservoir hose
and get immediate medical attention.
8. Loosen:
• Coolant bleed screw “1”
3-22
ECA13480 EAS1SD1001
NOTICE CHANGING THE FINAL TRANSMISSION OIL

• Adding water instead of coolant lowers the 1. Stand the vehicle on a level surface.
antifreeze content of the coolant. If water is TIP
used instead of coolant check, and if nec- • Place the vehicle on the centerstand.
essary, correct the antifreeze concentra- • Make sure the vehicle is upright.
tion of the coolant.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
3. Place a container under the final transmis-
be used.
sion.
• If coolant comes into contact with painted
4. Remove:
surfaces, immediately wash them with wa-
• Final transmission oil filler cap “1”
ter.
• Final transmission oil drain bolt “2”
• Do not mix different types of antifreeze.
Completely drain the final transmission oil.
11.Tighten:
• Coolant bleed screw
1
Coolant bleed screw
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
T.
R.
2
12.Install:
• Radiator cap
13.Fill:
• Coolant reservoir
(with the recommended coolant to the maxi-
mum level mark “a”) 5. Install:
• Final transmission oil drain bolt
Final transmission oil drain bolt

20 Nm (2.0 m·kgf, 14 ft·lbf)
T.
R.
a
6. Fill:
• Final transmission oil
(with the specified amount of the recom-
mended final transmission oil)
Final transmission oil

14.Install: Type
• Coolant reservoir cap YAMALUBE 10W-40 or SAE
10W-30 type SE motor oil
15.Start the engine, warm it up for several min-
Quantity
utes, and then turn it off. 0.25 L (0.26 US qt, 0.22 Imp.qt)
16.Check:
• Coolant level 7. Install:
Refer to “CHECKING THE COOLANT LEV- • Final transmission oil filler cap “1”
EL” on page 3-20.
• O-ring “2” New
TIP
Before checking the coolant level, wait a few
minutes until the coolant has settled.
17.Install:
• Front cowling
• Storage box
3-23
EWA1SD1004
1 WARNING
1
Damaged outer cable may cause the cable to
2 New corrode and interfere with its movement. Re-
place damaged outer cable and inner cables
as soon as possible.
1. Check:
• Outer cable
Damage → Replace.
2. Check:
8. Start the engine, warm it up for several min- • Cable operation
utes, and then turn it off. Rough movement → Lubricate.
9. Check:
• Final transmission oil leakage Engine oil or a suitable cable lu-
EAS1SD1011 bricant
REPLACING THE V-BELT
1. Remove: TIP
• V-belt case Hold the cable end upright and pour a few drops
Refer to “V-BELT AUTOMATIC TRANSMIS- of lubricant into the cable sheath or use a suit-
SION” on page 5-32. able lubricating device.
2. Check:
• V-belt EAS21740
Cranks/damage/wear → Replace. LUBRICATING THE REAR SUSPENSION

Grease/oil → Clean the primary and second- Lubricate the pivoting point and metal-to-metal
ary pulleys. moving parts of the rear suspension.
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-32. Recommended lubricant
TIP Lithium-soap-based grease
Replace the V-belt every 20000 km (12500 mi)
EAS1SD1002
of operation.
CHECKING THE THROTTLE GRIP
3. Install: OPERATION
• V-belt case 1. Check:
Refer to “V-BELT AUTOMATIC TRANSMIS- • Throttle cables
SION” on page 5-32. Damage/deterioration → Replace.
• Throttle cable installation
Incorrect → Reinstall the throttle cables.
EAS1SD1012
CHECKING THE BRAKE LIGHT SWITCHES

1. Check: Refer to “HANDLEBAR” on page 4-48.
• Front brake light switch operation 2. Check:
• Rear brake light switch operation • Throttle grip movement
When operating the brake levers, confirm Rough movement → Lubricate or replace the
that the brake light comes on. defective part(s).
Faulty → Refer to “CHECKING THE
SWITCHES” on page 8-81. Suitable cable lubricant
EAS21690
CHECKING AND LUBRICATING THE TIP

CABLES With the engine stopped, turn the throttle grip
The following procedure applies to all of the in- slowly and release it. Make sure that the throttle
ner and outer cables. grip turns smoothly and returns properly when
released.
3-24
Repeat this check with the handlebar turned all EWA1SD1005
the way to the left and right. WARNING

After adjusting the throttle grip free play,
3. Check: start the engine and turn the handlebars to
• Throttle grip free play “a” the right and to the left to ensure that this
Out of specification → Adjust. does not cause the engine idling speed to
Throttle grip free play change.
3.0–5.0 mm (0.12–0.20 in) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1SD1013
CHECKING THE SWITCHES, LIGHTS AND

SIGNALS
1. Check that all switches operate and that all
lights come on.
a Refer to “INSTRUMENT AND CONTROL
FUNCTIONS” in Owner’s manual.
Faulty → Refer to “CHECKING THE
SWITCHES” on page 8-81 and “CHECKING
THE BULBS AND BULB SOCKETS” on
page 8-84.
4. Adjust: EAS21810
• Throttle grip free play ADJUSTING THE HEADLIGHT BEAM
TIP The following procedure applies to both of the
Prior to adjusting the throttle grip free play, the headlights.
engine idling speed should be adjusted properly. 1. Adjust:
• Headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “1”. a. Open the front storage compartments and re-
b. Turn the adjusting nut “2” in direction “a” or “b” move the plugs.
until the specified throttle grip free play is ob- b. Turn the adjusting screw “1” in direction “a” or
tained. “b”.
Direction “a” Direction “a”
Throttle grip free play is increased. Headlight beam is raised.
Direction “b” Direction “b”
Throttle grip free play is decreased. Headlight beam is lowered.
c. Tighten the locknut.
1 b a 1
a
a b
b 2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21790
REPLACING THE HEADLIGHT BULB

headlight bulbs.
3-25
1. Remove: 6. Install:
• Headlight assembly • Headlight bulb holder
Refer to “GENERAL CHASSIS” on page 4-1. 7. Connect:
2. Remove: • Headlight coupler (right side)
• Headlight bulb cover “1” 8. Install:
3. Disconnect: • Headlight bulb cover
• Headlight coupler (right side) 9. Install:
• Headlight assembly
1 Refer to “GENERAL CHASSIS” on page 4-1.
4. Remove:
• Headlight bulb holder “1”
• Headlight bulb
A B
A. Right side
B. Left side
EWA13320
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
5. Install:
• Headlight bulb New
Secure the new headlight bulb with the head-
light bulb holder.
ECA13690
NOTICE
Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
3-26
3-27
CHASSIS
GENERAL CHASSIS.......................................................................................4-1
INSTALLING THE STORAGE BOX ........................................................ 4-10
REMOVING THE CENTER PANELS......................................................4-10
INSTALLING THE CENTER PANELS ....................................................4-10
REMOVING THE REAR UPPER COVER............................................... 4-11
INSTALLING THE REAR UPPER COVER ............................................. 4-11
REMOVING THE REAR PANELS........................................................... 4-11
INSTALLING THE REAR PANELS ......................................................... 4-12
REMOVING THE FRONT COWLING COVER AND UPPER PANEL..... 4-12
INSTALLING THE UPPER PANEL AND FRONT COWLING COVER ... 4-12
REMOVING THE FRONT UPPER PANEL ............................................. 4-13
INSTALLING THE FRONT UPPER PANEL............................................4-13
REMOVING THE FRONT COWLING .....................................................4-13
INSTALLING THE FRONT COWLING....................................................4-14
REMOVING THE MAIN SWITCH COVER.............................................. 4-14
INSTALLING THE MAIN SWITCH COVER ............................................4-15
REMOVING THE FOOTREST BOARD .................................................. 4-15
INSTALLING THE FOOTREST BOARD ................................................. 4-15
HANDLING THE SEAT HINGE DAMPER............................................... 4-16
DISPOSING OF A SEAT HINGE DAMPER ............................................4-16 4
FRONT WHEEL............................................................................................. 4-17
REMOVING THE FRONT WHEEL.......................................................... 4-19
DISASSEMBLING THE FRONT WHEEL................................................ 4-19
CHECKING THE FRONT WHEEL .......................................................... 4-19
ASSEMBLING THE FRONT WHEEL......................................................4-20
ADJUSTING THE FRONT WHEEL STATIC BALANCE ......................... 4-20
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC).................. 4-21
REAR WHEEL ...............................................................................................4-23

REMOVING THE REAR WHEEL ............................................................ 4-24
CHECKING THE REAR WHEEL............................................................. 4-24
ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-24
INSTALLING THE REAR WHEEL (REAR BRAKE DISC) ......................4-24
FRONT BRAKE ............................................................................................. 4-25

INTRODUCTION .....................................................................................4-30
CHECKING THE FRONT BRAKE DISCS............................................... 4-30
REPLACING THE FRONT BRAKE PADS .............................................. 4-31
REMOVING THE FRONT BRAKE CALIPERS ....................................... 4-32
DISASSEMBLING THE FRONT BRAKE CALIPERS..............................4-32
CHECKING THE FRONT BRAKE CALIPERS ........................................ 4-32
ASSEMBLING THE FRONT BRAKE CALIPERS.................................... 4-33
INSTALLING THE FRONT BRAKE CALIPERS ...................................... 4-33
REMOVING THE FRONT BRAKE MASTER CYLINDER .......................4-35
CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 4-35
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-35
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................4-35
REAR BRAKE ...............................................................................................4-37
INTRODUCTION .....................................................................................4-42
CHECKING THE REAR BRAKE DISC....................................................4-42
REPLACING THE REAR BRAKE PADS................................................. 4-42
REMOVING THE REAR BRAKE CALIPER ............................................4-43
DISASSEMBLING THE REAR BRAKE CALIPER ..................................4-43
CHECKING THE REAR BRAKE CALIPER............................................. 4-44
ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-44
INSTALLING THE REAR BRAKE CALIPER...........................................4-44
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-45
CHECKING THE REAR BRAKE MASTER CYLINDER .......................... 4-46
ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................4-46
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-46
HANDLEBAR ................................................................................................4-48
REMOVING THE HANDLEBAR..............................................................4-50
CHECKING THE HANDLEBAR ..............................................................4-50
INSTALLING THE HANDLEBAR ............................................................ 4-50
FRONT FORK................................................................................................4-52
REMOVING THE FRONT FORK LEGS.................................................. 4-54
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-54
CHECKING THE FRONT FORK LEGS .................................................. 4-55
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-55
INSTALLING THE FRONT FORK LEGS ................................................ 4-57
STEERING HEAD.......................................................................................... 4-59

REMOVING THE LOWER BRACKET.....................................................4-61
CHECKING THE STEERING HEAD .......................................................4-61
INSTALLING THE STEERING HEAD .....................................................4-61
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM................... 4-63

REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES ............... 4-64
REMOVING THE SWINGARM................................................................4-64
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-64
CHECKING THE SWINGARM ................................................................4-64
INSTALLING THE SWINGARM ..............................................................4-64
GENERAL CHASSIS
EAS21830
GENERAL CHASSIS
Removing the seat and center panels
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
T.R
.
.
1 2
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.
6
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
5
(4)
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
4 .
3
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.
Order Job/Parts to remove Q’ty Remarks

1 Seat 1
2 Storage box 1
3 Air duct 1 Disconnect from the left center panel.
4 Left center panel 1
5 Right center panel cover 1
6 Right center panel 1
For installation, reverse the removal proce-
dure.
4-1
GENERAL CHASSIS
Removing the rear panel and mudguard

23 Nm (2.3 m•kgf, 17 ft•Ibf) 3 1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
T.R
.
T.R
.
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf) 8
T.R
.
2
1
3
4 6
7 LT
7
9
2
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 2.3 Nm (0.23 m•kgf, 1.7 ft•Ibf) 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
T.R
T.R
.
.

Refer to “Removing the seat and center pan-
Center panel els”.
1 Rear upper cover 1
2 Rear panel 2
3 Grab bar 2
4 License plate light coupler 1 Disconnect.
5 Rear turn signal light coupler 2 Disconnect.
6 Tail/brake light coupler 2 Disconnect.
7 Tail/brake light assembly 2
8 Mudguard 1
9 Rear lower cover 1
dure.
4-2
GENERAL CHASSIS
Removing the headlight assembly

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.
0.4 Nm (0.04 m•kgf, 0.29 ft•Ibf)
T.R
.
10
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 3
T.R
.
8
(3) (2) (4)
(2) (6)
4 (2)
(2) (6)
(2)
9
6
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
6
7
5 7 (3)
2
(2) (2)
10 (3)
(2)
(2) 4
1
9 (2) 7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Fuse box cover/Coolant reservoir cover Refer to “Removing the meter assembly”.
1 Front cowling cover 1
2 Upper panel 1
3 Windshield 1
4 Front upper panel 2
5 Headlight assembly coupler 1 Disconnect.
6 Auxiliary light coupler 2 Disconnect.
7 Front turn signal light coupler 2 Disconnect.
8 Headlight assembly 1
9 Front turn signal light 2
10 Front cowling 2
dure.
4-3
GENERAL CHASSIS
Removing the windshield bracket
23 Nm (2.3 m•kgf, 17 ft•Ibf) 23 Nm (2.3 m•kgf, 17 ft•Ibf)

T.R
T.R
.
.
8
5
(2) 6
1 4
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Windshield/Front cowling Refer to “Removing the headlight assembly”.
1 Battery bracket 1
2 Battery cover 1
3 Battery positive lead 1 Disconnect.
4 Battery negative lead 1 Disconnect.
5 Battery 1
6 Starter relay 1
7 Air temperature sensor 1
8 Windshield bracket 1
dure.
4-4
GENERAL CHASSIS
Removing the meter assembly
2.3 Nm (0.23 m•kgf, 1.7 ft•Ibf) 2.3 Nm (0.23 m•kgf, 1.7 ft•Ibf)
T.R
.
T.R
.
3 1
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.
(2)
4 5
10
(3) 1
8
6
2
11
(2) (4)
(4) 9
(4)
(2)

Windshield Refer to “Removing the headlight assembly”.
1 Rearview mirror 2
2 Coolant reservoir cover 1
3 Fuse box cover 1
4 Main switch cover 1
5 Center handlebar cover 1
6 Upper handlebar cover 1
7 Lower handlebar cover 1
8 Meter assembly/meter assembly cover 1
9 Meter assembly coupler 1 Disconnect.
10 Meter assembly cover 1
11 Meter assembly 1
dure.
4-5
GENERAL CHASSIS
Removing the radiator cover
2 1
(4)
(2)
LT
4
LT
2
(2) (2)
(2)
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

Front cowling Refer to “Removing the headlight assembly”.
Front wheel Refer to “FRONT WHEEL” on page 4-17.
Front fender Refer to “FRONT FORK” on page 4-52.
1 Footrest board mat 2
2 Front lower panel 2
3 Relay holder 1
4 Radiator cover 1
dure.
4-6
GENERAL CHASSIS
Removing the footrest board and leg shield
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
(2)
5
4
8
7
6 LT
2 3
1

T.R
T.R
.

Refer to “Removing the seat and center pan-
Center panel els”.
Headlight assembly Refer to “Removing the headlight assembly”.
Main switch cover Refer to “Removing the meter assembly”.
Front lower panel Refer to “Removing the radiator cover”.
1 Bottom cover 1
2 Fuel tank filler lid 1 Open.
3 Footrest board 1
4 Radiator filler neck 1
5 Fuse box 1
6 Leg shield 1
7 Coolant level check hose 1
8 Coolant reservoir 1
dure.
4-7
GENERAL CHASSIS
Removing the air filter case assembly
3 7
5 1
2
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Storage box
1 Crankcase breather hose 1 Disconnect.
2 Air filter case breather hose 1 Disconnect.
3 Air induction system hose 1 Disconnect.
4 Intake air temperature sensor coupler 1 Disconnect.
5 Air filter case clamp screw 2 Loosen.
6 Left air filter case 1
7 Right air filter case 1
dure.
4-8
GENERAL CHASSIS
Removing the seat hinge
9 Nm (0.9 m•kgf, 6.5 ft•Ibf)
T.R
.
23 Nm (2.3 m•kgf, 17 ft•Ibf) LS
T.R
.
1
4 2
9 Nm (0.9 m•kgf, 6.5 ft•Ibf) LS

1
T.R
.

Refer to “Removing the footrest board and
Footrest board leg shield”.
1 Bolt 2
2 Bushing 2
3 Seat hinge 1
4 Damper 1
5 Seat damper pivot 1
dure.
4-9
GENERAL CHASSIS
EAS1SD1020
INSTALLING THE STORAGE BOX

1. Install:
• Storage box
b. Unhook the projections on the center panel

from the footrest board and sliding it upward.
Storage box bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
TIP
Tighten the storage box bolts in the proper tight-
ening sequence as shown.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1SD1017
2 INSTALLING THE CENTER PANELS

4 The following procedure applies to both of the
1
5 center panels.
3 1. Install:
• Center panels
EAS1SD1016
REMOVING THE CENTER PANELS

center panels.
1. Remove:
• Center panels
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Insert the projection on the center panel into
the footrest board.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pull the rear of the center panel outward to re-
move it from the grommet on the rear panel.
4-10
GENERAL CHASSIS
b. Make sure that the projection on the center

panel fits into the grommet in the rear panel.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the rear upper cover by fitting the pro-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
jection on the cover into the mudguard.
EAS1SD1014
REMOVING THE REAR UPPER COVER

1. Remove:
• Rear upper cover
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1SD1018
REMOVING THE REAR PANELS

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ rear panels.
a. Unhook the projection on the rear upper cov- 1. Remove:
er from the mudguard and sliding it back- • Rear panels
ward.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. Slide the rear panel to outward and remove it.
EAS1SD1015
INSTALLING THE REAR UPPER COVER

1. Install:
• Rear upper cover
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-11
GENERAL CHASSIS
EAS1SD1019
INSTALLING THE REAR PANELS

rear panels.
1. Install:
• Rear panels
b. Pull the upper panel forward to remove the

projections from the slots in the front cowling
and the grommet in the headlight assembly.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the projections on the rear panel into the
holes in the mudguard and rear lower cover.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1SD1022
INSTALLING THE UPPER PANEL AND

FRONT COWLING COVER
1. Install:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Upper panel
• Front cowling cover
EAS1SD1021
REMOVING THE FRONT COWLING COVER

AND UPPER PANEL
1. Remove:
• Front cowling cover
• Upper panel
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Push the upper panel rearward to fit the pro-
jections into the grommet in the headlight as-
sembly and the slots in the front cowling.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Unhook the projections on the front cowling
cover from the upper panel and radiator cov-
er.
4-12
GENERAL CHASSIS
b. Fit the projections on the front cowling cover

into the holes in the upper panel and radiator
cover.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the 2 projections on the upper portion of
the front upper panel into the holes in the
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
front cowling.
EAS1SD1040
REMOVING THE FRONT UPPER PANEL

1. Remove:
• Front upper panel
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1SD1042
REMOVING THE FRONT COWLING

1. Remove:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Front cowling/headlight assembly
a. Pull the upper portion of the front upper panel
outward to unhook the 2 projections from the
front cowling.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pull the upper portion of the front cowling out-
ward to unhook the projection from the hole in
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
the leg shield.
EAS1SD1041
INSTALLING THE FRONT UPPER PANEL

1. Install:
• Front upper panel
4-13
GENERAL CHASSIS
b. Pull the headlight assembly forward to re-

move the projections from the grommets in
the windshield bracket.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1SD1044
REMOVING THE MAIN SWITCH COVER

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1. Remove:
EAS1SD1043 • Coolant reservoir cover
INSTALLING THE FRONT COWLING • Fuse box cover
1. Install: • Main switch cover
• Front cowling/headlight assembly
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Pull the fuse box cover and coolant reservoir
a. Fit the projections on the headlight assembly cover rearward to unhook the projections
into the grommets in the windshield bracket. from the holes in the leg shield.
b. Fit the projection on the upper portion of the b. Pull the main switch cover rearward to un-
front cowling into the hole in the leg shield. hook the projections from the holes in the leg
shield.
4-14
GENERAL CHASSIS
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1SD1045 EAS1SD1046
INSTALLING THE MAIN SWITCH COVER REMOVING THE FOOTREST BOARD

1. Install: 1. Remove:
• Main switch cover • Footrest board
• Fuse box cover
• Coolant reservoir cover
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Push the front lower portion of the footrest
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ board downward, and then pull the board
a. Fit the projections on the main switch cover rearward to unhook the projections from the
into the holes in the leg shield. leg shield.
b. Fit the projections on the fuse box cover and ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

coolant reservoir cover into the holes in the EAS1SD1047
leg shield. INSTALLING THE FOOTREST BOARD

1. Install:
• Footrest board
4-15
GENERAL CHASSIS
in) hole through the seat hinge damper at a

point 15–20 mm (0.59–0.79 in) from its end
as shown.
EWA13760
WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Push the footrest board downward to fit the
projection on the front lower portion of the
board into the hole in the leg shield, and then
fit the projection on the front upper portion of
the board under the leg shield.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1SD1048
HANDLING THE SEAT HINGE DAMPER

EWA1SD1019
WARNING
This seat hinge damper contains highly com-
pressed nitrogen gas. Before handling the
seat hinge damper, read and make sure you
understand the following information. The
manufacturer cannot be held responsible for
property damage or personal injury that may
result from improper handling of the seat
hinge damper.
• Do not tamper or attempt to open the seat
hinge damper.
• Do not subject the seat hinge damper 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 seat hinge
damper in any way.
EAS1SD1049
DISPOSING OF A SEAT HINGE DAMPER

1. Gas pressure must be released before dis-
posing of a seat hinge damper. To release
the gas pressure, drill a 2–3 mm (0.08–0.12
4-16
FRONT WHEEL
EAS21870
FRONT WHEEL
Removing the front wheel and brake discs
40 Nm (4.0 m•kgf, 29 ft•Ibf)
T.R
.
LT
LT
59 Nm (5.9 m•kgf, 43 ft•Ibf)

T.R
.
3 1
5 LT
4
LS
1
8
3
2
1
(5) LT
23 Nm (2.3 m•kgf, 17 ft•Ibf)

T.R
.
LT 9
LS
7
6 (5)
9
12 Nm (1.2 m•kgf, 8.7 ft•Ibf) LT 12 Nm (1.2 m•kgf, 8.7 ft•Ibf)
T.R
T.R
.

Place the vehicle on a suitable stand so that
the front wheel is elevated.
1 Front brake caliper bracket bolt 4
2 Speed sensor lead guide 1
3 Front brake caliper 2
4 Wheel axle pinch bolt 1 Loosen.
5 Front wheel axle 1
6 Front wheel assembly 1
7 Speed sensor 1
8 Collar 1
9 Brake disc 2
dure.
4-17
FRONT WHEEL
Disassembling the front wheel
1 New
2
LS
3
2

1 Oil seal 1
2 Wheel bearing 2
3 Spacer 1
For assembly, reverse the disassembly pro-
cedure.
4-18
FRONT WHEEL
EAS21890
REMOVING THE FRONT WHEEL

EWA13120
WARNING
Securely support the vehicle so that there is
2. Remove:
• Front brake calipers
ECA1SD1004
NOTICE
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Do not operate the brake lever when remov-
EAS21920
ing the brake calipers. CHECKING THE FRONT WHEEL
3. Elevate: 1. Check:
• Front wheel • Wheel axle
TIP Roll the wheel axle on a flat surface.
Place the vehicle on a suitable stand so that the Bends → Replace.
EWA13460
front wheel is elevated. WARNING
EAS21910
Do not attempt to straighten a bent wheel ax-
DISASSEMBLING THE FRONT WHEEL le.
1. Remove:
• Oil seal
• Wheel bearings
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the surface of the front wheel hub.
b. Remove the oil seal “1” with a flat-head
screwdriver.
TIP
To prevent damaging the wheel, place a rag “2”
between the screwdriver and the wheel surface.
2. Check:
• Tire
• Front wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” on page
3-13 and “CHECKING THE WHEELS” on
page 3-13.
3. Measure:
• Radial wheel runout “1”
• Lateral wheel runout “2”
c. Remove the wheel bearings “3” with a gener- Over the specified limits → Replace.
al bearing puller. Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
4-19
FRONT WHEEL
TIP
Place a suitable washer “1” between the socket
“2” and the bearing so that both the inner race
“3” and outer race “4” are pressed at the same
time, and then press the bearing until the inner
race makes contact with the spacer “5”.
4. Check:
• Wheel bearings
Front wheel turns roughly or is loose → Re-
place the wheel bearings.
• Oil seal
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21970
ADJUSTING THE FRONT WHEEL STATIC

BALANCE
TIP
• After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.
• Adjust the front wheel static balance with the
brake disc installed.
EAS21960
ASSEMBLING THE FRONT WHEEL 1. Remove:

1. Install: • Balancing weight(s)
2. Find:
• Wheel bearings New • Front wheel’s heavy spot
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the new wheel bearing (right side). TIP
ECA37P1029
Place the front wheel on a suitable balancing
NOTICE stand.
Do not contact the wheel bearing inner race
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
“1” or balls “2”. Contact should be made a. Spin the front wheel.
only with the outer race “3”. b. When the front wheel stops, put an “X1” mark
TIP at the bottom of the wheel.
Use a socket “4” that matches the diameter of
the wheel bearing outer race.
c. Turn the front wheel 90° so that the “X1” mark

is positioned as shown.
d. Release the front wheel.
b. Install the spacer.
c. Install the new wheel bearing (left side).
4-20
FRONT WHEEL
e. When the wheel stops, put an “X2” mark at 4. Check:

the bottom of the wheel. • Front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the front wheel and make sure it stays at
each position shown.
f. Repeat steps (c) through (e) several times

until all the marks come to rest at the same
spot.
g. The spot where all the marks come to rest is b. If the front wheel does not remain stationary
the front wheel’s heavy spot “X”. at all of the positions, rebalance it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21990
3. Adjust:
INSTALLING THE FRONT WHEEL (FRONT
• Front wheel static balance
BRAKE DISC)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a balancing weight “1” onto the rim ex- 1. Install:
actly opposite the heavy spot “X”. • Front brake disc
TIP Front brake disc bolt
Start with the lightest weight. 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
T.
R.
LOCTITE®
TIP
Tighten the brake disc bolts in stages and in a
crisscross pattern.
b. Turn the front wheel 90° so that the heavy

spot is positioned as shown.
2. Check:
• Front brake disc
Refer to “CHECKING THE FRONT BRAKE
DISCS” on page 4-30.
3. Lubricate:
• Oil seal lips
• Speed sensor oil seal lip
c. If the heavy spot does not stay in that posi-
tion, install a heavier weight. Recommended lubricant
d. Repeat steps (b) and (c) until the front wheel Lithium-soap-based grease
is balanced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-21
FRONT WHEEL
4. Install:
• Collar
• Speed sensor
• Front wheel
TIP
• Make sure that the projections “a” on the wheel
hub do not contact the projections “b” on the
speed sensor.
• When installing the speed sensor, make sure
that the projection on the wheel hub does not
damage the lip of the speed sensor oil seal.
• Make sure that the slot “c” in the speed sensor
fits over the stopper “d” on the outer tube.
5. Install:
• Wheel axle
• Wheel axle pinch bolt
Wheel axle
59 Nm (5.9 m·kgf, 43 ft·lbf)
T.
R.
Wheel axle pinch bolt

23 Nm (2.3 m·kgf, 17 ft·lbf)
ECA37P1030
NOTICE
Before tightening the wheel axle, push down
hard on the handlebar several times and
check if the front fork rebounds smoothly.
4-22
REAR WHEEL
EAS22020
REAR WHEEL
Removing the rear wheel and brake disc
LS
(3)
LT
23 Nm (2.3 m•kgf, 17 ft•Ibf)

T.R
.

Muffler Refer to “ENGINE REMOVAL” on page 5-2.
Swingarm SEMBLIES AND SWINGARM” on page
4-63.
1 Rear wheel 1
2 Rear brake disc 1
dure.
4-23
REAR WHEEL
EAS28760
2. Check:
REMOVING THE REAR WHEEL
• Rear brake disc
EWA13120
Refer to “CHECKING THE REAR BRAKE
WARNING DISC” on page 4-42.
TIP
Place the vehicle on the centerstand so that the
rear wheel is elevated. Also, place a suitable
stand under the engine.
EAS22090
CHECKING THE REAR WHEEL

1. Check:
• Tire
• Rear wheel
Refer to “CHECKING THE TIRES” on page
3-13 and “CHECKING THE WHEELS” on
page 3-13.
2. Measure:
• Radial wheel runout
• Lateral wheel runout
Refer to “CHECKING THE FRONT WHEEL”
on page 4-19.
Radial wheel runout limit

1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
EAS22150
ADJUSTING THE REAR WHEEL STATIC

BALANCE
TIP
• 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 installed.
1. Adjust:
• Rear wheel static balance
Refer to “ADJUSTING THE FRONT WHEEL
STATIC BALANCE” on page 4-20.
EAS28770
INSTALLING THE REAR WHEEL (REAR

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

23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
R.
LOCTITE®
4-24
FRONT BRAKE
EAS22210
FRONT BRAKE
Removing the front brake pads
3
5
4
7
6
LT
6
1
2
1
40 Nm (4.0 m•kgf, 29 ft•Ibf)

T.R
.
18 Nm (1.8 m•kgf, 13 ft•Ibf)

T.R
.
2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)

T.R
.

The following procedure applies to both of
the front brake calipers.
1 Front brake caliper bolt 2
2 Speed sensor lead guide 1 Left side only.
4 Brake pad pin cap 1
5 Brake pad pin 1
6 Front brake pad 2
7 Brake pad spring 1
8 Brake pad support 1
dure.
4-25
FRONT BRAKE
Removing the front brake master cylinder
1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
(4)
1
2 10
11
8 New
4
7
6
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 9

T.R
.
5 23 Nm (2.3 m•kgf, 17 ft•Ibf)

T.R
.

Refer to “GENERAL CHASSIS” on page
Lower handlebar cover 4-1.
Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
1 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm hold-
2 1
er
3 Brake master cylinder reservoir diaphragm 1
4 Front brake lever 1
5 Front brake light switch connector 2 Disconnect.
6 Front brake light switch 1
7 Brake hose union bolt 1
8 Copper washer 2
9 Front brake hose 1
10 Front brake master cylinder holder 1
11 Front brake master cylinder 1
dure.
4-26
FRONT BRAKE
Disassembling the front brake master cylinder
1 New
BF

1 Brake master cylinder kit 1
2 Brake master cylinder body 1
cedure.
4-27
FRONT BRAKE
Removing the front brake caliper
40 Nm (4.0 m•kgf, 29 ft•Ibf)

T.R
.
23 Nm (2.3 m•kgf, 17 ft•Ibf)
T.R
.
7 9 3
LT
8 5
7 LT
1
2 New
4 New

Drain.
2 Copper washer 1 Left side only.
Front brake hose (left front brake caliper to right
3 1 Left brake caliper side.
front brake caliper)
4 Copper washer 2
Front brake hose (master cylinder to left front
5 1 Left side only.
brake caliper)
Front brake hose (left front brake caliper to right
6 1 Right brake caliper side.
front brake caliper)
7 Front brake caliper bolt 2
dure.
4-28
FRONT BRAKE
Disassembling the front brake caliper
New 8
S
6 Nm (0.6 m•kgf, 4.3 ft•Ibf) New 9

T.R
.
7
BF
10
S 8 New S
S
9 New
11 BF
5
2 4
1
3
18 Nm (1.8 m•kgf, 13 ft•Ibf)

T.R
.
2.5 Nm (0.25 m•kgf, 1.8 ft •Ibf)

T.
R.

1 Brake pad pin cap 1
2 Brake pad pin 1
3 Front brake pad 2
6 Brake caliper bracket 1
7 Brake caliper piston 2
8 Brake caliper piston dust seal 2
9 Brake caliper piston seal 2
10 Bleed screw 1
11 Brake caliper body 1
cedure.
4-29
FRONT BRAKE
EAS22220
e. Measure the deflection 1.5 mm (0.06 in) be-
INTRODUCTION
EWA14101
low the edge of the brake disc.
WARNING
Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
ventive measures:
• Never disassemble brake components un-
less absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
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
Brake disc thickness limit
up any spilt brake fluid immediately.
3.5 mm (0.14 in)
• Avoid brake fluid coming into contact with
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.
EAS22230
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 4-17. • Brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2. Check: a. Remove the brake disc.
• Brake disc b. Rotate the brake disc by one bolt hole.
Damage/galling → Replace. c. Install the brake disc.
3. Measure:
• Brake disc deflection Front brake disc bolt
Out of specification → Correct the brake disc 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
T.
R.
deflection or replace the brake disc. LOCTITE®
Brake disc deflection limit TIP

0.15 mm (0.0059 in)
Tighten the brake disc bolts in stages and in a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
crisscross pattern.
a. Place the vehicle on a suitable stand so that
the front wheel is elevated.
b. Before measuring the front brake disc deflec-
tion, turn the handlebar to the left or right to
ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
4-30
FRONT BRAKE
a
A
d. Measure the brake disc deflection. 2. Install:

e. If out of specification, repeat the adjustment • Brake pad support New
steps until the brake disc deflection is within
specification. • Brake pad spring New
f. If the brake disc deflection cannot be brought • Brake pads New
within specification, replace the brake disc. TIP
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Always install new brake pads, a new brake pad
6. Install: spring, and a new brake pad support as a set.
• Front wheel
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Refer to “FRONT WHEEL” on page 4-17. a. Connect a clear plastic hose “1” tightly to the
EAS22270 bleed screw “2”. Put the other end of the hose
REPLACING THE FRONT BRAKE PADS into an open container.
The following procedure applies to both brake b. Loosen the bleed screw and push the brake
calipers. caliper pistons into the brake caliper with your
TIP finger.
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem- 2 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-

ner)
6.5 mm (0.26 in) c. Tighten the bleed screw.
Limit
1.5 mm (0.06 in) Bleed screw
Brake pad lining thickness (out- 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
T.
R.
er)
6.5 mm (0.26 in) d. Install new brake pad support, new brake pad
Limit spring and new brake pads.
1.5 mm (0.06 in) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Brake pad pin
• Brake pad pin cap
• Front brake caliper
• Speed sensor lead guide
• Front brake caliper bolts
Front brake caliper bolt

40 Nm (4.0 m·kgf, 29 ft·lbf)
T.
R.
LOCTITE®
4-31
FRONT BRAKE
4. Check: 1. Remove:
• Brake fluid level • Brake caliper pistons “1”
Below the minimum level mark “a” → Add the • Brake caliper piston dust seals “2”
specified brake fluid to the proper level. • Brake caliper piston seals “3”
Refer to “CHECKING THE BRAKE FLUID
3
a 2
3
1
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose joint
5. Check: opening “a” to force out the pistons from the
• Brake lever operation brake caliper.
EWA1SD1006
Soft or spongy feeling → Bleed the brake sys- WARNING
tem.
Refer to “BLEEDING THE HYDRAULIC • Cover the brake caliper piston with a rag.
BRAKE SYSTEM” on page 3-12. Be careful not to get injured when the pis-
tons are expelled from the brake caliper.
EAS22290 • Never try to pry out the brake caliper pis-
REMOVING THE FRONT BRAKE CALIPERS tons.
calipers. a
TIP
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
• Brake hose union bolt “1”
• Copper washers “2”
• Front brake hoses “3”
TIP
Put the end of the brake hose into a container b. Remove the brake caliper piston dust seals
and pump out the brake fluid carefully. and brake caliper piston seals.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22380
3 CHECKING THE FRONT BRAKE CALIPERS
Recommended brake component replace-
1 ment schedule
Brake pads If necessary
Piston seals Every two years
2
Piston dust seals Every two years
Brake hoses Every four years
EAS22320 Every two years and
DISASSEMBLING THE FRONT BRAKE Brake fluid whenever the brake
CALIPERS is disassembled
calipers.
4-32
FRONT BRAKE
1. Check: EAS22420
INSTALLING THE FRONT BRAKE CALIPERS

• Brake caliper pistons “1”
Rust/scratches/wear → Replace the brake
calipers.
caliper pistons.
1. Install:
• Brake caliper cylinders “2”
• Front brake caliper “1”
Scratches/wear → Replace the brake caliper
(temporarily)
assembly.
• Brake caliper body “3” • Copper washers “2” New
Cracks/damage → Replace the brake caliper • Front brake hose (master cylinder to left front
assembly. brake caliper) “3”
• Brake fluid delivery passages • Front brake hose (left front brake caliper to
(brake caliper body) right front brake caliper) “4”
Obstruction → Blow out with compressed air. • Brake hose union bolt “5”
EWA37P1010
WARNING Front brake hose union bolt

Whenever a brake caliper is disassembled, 23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
R.
replace the brake caliper piston dust seals EWA1SD1008
and brake caliper piston seals. WARNING

Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CABLE
ROUTING” on page 2-31.
2 ECA1SD1021
3 NOTICE
Left side
• When installing the brake hose “3” onto the
brake caliper, make sure the brake pipe “a”
1 touches the projection “b” on the brake cal-
iper.
2. Check: • When installing the brake hose “4” onto the
• Brake caliper bracket brake caliper, make sure the projection “c”
Cracks/damage → Replace. on the brake hose “4” touches the projec-
EAS22400
tion “d” on the brake hose “3”.
ASSEMBLING THE FRONT BRAKE Right side
CALIPERS • When installing the brake hose “4” onto the
EWA37P1011
brake caliper, make sure the brake pipe “e”
WARNING touches the projection “f” on the brake cal-
• Before installation, all internal brake com- iper.
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 brake caliper
piston dust seals and brake caliper piston
seals to swell and distort.
• Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seals
and brake caliper piston seals.

DOT 4
4-33
FRONT BRAKE
EWA37P1012
A WARNING
3
• Use only the designated brake fluid. Other
4
a brake fluids may cause the rubber seals to
5 deteriorate, causing leakage and poor
1
brake performance.
b c
• Refill with the same type of brake fluid that
d is already in the system. Mixing brake fluids
2
may result in a harmful chemical reaction,
B
f voir. Water will significantly lower the boil-
4 ing point of the brake fluid and could cause
e vapor lock.
ECA13540
5 NOTICE
2 and plastic parts. Therefore, always clean up
1
A. Left side 5. Bleed:
B. Right side • Brake system
2. Remove: Refer to “BLEEDING THE HYDRAULIC
• Front brake caliper BRAKE SYSTEM” on page 3-12.
3. Install: 6. Check:
• Brake pad support • Brake fluid level
• Brake pad spring Below the minimum level mark “a” → Add the
• Brake pads specified brake fluid to the proper level.
• Brake pad pin Refer to “CHECKING THE BRAKE FLUID
• Brake pad pin cap LEVEL” on page 3-11.
• Front brake caliper
a
Brake pad pin
18 Nm (1.8 m·kgf, 13 ft·lbf)
T.
R.
Brake pad pin cap

2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Front brake caliper bolt
40 Nm (4.0 m·kgf, 29 ft·lbf)
LOCTITE®
Refer to “REPLACING THE FRONT BRAKE

PADS” on page 4-31. 7. Check:
4. Fill: • Brake lever operation
• Brake master cylinder reservoir Soft or spongy feeling → Bleed the brake sys-
(with the specified amount of the specified tem.
brake fluid) Refer to “BLEEDING THE HYDRAULIC
DOT 4
4-34
FRONT BRAKE
EAS22490 EAS22520
REMOVING THE FRONT BRAKE MASTER ASSEMBLING THE FRONT BRAKE MASTER
CYLINDER CYLINDER
EWA13520
TIP
WARNING
Before removing the front brake master cylinder,
• Before installation, all internal brake com-
drain the brake fluid from the entire brake sys-
ponents should be cleaned and lubricated
tem.
1. Remove: • Never use solvents on internal brake com-
• Brake hose union bolt “1” ponents.
• Front brake hose “3” Specified brake fluid
TIP DOT 4
To collect any remaining brake fluid, place a
container under the master cylinder and the end EAS22530
INSTALLING THE FRONT BRAKE MASTER

of the brake hose.
CYLINDER
1. Install:
2
• Brake master cylinder “1”
1 • Brake master cylinder holder
3 Brake master cylinder holder bolt

7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.
TIP
• Install the brake master cylinder holder with the
“UP” mark facing up.
EAS22500
• Align the projection “a” on the brake master cyl-
CHECKING THE FRONT BRAKE MASTER inder with the hole “b” in the handlebar.
CYLINDER • First, tighten the upper bolt, then the lower bolt.
1. Check:
• Brake master cylinder
Damage/scratches/wear → Replace.
• Brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed air.
2. Check:
• Brake master cylinder kit
3. Check:
• Brake master cylinder reservoir cap
• Brake master cylinder reservoir diaphragm
holder 1
b
4. Check:
• Front brake hose
a
2. Install:
• Copper washers “1” New
• Front brake hose “2”
4-35
FRONT BRAKE
• Brake hose union bolt “3” • When refilling, be careful that water does
Brake hose union bolt voir. Water will significantly lower the boil-
23 Nm (2.3 m·kgf, 17 ft·lbf) ing point of the brake fluid and could cause
T.
R.
EWA1SD1010
vapor lock.
WARNING ECA13540
Proper brake hose routing is essential to in- NOTICE

sure safe vehicle operation. Refer to “CABLE Brake fluid may damage painted surfaces
ROUTING” on page 2-31. and plastic parts. Therefore, always clean up
ECA14160
NOTICE 4. Bleed:
When installing the brake hose onto the • Brake system
brake master cylinder, make sure the brake Refer to “BLEEDING THE HYDRAULIC
pipe touches the projection “a” as shown. BRAKE SYSTEM” on page 3-12.
5. Check:
TIP
Turn the handlebar to the left and right to make Below the minimum level mark “a” → Add the
sure the brake hose does not touch other parts specified brake fluid to the proper level.
(e.g., wire harness, cables, leads). Correct if Refer to “CHECKING THE BRAKE FLUID
necessary. LEVEL” on page 3-11.
1
a
3
3. Fill: 6. Check:
• Brake master cylinder reservoir • Brake lever operation
(with the specified amount of the specified Soft or spongy feeling → Bleed the brake sys-
brake fluid) tem.
Refer to “BLEEDING THE HYDRAULIC
Specified brake fluid BRAKE SYSTEM” on page 3-12.
DOT 4
EWA13540
WARNING
brake fluids may cause the rubber seals to
brake performance.
is already in the system. Mixing brake fluids
4-36
REAR BRAKE
EAS22550
REAR BRAKE
Removing the rear brake pads
6 Nm (0.6 m•kgf, 4.3 ft•Ibf) S

T.R
.
1
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
S
40 Nm (4.0 m•kgf, 29 ft•Ibf)
T.R
.
4
3 5

Right air filter case 4-1.
1 Rear brake caliper retaining bolt 2
2 Rear brake caliper 1
3 Rear brake pad 2
dure.
4-37
REAR BRAKE
Removing the rear brake master cylinder
1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
(4)
1 10
23 Nm (2.3 m•kgf, 17 ft•Ibf) 2

T.R
.
3
7 11
8
9
8
New
S
New
4
6
5
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.

Drain.
1 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm hold-
2 1
er
3 Brake master cylinder reservoir diaphragm 1
4 Rear brake lever 1
5 Rear brake light switch connector 2 Disconnect.
6 Rear brake light switch 1
8 Copper washer 2
9 Rear brake hose 1
10 Rear brake master cylinder holder 1
11 Rear brake master cylinder 1
dure.
4-38
REAR BRAKE
Disassembling the rear brake master cylinder
1 New
BF S

1 Brake master cylinder kit 1
2 Brake master cylinder body 1
cedure.
4-39
REAR BRAKE
Removing the rear brake caliper
23 Nm (2.3 m•kgf, 17 ft•Ibf) 1 3 7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
T.R
.
.
New 2
4 40 Nm (4.0 m•kgf, 29 ft•Ibf)

T.R
.

Drain.
2 Copper washer 2
3 Rear brake hose 1
4 Rear brake caliper bolt 2
dure.
4-40
REAR BRAKE
Disassembling the rear brake caliper
9 6 Nm (0.6 m•kgf, 4.3 ft•Ibf)
T.R
.
S
BF
10
1
6
7 New
8 New
S
1
2
40 Nm (4.0 m•kgf, 29 ft•Ibf)
T.R
.
4
3 5

1 Rear brake caliper retaining bolt 2
2 Brake caliper bracket 1
3 Rear brake pad 2
6 Brake caliper piston 2
7 Brake caliper piston dust seal 2
8 Brake caliper piston seal 2
9 Bleed screw 1
10 Brake caliper body 1
cedure.
4-41
REAR BRAKE
EAS22560
INTRODUCTION Brake disc thickness limit

EWA14101
4.5 mm (0.18 in)
WARNING
Disc brake components rarely require disas- 5. Adjust:
sembly. Therefore, always follow these pre- • Brake disc deflection
ventive measures: Refer to “CHECKING THE FRONT BRAKE
• Never disassemble brake components un- DISCS” on page 4-30.
less absolutely necessary.
• If any connection on the hydraulic brake Rear brake disc bolt
system is disconnected, the entire brake 23 Nm (2.3 m·kgf, 17 ft·lbf)
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 4-23.
• Use only clean or new brake fluid for clean- EAS1SD1023
ing brake components. REPLACING THE REAR BRAKE PADS

• Brake fluid may damage painted surfaces TIP
and plastic parts. Therefore, always clean When replacing the brake pads, it is not neces-
up any spilt brake fluid immediately. sary to disconnect the brake hose or disassem-
• Avoid brake fluid coming into contact with ble the brake caliper.
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID 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.
Brake pad lining thickness (in-

EAS22570
CHECKING THE REAR BRAKE DISC ner)

6.5 mm (0.26 in)
1. Remove:
Limit
• Rear wheel 1.5 mm (0.06 in)
Refer to “REAR WHEEL” on page 4-23. Brake pad lining thickness (out-
2. Check: er)
• Brake disc 6.5 mm (0.26 in)
Damage/galling → Replace. Limit
3. Measure: 1.5 mm (0.06 in)
• Brake disc deflection
Out of specification → Correct the brake disc
deflection or replace the brake disc.
Refer to “CHECKING THE FRONT BRAKE
DISCS” on page 4-30.
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- 2. Install:
ferent locations.
Out of specification → Replace. • Brake pad supports New
Refer to “CHECKING THE FRONT BRAKE • Brake pad spring New
DISCS” on page 4-30. • Brake pads New
4-42
REAR BRAKE
TIP 5. Check:
Always install new brake pads, brake pad • Brake lever operation
spring, and brake pad supports as a set. Soft or spongy feeling → Bleed the brake sys-
tem.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Refer to “BLEEDING THE HYDRAULIC
a. Connect a clear plastic hose “1” tightly to the
bleed screw “2”. Put the other end of the hose
into an open container. EAS22590
b. Loosen the bleed screw and push the brake REMOVING THE REAR BRAKE CALIPER
caliper pistons into the brake caliper with your TIP
finger. Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
• Brake hose union bolt “1”
2
1 • Rear brake hose “3”
TIP
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
c. Tighten the bleed screw.

1
Bleed screw 3
6 Nm (0.6 m·kgf, 4.3 ft·lbf) 2
T.
R.
d. Install new brake pad spring.

e. Install new brake pad supports and new
brake pads.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Rear brake caliper EAS1SD1024
DISASSEMBLING THE REAR BRAKE

• Rear brake caliper retaining bolts
CALIPER
Rear brake caliper retaining bolt 1. Remove:
40 Nm (4.0 m·kgf, 29 ft·lbf) • Brake caliper pistons “1”
T.
R.
• Brake caliper piston dust seals “2”

4. Check: • Brake caliper piston seals “3”
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-11. 1 1
2 2
a 3 3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose joint
opening “a” to force out the pistons from the
brake caliper.
4-43
REAR BRAKE
EWA13550
WARNING
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.
2. Check:
• Brake caliper bracket
EAS22650
ASSEMBLING THE REAR BRAKE CALIPER

EWA1SD1012
WARNING
b. Remove the brake caliper piston dust seals • Before installation, all internal brake com-
and brake caliper piston seals. ponents should be cleaned and lubricated
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22640
• Never use solvents on internal brake com-
CHECKING THE REAR BRAKE CALIPER ponents as they will cause the brake caliper
piston dust seals and brake caliper piston
Recommended brake component replace- seals to swell and distort.
ment schedule
• Whenever a brake caliper is disassembled,
Brake pads If necessary replace the brake caliper piston dust seals
Piston seals Every two years and brake caliper piston seals.
Piston dust seals Every two years
Brake hose Every four years DOT 4
Every two years and
Brake fluid whenever the brake EAS22670
is disassembled INSTALLING THE REAR BRAKE CALIPER

1. Install:
1. Check: • Rear brake caliper “1”
• Brake caliper pistons “1” (temporarily)
Rust/scratches/wear → Replace the brake • Copper washers “2” New
caliper pistons. • Rear brake hose “3”
• Brake caliper cylinders “2” • Brake hose union bolt “4”
Scratches/wear → Replace the brake caliper
assembly. Rear brake hose union bolt
• Brake caliper body “3” 23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
R.
Cracks/damage → Replace the brake caliper

EWA13530
assembly.
WARNING
(brake caliper body) Proper brake hose routing is essential to in-
Obstruction → Blow out with compressed air. sure safe vehicle operation. Refer to “CABLE
EWA37P1014 ROUTING” on page 2-31.
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seals
and brake caliper piston seals.
4-44
REAR BRAKE
ECA14170 ECA13540
NOTICE NOTICE
When installing the brake hose onto the Brake fluid may damage painted surfaces
brake caliper “1”, make sure the brake pipe and plastic parts. Therefore, always clean up
“a” touches the projection “b” on the brake any spilt brake fluid immediately.
caliper. 5. Bleed:
• Brake system
4 a Refer to “BLEEDING THE HYDRAULIC
3 BRAKE SYSTEM” on page 3-12.
6. Check:
New 2 • Brake fluid level
b Refer to “CHECKING THE BRAKE FLUID
1
2. Remove:
• Rear brake caliper a
3. Install:
• Brake pad supports
• Brake pad spring
• Brake pads
• Rear brake caliper
Rear brake caliper bolt

40 Nm (4.0 m·kgf, 29 ft·lbf) 7. Check:
T.
R.
Rear brake caliper retaining bolt • Brake lever operation

40 Nm (4.0 m·kgf, 29 ft·lbf)
Soft or spongy feeling → Bleed the brake sys-
Refer to “REPLACING THE REAR BRAKE tem.
PADS” on page 4-42. Refer to “BLEEDING THE HYDRAULIC
4. Fill: BRAKE SYSTEM” on page 3-12.
• Brake master cylinder reservoir EAS22700
(with the specified amount of the specified REMOVING THE REAR BRAKE MASTER
brake fluid) CYLINDER
TIP
Before removing the rear brake master cylinder,
DOT 4
drain the brake fluid from the entire brake sys-
EWA13540 tem.
WARNING
1. Remove:
• Use only the designated brake fluid. Other • Brake hose union bolt “1”
brake fluids may cause the rubber seals to • Copper washers “2”
deteriorate, causing leakage and poor • Brake hose “3”
brake performance.
TIP
is already in the system. Mixing brake fluids To collect any remaining brake fluid, place a
may result in a harmful chemical reaction, container under the master cylinder and the end
leading to poor brake performance. of the brake hose.
vapor lock.
4-45
REAR BRAKE
2 Brake master cylinder holder bolt

7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.
1 TIP
• Install the brake master cylinder holder with the
“UP” mark facing up.
• Align the projection “a” on the brake master cyl-
inder with the hole “b” in the handlebar.
3 • First, tighten the upper bolt, then the lower bolt.
EAS22710
CHECKING THE REAR BRAKE MASTER

CYLINDER
1. Check:
• Brake master cylinder
(brake master cylinder body)
2. Check:
• Brake master cylinder kit
3. Check: b 1
• Brake master cylinder reservoir cap
holder
Damage/wear → Replace. a
4. Check:
• Rear brake hose
2. Install:
EAS22730
ASSEMBLING THE REAR BRAKE MASTER • Copper washers “1” New

CYLINDER • Rear brake hose “2”
EWA13520 • Brake hose union bolt “3”
WARNING
• Before installation, all internal brake com- Brake hose union bolt
ponents should be cleaned and lubricated 23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
R.
with clean or new brake fluid. EWA1SD1013
• Never use solvents on internal brake com- WARNING

ponents. Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CABLE
Specified brake fluid ROUTING” on page 2-31.
DOT 4 ECA14160
NOTICE
EAS22750
INSTALLING THE REAR BRAKE MASTER When installing the brake hose onto the
CYLINDER brake master cylinder, make sure the brake
1. Install: pipe touches the projection “a” as shown.
• Brake master cylinder “1”
• Brake master cylinder holder
4-46
REAR BRAKE
TIP Refer to “CHECKING THE BRAKE FLUID

Turn the handlebar to the left and right to make LEVEL” on page 3-11.
sure the brake hose does not touch other parts
(e.g., wire harness, cables, leads). Correct if
a
necessary.
1 New
a 6. Check:
• Brake lever operation
2 Soft or spongy feeling → Bleed the brake sys-
tem.
3. Fill: Refer to “BLEEDING THE HYDRAULIC
• Brake master cylinder reservoir
(with the specified amount of the specified
brake fluid)

DOT 4
EWA13540
WARNING
brake fluids may cause the rubber seals to
brake performance.
is already in the system. Mixing brake fluids
vapor lock.
ECA13540
NOTICE
and plastic parts. Therefore, always clean up
4. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
5. Check:
4-47
HANDLEBAR
EAS22840
HANDLEBAR
Removing the handlebar
23 Nm (2.3 m•kgf, 17 ft•Ibf) 4
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 3
T.R
.
T.R
.
10
26 Nm (2.6 m•kgf, 19 ft•Ibf)
2
T.R
.
9 7 1
5
8
LS
5
14 13
6
LS
6
11
12
2.3 Nm (0.23 m•kgf, 1.7 ft•Ibf)

T.R
.
T.R
T.R
.
26 Nm (2.6 m•kgf, 19 ft•Ibf)

T.R
.

1 Grip end 2
2 Front brake light switch connector 2 Disconnect.
3 Front brake master cylinder holder 1
4 Front brake master cylinder 1
5 Right handlebar switch 1
6 Throttle cable 2 Disconnect.
7 Throttle grip 1
8 Rear brake light switch connector 2 Disconnect.
9 Rear brake master cylinder holder 1
10 Rear brake master cylinder 1
11 Left handlebar switch 1
12 Handlebar grip 1
13 Upper handlebar holder 2
4-48
HANDLEBAR
Removing the handlebar
23 Nm (2.3 m•kgf, 17 ft•Ibf) 4
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 3
T.R
.
T.R
.
10
26 Nm (2.6 m•kgf, 19 ft•Ibf)
2
T.R
.
9 7 1
5
8
LS
5
14 13
6
LS
6
11
12
2.3 Nm (0.23 m•kgf, 1.7 ft•Ibf)

T.R
.
T.R
T.R
.
26 Nm (2.6 m•kgf, 19 ft•Ibf)

T.R
.

14 Handlebar 1
dure.
4-49
HANDLEBAR
EAS22860
REMOVING THE HANDLEBAR TIP

1. Stand the vehicle on a level surface. The upper handlebar holders should be installed
EWA13120 with the arrow marks “a” facing forward “A”.
WARNING
2. Remove:
• Handlebar grip “1”
TIP
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
3. Install:
• Handlebar grip
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of a rubber adhesive to the
left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
EWA13700
EAS22880
WARNING
CHECKING THE HANDLEBAR Do not touch the handlebar grip until the rub-
1. Check: ber adhesive has fully dried.
• Handlebar
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Bends/cracks/damage → Replace.
EWA13690 4. Install:
WARNING • Left handlebar switch “1”
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it. Left handlebar switch screw
2.3 Nm (0.23 m·kgf, 1.7 ft·lbf)
T.
R.
EAS22920
INSTALLING THE HANDLEBAR TIP

1. Stand the vehicle on a level surface. Align the projection “a” on the left handlebar
EWA13120
switch with the hole “b” in the handlebar.
WARNING
no danger of it falling over. 1
2. Install:
• Handlebar a
• Upper handlebar holders
Upper handlebar holder bolt b

23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
R.
ECA37P1031
NOTICE 5. Install:
First, tighten the front bolt on each handle- • Rear brake master cylinder “1”
bar holder, then the rear bolt. • Rear brake master cylinder holder
4-50
HANDLEBAR
Brake master cylinder holder bolt Brake master cylinder holder bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf) 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
T.
R.
R.
TIP TIP
• Align the projection “a” on the brake master cyl- • Align the projection “a” on the brake master cyl-
inder with the hole “b” in the handlebar. inder with the hole “b” in the handlebar.
• First, tighten the upper bolt, then the lower bolt. • First, tighten the upper bolt, then the lower bolt.
b 1 1
b
a
a
6. Install: 8. Adjust:
• Throttle grip “1” • Throttle grip free play
• Throttle cables “2” Refer to “CHECKING THE THROTTLE GRIP
• Right handlebar switch “3” OPERATION” on page 3-24.
Throttle cable bracket screw Throttle grip free play

2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) 3.0–5.0 mm (0.12–0.20 in)
T.
R.
Right handlebar switch screw

2.3 Nm (0.23 m·kgf, 1.7 ft·lbf)
TIP
• Be sure to position the washer between the
throttle grip and the right handlebar switch.
• Lubricate the end of the throttle cables and the
inside of the throttle grip with a thin coat of lith-
ium-soap-based grease.
• Align the projection “a” on the right handlebar
switch with the hole “b” in the handlebar.
• Be sure to slide the throttle cable rubber cover
to its original position.
a 1
2 LS
b
3
7. Install:
• Front brake master cylinder “1”
• Front brake master cylinder holder
4-51
FRONT FORK
EAS22950
FRONT FORK
Removing the front fork legs
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 70 Nm (7.0 m•kgf, 51 ft•Ibf)

T.R
.
T.R
.
New
6 23 Nm (2.3 m•kgf, 17 ft•Ibf)
T.R
1
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
6
LT 7
40 Nm (4.0 m•kgf, 29 ft•Ibf) 1

T.R
.
3
9 Nm (0.9 m•kgf, 6.5 ft•Ibf)
T.R
.
2
4 LT
40 Nm (4.0 m•kgf, 29 ft•Ibf)

T.R
.

T.R
T.R
.
.
9 Nm (0.9 m•kgf, 6.5 ft•Ibf)

T.R
.

the front fork legs.
Front cowling assembly 4-1.
Front wheel Refer to “FRONT WHEEL” on page 4-17.
1 Brake hose holder 2
3 Clamp 1
4 Front fender 1
5 Cap bolt 1
6 Lower bracket pinch bolt 2 Loosen.
7 Front fork leg 1
dure.
4-52
FRONT FORK
Disassembling the front fork legs
New 2
New 3
New 9 1
10
6
New 5
8
4
LT
30 Nm (3.0 m•kgf, 22 ft•Ibf)

T.R
.

the front fork legs.
1 Fork spring 1
2 Dust seal 1
3 Oil seal clip 1
4 Damper rod bolt 1
5 Copper washer 1
6 Damper rod 1
7 Inner tube 1
8 Oil flow stopper 1
9 Oil seal 1
10 Outer tube 1
cedure.
4-53
FRONT FORK
EAS22960
REMOVING THE FRONT FORK LEGS

front fork legs.
EWA13120
WARNING
TIP
Place the vehicle on a suitable stand so that the 2. Remove:
front wheel is elevated. • Dust seal “1”
• Oil seal clip “2”
2. Remove: (with a flat-head screwdriver)
• Cap bolt “1” ECA14180
TIP NOTICE
If the cap bolt is difficult to loosen, slightly loosen Do not scratch the inner tube.
the lower bracket pinch bolts “2”.
3. Loosen:
1
• Lower bracket pinch bolts “2”
EWA37P1022
WARNING
Before loosening the lower bracket pinch
2
bolts, support the front fork leg.
1 3. Remove:
• Damper rod bolt “1”
• Copper washer
2 • Damper rod
TIP
While holding the damper rod with the damper
rod holder “2” and T-handle “3”, loosen the
EAS22980 damper rod bolt.
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the Damper rod holder
front fork legs. 90890-01294
1. Drain: Damping rod holder set
• Fork oil YM-01300
TIP T-handle
90890-01326
Stroke the inner tube several times while drain-
ing the fork oil. YM-01326
4-54
FRONT FORK
EAS23030
1 ASSEMBLING THE FRONT FORK LEGS

2 front fork legs.
EWA13660
WARNING
• Make sure the oil levels in both front fork
3 legs are equal.
• Uneven oil levels can result in poor han-
dling and a loss of stability.
EAS23010 TIP
CHECKING THE FRONT FORK LEGS • When assembling the front fork leg, be sure to
The following procedure applies to both of the replace the following parts:
front fork legs. –Oil seal
1. Check: –Dust seal
• Inner tube –Clip
• Outer tube • Before assembling the front fork leg, make
Bends/damage/scratches → Replace. sure all of the components are clean.
EWA13650
WARNING 1. Install:
Do not attempt to straighten a bent inner • Damper rod “1”
ECA37P1033
tube as this may dangerously weaken it.
NOTICE
2. Measure: Allow the damper rod to slide slowly down
• Spring free length “a” the inner tube “2” until it protrudes from the
Out of specification → Replace. bottom of the inner tube. Be careful not to
damage the inner tube.
Fork spring free length
303.1 mm (11.93 in)
Limit
297.0 mm (11.69 in) 1 2
2. Lubricate:
• Inner tube’s outer surface
Recommended oil
3. Check: Fork oil 10W or equivalent
• Damper rod
Damage/wear → Replace. 3. Tighten:
Obstruction → Blow out all of the oil passag- • Damper rod bolt “1”
es with compressed air.
• Oil flow stopper Damper rod bolt
Damage → Replace. 30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
R.
ECA37P1032 LOCTITE®
NOTICE
When disassembling and assembling the
front fork leg, do not allow any foreign mate-
rial to enter the front fork.
4-55
FRONT FORK
TIP
While holding the damper rod with the damper
rod holder “2” and T-handle “3”, tighten the
damper rod bolt.
Damper rod holder

90890-01294
Damping rod holder set
YM-01300
T-handle
90890-01326
YM-01326
5. Install:
3
• Oil seal clip “1”
TIP
4. Install: Adjust the oil seal clip so that it fits into the outer
tube’s groove.
• Oil seal “1” New
(with the fork seal driver weight “2” and fork
seal driver attachment “3”)
Fork seal driver weight

90890-01367
Replacement hammer
YM-A9409-7
Fork seal driver attachment (ø38)
90890-01372
Replacement 38 mm
YM-A5142-1
6. Install:
ECA14220
• Dust seal “1” New
NOTICE
(with the fork seal driver weight “2” and fork
Make sure the numbered side of the oil seal seal driver attachment “3”)
faces up.
Fork seal driver weight
TIP 90890-01367
• Before installing the oil seal, lubricate its lips Replacement hammer
with lithium-soap-based grease. YM-A9409-7
• Lubricate the outer surface of the inner tube Fork seal driver attachment (ø38)
with fork oil. 90890-01372
• Before installing the oil seal, cover the top of Replacement 38 mm
the front fork leg with a plastic bag to protect YM-A5142-1
the oil seal during installation.
4-56
FRONT FORK
10.Measure:
• Front fork leg oil level “a”
(from the top of the inner tube, with the inner
tube fully compressed and without the fork
spring)
3 Out of specification → Correct.
Level
110.0 mm (4.33 in)
7. Fill: TIP
• Front fork leg • While filling the front fork leg, keep it upright.
(with the specified amount of the recom- • After filling, slowly pump the front fork leg up
mended fork oil) and down to distribute the fork oil.
Recommended oil
Fork oil 10W or equivalent
Quantity
130.0 cm³ (4.40 US oz, 4.59
Imp.oz)
ECA14230
NOTICE
• Be sure to use the recommended fork oil.
Other oils may have an adverse effect on
front fork performance.
11.Install:
• When disassembling and assembling the
front fork leg, do not allow any foreign ma- • Fork spring “1”
terial to enter the front fork.
8. After filling the front fork leg, slowly stroke the
inner tube “1” up and down (at least ten
times) to distribute the fork oil. a
TIP 1
Be sure to stroke the inner tube slowly because
the fork oil may spurt out.
TIP
Install the fork spring with the smaller pitch “a”
facing up.
EAS23050
INSTALLING THE FRONT FORK LEGS

front fork legs.
9. Before measuring the fork oil level, wait ten 1. Install:
minutes until the oil has settled and the air • Front fork leg “1”
EWA37P1023
bubbles have dispersed.
WARNING
TIP
Make sure the brake hose is routed properly.
Be sure to bleed the front fork leg of any residual
air.
4-57
FRONT FORK
TIP
Pull up the inner tube until it stops, and then
tighten the lower bracket pinch bolts.
Lower bracket pinch bolt

23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
R.
2. Lower bracket
2. Install:
• Cap bolt
(along with the O-ring New )
Cap bolt
70 Nm (7.0 m·kgf, 51 ft·lbf)
T.
R.
TIP
• Before installing the cap bolt, lubricate its O-
ring with grease.
• If the cap bolt is difficult to install, slightly loos-
en the lower bracket pinch bolts.
4-58
STEERING HEAD
EAS23090
STEERING HEAD
Removing the lower bracket
120 Nm (12 m•kgf, 87 ft•lbf) 1

T.R
.
2
75 Nm (7.5 m•kgf, 54 ft•Ibf)
T.R
.
LS
16
1st 38 Nm (3.8 m•kgf, 27 ft•lbf) 13
4
T.R
2nd 22 Nm (2.2 m•kgf, 16 ft•lbf)

.
5 14
6 15
7
LS 8
10
9 3
11
12
17
18

Windshield bracket 4-1.
Meter assembly cover 4-1.
Front fork legs Refer to “FRONT FORK” on page 4-52.
1 Steering stem nut 1
2 Lower handlebar holder 1
3 Woodruff key 1
4 Upper ring nut 1
5 Lock washer 1
6 Center ring nut 1
7 Rubber washer 1
8 Lower ring nut 1
9 Lower bracket 1
10 Upper bearing cover 1
11 Upper bearing inner race 1
4-59
STEERING HEAD
Removing the lower bracket
T.R
.
120 Nm (12 m•kgf, 87 ft•lbf) 1
2
75 Nm (7.5 m•kgf, 54 ft•Ibf)
T.R
.
LS
16
1st 38 Nm (3.8 m•kgf, 27 ft•lbf) 13
4
T.R
2nd 22 Nm (2.2 m•kgf, 16 ft•lbf)

.
5 14
6 15
7
LS 8
10
9 3
11
12
17
18

12 Upper bearing 1
13 Lower bearing 1
14 Lower bearing inner race 1
15 Dust seal 1
16 Lower bearing outer race 1
17 Upper bearing outer race 1
18 Cover 1
dure.
4-60
STEERING HEAD
EAS23110
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
REMOVING THE LOWER BRACKET a. Remove the bearing races from the steering
1. Stand the vehicle on a level surface. head pipe “1” with a long rod “2” and hammer.
EWA13120
b. Remove the bearing race from the lower
WARNING
bracket “3” with a floor chisel “4” and ham-
Securely support the vehicle so that there is mer.
no danger of it falling over. c. Install new bearing races.
ECA14270
2. Remove:
NOTICE
• Upper ring nut “1”
• Lock washer If the bearing race is not installed properly,
• Center ring nut the steering head pipe could be damaged.
• Rubber washer TIP
• Lower ring nut “2”
Always replace the bearings and bearing races
• Lower bracket
EWA13730 as a set.
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
TIP
Remove the upper ring nut and lower ring nut
with the steering nut wrench “3”.
Steering nut wrench

90890-01403
YU-A9472
1 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2 4. Check:
EAS23120 • Lower handlebar holder
CHECKING THE STEERING HEAD • Lower bracket
1. Wash: (along with the steering stem)
• Bearings Bends/cracks/damage → Replace.
• Bearing races
EAS23150
Recommended cleaning solvent INSTALLING THE STEERING HEAD

Kerosene 1. Lubricate:
• Upper bearing
2. Check: • Lower bearing
• Bearings • Bearing races
• Bearing races
Damage/pitting → Replace.
Lithium-soap-based grease
3. Replace:
• Bearings 2. Install:
• Bearing races • Lower ring nut “1”
4-61
STEERING HEAD
• Rubber washer
• Center ring nut “2”
• Lock washer “3”
• Upper ring nut “4”
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-15.
3. Install:
• Woodruff key “1”
• Lower handlebar holder “2”
• Steering stem nut
Steering stem nut

120 Nm (12 m·kgf, 87 ft·lbf)
T.
R.
TIP
Align the woodruff key with the groove “a” in the
lower handlebar holder.
2
1
4-62
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM
EAS23160

Removing the rear shock absorber assemblies and swingarm
32 Nm (3.2 m•kgf, 23 ft•Ibf)

T.R
.

T.R
.
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
2
3
LT
LT
LS
4
5
7
4 New 8
32 Nm (3.2 m•kgf, 23 ft•Ibf)
T.R
.
11
New 10
New 9 6
LS
1
135 Nm (13.5 m•kgf, 98 ft•lbf)

T.R
.

T.R
T.R
.
.

1 Rear wheel axle nut 1
2 Brake hose holder 1
4 Rear shock absorber assembly 2
5 Swingarm 1
6 Collar 1
7 Spacer 1
8 Oil seal 1
9 Oil seal 1
10 Circlip 1
11 Bearing 1
dure.
4-63
EAS23220
• Rear shock absorber
REMOVING THE REAR SHOCK ABSORBER
Oil leaks → Replace the rear shock absorber
ASSEMBLIES
assembly.
EWA13120
• Spring
WARNING Damage/wear → Replace the rear shock ab-
Securely support the vehicle so that there is sorber assembly.
no danger of it falling over. • Bushings
Damage/wear → Replace the rear shock ab-
TIP sorber assembly.
Place the vehicle on the centerstand so that the • Bolts
rear wheel is elevated. Bends/damage/wear → Replace.
EAS23370
EAS23340
CHECKING THE SWINGARM
REMOVING THE SWINGARM 1. Check:
1. Stand the vehicle on a level surface. • Swingarm
EWA13120
WARNING Bends/cracks/damage → Replace.

2. Check:
• Spacer
• Collar
TIP • Oil seals
Place the vehicle on the centerstand so that the • Bearing
rear wheel is elevated. Damage/wear → Replace.
2. Remove: EAS28780
• Rear wheel axle nut “1” INSTALLING THE SWINGARM

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

side)
1. Check:
44 Nm (4.4 m·kgf, 32 ft·lbf)
• Rear shock absorber rod Swingarm mounting bolt (lower
Bends/damage → Replace the rear shock side)
absorber assembly. 44 Nm (4.4 m·kgf, 32 ft·lbf)
4-64
1
3
2
4
4-65
ENGINE
ENGINE INSPECTION .................................................................................... 5-1

MEASURING THE COMPRESSION PRESSURE....................................5-1
ENGINE REMOVAL ........................................................................................5-2

INSTALLING THE ENGINE....................................................................... 5-6
CAMSHAFTS...................................................................................................5-7
REMOVING THE CAMSHAFTS................................................................5-9
CHECKING THE CAMSHAFTS ..............................................................5-10
CHECKING THE CAMSHAFT SPROCKETS .........................................5-11
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-11
CHECKING THE DECOMPRESSION SYSTEM..................................... 5-12
INSTALLING THE CAMSHAFTS ............................................................ 5-12
CYLINDER HEAD.......................................................................................... 5-15

REMOVING THE CYLINDER HEAD.......................................................5-17
CHECKING THE CYLINDER HEAD .......................................................5-17
CHECKING THE TIMING CHAIN GUIDE ............................................... 5-17
INSTALLING THE CYLINDER HEAD .....................................................5-17
VALVES AND VALVE SPRINGS.................................................................. 5-19

REMOVING THE VALVES...................................................................... 5-20
CHECKING THE VALVES AND VALVE GUIDES ..................................5-20
CHECKING THE VALVE SEATS ............................................................ 5-22
5
CHECKING THE VALVE SPRINGS........................................................ 5-24
CHECKING THE VALVE LIFTERS ......................................................... 5-24
INSTALLING THE VALVES .................................................................... 5-24
CYLINDER AND PISTON.............................................................................. 5-27

REMOVING THE PISTON ...................................................................... 5-28
CHECKING THE CYLINDER AND PISTON ...........................................5-28
CHECKING THE PISTON RINGS........................................................... 5-29
CHECKING THE PISTON PIN ................................................................5-30
INSTALLING THE PISTON AND CYLINDER .........................................5-30
V-BELT AUTOMATIC TRANSMISSION .......................................................5-32
REMOVING THE PRIMARY SHEAVE....................................................5-35
REMOVING THE SECONDARY SHEAVE ............................................. 5-35
DISASSEMBLING THE SECONDARY SHEAVE.................................... 5-36
CHECKING THE CLUTCH HOUSING ....................................................5-36
CHECKING THE CLUTCH SHOES ........................................................ 5-36
CHECKING THE V-BELT........................................................................5-37
CHECKING THE PRIMARY SHEAVE ....................................................5-37
CHECKING THE PRIMARY SHEAVE WEIGHTS................................... 5-37
CHECKING THE SLIDER ....................................................................... 5-37
CHECKING THE SECONDARY SHEAVE .............................................. 5-37
ASSEMBLING THE PRIMARY SHEAVE ................................................ 5-38
ASSEMBLING THE SECONDARY SHEAVE..........................................5-38
INSTALLING THE V-BELT...................................................................... 5-39
STARTER CLUTCH AND GENERATOR......................................................5-41

REMOVING THE GENERATOR ............................................................. 5-44
CHECKING THE STARTER CLUTCH ....................................................5-44
INSTALLING THE STARTER CLUTCH .................................................. 5-45
INSTALLING THE GENERATOR............................................................ 5-45
OIL PUMP...................................................................................................... 5-47

CHECKING THE OIL PUMP ................................................................... 5-48
CHECKING THE OIL PUMP DRIVE CHAIN ...........................................5-48
ASSEMBLING THE OIL PUMP...............................................................5-48
INSTALLING THE OIL PUMP .................................................................5-49
ELECTRIC STARTER ...................................................................................5-50

CHECKING THE STARTER MOTOR .....................................................5-52
ASSEMBLING THE STARTER MOTOR................................................. 5-53
INSTALLING THE STARTER MOTOR ...................................................5-53
CRANKCASE ................................................................................................5-54
DISASSEMBLING THE CRANKCASE....................................................5-56
CHECKING THE CRANKCASE ..............................................................5-56
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE............. 5-56
CHECKING THE OIL PUMP GEAR AND OIL PUMP SHAFT ................ 5-56
CHECKING THE RELIEF VALVE ........................................................... 5-56
ASSEMBLING THE CRANKCASE.......................................................... 5-57
CRANKSHAFT ASSEMBLY .........................................................................5-58

REMOVING THE CRANKSHAFT JOURNAL BEARINGS ......................5-60
CHECKING THE CRANKSHAFT AND CONNECTING ROD ................. 5-60
CHECKING THE BALANCER SHAFT ....................................................5-62
CHECKING THE BEARING .................................................................... 5-62
INSTALLING THE CRANKSHAFT JOURNAL BEARING .......................5-62
INSTALLING THE CRANKSHAFT AND BALANCER SHAFT ................ 5-63
TRANSMISSION............................................................................................ 5-64
CHECKING THE TRANSMISSION ......................................................... 5-66
INSTALLING THE TRANSMISSION .......................................................5-66
ENGINE INSPECTION
EAS1SD1025
ENGINE INSPECTION Standard compression pressure

(at sea level)
EAS20710
1400 kPa/500 r/min (14.0
MEASURING THE COMPRESSION kgf/cm²/500 r/min, 199.1 psi/500
PRESSURE r/min)
TIP Minimum-maximum
Insufficient compression pressure will result in a 1100–1650 kPa (11.0–16.5
loss of performance. kgf/cm², 156.5–234.7 psi)
1. Remove: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Storage box a. Turn the main switch to “ON”.
Refer to “GENERAL CHASSIS” on page 4-1. b. With the throttle wide open, crank the engine
2. Measure: until the reading on the compression gauge
• Valve clearance stabilizes.
Out of specification → Adjust. EWA12940
WARNING
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-4. To prevent sparking, ground all spark plug
3. Start the engine, warm it up for several min- leads before cranking the engine.
utes, and then turn it off. c. If the compression pressure is above the
4. Disconnect: maximum specification, check the cylinder
• Spark plug cap head, valve surfaces and piston crown for
5. Remove: carbon deposits.
• Spark plug Carbon deposits → Eliminate.
ECA1SD1010
d. If the compression pressure is below the min-
NOTICE
imum specification, pour a teaspoonful of en-
Before removing the spark plug, use com- gine oil into the spark plug bore and measure
pressed air to blow away any dirt accumulat- again.
ed in the spark plug wells to prevent it from Refer to the following table.
falling into the cylinder.
Compression pressure (with oil applied into
6. Install: the cylinder)
• Compression gauge “1” Reading Diagnosis
Compression gauge Higher than without Piston ring(s) wear or
90890-03081 oil damage → Repair.
Engine compression tester Piston, valves, cylin-
YU-33223 der head gasket or
Same as without oil piston ring(s) possi-
bly defective → Re-
pair.
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Install:
• Spark plug
Spark plug
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
T.
R.
9. Connect:
7. Measure: • Spark plug cap
• Compression pressure 10.Install:
Out of specification → Refer to steps (c) and • Storage box
(d). Refer to “GENERAL CHASSIS” on page 4-1.
5-1
ENGINE REMOVAL
EAS23710
ENGINE REMOVAL
Removing the muffler and exhaust pipe
3
45 Nm (4.5 m•kgf, 33 ft•Ibf)
T.R
.
20 Nm (2.0 m•kgf, 14 ft•Ibf) 4
T.R
.
New 6
2 New
LT 53 Nm (5.3 m•kgf, 38 ft•Ibf)

T.R
.

Right center panel cover 4-1.
1 Muffler 1
2 Gasket 1
3 O2 sensor coupler 1 Disconnect.
4 O2 sensor 1
5 Exhaust pipe 1
6 Gasket 1
dure.
5-2
ENGINE REMOVAL
Disconnecting the leads and hoses
3.8 Nm (0.38 m•kgf, 2.8 ft•Ibf) 12 Nm (1.2 m•kgf, 8.7 ft•Ibf)
T.R
T.R
.
.
7
3 5
2 6

Footrest board 4-1.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-19.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-21.
Air filter case 4-1.
Fuel injector assembly/Throttle body/Intake Refer to “THROTTLE BODY” on page 7-4.
manifold
1 Spark plug cap 1 Disconnect.
Crankshaft position sensor/stator assembly
2 1/1 Disconnect.
coupler
3 Radiator inlet hose 1 Disconnect.
4 Radiator outlet hose 1 Disconnect.
5 Coolant temperature sensor coupler 1 Disconnect.
6 Air induction system solenoid coupler 1 Disconnect.
7 Starter motor lead 1 Disconnect.
5-3
ENGINE REMOVAL
Disconnecting the leads and hoses
T.R
T.R
.
.
7
3 5
2 6

8 Ground lead 1 Disconnect.
dure.
5-4
ENGINE REMOVAL
Removing the engine

4 56 Nm (5.6 m•kgf, 41 ft•Ibf)
(4)
T.R
.
LS 32 Nm (3.2 m•kgf, 23 ft•Ibf)
New
T.R
.
LT
2 7
59 Nm (5.9 m•kgf, 43 ft•Ibf)

T.R
.
2 29 Nm (2.9 m•kgf, 21 ft•Ibf)
T.R
.
1
2
8 59 Nm (5.9 m•kgf, 43 ft•Ibf)
New
T.R
.
2 6
2 5
LS
LS 8
3
LS 65 Nm (6.5 m•kgf, 47 ft•Ibf)
T.R
.

Refer to “REMOVING THE REAR BRAKE
Rear brake caliper CALIPER” on page 4-43.
TIP
Place a suitable stand under the engine.
1 Rear shock absorber bolt 2

2 Engine bracket mounting nut/bolt 4/4
3 Engine 1
4 Engine bracket bolt 4
5 Engine mounting nut/bolt 1/1
6 Engine bracket (left and right) 2
7 Engine bracket (center) 1
8 Collar 2
dure.
5-5
ENGINE REMOVAL
EAS23720
INSTALLING THE ENGINE Engine bracket mounting nut

1. Install: 59 Nm (5.9 m·kgf, 43 ft·lbf)
T.
R.
• Engine bracket (right) “1”
• Engine bracket (center) “2” 6. Install:
• Engine bracket (left) “3” • Rear shock absorber assembly
• Engine mounting bolt/nut “4”
• Engine bracket bolt “5” Rear shock absorber assembly
(Apply the LOCTITE®) upper bolt
T.
R.
• Engine bracket mounting bolts/nuts “6” 32 Nm (3.2 m·kgf, 23 ft·lbf)
TIP lower bolt
• Apply lithium-soap-based grease to the un- 29 Nm (2.9 m·kgf, 21 ft·lbf)
threaded portion of the engine mounting bolt
“4”.
• Do not fully tighten the bolts.
5 (4)
2
6
6
1
4
3
6
2. Place a suitable stand under the engine to el-

evate the rear wheel.
3. Tighten:
• Engine mounting nut
• Engine bracket bolt
Engine mounting nut

65 Nm (6.5 m·kgf, 47 ft·lbf)
T.
R.
Engine bracket bolt

56 Nm (5.6 m·kgf, 41 ft·lbf)
LOCTITE®
4. Remove the suitable stand so that the rear

wheel is on the ground.
5. Tighten:
• Engine bracket mounting nut
5-6
CAMSHAFTS
EAS23760
CAMSHAFTS
Removing the cylinder head cover
5
New 4
3
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
5
(9)
2
1
13 Nm (1.3 m•kgf, 9.4 ft•Ibf)

T.R
.

Storage box 4-1.
Throttle body/Fuel injector Refer to “THROTTLE BODY” on page 7-4.
1 Spark plug cap 1 Disconnect.
2 Spark plug 1
3 Cylinder head cover 1
4 Cylinder head cover gasket 1
5 Plug 2
dure.
5-7
CAMSHAFTS
Removing the camshafts
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
3.5 Nm (0.35 m•kgf, 2.5 ft•Ibf)
T.R
.
20 Nm (2.0 m•kgf, 14 ft•Ibf) 1

T.R
.
LS
9
3
2
2 7
10 4 New
M
11
E 6
(8) 12
E 8
M
6
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

V-belt case air filter element SION” on page 5-32.
Footrest board 4-1.
1 Timing mark accessing screw 1
2 Camshaft sprocket bolt 4 Loosen.
3 Timing chain tensioner assembly 1
4 Gasket 1
5 Camshaft cap 1
6 Dowel pin 2
7 Intake camshaft 1
8 Exhaust camshaft 1
9 Intake camshaft sprocket 1
10 Exhaust camshaft sprocket 1
11 Decompression lever 1
12 Pin 1
dure.
5-8
CAMSHAFTS
EAS23810
haust camshaft sprocket must align with the
REMOVING THE CAMSHAFTS
cylinder head mating surface as shown in the
1. Remove:
illustration.
• Storage box
• Timing mark accessing screw
• V-belt case air filter cover
SION” on page 5-32.
2. Loosen:
c d
• Camshaft sprocket bolts “1”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Remove:
• Timing chain tensioner cap bolt “1”
• Timing chain tensioner “2”
• Gasket
1
1
3. Align: 1
• “I” mark on the generator rotor
(with the mark on the crankcase cover)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise by 2
turning the primary sheave nut at the crank-
shaft.
b. When piston is at TDC on the compression
5. Remove:
stroke, align the mark “a” on the generator ro-
• Camshaft cap “1”
tor with the mark “b” on the crankcase cover.
• Dowel pins
(TDC) ECA1SD1013
NOTICE
To prevent damage to the cylinder head,
camshafts or camshaft cap, loosen the cam-
shaft cap bolts in stages and in a crisscross
pattern, working from the outside in.
4
1
1
6
7
TIP
• TDC on the compression stroke can be found
5
when the camshaft lobes are turned away from

each other.
3
• In order to be sure that the piston is at TDC, the

match marks “c” on the intake camshaft
6. Remove:
sprocket and the match mark “d” on the ex-
• Intake camshaft “1”
• Exhaust camshaft “2”
5-9
CAMSHAFTS
TIP
To prevent the timing chain from falling into the
crankcase, fasten it with a wire “3” to it.
3
1
EAS23850
CHECKING THE CAMSHAFTS

1. Check:
• Camshaft lobes
Blue discoloration/pitting/scratches → Re-
place the camshaft.
2. Measure:
• Camshaft lobe dimensions “A” and “B” 3. Measure:
Out of specification→Replace the camshaft. • Camshaft runout
Out of specification → Replace.
Camshaft lobe dimensions
Intake A Camshaft runout limit
34.350–34.450 mm (1.3524– 0.030 mm (0.0012 in)
1.3563 in)
Limit
34.250 mm (1.3484 in)
Intake B
24.950–25.050 mm (0.9823–
0.9862 in)
Limit
24.850 mm (0.9783 in)
Exhaust A
33.450–33.550 mm (1.3169–
1.3209 in)
Limit
33.350 mm (1.3130 in) 4. Measure:
Exhaust B • Camshaft-journal-to-camshaft-cap clearance
24.950–25.050 mm (0.9823– Out of specification → Measure the camshaft
0.9862 in) journal diameter.
Limit
24.850 mm (0.9783 in) Limit
0.080 mm (0.0032 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the camshaft into the cylinder head
(without the dowel pins and camshaft cap).
b. Position a strip of Plastigauge® “1” onto the
camshaft journal as shown.
5-10
CAMSHAFTS
c. Install the dowel pins and camshaft cap. EAS1SD1026
TIP CHECKING THE CAMSHAFT SPROCKETS

1. Check:
• Tighten the camshaft cap bolts in the order of
• Camshaft sprockets
the embossed numbers on the camshaft cap.
More than 1/4 tooth wear “a”→ Replace the
• Do not turn the camshaft when measuring the
camshaft sprockets, crankshaft and timing
camshaft journal-to-camshaft cap clearance.
chain as a set.
Camshaft cap bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
d. Remove the camshaft cap and then measure

the width of the Plastigauge® “1”.
a. 1/4 tooth
b. Correct
1. Timing chain roller
2. Camshaft sprockets
EAS23960
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING THE TIMING CHAIN TENSIONER

5. Measure: 1. Check:
• Camshaft journal diameter “a” • Timing chain tensioner
Out of specification → Replace the camshaft. Cracks/damage → Replace.
Within specification → Replace the cylinder 2. Check:
head and the camshaft cap as a set. • One-way cam operation
Rough movement → Replace the timing
Camshaft journal diameter chain tensioner.
24.459–24.472 mm (0.9630– ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
0.9635 in) a. While lightly pressing the timing chain ten-
sioner rod by hand, turn the tensioner rod ful-
ly clockwise with a thin screwdriver “1”.
5-11
CAMSHAFTS
2 1
a a
b. Remove the screwdriver and slowly release 2. Install:

the timing chain tensioner rod. • Exhaust camshaft “1”
c. Make sure that the timing chain tensioner rod • Intake camshaft “2”
comes out of the timing chain tensioner hous- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
ing smoothly. If there is rough movement, re- a. Turn the crankshaft counter clockwise.
place the timing chain tensioner. b. Make sure that the mark “a” on the generator
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ rotor with the mark “b” on the crankcase cov-
EAS1SD1032
er as shown. (T.D.C.)
CHECKING THE DECOMPRESSION SYSTEM
1. Check:
• Decompression system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check that the decompressor lever pin “1”
projects from the camshaft.
b. Check that the decompressor cam “2” moves
smoothly.
1
2
c. Install the timing chain “3” onto both camshaft
sprockets, and then install the camshafts
onto the cylinder head.
3
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24000
INSTALLING THE CAMSHAFTS 1

1. Install:
• Exhaust camshaft sprocket “1”
• Intake camshaft sprocket “2”
(with the camshaft sprocket bolts temporarily TIP
tightened) The camshafts should be installed onto the cyl-
TIP inder head so that the match marks “c” on the in-
• Make sure that the match marks “a” on the take camshaft sprocket and the match mark “d”
camshaft sprockets are in the position shown on the exhaust camshaft sprocket align with the
in the illustration. cylinder head mating surface, as shown in the il-
• Temporarily tighten the camshaft sprocket lustration.
bolts.
• Install the bolt hole of the camshaft sprocket “I”
side to the intake camshaft.
5-12
CAMSHAFTS
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. While lightly pressing the timing chain ten-
sioner rod by hand, turn the tensioner rod ful-
ly clockwise with a thin screwdriver “1”.
c d
ECA13740
NOTICE
Do not turn the crankshaft when installing
the camshaft(s) to avoid damage or improper
valve timing. b. With the timing chain tensioner rod turned all
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
the way into the timing chain tensioner hous-
ing (with the thin screwdriver still installed), in-
3. Install:
stall the gasket and the timing chain tensioner
• Dowel pins
“2” onto the cylinder block.
• Camshaft cap
• Camshaft cap bolts
3
TIP
• Lubricate the camshaft cap bolt threads with
1
engine oil.
• Finger tighten the camshaft cap bolts.
4. Tighten: 3
• Camshaft cap bolts 2
Camshaft cap bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
TIP
TIP Always use a new gasket.
Tighten the camshaft cap bolts in the order of the c. Tighten the timing chain tensioner bolts “3” to
embossed numbers on the camshaft cap. the specified torque.
Timing chain tensioner bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
5
8
d. Remove the screwdriver, make sure the tim-

3
2
ing chain tensioner rod releases, and then

tighten the cap bolt to the specified torque.
4
Cap bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
6
T.
R.
ECA1SD1014
TIP
NOTICE Return the timing chain tensioner rod by remov-
The camshaft cap bolts must be tightened ing the screwdriver.
evenly or damage to the cylinder head, cam- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
shaft cap, and camshafts will result. 6. Tighten:
5. Install: • Camshaft sprocket bolt “1”
• Timing chain tensioner
5-13
CAMSHAFTS
Camshaft sprocket bolt

20 Nm (2.0 m·kgf, 14 ft·lbf)
T.
R.
TIP
Tighten the camshaft sprocket bolts in the prop-
er tightening sequence as shown.
5
4,6
1 1,3
1
7. Turn:
• Crankshaft
(several turns counterclockwise)
8. Check:
• Mark
Make sure the TDC mark is aligned with the
alignment mark.
• Camshaft sprocket match mark
Make sure the match marks on the camshaft
sprockets are aligned with the cylinder head
mating surface.
Out of alignment → Reinstall.
Refer to the installation steps above.
9. Measure:
• Valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-4.
10.Install:
• Plug
• Cylinder head cover gasket New
Cylinder head cover volt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
TIP
Apply Yamaha bond No. 1215 onto the mating
surface of the plug and cylinder head.
Yamaha bond No. 1215

90890-85505
5-14
CYLINDER HEAD
EAS24100
CYLINDER HEAD
Removing the cylinder head
(4) New
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
18 Nm (1.8 m•kgf, 13 ft•Ibf)

T.R
.
New
5 7
1
6 New
3 New
2
E
E
52 Nm (5.2 m•kgf, 38 ft•Ibf)
T.R
.
12 Nm (1.2 m•kgf, 8.7 ft•Ibf)

40 Nm (4.0 m•kgf, 29 ft•Ibf)
T.R
.
T.R
.

Exhaust pipe Refer to “ENGINE REMOVAL” on page 5-2.
Drain.
page 3-21.
Thermostat Refer to “THERMOSTAT” on page 6-4.
Camshaft Refer to “CAMSHAFTS” on page 5-7.
Intake manifold Refer to “THROTTLE BODY” on page 7-4.
Rear shock absorber assembly SEMBLIES AND SWINGARM” on page
4-63.
1 Coolant temperature sensor 1
2 Air induction system pipe 1
3 Gasket 1
4 Heat protector 1
5 Cylinder head 1
6 Gasket 1
7 Dowel pin 2
5-15
CYLINDER HEAD
Removing the cylinder head
(4) New
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
18 Nm (1.8 m•kgf, 13 ft•Ibf)

T.R
.
New
5 7
1
6 New
3 New
2
E
E
52 Nm (5.2 m•kgf, 38 ft•Ibf)
T.R
.
12 Nm (1.2 m•kgf, 8.7 ft•Ibf)

40 Nm (4.0 m•kgf, 29 ft•Ibf)
T.R
.
T.R
.

8 Timing chain guide (exhaust side) 1
dure.
5-16
CYLINDER HEAD
EAS24120
REMOVING THE CYLINDER HEAD Warpage limit

1. Remove: 0.05 mm (0.0020 in)
• Cylinder head bolts
• Cylinder head nuts ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
TIP
a. Place a straightedge “1” and a thickness
gauge “2” across the cylinder head.
• 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.
×
4 2 2
×
2
1 3
×
2 1 2
EAS24160
CHECKING THE CYLINDER HEAD

1. Eliminate:
• Combustion chamber carbon deposits
(with a rounded scraper)
TIP
Do not use a sharp instrument to avoid damag-
b. Measure the warpage.
ing or scratching:
c. If the limit is exceeded, resurface the cylinder
• Spark plug bore threads
head as follows.
• Valve seats
d. Place a 400–600 grit wet sandpaper on the
surface plate and resurface the cylinder head
using a figure-eight sanding pattern.
TIP
To ensure an even surface, rotate the cylinder
head several times.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24180
CHECKING THE TIMING CHAIN GUIDE

1. Check:
• Timing chain guide (exhaust side)
2. Check: Damage/wear → Replace.
• Cylinder head
Damage/scratches → Replace. EAS24240
• Cylinder head water jacket INSTALLING THE CYLINDER HEAD

1. Install:
Mineral deposits/rust → Eliminate.
3. Measure: • Cylinder head gasket New
• Cylinder head warpage • Dowel pins
Out of specification → Resurface the cylinder 2. Install:
head. • Cylinder head
5-17
CYLINDER HEAD
TIP
Pass the timing chain through the timing chain
cavity.
3. Tighten:
• Cylinder head nuts “1”
• Cylinder head nuts “2”
• Cylinder head bolts
Cylinder head nut (Timing chain

side)
T.
R.
40 Nm (4.0 m·kgf, 29 ft·lbf)

Cylinder head nut (V-belt side)
52 Nm (5.2 m·kgf, 38 ft·lbf)
Cylinder head bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
TIP
• Lubricate the cylinder head nuts and washers
with engine oil.
• Tighten the cylinder head nuts in the proper
tightening sequence as shown and torque
them in two stages.
×
1 3 2
1 2
×
2
4 2
×
2
5-18
VALVES AND VALVE SPRINGS
EAS24270

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

Cylinder head Refer to “CYLINDER HEAD” on page 5-15.
1 Valve lifter 4
2 Valve pad 4
3 Valve cotter 8
4 Upper valve spring seat 4
5 Valve spring 4
6 Exhaust valve 2
7 Intake valve 2
8 Valve stem seal 4
9 Lower valve spring seat 4
10 Valve guide 4
dure.
5-19
EAS24280
REMOVING THE VALVES TIP

The following procedure applies to all of the Remove the valve cotters by compressing the
valves and related components. valve spring with the valve spring compressor
TIP
“2” and the valve spring compressor attachment
“3”.
Before removing the internal parts of the cylinder
head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal. Valve spring compressor
90890-04019
1. Remove: YM-04019
• Valve lifter “1” Valve spring compressor attach-
• Valve pad “2” ment
TIP 90890-01243
Valve spring compressor adapt-
Make a note of the position of each valve lifter er (26 mm)
and valve pad so that they can be reinstalled in YM-01253-1
their original place.
2. Check: 4. Remove:
• Valve sealing • Upper spring seat “1”
Leakage at the valve seat → Check the valve • Valve spring “2”
face, valve seat, and valve seat width. • Valve “3”
Refer to “CHECKING THE VALVE SEATS” • Valve stem seal “4”
on page 5-22. • Lower spring seat “5”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ TIP
a. Pour a clean solvent “a” into the intake and Identify the position of each part very carefully so
exhaust ports. that it can be reinstalled in its original place.
b. Check that the valves properly seal.
TIP
There should be no leakage at the valve seat “1”.
1
5 4
2
3
1 a
EAS24290
CHECKING THE VALVES AND VALVE

GUIDES
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ The following procedure applies to all of the
3. Remove: valves and valve guides.
• Valve cotters “1”
5-20
1. Measure:
• Valve-stem-to-valve-guide clearance
Out of specification → Replace the valve
guide.
• Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” -
Valve stem diameter “b”
Valve-stem-to-valve-guide clear-
ance (intake)
0.010–0.037 mm (0.0004–0.0015 b. Install the new valve guide with the valve
in) guide installer “2” and valve guide remover
Limit “1”.
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
0.100 mm (0.0039 in)
c. After installing the valve guide, bore the valve

guide with the valve guide reamer “3” to ob-
tain the proper valve-stem-to-valve-guide
clearance.
TIP
After replacing the valve guide, reface the valve
seat.
2. Replace:
• Valve guide
TIP
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100°C (212°F).
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve guide with the valve guide
remover “1”.
5-21
Valve guide remover (ø5) Valve stem runout

90890-04097 0.010 mm (0.0004 in)
Valve guide remover (5.0 mm)
YM-04097
Valve guide installer (ø5)
90890-04098
Valve guide installer (5.0 mm)
YM-04098
Valve guide reamer (ø5)
90890-04099
Valve guide reamer (5.0 mm)
YM-04099
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate: EAS24300
• Carbon deposits CHECKING THE VALVE SEATS

(from the valve face and valve seat) The following procedure applies to all of the
4. Check: valves and valve seats.
• Valve face 1. Eliminate:
Pitting/wear → Grind the valve face. • Carbon deposits
• Valve stem end (from the valve face and valve seat)
Mushroom shape or diameter larger than the 2. Check:
body of the valve stem → Replace the valve. • Valve seat
5. Measure: Pitting/wear → Replace the cylinder head.
• Valve margin thickness D “a” 3. Measure:
Out of specification → Replace the valve. • Valve seat width C “a”
Out of specification → Replace the cylinder
Valve margin thickness D (intake) head.
1.15–1.45 mm (0.0453–0.0571 in)
Valve margin thickness D (ex- Valve seat width C (intake)
haust) 0.90–1.10 mm (0.0354–0.0433 in)
1.15–1.45 mm (0.0453–0.0571 in) Limit
1.6 mm (0.06 in)
Valve seat width C (exhaust)
1.00–1.20 mm (0.0394–0.0472 in)
Limit
1.6 mm (0.06 in)
6. Measure:
• Valve stem runout
Out of specification → Replace the valve.
TIP
• When installing a new valve, always replace ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
the valve guide. a. Apply blue layout fluid “b” onto the valve face.
• If the valve is removed or replaced, always re-
place the valve stem seal.
5-22
d. Turn the valve until the valve face and valve

seat are evenly polished, then clean off all of
the lapping compound.
TIP
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth be-
tween your hands.
b. Install the valve into the cylinder head.

c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat width.
TIP
Where the valve seat and valve face contacted
one another, the blue layout fluid will have been
e. Apply a fine lapping compound to the valve
removed.
face and repeat the above steps.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ f. After every lapping procedure, be sure to
4. Lap: clean off all of the lapping compound from the
• Valve face valve face and valve seat.
• Valve seat g. Apply blue layout fluid “b” onto the valve face.
TIP
After replacing the cylinder head or replacing the
valve and valve guide, the valve seat and valve
face should be lapped.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound “a” to the
valve face.
ECA13790
NOTICE
Do not let the lapping compound enter the
gap between the valve stem and the valve h. Install the valve into the cylinder head.
guide. i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width “c” again. If the
valve seat width is out of specification, reface
and lap the valve seat.
b. Apply molybdenum disulfide oil onto the

valve stem.
c. Install the valve into the cylinder head.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-23
EAS24310
CHECKING THE VALVE SPRINGS

valve springs.
1. Measure:
• Valve spring free length “a”
spring.
Free length (intake)

46.45 mm (1.83 in)
Limit b. Installed length
44.13 mm (1.74 in)
Free length (exhaust) 3. Measure:
46.45 mm (1.83 in) • Valve spring tilt “a”
Limit Out of specification → Replace the valve
44.13 mm (1.74 in) spring.
Spring tilt limit

2.5°/2.0 mm (2.5°/0.08 in)
2. Measure:
• Compressed valve spring force “a”
spring. EAS24320
CHECKING THE VALVE LIFTERS

Installed compression spring The following procedure applies to all of the
force (intake) valve lifters.
160.50–184.70 N (16.37–18.83 1. Check:
kgf, 36.08–41.52 lbf) • Valve lifter
Installed compression spring
Damage/scratches → Replace the valve lift-
force (exhaust)
160.50–184.70 N (16.37–18.83 ers and cylinder head.
kgf, 36.08–41.52 lbf)
Installed length (intake)
35.10 mm (1.38 in)
Installed length (exhaust)
35.10 mm (1.38 in)
EAS24340
INSTALLING THE VALVES

valves and related components.
5-24
1. Deburr:
• Valve stem end 5
(with an oil stone) 1
4
3
2 New
2. Lubricate:
• Valve stem “1”
• Valve stem end
• Valve stem seal “2”
(with the recommended lubricant)
Molybdenum disulfide oil
b. Smaller pitch
4. Install:
• Valve cotters “1”
TIP
M Install the valve cotters by compressing the
valve springs with the valve spring compressor
“2” and the valve spring compressor attachment
M “3”.
Valve spring compressor

3. Install: 90890-04019
• Lower spring seat “1” YM-04019
Valve spring compressor attach-
• Valve stem seal “2” New ment
• Valve “3” 90890-01243
• Valve spring “4” Valve spring compressor adapt-
• Upper spring seat “5” er (26 mm)
(into the cylinder head) YM-01253-1
TIP
• Make sure each valve is installed in its original
place. 2
• Install the valve springs with the larger pitch “a”
facing up. 3
5-25
5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
ECA13800
NOTICE
Hitting the valve tip with excessive force
could damage the valve.
6. Lubricate:
• Valve pad
Molybdenum disulfide oil
• Valve lifter
Engine oil
7. Install:
• Valve pad “1”
• Valve lifter “2”
TIP
• The valve lifter must move smoothly when ro-
tated with a finger.
• Each valve lifter and valve pad must be rein-
stalled in its original position.
• Install the valve pads with the number side fac-
ing valve lifter side.
2
1
5-26
CYLINDER AND PISTON
EAS24350
CYLINDER AND PISTON

Removing the cylinder and piston
7 New
9
12
11
10 8
New 7
E
E
4
LS
New 5 New
2 New
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 3

1
T.R
.

T.R
T.R
LT
.

Cylinder head Refer to “CYLINDER HEAD” on page 5-15.
1 Water head pipe 1
2 O-ring 1
3 Air induction system pipe stay bolt 1
4 Cylinder 1
5 Cylinder gasket 1
6 Dowel pin 2
7 Piston pin clip 2
8 Piston pin 1
9 Piston 1
10 Top ring 1
11 Second ring 1
12 Oil ring 1
dure.
5-27
CYLINDER AND PISTON
EAS24380
REMOVING THE PISTON TIP

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
NOTICE
Do not use a hammer to drive the piston pin
out.
TIP
• Before removing the piston pin clips, cover the
crankcase opening with a clean rag to prevent
them from falling into the crankcase.
• Before removing the piston pin, deburr the pis-
ton pin clip groove and the piston pin bore ar- EAS24400
ea. If both areas are deburred and the piston CHECKING THE CYLINDER AND PISTON
pin is still difficult to remove, remove it with the 1. Check:
piston pin puller set “4”. • Piston wall
• Cylinder wall
Piston pin puller set Vertical scratches → Replace the cylinder,
90890-01304 piston and piston 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.
TIP
Measure cylinder bore “C” by taking side-to-side
3 1 and front-to-back measurements of the cylinder.
Then, find the average of the measurements.
2
Bore
83.000–83.010 mm (3.2677–
3.2681 in)
“C” = (X + Y)/2
2. Remove:
• Top ring
a. 40mm (1.57 in)
• 2nd ring
• Oil ring b. If out of specification, replace the cylinder,
piston and piston rings as a set.
c. Measure piston skirt diameter D “a” with the
micrometer.
5-28
CYLINDER AND PISTON
Piston ring side clearance

Top ring
Ring side clearance
0.030–0.070 mm (0.0012–
0.0028 in)
Limit
0.100 mm (0.0039 in)
2nd ring
Ring side clearance
0.020–0.055 mm (0.0008–
0.0022 in)
b. 5 mm (0.20 in) from the bottom edge of the
piston
Limit
0.100 mm (0.0039 in)
Diameter D
82.930–82.945 mm (3.2650–
3.2655 in)
d. If out of specification, replace the piston and

piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance
Cylinder bore “C” -
Piston skirt diameter “D”
2. Install:
• Piston ring
Piston-to-cylinder clearance (into the cylinder)
0.060–0.075 mm (0.0024–0.0030
in) TIP
Limit Level the piston ring into the cylinder with the
0.15 mm (0.0059 in) piston crown.
f. If out of specification, replace the cylinder,

piston and piston rings as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24430
CHECKING THE PISTON RINGS

1. Measure:
• Piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set.
TIP
Before measuring the piston ring side clearance, a. 40 mm (1.57 in)
eliminate any carbon deposits from the piston 3. Measure:
ring grooves and piston rings. • Piston ring end gap
Out of specification → Replace the piston
ring.
TIP
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings.
5-29
CYLINDER AND PISTON
Piston ring end gap

Top ring
End gap (installed)
0.20–0.35 mm (0.0079–0.0138
in)
Limit
0.50 mm (0.0197 in)
2nd ring
End gap (installed)
0.40–0.55 mm (0.0157–0.0217
in)
4. Calculate:
Limit
0.80 mm (0.0315 in) • Piston-pin-to-piston-pin-bore clearance
Oil ring Out of specification → Replace the piston pin
End gap (installed) and piston as a set.
0.10–0.40 mm (0.0039–0.0157 Piston-pin-to-piston-pin-bore clearance =
in) Piston pin bore diameter “b”–
Piston pin outside diameter “a”
EAS24440
CHECKING THE PISTON PIN

1. Check: Piston-pin-to-piston-pin-bore
• Piston pin clearance
0.004–0.024 mm (0.0002–0.0009
Blue discoloration/grooves → Replace the
in)
piston pin and then check the lubrication sys-
tem. EAS24450
2. Measure: INSTALLING THE PISTON AND CYLINDER
• Piston pin outside diameter “a” 1. Install:
Out of specification → Replace the piston pin. • Top ring
• 2nd ring
Piston pin outside diameter
• Upper oil ring rail
19.991–20.000 mm (0.7870–
0.7874 in) • Lower oil ring rail
Limit • Oil ring expander
19.971 mm (0.7862 in) TIP
Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up.
3. Measure:
• Piston pin bore diameter “b”
Out of specification → Replace the piston. 2. Install:
• Piston “1”
Piston pin bore inside diameter • Piston pin “2”
20.004–20.015 mm (0.7876– • Piston pin clips “3” New
0.7880 in)
Limit TIP
20.045 mm (0.7892 in) • Apply engine oil the piston pin.
5-30
CYLINDER AND PISTON
• Make sure the arrow mark “a” on the piston TIP

points towards the exhaust side of the cylinder. • While compressing the piston rings with one
• Before installing the piston pin clips, cover the hand, install the cylinder with the other hand.
crankcase opening with a clean rag to prevent • Pass the timing chain and timing chain guide
the clips from falling into the crankcase. (intake side) through the timing chain cavity.
1
a
3
2
3. Install:
• Cylinder gasket New
• Dowel pins
4. Lubricate:
• Piston
• Piston rings
• Cylinder
Engine oil
5. Offset:
• Piston ring end gap
d b
135˚ 135˚
e a,c
90˚ 90˚
EX
a. Top ring
b. Upper oil ring rail
c. Oil ring expander
d. Lower oil ring rail
e. 2nd ring
6. Install:
• Cylinder “1”
Cylinder bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
5-31
V-BELT AUTOMATIC TRANSMISSION
EAS24610

Removing the V-belt case cover
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
LT
LT 8
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
LT
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
(9)
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
7
.
LT
9 (6)
6
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
5
22 Nm (2.2 m•kgf, 16 ft•Ibf) 4
1
T.R
.
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

(4)
T.R
.
(4)
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.

Left air filter case 4-1.
1 V-belt case cover mole 1
2 V-belt case air filter cover 1
3 V-belt case air filter element 1
4 V-belt case cover 1
5 V-belt case cover gasket 1
6 V-belt case 1
7 V-belt case air duct 1 1
dure.
5-32
Removing the V-belt, primary sheave and secondary sheave
6
5
4
*1
LS
New
*2 3
13
12 8 3
New
2 1
11 1
9
10
*1
7
*2 83 Nm (8.3 m•kgf, 60 ft•Ibf)

T.R
.
60 Nm (6.0 m•kgf, 43 ft•Ibf)

T.R
.

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

*2 Apply BEL-RAY assembly lube®.
5-33
Disassembling the secondary sheave

9 New
5
New
4
3 New
90 Nm (9.0 m•kgf, 65 ft •Ibf)
*
T.
R.
2
10
6
9 New
* 1
7
* New
8
* *
1 Clutch carrier nut 1
2 Clutch carrier 1
3 Clutch shoe spring 5
4 Compression spring 1
5 Spring seat 1
6 Guide pin 4
7 Secondary sliding sheave 1
8 O-ring 2
9 Oil seal 2
10 Secondary fixed sheave 1
cedure.
* Apply BEL-RAY assembly lube®.
5-34
EAS24620
REMOVING THE PRIMARY SHEAVE

1. Remove:
• V-belt case 2
TIP
Loosen each bolt 1/4 of a turn at a time, in stag-
1
es and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.
2. Remove: 3
• Primary sheave nut “1”
• Collar 2. Loosen:
• Primary fixed sheave “2” • Clutch carrier nut “1”
TIP ECA13860
NOTICE
While holding the primary fixed sheave with the
rotor holding tool “3”, loosen the primary sheave Do not remove the clutch carrier nut at this
nut “1”. stage.
TIP
Rotor holding tool While holding the clutch carrier with the rotor
90890-01235 holding tool “2”, loosen the clutch carrier nut one
Universal magneto & rotor holder full turn with the locknut wrench “3”.
YU-01235
Rotor holding tool

90890-01235
3 YU-01235
Locknut wrench
90890-01348
YM-01348
2 1
2
EAS24630
REMOVING THE SECONDARY SHEAVE

1. Remove: 3
• Secondary sheave nut “1”
• Collar
• Clutch housing “2” 1
TIP
While holding the clutch housing with the sheave 3. Remove:
holder “3”, loosen the secondary sheave nut “1”. • Secondary sheave assembly “1”
• V-belt “2”
Sheave holder TIP
90890-01701 Remove the V-belt and secondary sheave as-
Primary clutch holder sembly from the primary sheave side.
YS-01880-A
5-35
Clutch housing inside diameter

160.0 mm (6.30 in)
Limit
160.5 mm (6.32 in)
2 1 a
EAS24640
DISASSEMBLING THE SECONDARY

SHEAVE
1. Remove:
• Clutch carrier nut “1”
TIP EAS24660
Install the sheave spring compressor “2” and CHECKING THE CLUTCH SHOES
sheave fixed block “3” onto the secondary The following procedure applies to all of the
sheave as shown. Then, compress the spring, clutch shoes.
and remove the clutch carrier nut. 1. Check:
• Clutch shoe
Sheave spring compressor Damage/wear → Replace the clutch shoes
90890-04134 and springs as a set.
YM-04134 Glazed areas → Sand with course sandpa-
Sheave fixed block per.
90890-04135 TIP
Sheave fixed bracket
YM-04135 • After sanding the glazed areas, clean the
clutch with a cloth.
• Do not apply the grease or oil on the clutch
shoes.
2
2. Measure:
• Clutch shoe thickness “a”
Out of specification → Replace the clutch
1 shoes and springs as a set.
a a
3
a a
EAS24650
CHECKING THE CLUTCH HOUSING a a

1. Check:
• Clutch housing a a
2. Measure: a a
• Clutch housing inside diameter “a”
Out of specification → Replace the clutch Clutch shoe thickness
housing. 4.0 mm (0.16 in)
Limit
2.5 mm (0.10 in)
5-36
EAS24670
CHECKING THE V-BELT

1. Check:
• V-belt “1”
Grease/oil → Clean the primary and second-
ary sheave.
2. Measure:
• V-belt width “a”
V-belt width EAS24700

30 mm (1.18 in) CHECKING THE SLIDER
Limit 1. Check:
27 mm (1.06 in) • Slider
1 EAS24710
CHECKING THE SECONDARY SHEAVE

a 1. Check:
• Secondary fixed sheave
• Secondary sliding sheave
Cracks/damage/wear → Replace the sec-
ondary fixed and sliding sheaves as a set.
2. Check:
• Torque cam groove “1”
Damage/wear → Replace the secondary
EAS24680
fixed and sliding sheaves as a set.
CHECKING THE PRIMARY SHEAVE 3. Check:
1. Check: • Guide pin “2”
• Primary sliding sheave Damage/wear → Replace the secondary
• Primary fixed sheave fixed and sliding sheaves as a set.
• Spacer
Cracks/damage/wear → Replace the primary
sliding sheave and primary fixed sheave as a
set.
EAS24690
CHECKING THE PRIMARY SHEAVE

WEIGHTS
The following procedure applies to all of the pri-
mary sheave weights.
1. Check:
• Primary sheave weight
4. Check:
• Compression spring free length
2. Measure:
Out of specification → Replace the spring.
• Primary sheave weight outside diameter
Out of specification → Replace. Compression spring free length
127.0 mm (5.00 in)
Weight outside diameter Limit
25.0 mm (0.98 in) 111.5 mm (4.39 in)
Limit
24.5 mm (0.96 in)
5-37
BEL-RAY assembly lube®
EAS24720
ASSEMBLING THE PRIMARY SHEAVE 1

1. Clean:
2
• Primary fixed sheave “1”
• Primary sliding sheave “2” 2. Install:
• Spacer “3” • Secondary sliding sheave “1”
• Primary sheave weights “4” TIP
• Cam
Install the secondary sliding sheave onto the
secondary fixed sheave “2” with the oil seal
guide “3”.
Oil seal guide (ø41)

90890-01396
2 3 4 3 1
1
2
2. Install:
• Primary sheave weights
• Spacer
TIP 3. Install:
Before installing the primary sheave weights, lu- • Guide pin “1”
bricate the inside and outside of each weight 4. Lubricate:
with BEL-RAY assembly lube®. • Guide pin groove “2”
• O-ring “3” New
3. Install:
• Slider
• Cam Recommended lubricant
EAS24730
ASSEMBLING THE SECONDARY SHEAVE
1. Lubricate:
• Secondary fixed sheave inner surface “1”
• Secondary sliding sheave inner surface “2”
• Oil seals
• Bearings
5-38
• Install the V-belt with the printed arrow mark on

the V-belt facing in the direction shown in the il-
lustration.
New 3 1
5. Install:
• Spring seat
• Compression spring 1 2
• Clutch carrier 2. Tighten:
• Clutch carrier nut “1” • Clutch carrier nut “1”
TIP
Install the sheave spring compressor “2” and Clutch carrier nut
sheave fixed block “3” onto the secondary 90 Nm (9.0 m·kgf, 65 ft·lbf)
T.
R.
sheave as shown. Then, compress the spring,
and install the clutch carrier nut. TIP
While holding the clutch carrier with the rotor
Sheave spring compressor holding tool “2”, tighten the clutch carrier nut with
90890-04134 the locknut wrench “3”.
YM-04134
Sheave fixed block Rotor holding tool
90890-04135 90890-01235
Sheave fixed bracket Universal magneto & rotor holder
YM-04135 YU-01235
Locknut wrench
90890-01348
2 YM-01348
1 2
3
3
EAS24740
INSTALLING THE V-BELT 1

1. Install:
• V-belt “1” 3. Install:
• Secondary sheave assembly “2” • Clutch housing “1”
ECA1SD1011
• Collar
NOTICE • Secondary sheave nut “2”
Do not allow grease to contact the V-belt, pri-
mary and secondary sheave. Secondary sheave nut
60 Nm (6.0 m·kgf, 43 ft·lbf)
T.
R.
TIP
• Install the V-belt onto the primary sheave side.
5-39
TIP
While holding the clutch housing with the sheave
holder “3”, tighten the secondary sheave nut.
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
1
2
5. Install:
1 • V-belt case
V-belt case bolt (M8)

2 22 Nm (2.2 m·kgf, 16 ft·lbf)
T.
R.
V-belt case bolt (M6)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
3 TIP
Tighten the V-belt case bolts in stages and in a
4. Install:
crisscross pattern.
• V-belt
• Primary fixed sheave
• Collar
• Primary sheave nut
Primary sheave nut

83 Nm (8.3 m·kgf, 60 ft·lbf)
T.
R.
TIP
• Install the V-belt onto the primary sheave “1”
(when the pulley is at its widest position) and
onto the secondary sheave assembly “2”
(when the pulley is at its narrowest position),
and make sure the V-belt is tight.
• While holding the primary fixed sheave with the
rotor holding tool, tighten the primary sheave
nut.
• After replacing the V-belt, and then reset the V-
belt replacement indicator. Refer to “INSTRU-
MENT FUNCTIONS” on page 1-4.
Rotor holding tool

90890-01235
YU-01235
5-40
STARTER CLUTCH AND GENERATOR
EAS24520

Removing the generator cover and stator coil
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
2
5
5
1
4
10
New 7
9
3 8
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
LT
8
6
(11)
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.

Footrest board/Right air filter case 4-1.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-19.
Drain.
page 3-21.
Muffler/Exhaust pipe Refer to “ENGINE REMOVAL” on page 5-2.
Refer to “AIR INDUCTION SYSTEM” on
Air cut-off valve page 7-11.
1 Catch tank 1 Disconnect.
2 Thermostat inlet hose 1 Disconnect.
3 Water pump inlet hose 1 Disconnect.
4 Heat exchanger outlet hose 1 Disconnect.
Crankshaft position sensor coupler/Stator coil
5 1/1 Disconnect.
assembly coupler
5-41
Removing the generator cover and stator coil
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
2
5
5
1
4
10
New 7
9
3 8
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
LT
8
6
(11)
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.

6 Generator cover 1
7 Gasket 1
8 Dowel pin 2
Refer to “INSTALLING THE GENERATOR”
9 Stator coil assembly 1 on page 5-45.
10 Crankshaft position sensor 1
dure.
5-42
Removing the generator rotor and starter clutch
130 Nm (13 m•kgf, 94 ft•lbf)
T.R
.
5
4
6
3
2
E
1
E
LT (6)
30 Nm (3.0 m•kgf, 22 ft•Ibf)

T.R
.

1 Generator rotor 1
2 Starter clutch 1
3 Woodruff key 1
4 Starter clutch idle gear shaft 1
5 Starter clutch idle gear 1
6 Starter clutch gear 1
dure.
5-43
EAS1SD1027 ECA1SD1012
REMOVING THE GENERATOR NOTICE

1. Remove: To protect the end of the crankshaft, place
• Generator cover bolt the flywheel puller attachment between the
• Generator cover flywheel puller set center bolt and the crank-
TIP shaft.
Loosen each bolt 1/4 of a turn at a time, in stag-
TIP
es and in a crisscross pattern. After all of the
bolts are fully loosened, remove them. • Install the flywheel puller bolts to the threaded
holes of the starter clutch.
2. Remove: • Make sure the flywheel puller “2” and flywheel
• Generator rotor nut “1” puller attachment “3” are centered over the
• Washer generator rotor.
• Starter clutch bolt “2”
TIP
• While holding the generator rotor “3” with the 2
3
sheave holder “4”, loosen the generator rotor
nut and all starter clutch bolts.
• Do not allow the sheave holder to touch the
projection on the generator rotor.
• Remove every other starter clutch bolt “2” (3
bolts only) to install the flywheel puller.
Sheave holder
90890-01701
Primary clutch holder Flywheel puller
YS-01880-A 90890-01362
Heavy duty puller
YU-33270-B
Flywheel puller attachment
2 1 90890-04155
4. Remove:
4 • Starter clutch bolt
3 • Starter clutch
EAS24570
2 CHECKING THE STARTER CLUTCH
1. Check:
• Starter clutch rollers “1”
3. Remove: Damage/wear → Replace.
• Generator rotor “1”
(with the starter clutch)
• Woodruff key
• Starter clutch gear
2. Check:
• Starter clutch idle gear
5-44
• Starter clutch gear TIP

Burrs/chips/roughness/wear → Replace the • While holding the generator rotor “1” with the
defective part(s). sheave holder “2”, tighten the starter clutch bolt
3. Check: “3”.
• Starter clutch gear contacting surfaces • Do not allow the sheave holder to touch the
Damage/pitting/wear → Replace the starter projection on the generator rotor.
clutch gear.
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
4. Check:
• Starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch gear “1” onto the
starter clutch “2” and hold the starter clutch.
b. When turning the starter clutch gear clock-
EAS1SD1028
wise “A”, the starter clutch and the starter INSTALLING THE GENERATOR
clutch gear should engage. Otherwise the 1. Install:
starter clutch is faulty and must be replaced. • Starter clutch gear “1”
c. When turning the starter clutch gear counter- • Woodruff key “2”
clockwise “B”, it should turn freely. Otherwise • Generator rotor
the starter clutch is faulty and must be re- • Washer
placed. • Generator rotor nut
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TIP
EAS24600
INSTALLING THE STARTER CLUTCH • Clean the tapered portion of the crankshaft and
1. Install: the generator rotor hub.
• Starter clutch • When installing the generator rotor, make sure
the woodruff key is properly seated in the key-
Starter clutch bolt way of the crankshaft.
30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
2. Tighten:
R.
LOCTITE®
• Generator rotor nut “1”
Generator rotor nut

130 Nm (13 m·kgf, 94 ft·lbf)
T.
R.
5-45
TIP • Tighten the generator rotor cover bolts in stag-

• While holding the generator rotor “2” with the es and in a crisscross pattern.
sheave holder “3”, tighten the generator rotor
nut.
• Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder
90890-01701
Primary clutch holder b a
YS-01880-A
3
2
3. Apply:
• Sealant
(onto the crankshaft position sensor/stator
assembly lead grommet)

90890-85505
4. Install:
• Generator cover
• Generator cover bolt
Generator cover bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
TIP
• Align the projection “a” on the impeller shaft
with the slit “b” on the balancer shaft.
5-46
OIL PUMP
EAS24910
OIL PUMP
Removing the oil pump
11
12
New
5
7 10
8
New 2
4
6 9
1.0 Nm (0.10 m•kgf, 0.72 ft•Ibf)
T.R
.
1 4
E
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Refer to “STARTER CLUTCH AND GENER-
Generator rotor ATOR” on page 5-41.
1 Oil pump assembly 1
2 Oil pump gasket 1
3 Oil pump housing cover 1
4 Pin 2
5 Oil pump shaft 1
6 Pin 1
7 Oil pump inner rotor 1
8 Oil pump outer rotor 1
9 Oil pump housing 1
10 Oil pump driven sprocket 1
11 Oil pump drive chain 1
12 Oil pump drive sprocket 1
dure.
5-47
OIL PUMP
EAS24960
CHECKING THE OIL PUMP

1. Check:
• Oil pump drive gear
• Oil pump driven gear
• Oil pump housing
• Oil pump housing cover
Cracks/damage/wear → Replace the defec-
tive part(s).
2. Measure:
• Inner-rotor-to-outer-rotor-tip clearance “a”
• Outer-rotor-to-oil-pump-housing clearance
“b”
• Oil-pump-housing-to-inner-rotor-and-outer-
rotor clearance “c”
Out of specification → Replace the oil pump.
Inner-rotor-to-outer-rotor-tip
clearance
Less than 0.150 mm (0.0059 in)
Limit
0.23 mm (0.0091 in) 1. Inner rotor
Outer-rotor-to-oil-pump-housing
2. Outer rotor
clearance
3. Rotor housing
0.010–0.034 mm (0.0005–0.0013
in) 3. Check:
Limit • Oil pump operation
0.104 mm (0.0041 in) Rough movement → Repeat steps (1) and
Oil-pump-housing-to-inner-and- (2) or replace the defective part(s).
outer-rotor clearance
0.040–0.096 mm (0.0016–0.0038 EAS25620
in) CHECKING THE OIL PUMP DRIVE CHAIN

Limit 1. Check:
0.166 mm (0.0065 in) • Oil pump drive chain
Damage/stiffness → Replace the oil pump
drive chain, oil pump drive sprocket and oil
pump driven sprocket as a set.
2. Check:
• Oil pump drive sprocket
• OIl pump driven sprocket
Cracks/damage/wear → Replace the oil
pump drive sprocket, oil pump driven sprock-
et and oil pump drive chain as a set.
EAS25000
ASSEMBLING THE OIL PUMP

1. Lubricate:
• Inner rotor
• Outer rotor
• Oil pump shaft
Engine oil
5-48
OIL PUMP
2. Install:
• Oil pump shaft “1”
(to the oil pump cover “2”) a
• Pin “3”
• Inner rotor “4”
• Outer rotor “5”
• Oil pump housing “6”
• Oil pump housing screw
b
Oil pump housing screw
1.0 Nm (0.10 m·kgf, 0.72 ft·lbf)
T.
R.
TIP
When installing the inner rotor, align the pin “3”
in the oil pump shaft with the groove in the inner
rotor “4”.
3. Check:
• Oil pump operation
Refer to “CHECKING THE OIL PUMP” on
page 5-48.
EAS25020
INSTALLING THE OIL PUMP

1. Install:
• Oil pump gasket New
• Oil pump assembly
Oil pump assembly bolt

7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.
ECA13890
NOTICE
After tightening the bolts, make sure the oil
pump turns smoothly.
TIP
Align the projection “a” on the oil pump shaft with
the groove in the oil pump driven gear shaft “b”.
5-49
ELECTRIC STARTER
EAS1SD1029
ELECTRIC STARTER
Removing the starter motor
3.8 Nm (0.38 m•kgf, 2.8 ft•Ibf)
T.R
.
3 2
LS
New
1
12 Nm (1.2 m•kgf, 8.7 ft•Ibf)
T.R
.

Air filter case 4-1.
Throttle body Refer to “THROTTLE BODY” on page 7-4.
1 Ground lead 1 Disconnect.
2 Starter motor lead 1 Disconnect.
3 Starter motor assembly 1
dure.
5-50
ELECTRIC STARTER
Disassembling the starter motor
5 Nm (0.5 m•kgf, 3.6 ft•Ibf)
T.R
.
New 1
New 2
6
New 5
4 7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
3
.
11
New
12
New 8
10
7

1 Starter motor front cover 1
2 O-ring 1
3 Shim 1
4 Lock washer 1
5 Oil seal 1
6 Bearing 1
7 Starter motor rear cover 1
8 O-ring 1
9 Brush holder set 1
10 Bushing 1
11 Armature assembly 1
12 Starter motor yoke 1
dure.
5-51
ELECTRIC STARTER
EAS24790
CHECKING THE STARTER MOTOR Digital circuit tester

1. Check: 90890-03174
• Commutator Model 88 Multimeter with ta-
Dirt → Clean with 600 grit sandpaper. chometer
2. Measure: YU-A1927
• Commutator diameter “a”
Out of specification → Replace the starter
Armature coil
motor.
Commutator resistance “1”
Limit Continuity (0.0100–0.0140 Ω)
22.4 mm (0.88 in) Insulation resistance “2”
No continuity (Above 1 MΩ)
2
1
1
2
3. Measure:
• Mica undercut “a” b. If any resistance is out of specification, re-
Out of specification → Scrape the mica to the place the starter motor.
proper measurement with a hacksaw blade ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
that has been grounded to fit the commutator. 5. Measure:
• Brush length “a”
Mica undercut (depth) Out of specification → Replace the brushes
1.00 mm (0.04 in) as a set.
TIP Brush overall length

The mica of the commutator must be undercut to 9.0 mm (0.35 in)
ensure proper operation of the commutator. Limit
3.00 mm (0.12 in)
4. Measure:
• Armature assembly resistances (commutator 6. Measure:
and insulation) • Brush spring force
Out of specification → Replace the starter Out of specification → Replace the brush
motor. holder.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the armature assembly resistances Brush spring force
with the digital circuit tester. 7.75 N (790 gf, 27.90 oz)
5-52
ELECTRIC STARTER
7. Check:
• Gear teeth
Damage/wear → Replace the starter motor.
8. Check:
• Bearing
• Oil seal
Damage/wear → Replace the starter motor.
EAS24800
ASSEMBLING THE STARTER MOTOR

1. Install:
• Starter motor yoke “1”
• Starter motor front cover “2”
• Starter motor rear cover “3”
TIP
Align the match marks “a” on the starter motor
yoke with the match marks “b” on the starter mo-
tor front and rear covers.
3 1 2
b a b
EAS24810
INSTALLING THE STARTER MOTOR

1. Install:
• Starter motor
• Starter motor bolts
Starter motor bolt

12 Nm (1.2 m·kgf, 8.7 ft·lbf)
T.
R.
2. Connect:
• Starter motor lead
5-53
CRANKCASE
EAS25540
CRANKCASE
Separating the crankcase
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
LT
LT
New
6
LT
LT
7
2
3
1 10
4 New
5
New
6
9
E 8
(3)
E (7)
11
New 12
30 Nm (3.0 m•kgf, 22 ft•Ibf)
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
T.R
.
16 Nm (1.6 m•kgf, 12 ft•Ibf)

T.R
.

Engine Refer to “ENGINE REMOVAL” on page 5-2.
Refer to “CYLINDER AND PISTON” on page
Cylinder/piston 5-27.
V-belt automatic transmission SION” on page 5-32.
Oil pump Refer to “OIL PUMP” on page 5-47.
Transmission Refer to “TRANSMISSION” on page 5-64.
1 Timing chain 1
2 Timing chain guide (intake side) 1
3 Right crankcase 1
4 Dowel pin 1
5 O-ring 1
6 Dowel pin 2
7 Left crankcase 1
8 Relief valve assembly 1
5-54
CRANKCASE
Separating the crankcase
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
LT
LT
New
6
LT
LT
7
2
3
1 10
4 New
5
New
6
9
E 8
(3)
E (7)
11
New 12
30 Nm (3.0 m•kgf, 22 ft•Ibf)
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
T.R
.
16 Nm (1.6 m•kgf, 12 ft•Ibf)

T.R
.

9 Oil pump drive gear 1
10 Oil pump drive gear shaft 1
11 Oil pump driven gear 1
12 Oil pump driven gear shaft 1
dure.
5-55
CRANKCASE
EAS25560 EAS25580
DISASSEMBLING THE CRANKCASE CHECKING THE CRANKCASE

1. Remove: 1. Thoroughly wash the crankcase halves in a
• Crankcase bolts mild solvent.
TIP 2. Thoroughly clean all the gasket surfaces and
Loosen each bolt 1/4 of a turn at a time, in stag- crankcase mating surfaces.
es and in a crisscross pattern. After all of the 3. Check:
bolts are fully loosened, remove them. • Crankcase
• M6 × 70 mm (2.76 in) bolts “1” • Oil delivery passages
• M8 × 60 mm (2.36 in) bolts “2” Obstruction → Blow out with compressed air.
• M8 × 80 mm (3.15 in) bolts “3”
• M8 × 90 mm (3.54 in) bolts “4” EAS1SD1033
CHECKING THE TIMING CHAIN AND TIMING

• M8 × 100 mm (3.94 in) bolts “5”
CHAIN GUIDE
3 1 1. Check:
4 • Timing chain
Damage/stiffness → Replace the timing
chain, crankshaft and camshaft sprockets as
2 a set.
×
5 12
×
1
1 1
2. Remove:
• Right crankcase
ECA13900
NOTICE
Tap on one side of the crankcase with a soft-
face hammer. Tap only on reinforced por-
2. Check:
tions of the crankcase, not on the crankcase
• Timing chain guide (intake side)
mating surfaces. Work slowly and carefully
and make sure the crankcase halves sepa-
rate evenly. EAS1SD1030
CHECKING THE OIL PUMP GEAR AND OIL

PUMP SHAFT
1. Check:
• Oil pump drive gear
• Oil pump driven gear
• Oil pump drive gear shaft
• Oil pump driven gear shaft
Cracks/damage/wear → Replace the defec-
tive part(s).
EAS1SD1034
CHECKING THE RELIEF VALVE

1. Check:
• Relief valve body “1”
• Relief valve “2”
• Spring “3”
Damage/wear → Replace the defective
part(s).
5-56
CRANKCASE
• M8 × 60 mm (2.36 in) bolts “4”

• M6 × 70 mm (2.76 in) bolts “5”
3 2 3 5
1 4 ×
1 12
×
EAS25700
5 1
ASSEMBLING THE CRANKCASE 5
1. Thoroughly clean all the gasket mating sur-
faces and crankcase mating surfaces.
2. Apply:
• Sealant
(onto the crankcase mating surfaces)

90890-85505
TIP
Do not allow any sealant to come into contact
with the oil gallery.
3. Tighten:
• Crankcase bolts (M8)
• Crankcase bolts (M6)
Crankcase bolts (M8) “1”

30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
R.
Crankcase bolts (M8) “2–4”

16 Nm (1.6 m·kgf, 12 ft·lbf)
Crankcase bolts (M6) “5”
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
TIP
Tighten the crankcase bolts in stages and in a
crisscross pattern.
• M8 × 100 mm (3.94 in) bolts “1”
• M8 × 90 mm (3.54 in) bolts “2”
• M8 × 80 mm (3.15 in) bolts “3”
5-57
CRANKSHAFT ASSEMBLY
EAS25970
CRANKSHAFT ASSEMBLY
Removing the crankshaft assembly
2
E

Separate.
Crankcase Refer to “CRANKCASE” on page 5-54.
1 Crankshaft assembly 1
2 Balancer shaft assembly 1
dure.
5-58
CRANKSHAFT ASSEMBLY
Removing the crankcase bearing
E
2
1
E
LS
3 New

1 Crankshaft journal bearings 2
2 Bearings 2
3 Oil seal 1
dure.
5-59
CRANKSHAFT ASSEMBLY
EAS26050
REMOVING THE CRANKSHAFT JOURNAL

BEARINGS
1. Remove:
• Crankshaft journal bearings “1”
TIP
Remove the crankshaft journal bearing by the
bearing installer “2”.
Plane bearing installer

90890-04146
2. Check:
• Crankshaft journal surfaces
Scratches/wear → Replace the crankshaft.
3. Measure:
2
• Big end side clearance
1
Out of specification → Replace the crank-
shaft assembly.
Big end side clearance D

0.350–0.850 mm (0.0138–0.0335
in)
4. Measure:
• Crankshaft-journal-to-crankshaft-journal-
bearing oil clearance
2
shaft journal bearings as a set.
Journal oil clearance

0.030–0.077 mm (0.0012–0.0030
in)
1
crankshaft journal bearings.
TIP ECA13920
Identify the position of each crankshaft journal NOTICE

bearing so that it can be reinstalled in its original Do not interchange the crankshaft journal
place. bearings. To obtain the correct crankshaft-
journal-to-crankshaft-journal-bearing clear-
EAS26060 ance and prevent engine damage, the crank-
CHECKING THE CRANKSHAFT AND shaft journal bearings must be installed in
CONNECTING ROD their original positions.
1. Measure:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Crankshaft runout a. Clean the surface of the journal and the jour-
Out of specification → Replace the crank- nal bearing.
shaft, bearing or both. b. Check the bearing surface. If the bearing sur-
TIP face is worn or scratched, replace the bear-
Turn the crankshaft slowly. ings as a set.
TIP
Runout limit C If either of the left or right journal bearing is worn
0.030 mm (0.0012 in) or scratched, replace both bearings as a set.
5-60
CRANKSHAFT ASSEMBLY
c. Measure the crankshaft journal outside diam- A: Left crankcase

eter “a” in two places. If it is out of specifica- B: Right crankcase
tion, replace the crankshaft.
A
Crankshaft journal diameter 1
35.008–35.017 mm (1.3783–
1.3786 in)
d. Measure the journal bearing inside diameter

“b” in two places.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Select the crankshaft journal bearings from
the following table according to the number
stamped on the inside of the crankcase.
b Bearing color code
0 white
TIP 1 blue
When calculating the journal oil clearance, use 2 black
the larger of the two values from the crankshaft
3 brown
journal and use the smaller of the two values
from the journal bearing. 4 green
e. If the journal bearing inside diameter is ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
“35.064” and the crankshaft journal outside 6. Measure:
diameter is “35.014”, then the journal oil • Crank width
clearance is: Out of specification → Replace the crank-
Crankshaft-journal-to-crank-shaft-journal- shaft.
bearing oil clearance
Journal bearing inside diameter- Width A
Crankshaft journal outside diameter 63.95–64.00 mm (2.518–2.520 in)
=35.064–35.014 = 0.050mm
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Select:
• Crankshaft journal bearings
TIP
The numbers “1” on the crankcase are used to
determine the replacement crankshaft journal
bearing size.
5-61
CRANKSHAFT ASSEMBLY
7. Check: EAS1SD1035
• Crankshaft sprocket “1” CHECKING THE BEARING

Damage/wear → Replace the crankshaft. 1. Check:
• Balancer drive gear “2” • Bearings
Damage/wear → Replace the crankshaft. Clean and lubricate the bearings, then rotate
the inner race with your finger.
2 Rough movement → Replace.
EAS25630
INSTALLING THE CRANKSHAFT JOURNAL

BEARING
1. Attach:
1 • Crankshaft journal bearings “1”
TIP
Attach the crankshaft journal bearing to the
plane bearing installer “2”.
8. Check:
• Crankshaft journal Plane bearing installer
Scratches/wear → Replace the crankshaft. 90890-04146
• Oil delivery passages
A B
EAS26130
a
CHECKING THE BALANCER SHAFT
1. Check: a
• Balancer shaft
Scratches/wear → Replace the balancer b
shaft b
A. Left crankcase side

B. Right crankcase side
5-62
CRANKSHAFT ASSEMBLY
2. Install:
• Crankshaft journal bearings
TIP
• Install each crankshaft journal bearing from the
inside of the crankcase with the notch “a”
aligned with groove “b” on the crankcase jour-
nal as shown.
• To install the crankshaft journal bearings,
press each bearing into the left crankcase “3”
and right crankcase “4” as shown in the illustra-
tion.
Install depth of bearing “c”

1.9–2.7 mm (0.075–0.106 in)
c c 3
4
EAS26220
INSTALLING THE CRANKSHAFT AND

BALANCER SHAFT
1. Install:
• Crankshaft assembly
• Balancer shaft assembly
TIP
Align the match mark “a” in the balancer drive
gear with the match mark “b” in the balancer
shaft gear.
b a
5-63
TRANSMISSION
EAS26240
TRANSMISSION
Removing the transmission
LS
E
New
LS
8 New
12
11 A 10 7
9 6
New 5
New
E
E
4 LS
E
New
3
1
A 11 10
9
12 New 2
3
LS
16 Nm (1.6 m•kgf, 12 ft •Ibf) (7)

T.
R.

Rear wheel Refer to “REAR WHEEL” on page 4-23.
Drain.
Final transmission oil Refer to “CHANGING THE FINAL TRANS-
MISSION OIL” on page 3-23.
Secondary sheave assembly SION” on page 5-32.
1 Transmission case cover 1
2 Gasket 1
3 Dowel pin 2
4 Primary drive gear 1
5 Washer 1
6 Washer 1
7 1st wheel gear 1
8 Drive axle 1
9 Main axle 1
5-64
TRANSMISSION
Removing the transmission
LS
E
New
LS
8 New
12
11 A 10 7
9 6
New 5
New
E
E
4 LS
E
New
3
1
A 11 10
9
12 New 2
3
LS
16 Nm (1.6 m•kgf, 12 ft •Ibf) (7)

T.
R.

10 Primary driven gear 1
11 Conical spring washer 1
12 Washer 1
dure.
5-65
TRANSMISSION
EAS26300
CHECKING THE TRANSMISSION

1. Check:
• Transmission gears
Blue discoloration/pitting/wear → Replace.
2. Check:
• Transmission gear movement
Rough movement → Replace the defective
part(s).
EAS1SD1031
INSTALLING THE TRANSMISSION

1. Install:
• Main axle assembly
• Drive axle assembly
• Circlips New
• Washer
2. Install:
• Primary drive gear oil seal “1” New
TIP
Press the primary drive gear oil seal into the
transmission case cover as shown in the illustra-
tion.
Installed depth of oil seal “a”

1.5–2.0 mm (0.059–0.079 in)
a
1 New
5-66
TRANSMISSION
5-67
COOLING SYSTEM
RADIATOR ...................................................................................................... 6-1

CHECKING THE RADIATOR.................................................................... 6-2
INSTALLING THE RADIATOR..................................................................6-2
THERMOSTAT ................................................................................................6-4
CHECKING THE THERMOSTAT.............................................................. 6-5
INSTALLING THE THERMOSTAT ASSEMBLY ....................................... 6-5
WATER PUMP.................................................................................................6-6
CHECKING THE WATER PUMP .............................................................. 6-8
ASSEMBLING THE WATER PUMP.......................................................... 6-8
6
RADIATOR
EAS26380
RADIATOR
Removing the radiator
9
6
1
4 8
5
10
7
(4)

T.R
T.R
.

Radiator cover/Leg shield 4-1.
Drain.
page 3-21.
1 Radiator filler hose 1
2 Coolant reservoir hose 1
3 Coolant reservoir 1
4 Radiator inlet hose 1 Disconnect.
5 Radiator outlet hose 1 Disconnect.
6 Radiator fan motor coupler 1 Disconnect.
7 Radiator bracket 1
8 Radiator 1
9 Radiator air shroud 1
10 Radiator fan 1
dure.
6-1
RADIATOR
EAS26390
CHECKING THE RADIATOR

1. Check:
• Radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the radia-
tor.
Damage → Repair or replace.
TIP
Straighten any flattened fins with a thin, flathead
screwdriver.
b. Apply the specified pressure for ten seconds
and make sure there is no drop in pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” on page 8-27.
EAS26400
INSTALLING THE RADIATOR

1. Fill:
2. Check: • Cooling system
• Radiator hoses (with the specified amount of the recom-
• Radiator filler hose mended coolant)
• Coolant reservoir hose Refer to “CHANGING THE COOLANT” on
Cracks/damage → Replace. page 3-21.
3. Measure: 2. Check:
• Radiator cap opening pressure • Cooling system
Below the specified pressure → Replace the Leaks → Repair or replace any faulty part.
radiator cap. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Attach the radiator cap tester “1” to the radia-
Radiator cap opening pressure tor.
110.0–140.0 kPa (1.10–1.40
kgf/cm², 15.6–19.9 psi) Radiator cap tester
90890-01325
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Mityvac cooling system tester kit
a. Install the radiator cap tester “1” and radiator YU-24460-A
cap tester adapter “2” to the radiator cap “3”.
Radiator cap tester

90890-01325
Mityvac cooling system tester kit
YU-24460-A 1
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984
b. Apply 100 kPa (1.0 kg/cm², 14.22 psi) of pres-

sure.
6-2
RADIATOR
c. Measure the pressure to check its maintain-

ing applied pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-2.
6-3
THERMOSTAT
EAS26440
THERMOSTAT
Removing the thermostat assembly
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
4
New
5 6 Nm (0.6 m•kgf, 4.3 ft•Ibf)
T.R
.

Storage box 4-1.
Drain.
page 3-21.
1 Bleed hose 1 Disconnect.
2 Thermostat inlet hose 1 Disconnect.
3 Thermostat outlet hose 1 Disconnect.
4 Thermostat cover 1
5 Thermostat 1
dure.
6-4
THERMOSTAT
EAS26450
2. Check:
CHECKING THE THERMOSTAT
• Thermostat housing cover
1. Check:
• Thermostat “1”
Does not open at 70.5–73.5°C (159–164°F) EAS26480
→ Replace. INSTALLING THE THERMOSTAT

ASSEMBLY
1. Install:
• Thermostat “1”
• Thermostat cover
Bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Suspend the thermostat “1” in a container “2”
filled with water. 1
b. Slowly heat the water.
c. Place a thermometer “3” in the water.
d. While stirring the water “4”, observe the ther-
mostat and thermometer’s indicated temper-
ature.
2. Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-21.
3. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
4. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-2.
A. Fully closed
B. Fully open
TIP
If the accuracy of the thermostat is in doubt, re-
place it. A faulty thermostat could cause serious
overheating or overcooling.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-5
WATER PUMP
EAS26500
WATER PUMP
Removing the water pump
7 Nm (0.7 m•kgf, 5.1 ft •Ibf)
T.
R.
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)
T.
R.
3
*
New 9
New 5 4
LS
LT
6
12
New
10
New 13 E
11
1
New New 8
LT
7
LS
2 New
LT
LS
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)
T.
R.
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)

T.
R.

Refer to “STARTER CLUTCH AND GENER-
Generator cover ATOR” on page 5-41.
1 Heat exchanger pipe 1
2 O-ring 2
3 Water pump outlet hose 1
4 Heat exchanger cover 1
5 Gasket 1
6 Generator rotor inner bracket 1
7 Water pump cover 1
8 O-ring 1
9 Circlip 1
10 Impeller shaft 1
11 Water pump seal 1
12 Circlip 1
6-6
WATER PUMP
Removing the water pump

7 Nm (0.7 m•kgf, 5.1 ft •Ibf)
T.
R.
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)
T.
R.
3
*
New 9
New 5 4
LS
LT
6
12
New
10
New 13 E
11
1
New New 8
LT
7
LS
2 New
LT
LS
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)
T.
R.
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)

T.
R.

13 Bearing 1
dure.
* Apply Three bond No.1215®
6-7
WATER PUMP
EAS26530
CHECKING THE WATER PUMP Middle driven shaft bearing driv-

1. Check: er
• Water pump cover 90890-04058
• Impeller shaft Middle drive bearing installer 40
Cracks/damage/wear → Replace. & 50 mm
2. Check: YM-04058
• Water pump inlet hose Mechanical seal installer
• Water pump outlet hose 90890-04145
3. Check:
• Heat exchanger pipe “1” 4
3
1 1 New
2. Apply the lithium-soap-based grease to the

water pump seal lip.
4. Check:
• Heat exchanger cover “1”
5. Check:
• Heat exchanger outlet hose
EAS26560
ASSEMBLING THE WATER PUMP

1. Install:
• Bearings
• Circlip New
• Water pump seal “1” New
(to the generator cover “2”)
TIP
Install the water pump seal with the mechanical
seal installer “3” and middle driven shaft bearing
driver “4”
6-8
WATER PUMP
6-9
FUEL SYSTEM
FUEL TANK..................................................................................................... 7-1

REMOVING THE FUEL TANK ..................................................................7-2
REMOVING THE FUEL PUMP .................................................................7-2
CHECKING THE FUEL PUMP BODY.......................................................7-2
INSTALLING THE FUEL PUMP................................................................7-2
INSTALLING THE FUEL TANK.................................................................7-2
CHECKING THE FUEL PRESSURE ........................................................7-3
THROTTLE BODY........................................................................................... 7-4

REMOVING THE FUEL HOSE .................................................................7-7
CHECKING THE FUEL INJECTOR .......................................................... 7-7
CHECKING THE THROTTLE BODY ........................................................7-7
INSTALLING THE FUEL HOSE ................................................................7-7
INSTALLING THE THROTTLE BODY ......................................................7-8
CHECKING THE THROTTLE POSITION SENSOR .................................7-9
CHECKING THE ISC (IDLE SPEED CONTROL) UNIT............................ 7-9
AIR INDUCTION SYSTEM ............................................................................7-11

CHECKING THE AIR INDUCTION SYSTEM..........................................7-14
7
FUEL TANK
EAS26620
FUEL TANK
Removing the fuel tank
14 Nm (1.4 m•kgf, 10 ft•Ibf) 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
T.R
.
1
6 (6)
3 4
11
10
(4)
8
9 LT
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
13 Nm (1.3 m•kgf, 9.4 ft•Ibf)

T.R
.
14 Nm (1.4 m•kgf, 10 ft•Ibf)

T.R
.

Leg shield 4-1.
Radiator Refer to “RADIATOR” on page 6-1.
1 Fuel tank cap 1
2 Fuel filler cover 1
3 Fuel pump coupler 1 Disconnect.
4 Fuel hose connector cover 1
5 Fuel hose 1 Disconnect.
6 Fuel pump bracket 1
7 Fuel pump 1
8 Rectifier/regulator coupler 1 Disconnect.
9 Rectifier/regulator 1
10 Fuel tank bracket 1
11 Fuel tank 1
dure.
7-1
FUEL TANK
EAS26630
• Do not touch the base section of the fuel
REMOVING THE FUEL TANK
sender.
1. Extract the fuel in the fuel tank through the
fuel tank filler hole with a pump. EAS26670
2. Disconnect: CHECKING THE FUEL PUMP BODY
• Fuel pump coupler “1” 1. Check:
3. Remove: • Fuel pump body
• Fuel hose connector cover “2” Obstruction → Clean.
4. Disconnect: Cracks/damage → Replace fuel pump as-
• Fuel hose “3” sembly.
EWA1SD1017
WARNING EAS26700
Cover fuel hose connection with a cloth INSTALLING THE FUEL PUMP
when disconnecting it. Residual pressure in 1. Install:
the fuel lines could cause fuel to spurt out • Fuel pump
when removing the hose. Fuel pump nut
ECA37P1023
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
NOTICE
• Be sure to disconnect the fuel hose by TIP
hand. Do not forcefully disconnect the • Do not damage the installation surfaces of the
hose with tools. fuel tank when installing the fuel pump.
• Although the fuel has been removed from • Always use a new fuel pump gasket.
the fuel tank, be careful when removing the • Install the fuel pump as shown in the illustra-
fuel hose, since there may be fuel remain- tion.
ing in it. • Align the projection “a” on the fuel tank with the
• Do not disconnect the fuel hose from the slot in the fuel pump bracket.
fuel hose connector. Disconnect the con- • Tighten the fuel pump nuts in the proper tight-
nector from the fuel pump. ening sequence as shown.
TIP
3 1
Before removing the hose, place a few rags in
the area under where it will be removed.
1 FWD 5 6
2
3
2 a 4
EAS37P1072
INSTALLING THE FUEL TANK

1. Install:
• Fuel hose
5. Remove: • Fuel hose connector cover
• Fuel tank ECA1SD1015
NOTICE
EAS26640
REMOVING THE FUEL PUMP When installing the fuel hose, make sure that
1. Remove: it is securely connected, and that the fuel
• Fuel pump hose connector cover on the fuel hose is in
ECA14720 the correct position, otherwise the fuel hose
NOTICE will not be properly installed.
• Do not drop the fuel pump or give it a
strong shock.
7-2
FUEL TANK
TIP TIP
• Wipe up any fuel remaining in the recess “a” in Before removing the hose, place a few rags in
the fuel pump with a dry rag “1”. the area under where it will be removed.
• After installing the fuel hose connector cover
“2”, make sure that it is installed securely.
1
2
a b. Connect the pressure gauge “3” and fuel

pressure adapter “4”.
Pressure gauge
90890-03153
2 YU-03153
Fuel pressure adapter
90890-03181
YM-03181
EAS37P1071
CHECKING THE FUEL PRESSURE 4

1. Check: 2
• Pressure regulator operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the fuel hose connector cover “1”,
and then remove the fuel hose “2” from the
fuel pump.
EWA1SD1017
c. Start the engine.
WARNING
d. Measure the fuel pressure.
Cover fuel hose connection with a cloth
when disconnecting it. Residual pressure in Output pressure
the fuel lines could cause fuel to spurt out 246–254 kPa (2.46–2.54 kgf/cm²,
when removing the hose. 35.0–36.1 psi)
ECA37P1023
NOTICE Faulty → Replace the fuel pump.

e. Connect the fuel hose and install the fuel
• Be sure to disconnect the fuel hose by hose connector cover.
hand. Do not forcefully disconnect the Refer to “INSTALLING THE FUEL TANK” on
hose with tools. page 7-2.
• Although the fuel has been removed from
the fuel tank, be careful when removing the ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
fuel hose, since there may be fuel remain-

ing in it.
• Do not disconnect the fuel hose from the
fuel hose connector. Disconnect the con-
nector from the fuel pump.
7-3
THROTTLE BODY
EAS26970
THROTTLE BODY
Removing the throttle body
12 Nm (1.2 m•kgf, 8.7 ft•Ibf) 2.8 Nm (0.28 m•kgf, 2.0 ft•Ibf)
T.R
T.R
.
.
2.8 Nm (0.28 m•kgf, 2.0 ft•Ibf)
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
.
T.R
.
1 4 10
11 2
9
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
LT
LT 7
3
12
New 6
5
8
LS
13
E
14 5
New
LT
LT
LS New
15
New 5 Nm (0.5 m•kgf, 3.6 ft•Ibf)

T.R
.
LS
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Storage box 4-1.
1 Intake air pressure sensor coupler 1 Disconnect.
2 Intake air pressure sensor 1
3 Intake air pressure sensor hose 1
4 ISC (idle speed control) unit coupler 1 Disconnect.
5 Throttle cable 2 Disconnect.
6 Breather hose (air filter case to throttle body) 1
7 Air filter case joint clamp screw 1 Loosen.
8 Throttle body joint clamp screw 1 Loosen.
9 Throttle body assembly 1
10 Throttle position sensor coupler 1 Disconnect.
11 Fuel injector coupler 1 Disconnect.
12 Fuel injector assembly 1
13 Throttle body joint 1
7-4
THROTTLE BODY
Removing the throttle body

12 Nm (1.2 m•kgf, 8.7 ft•Ibf) 2.8 Nm (0.28 m•kgf, 2.0 ft•Ibf)
T.R
T.R
.
.
2.8 Nm (0.28 m•kgf, 2.0 ft•Ibf)
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
.
T.R
.
1 4 10
11 2
9
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
LT
LT 7
3
12
New 6
5
8
LS
13
E
14 5
New
LT
LT
LS New
15
New 5 Nm (0.5 m•kgf, 3.6 ft•Ibf)

T.R
.
LS
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

14 Intake manifold 1
15 Intake manifold joint 1
dure.
7-5
THROTTLE BODY
Disassembling the throttle body assembly

1 Throttle position sensor 1
2 Vacuum chamber cover 1
3 Piston valve spring 1
4 Piston valve 1
5 Throttle body 1
cedure.
7-6
THROTTLE BODY
EAS37P1074
REMOVING THE FUEL HOSE

1. Disconnect:
• Fuel hose
Refer to “REMOVING THE FUEL TANK” on
page 7-2.
EAS26980
CHECKING THE FUEL INJECTOR

1. Check:
• Injector
Obstruction → Replace and check the fuel 5. Check:
pump/fuel supply system. • Fuel passages
Deposit → Replace. Obstructions → Clean.
Damage → Replace.
2. Check: EAS37P1075
INSTALLING THE FUEL HOSE

• Injector resistance
1. Install:
Refer to “CHECKING THE FUEL INJEC-
• Fuel hose
TOR” on page 7-7.
• Fuel hose connector cover
ECA37P1026
EAS26990
CHECKING THE THROTTLE BODY NOTICE

TIP When installing the fuel hose, make sure that
Before cleaning the throttle body, check the fol- it is securely connected, and that the fuel
lowing items: hose connector cover is in the correct posi-
• Valve clearance tion, otherwise the fuel hose will not be prop-
• Spark plug erly installed.
• Air filter element TIP
• Throttle body joint
• Wipe up any fuel remaining in the recess “a” in
• Fuel hose
the fuel pump with a dry rag “1”.
• Exhaust system
• After installing the fuel hose connector cover
• Cylinder head breather hose
“2”, make sure that it is installed securely.
EWA1SD1018
WARNING
If the throttle body is subjected to strong
shocks or dropped during cleaning, replace
them as a set.
1. Check:
• Throttle body 1
Cracks/damage → Replace the throttle body.
2. Check:
• Piston valve a
• Piston valve diaphragm
Cracks/tears → Replace.
3. Check: 2
• Vacuum chamber cover
• Piston valve spring
4. Check:
• Piston valve movement
Insert the piston valve into the throttle body
and move it up and down.
Tightness → Replace the piston valve.
7-7
THROTTLE BODY
EAS1SD1050
tape “e” on the engine sub-wire harness and
INSTALLING THE THROTTLE BODY
the white tape “f” on the AC magneto lead
1. Install:
with the holder.
• Throttle body
e. Connect the ISC (idle speed control) unit cou-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fasten one portion (wire harness side) of the pler “7”.
engine sub-wire harness “1” to the throttle po-
sition sensor with a plastic locking tie “2” and f
fasten the other portion (coupler side) with e
the holder “3”. Align the white tape sections 5
“a” and “b” on the engine sub-wire harness
with the plastic locking tie and holder respec-
tively.
1 7 6
3
f. Fasten the intake air pressure sensor lead “8”
a with the holder on the left side of the throttle
body. Align the white tape “g” on the intake air
pressure sensor lead with the holder.
b
2
8
b. Connect the throttle position sensor coupler g
“4” to the wire harness.
g. Install the intake air pressure sensor “9” to the

intake manifold.
h. Connect the intake air pressure sensor cou-
pler “10”.
9
c. Install the throttle body to the intake manifold.
TIP
Align the projection “c” on the throttle body with
the slot “d” in the throttle body joint.
10
i. Connect the injector coupler “11”, bundle the

slack in the lead, and then place the coupler
d and slack in the coupler cover “h”. Fasten a
plastic locking tie “12” around the coupler
cover.
d. Fasten the engine sub-wire harness “5” and

AC magneto lead “6” with the holder on the
right side of the throttle body. Align the white
7-8
THROTTLE BODY
11
12
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS37P1077
CHECKING THE THROTTLE POSITION

SENSOR
1. Check:
• Throttle position sensor
Refer to “CHECKING THE THROTTLE PO-
SITION SENSOR” on page 8-96.
EAS37P1078
CHECKING THE ISC (IDLE SPEED

CONTROL) UNIT
1. Check:
• ISC (idle speed control) unit
Refer to “CHECKING THE ISC (IDLE
SPEED CONTROL) UNIT” on page 8-99.
7-9
THROTTLE BODY
7-10
AIR INDUCTION SYSTEM
EAS27040
7-11
1. Air induction system hose (air filter case to air

cut-off valve)
2. Air cut-off valve
3. Air induction system hose (air cut-off valve to
cylinder head)
4. Air induction system pipe
5. Right air filter case
A. Face the white paint mark on the hose
outward.
7-12
Removing the air cut-off valve assembly and hoses
3
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.

Right center panel 4-1.
1 Thermostat breather hose 1
Air induction system hose (air filter case to air
2 1 Disconnect.
cut-off valve)
Air induction system hose (air cut-off valve to
3 1 Disconnect.
cylinder head)
4 Air induction system solenoid coupler 1 Disconnect.
5 Air cut-off valve 1
dure.
7-13
EAS27060
CHECKING THE AIR INDUCTION SYSTEM
Air induction system

The air induction system burns unburned ex-
haust gases by injecting fresh air (secondary air)
into the exhaust port, reducing the emission of
hydrocarbons. When there is negative pressure
at the exhaust port, the reed valve opens, allow-
ing secondary air to flow into the exhaust port.
The required temperature for burning the un-
burned exhaust gases is approximately 600 to
700 °C (1112 to 1292 °F).
Air cut-off valve

The air cut-off valve prevents air backflow from
the exhaust port of the cylinder head to the air fil-
ter.
A
B
A. From the air filter case
B. To the cylinder head
1. Check:
• Air induction system hose
Loose connections → Connect properly.
• Pipes
2. Check:
• Air induction system solenoid
Refer to “CHECKING THE AIR INDUCTION
SYSTEM SOLENOID” on page 8-94.
7-14
7-15
ELECTRICAL SYSTEM
IGNITION SYSTEM ......................................................................................... 8-1

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

CIRCUIT DIAGRAM .................................................................................. 8-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .......................... 8-7
TROUBLESHOOTING ..............................................................................8-9
CHARGING SYSTEM....................................................................................8-11
CIRCUIT DIAGRAM ................................................................................ 8-11
TROUBLESHOOTING ............................................................................8-13
LIGHTING SYSTEM ......................................................................................8-15

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

CIRCUIT DIAGRAM ................................................................................ 8-19
COOLING SYSTEM....................................................................................... 8-27

CIRCUIT DIAGRAM ................................................................................ 8-27
FUEL INJECTION SYSTEM..........................................................................8-31

CIRCUIT DIAGRAM ................................................................................ 8-31
ECU SELF-DIAGNOSTIC FUNCTION....................................................8-33
TROUBLESHOOTING METHOD............................................................ 8-34
DIAGNOSTIC MODE .............................................................................. 8-35
TROUBLESHOOTING DETAILS ............................................................ 8-37
FUEL PUMP SYSTEM...................................................................................8-65

CIRCUIT DIAGRAM ................................................................................ 8-65
IMMOBILIZER SYSTEM................................................................................ 8-69

CIRCUIT DIAGRAM ................................................................................ 8-69
8
GENERAL INFORMATION ..................................................................... 8-71
PART REPLACEMENT AND KEY CODE REGISTRATION
REQUIREMENTS...................................................................................8-71
SELF-DIAGNOSIS FAULT CODE INDICATION..................................... 8-75
ELECTRICAL COMPONENTS...................................................................... 8-79
CHECKING THE SWITCHES .................................................................8-81
CHECKING THE BULBS AND BULB SOCKETS ................................... 8-84
CHECKING THE FUSES ........................................................................8-85
CHECKING AND CHARGING THE BATTERY....................................... 8-85
CHECKING THE RELAYS ...................................................................... 8-89
CHECKING THE TURN SIGNAL/HAZARD RELAY................................8-90
CHECKING THE DIODE .........................................................................8-90
CHECKING THE SPARK PLUG CAP .....................................................8-91
CHECKING THE IGNITION COIL ........................................................... 8-91
CHECKING THE IGNITION SPARK GAP............................................... 8-92
CHECKING THE CRANKSHAFT POSITION SENSOR.......................... 8-92
CHECKING THE LEAN ANGLE SENSOR.............................................. 8-92
CHECKING THE STARTER MOTOR OPERATION ...............................8-93
CHECKING THE STATOR COIL ............................................................ 8-93
CHECKING THE RECTIFIER/REGULATOR ..........................................8-94
CHECKING THE AIR INDUCTION SYSTEM SOLENOID ......................8-94
CHECKING THE FUEL SENDER ........................................................... 8-94
CHECKING THE FUEL LEVEL WARNING LIGHT .................................8-95
CHECKING THE SPEED SENSOR ........................................................ 8-95
CHECKING THE RADIATOR FAN MOTOR ...........................................8-96
CHECKING THE COOLANT TEMPERATURE SENSOR.......................8-96
CHECKING THE THROTTLE POSITION SENSOR ...............................8-96
CHECKING THE INTAKE AIR PRESSURE SENSOR ........................... 8-97
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....................8-98
CHECKING THE AIR TEMPERATURE SENSOR ..................................8-98
CHECKING THE FUEL INJECTOR ........................................................ 8-99
CHECKING THE ISC (IDLE SPEED CONTROL) UNIT.......................... 8-99
CHECKING THE V-BELT REPLACEMENT INDICATOR
RESET COUPLER ................................................................................. 8-99
A
P/W Y/G Br/W R/B B/W W/R L/Y L/B B/Y Sb G/W Gy B W/B Br/R
Gy/G Br/R G/W G/W Br/R Gy/G
G/R Y Gy/G L B/L Y/L R/W W R/B G/B G/Y G/B P B O/B O
EAS27100
EAS27090
P O/B R/B Y Y R/B O/B P
Sb Gy G/Y G/R G/R G/Y Gy Sb
Br/W L B/L P/W P/W B/L L Br/W
(Gy) (Gy)
1 B/L W/R
W R
A B
L/Y
B/L W/R R W R/W
(B) W W R B R/B L/Y G/Y
B R/B G G/R B/L B/L R/B
18 20 G/Y R/B W/Y
2 W W 3 32
W W B B (Gy) O O
17 B 19 G B 21 26
L B/L Y
W W W R
(B) R/B B/Y G/R G/R A G/R P 33
(B)
B R R G/Y Sb
B (B) W/R G/Y P A P P
B L/B L/Y P Gy
W W W 27 G/Y A G/Y G/Y
(B) B B/Y B
W W W 12 13 B/L Y Gy Gy A Gy Gy 34 (B)
(B)
CIRCUIT DIAGRAM
(L) W/Y Y Y A Y Sb A Sb Sb
B L/Y
L/B L L Sb
14 L/B 35
4 B P/W O/B R/B
B B L/B L Y
R/L R B L/B 22 W/Y L L A L R/B
28 (B)
B/L P/W L P/W P/W A P/W G/R (B)
B B
IGNITION SYSTEM
L/W B/L O/B O/B A O/B O/B Y L R/B

25 (B)
15 16 G/B
23 24 B/L Br/W
R 29
Br/W B/L B/L A B/L B/L
B
5 (G) Br/W Br/W A Br/W Y/G B/Y
ON Dg Br/W Ch 31
Br/R Br/R W P
OFF L/W W/Y G/Y Br G/Y P O/R L W
Br
W/B W L O/R
OPEN 36 B/W B/L
R R L B/L B/W
LOCK Dg Ch Br G/Y 30
Ch Br/W Dg Y/G L/Y Br/R
Br/L Br/L P Br/W L Y/G B/L
G/Y Br W/Y L/B B/L
G/B Br/R R/B
6
Br/R R R/W R/B (L)
Br/L B 37
7 Y/L Br/R A Br/R Br/R R/B
R R/W
L/B B
8
Br/R L/R B/W
Gy/G A Gy/G Gy/G L W B/L
B/W B R/L 9
Br/L R/B G/W G/W A G/W G/W B B R/B
Y/L G/L R/B
10 Gy/G B B R/B G/W

Br/L R/Y
38 W L Gy/G B/L
R/G B B 77
R/W Lg Y/L (B)
(B)
11
Br/L Br
B
8-1
R/W R/B R/Y R/Y
B B/W
L/R
R/B A R/B
Y/L R/Y
42 Br
R/G R/L L/B
Br/W 40
R/Y W/B P
R/W R/B L/R 41
Lg
R/W L/B W/B (B)

75 Br/W
B B G/L L Br/W
B/W R/L R/B G/B 43 L/B R/Y P
Y/L Y/L
78 B B L G/B
L
44 45 46 47
G/B Br/R Br/R G/B
B R/L B/W 48
B Y/L R Br P/B P/B Br
Y/L 39
B B/L
B B/L B
Y/L B
B P B G/Y
B/W Y/L L R 74 Y G (B)
B 76 L/B R/Y Br
R/L Dg Br/W Ch
(B) (B)
B
B B G Y Ch Dg B G/Y Br
G Y G/Y B P
Ch Br/W Dg
Br R/Y L/B
B B
B B
B B 61 G/L R/L R/B Y/L Br Y Dg Ch Br

B B
B L/R B Br B G/Y G/Y
62 G Ch Dg Ch Dg
56 G Y Br Br Br Br
Gy
63 59
L/R 57 55 54 52 49
66 67 68 69 70 71 72 B B Br G/Y B Br G/Y
64 65 58 53 50
Ch B Dg B
G Y Y G
Gy
B B 51 51
B/L B B B
60 B
B/L Ch Dg Y R/B R/L G
B B B
G/L Br Y/L B/L Gy B
B B
B B B B B
73 B Br B Br Ch B Dg B
B
B Gy
B B
(B)
B B B/L
(B)
IGNITION SYSTEM
IGNITION SYSTEM

5. Main switch
6. ECU fuse
9. Ignition fuse
12.Battery
13.Main fuse
17.Frame ground
18.Sidestand switch
30.Lean angle sensor
31.ECU (engine control unit)
32.Ignition coil
33.Spark plug
8-2
IGNITION SYSTEM
EAS27120
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
• Before troubleshooting, remove the following part(s):
1. Storage box
2. Leg shield
1. Check the fuses. NG →

(Main, ECU, and ignition)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-85.
OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-85.
OK ↓
3. Check the spark plug. NG →
Refer to “CHECKING THE SPARK Re-gap or replace the spark plug.
PLUG” on page 3-4.
OK ↓
4. Check the ignition spark gap. OK →
Refer to “CHECKING THE IGNI- Ignition system is OK.
TION SPARK GAP” on page 8-92.
NG ↓
5. Check the spark plug cap. NG →
Refer to “CHECKING THE SPARK Replace the spark plug cap.
PLUG CAP” on page 8-91.
OK ↓
6. Check the ignition coil. NG →
Refer to “CHECKING THE IGNI- Replace the ignition coil.
TION COIL” on page 8-91.
OK ↓
7. Check the crankshaft position sen- NG →
sor.
Replace the crankshaft position sen-
Refer to “CHECKING THE CRANK-
sor/stator assembly.
SHAFT POSITION SENSOR” on
page 8-92.
OK ↓
8. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch/immobilizer unit.
SWITCHES” on page 8-81.
OK ↓
8-3
IGNITION SYSTEM
9. Check the sidestand switch. NG →

Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
10.Check the lean angle sensor. NG →
Refer to “CHECKING THE LEAN Replace the lean angle sensor.
ANGLE SENSOR” on page 8-92.
OK ↓
11.Check the entire ignition system NG →
wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-1.
OK ↓
Replace the ECU.
8-4
A
EAS27170
EAS27160
(Gy) (Gy)
1 B/L W/R
W R
A B
L/Y
B/L W/R R W R/W
18 20 G/Y R/B W/Y
2 W W 3 32
W W B B (Gy) O O
17 B 19 G B 21 26
L B/L Y
W W W R
(B)
B R R G/Y Sb
B L/B L/Y P Gy
(B) B B/Y B
(B)
CIRCUIT DIAGRAM
B L/Y
L/B L L Sb
14 L/B 35
4 B P/W O/B R/B
B B L/B L Y
28 (B)
B B
25 (B)
15 16 G/B
23 24 B/L Br/W
R 29
B
ON Dg Br/W Ch 31
Br/R Br/R W P
Br
W/B W L O/R
OPEN 36 B/W B/L
R R L B/L B/W
G/Y Br W/Y L/B B/L
G/B Br/R R/B
6
Br/R R R/W R/B (L)
Br/L B 37
R R/W
L/B B
ELECTRIC STARTING SYSTEM
8
Br/R L/R B/W
B/W B R/L 9
Y/L G/L R/B
10 Gy/G B B R/B G/W

Br/L R/Y
38 W L Gy/G B/L
R/G B B 77
R/W Lg Y/L (B)
(B)
11
Br/L Br
B
8-5
R/W R/B R/Y R/Y
B B/W
L/R
R/B A R/B
Y/L R/Y
42 Br
R/G R/L L/B
Br/W 40
R/Y W/B P
R/W R/B L/R 41
Lg
R/W L/B W/B (B)

75 Br/W
B B G/L L Br/W
Y/L Y/L
78 B B L G/B
L
44 45 46 47
G/B Br/R Br/R G/B
B R/L B/W 48
Y/L 39
B B/L
B B/L B
Y/L B
B P B G/Y
B 76 L/B R/Y Br
R/L Dg Br/W Ch
(B) (B)
B
G Y G/Y B P
Ch Br/W Dg
Br R/Y L/B
B B
B B

B B
62 G Ch Dg Ch Dg
56 G Y Br Br Br Br
Gy
63 59
L/R 57 55 54 52 49
66 67 68 69 70 71 72 B B Br G/Y B Br G/Y
64 65 58 53 50
Ch B Dg B
G Y Y G
Gy
B B 51 51
B/L B B B
60 B
B B B
G/L Br Y/L B/L Gy B
B B
B B B B B
B
B Gy
B B
(B)
B B B/L
(B)
5. Main switch
9. Ignition fuse
11.Signaling system fuse
12.Battery
13.Main fuse
14.Starter relay
15.Starter motor
16.Diode
17.Frame ground
18.Sidestand switch
21.Starting circuit cut-off relay
23.Start switch
25.Front brake light switch
48.Rear brake light switch
8-6
EAS27180
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the main switch is set to “ON” (switch circuit is closed), the starter motor can only operate if the fol-
lowing conditions are met:
• The brake lever is pulled to the handlebar (the brake switch is closed) and the sidestand is up (the
sidestand switch is closed).
The starting circuit cut-off relay prevents the starter motor from operating when neither of these condi-
tions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the
starter motor. When at least one of the above conditions has been met, the starting circuit cut-off relay
is closed and the engine can be started by pressing the start switch “ ”.
13
12
11
1
10
2 4
5
3
7 8 9
8-7
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
6. Sidestand switch
7. Signaling system fuse
8. Front brake light switch
9. Rear brake light switch
10. Start switch
11. Diode
12. Starter relay
13. Starter motor
8-8
EAS27190
TROUBLESHOOTING
The starter motor fails to turn.
TIP
1. Storage box
2. Leg shield

(Main, ignition, and signaling sys-
tem) Replace the fuse(s).
ES” on page 8-85.
OK ↓
page 8-85.
OK ↓
3. Check the starter motor operation. OK →
Starter motor is OK. Perform the electric
Refer to “CHECKING THE START-
starting system troubleshooting, starting
ER MOTOR OPERATION” on page
with step 5.
8-93.
NG ↓
4. Check the starter motor. NG →
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-52.
OK ↓
5. Check the starting circuit cut-off re- NG →
lay.
Replace the starting circuit cut-off relay.
Refer to “CHECKING THE RE-
LAYS” on page 8-89.
OK ↓
6. Check the starter relay. NG →
Refer to “CHECKING THE RE- Replace the starter relay.
OK ↓
OK ↓
8. Check the sidestand switch. NG →
Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
8-9
9. Check the brake light switches NG →

(front and rear).
Replace the brake light switch(es).
Refer to “CHECKING THE
OK ↓
10.Check the start switch. NG →
The start switch is faulty. Replace the right
handlebar switch.
OK ↓
11.Check the entire starting system NG →
page 8-5.
OK ↓
The starting system circuit is OK.
8-10
EAS27210
EAS27200
1 B/L W/R
W R
CIRCUIT DIAGRAM
L/Y
B/L W/R R W
(B) W W R B
B R/B G
W W
18 20
2 3
CHARGING SYSTEM
W W B B
17 B 19 G B
W W W R
(B) R/B B/Y
B R R
B (B)
B L/B L/Y
W W W
13 (B) B B/Y B
W W W 12
(B) (L)
B
L/B
14 L/B
4 B L/B
B B L/B
R/L R B 22 W/Y
B B
L/W
2
8-11
15 16 23 24
R
B
5
ON Dg Br/W Ch
Br/R Br/R
OFF L/W W/Y G/Y Br G/Y
OPEN
R R LOCK Dg Ch Br G
Br/L P Ch Br/W Dg
Br/L Br/W
G/Y Br W/Y L/B
6
Br/R R R/W
Br/L
7
R R/W
8
Br/R L/R
B/W B R/L 9
Br/L R/B
Y/L G/L R/B
Br/L
10 R/Y
R/G B B 77
R/W Lg Y/L
11
CHARGING SYSTEM
CHARGING SYSTEM
2. AC magneto
12.Battery
13.Main fuse
17.Frame ground
8-12
CHARGING SYSTEM
EAS27230
TROUBLESHOOTING
The battery is not being charged.
TIP
1. Storage box
2. Front cowling
3. Bottom cover
1. Check the fuse. NG →

(Main)
Replace the fuse.
ES” on page 8-85.
OK ↓
page 8-85.
OK ↓
3. Check the stator coil. NG →
Refer to “CHECKING THE STATOR
COIL” on page 8-93.
OK ↓
4. Check the rectifier/regulator. NG →
Refer to “CHECKING THE RECTI- Replace the rectifier/regulator.
FIER/REGULATOR” on page 8-94.
OK ↓
5. Check the entire charging system NG →
page 8-11.
OK ↓
The charging system circuit is OK.
8-13
CHARGING SYSTEM
8-14
A
EAS27250
EAS27240
(Gy) (Gy)
1 B/L W/R
W R
A B
L/Y
B/L W/R R W R/W
18 20 G/Y R/B W/Y
2 W W 3 32
W W B B (Gy) O O
17 B 19 G B 21 26
L B/L Y
W W W R
(B)
B R R G/Y Sb
B L/B L/Y P Gy
(B) B B/Y B
(B)
CIRCUIT DIAGRAM
B L/Y
L/B L L Sb
14 L/B 35
4 B P/W O/B R/B
B B L/B L Y
28 (B)
B B
LIGHTING SYSTEM
25 (B)
15 16 G/B
23 24 B/L Br/W
R 29
B
ON Dg Br/W Ch 31
Br/R Br/R W P
Br
W/B W L O/R
OPEN 36 B/W B/L
R R L B/L B/W
G/Y Br W/Y L/B B/L
G/B Br/R R/B
6
Br/R R R/W R/B (L)
Br/L B 37
R R/W
L/B B
8
Br/R L/R B/W
B/W B R/L 9
Y/L G/L R/B
10 Gy/G B B R/B G/W

Br/L R/Y
38 W L Gy/G B/L
R/G B B 77
R/W Lg Y/L (B)
(B)
11
Br/L Br
B
R/W R/B
8-15
R/Y R/Y
B B/W
L/R
R/B A R/B
Y/L R/Y
42 Br
R/G R/L L/B
Br/W 40
R/Y W/B P
R/W R/B L/R 41
Lg
R/W L/B W/B (B)

75 Br/W
B B G/L L Br/W
Y/L Y/L
78 B B L G/B
L
44 45 46 47
G/B Br/R Br/R G/B
B R/L B/W 48
Y/L 39
B B/L
B B/L B
Y/L B
B P B G/Y
B 76 L/B R/Y Br
R/L Dg Br/W Ch
(B) (B)
B
G Y G/Y B P
Ch Br/W Dg
Br R/Y L/B
B B
B B

B B
62 G Ch Dg Ch Dg
56 G Y Br Br Br Br
Gy
63 59
L/R 57 55 54 52 49
66 67 68 69 70 71 72 B B Br G/Y B Br G/Y
64 65 58 53 50
Ch B Dg B
G Y Y G
Gy
B B 51 51
B/L B B B
60 B
B B B
G/L Br Y/L B/L Gy B
B B
B B B B B
B
B Gy
B B
(B)
B B B/L
(B)
LIGHTING SYSTEM
LIGHTING SYSTEM
5. Main switch
6. ECU fuse
9. Ignition fuse
10.Headlight fuse
12.Battery
13.Main fuse
17.Frame ground
42.Headlight relay
44.Dimmer switch
45.Pass switch
51.Tail/brake light
57.Headlight
58.Auxiliary light
59.License plate light
69.Meter light
70.High beam indicator light
8-16
LIGHTING SYSTEM
EAS27260
TROUBLESHOOTING
Any of the following fail to light: headlight, high beam indicator light, taillights, license plate light, auxiliary
lights or meter light.
TIP
1. Leg shield
1. Check the condition of each bulb NG →

and bulb socket.
Refer to “CHECKING THE BULBS Replace the bulb(s) and bulb socket(s).
AND BULB SOCKETS” on page
8-84.
OK ↓
(Main, headlight, ignition, ECU, and
signaling system) Replace the fuse(s).
ES” on page 8-85.
OK ↓
page 8-85.
OK ↓
OK ↓
5. Check the dimmer switch. NG →
The dimmer switch is faulty. Replace the
left handlebar switch.
OK ↓
6. Check the pass switch. NG →
The pass switch is faulty. Replace the left
handlebar switch.
OK ↓
7. Check the headlight relay. NG →
Refer to “CHECKING THE RE- Replace the headlight relay.
OK ↓
8-17
LIGHTING SYSTEM
8. Check the entire lighting system NG →

page 8-15.
OK ↓
Replace the ECU, headlight or
tail/brake light assembly.
8-18
A
EAS27280
EAS27270
(Gy) (Gy)
1 B/L W/R
W R
A B
L/Y
B/L W/R R W R/W
18 20 G/Y R/B W/Y
2 W W 3 32
W W B B (Gy) O O
17 B 19 G B 21 26
L B/L Y
W W W R
(B)
B R R G/Y Sb
B L/B L/Y P Gy
(B) B B/Y B
(B)
CIRCUIT DIAGRAM
B L/Y
L/B L L Sb
14 L/B 35
4 B P/W O/B R/B
B B L/B L Y
28 (B)
B B
25 (B)
15 16 G/B
23 24 B/L Br/W
SIGNALING SYSTEM
R 29
B
ON Dg Br/W Ch 31
Br/R Br/R W P
Br
W/B W L O/R
OPEN 36 B/W B/L
R R L B/L B/W
G/Y Br W/Y L/B B/L
G/B Br/R R/B
6
Br/R R R/W R/B (L)
Br/L B 37
R R/W
L/B B
8
Br/R L/R B/W
B/W B R/L 9
Y/L G/L R/B
10 Gy/G B B R/B G/W

Br/L R/Y
38 W L Gy/G B/L
R/G B B 77
R/W Lg Y/L (B)
(B)
11
Br/L Br
B
R/W R/B
8-19
R/Y R/Y
B B/W
L/R
R/B A R/B
Y/L R/Y
42 Br
R/G R/L L/B
Br/W 40
R/Y W/B P
R/W R/B L/R 41
Lg
R/W L/B W/B (B)

75 Br/W
B B G/L L Br/W
Y/L Y/L
78 B B L G/B
L
44 45 46 47
G/B Br/R Br/R G/B
B R/L B/W 48
Y/L 39
B B/L
B B/L B
Y/L B
B P B G/Y
B 76 L/B R/Y Br
R/L Dg Br/W Ch
(B) (B)
B
G Y G/Y B P
Ch Br/W Dg
Br R/Y L/B
B B
B B

B B
62 G Ch Dg Ch Dg
56 G Y Br Br Br Br
Gy
63 59
L/R 57 55 54 52 49
66 67 68 69 70 71 72 B B Br G/Y B Br G/Y
64 65 58 53 50
Ch B Dg B
G Y Y G
Gy
B B 51 51
B/L B B B
60 B
B B B
G/L Br Y/L B/L Gy B
B B
B B B B B
B
B Gy
B B
(B)
B B B/L
(B)
SIGNALING SYSTEM
SIGNALING SYSTEM

5. Main switch
6. ECU fuse
8. Turn signal/hazard fuse
9. Ignition fuse
12.Battery
13.Main fuse
17.Frame ground
20.Fuel sender
24.Hazard switch
25.Front brake light switch
26.Coolant temperature sensor
36.Speed sensor
40.Horn
41.Turn signal/hazard relay
46.Turn signal switch
47.Horn switch
48.Rear brake light switch
50.Right rear turn signal light
51.Tail/brake light
53.Left rear turn signal light
54.Right front turn signal light
55.Left front turn signal light
60.V-belt replacement indicator reset coupler
63.Multi-function meter
64.Speedometer
65.Tachometer
66.Engine oil change indicator
67.V-belt replacement indicator
71.Right turn signal indicator light
72.Left turn signal indicator light
73.Air temperature sensor
76.Self-diagnosis signal coupler
A. Wire harness
B. Engine sub-wire harness
8-20
SIGNALING SYSTEM
EAS27290
TROUBLESHOOTING
• Any of the following fail to light: turn signal lights, brake lights, warning light or indicator lights.
• The horn fails to sound.
• The fuel meter fails to operate.
• The coolant temperature meter fails to operate.
• The speedometer fails to operate.
• The tachometer fails to operate.
• The air temperature meter fails to operate.
TIP
1. Storage box
2. Leg shield

(Main, signaling system, ignition,
ECU, and turn signal/hazard) Replace the fuse(s).
ES” on page 8-85.
OK ↓
page 8-85.
OK ↓
OK ↓
4. Check the entire signaling system NG →
page 8-19.
OK ↓
Check the condition of each of the sig-
naling system circuits. Refer to
“Checking the signaling system”.
Checking the signaling system

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

page 8-19.
OK ↓
Replace the horn.
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 8-19.
OK ↓
Replace the tail/brake light assembly.
The turn signal light, turn signal indicator light or both fail to blink.
1. Check the turn signal light bulb and NG →
socket.
Replace the turn signal light bulb, socket or
Refer to “CHECKING THE BULBS
both.
8-84.
OK ↓
2. Check the turn signal indicator light NG →
bulb and socket.
Replace the turn signal indicator light bulb,
Refer to “CHECKING THE BULBS
socket or both.
8-84.
OK ↓
3. Check the turn signal switch. NG →
The turn signal switch is faulty. Replace
the left handlebar switch.
OK ↓
8-22
SIGNALING SYSTEM
4. Check the hazard switch. NG →

The hazard switch is faulty. Replace the
right handlebar switch.
OK ↓
5. Check the turn signal/hazard relay. NG →
Refer to “CHECKING THE TURN
Replace the turn signal/hazard relay.
SIGNAL/HAZARD RELAY” on page
8-90.
OK ↓
page 8-19.
OK ↓
This circuit is OK.
The fuel meter fails to operate.

1. Check the fuel sender. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump.
SENDER” on page 8-94.
OK ↓
page 8-19.
OK ↓
Replace the meter assembly.
The coolant temperature meter fails to operate.

1. Check the coolant temperature sen- NG →
sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 8-96.
OK ↓
. 2. Check the entire signaling system NG →
page 8-19.
OK ↓
Replace the ECU or meter assembly.
8-23
SIGNALING SYSTEM
The speedometer fails to operate.

1. Check the speed sensor. NG →
Refer to “CHECKING THE SPEED Replace the speed sensor.
SENSOR” on page 8-95.
OK ↓
page 8-19.
OK ↓
The tachometer fails to operate.

1. Check the crankshaft position sen- NG →
sor.
Refer to “CHECKING THE CRANK-
SHAFT POSITION SENSOR” on
page 8-92.
OK ↓
page 8-19.
OK ↓
The air temperature meter fails to operate.

1. Check the air temperature sensor. NG →
Refer to “CHECKING THE AIR
Replace the air temperature sensor.
TEMPERATURE SENSOR” on
page 8-98.
OK ↓
. 2. Check the entire signaling system NG →
page 8-19.
OK ↓
8-24
SIGNALING SYSTEM
The V-belt replacement indicator fails to come on.

1. Check the V-belt replacement indi- NG →
cator reset coupler.
Replace the V-belt replacement indicator
Refer to “CHECKING THE V-BELT
reset coupler.
REPLACEMENT INDICATOR RE-
SET COUPLER” on page 8-99.
OK ↓
page 8-19.
OK ↓
The engine oil change indicator fails to come on.

page 8-19.
OK ↓
8-25
SIGNALING SYSTEM
8-26
A
EAS27310
EAS27300
(Gy) (Gy)
1 B/L W/R
W R
A B
L/Y
B/L W/R R W R/W
18 20 G/Y R/B W/Y
2 W W 3 32
W W B B (Gy) O O
17 B 19 G B 21 26
L B/L Y
W W W R
(B)
B R R G/Y Sb
B L/B L/Y P Gy
(B) B B/Y B
(B)
CIRCUIT DIAGRAM
B L/Y
L/B L L Sb
14 L/B 35
4 B P/W O/B R/B
B B L/B L Y
28 (B)
B B
COOLING SYSTEM
25 (B)
15 16 G/B
23 24 B/L Br/W
R 29
B
ON Dg Br/W Ch 31
Br/R Br/R W P
Br
W/B W L O/R
OPEN 36 B/W B/L
R R L B/L B/W
G/Y Br W/Y L/B B/L
G/B Br/R R/B
6
Br/R R R/W R/B (L)
Br/L B 37
R R/W
L/B B
8
Br/R L/R B/W
B/W B R/L 9
Y/L G/L R/B
10 Gy/G B B R/B G/W

Br/L R/Y
38 W L Gy/G B/L
R/G B B 77
R/W Lg Y/L (B)
(B)
11
Br/L Br
B
R/W R/B
8-27
R/Y R/Y
B B/W
L/R
R/B A R/B
Y/L R/Y
42 Br
R/G R/L L/B
Br/W 40
R/Y W/B P
R/W R/B L/R 41
Lg
R/W L/B W/B (B)

75 Br/W
B B G/L L Br/W
Y/L Y/L
78 B B L G/B
L
44 45 46 47
G/B Br/R Br/R G/B
B R/L B/W 48
Y/L 39
B B/L
B B/L B
Y/L B
B P B G/Y
B 76 L/B R/Y Br
R/L Dg Br/W Ch
(B) (B)
B
G Y G/Y B P
Ch Br/W Dg
Br R/Y L/B
B B
B B

B B
62 G Ch Dg Ch Dg
56 G Y Br Br Br Br
Gy
63 59
L/R 57 55 54 52 49
66 67 68 69 70 71 72 B B Br G/Y B Br G/Y
64 65 58 53 50
Ch B Dg B
G Y Y G
Gy
B B 51 51
B/L B B B
60 B
B B B
G/L Br Y/L B/L Gy B
B B
B B B B B
B
B Gy
B B
(B)
B B B/L
(B)
COOLING SYSTEM
COOLING SYSTEM
5. Main switch
6. ECU fuse
7. Radiator fan motor fuse
9. Ignition fuse
12.Battery
13.Main fuse
17.Frame ground
74.Radiator fan motor
75.Radiator fan motor relay
A. Wire harness
8-28
COOLING SYSTEM
EAS27320
TROUBLESHOOTING
• The radiator fan motor fails to turn.
TIP
1. Storage box
2. Leg shield

(Main, ignition, ECU, and radiator
fan motor) Replace the fuse(s).
ES” on page 8-85.
OK ↓
page 8-85.
OK ↓
OK ↓
4. Check the radiator fan motor. NG →
Refer to “CHECKING THE RADIA- Replace the radiator fan motor.
TOR FAN MOTOR” on page 8-96.
OK ↓
5. Check the radiator fan motor relay. NG →
Refer to “CHECKING THE RE- Replace the radiator fan motor relay.
OK ↓
6. Check the coolant temperature sen- NG →
sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 8-96.
OK ↓
7. Check the entire cooling system NG →
page 8-27.
OK ↓
Replace the ECU.
8-29
COOLING SYSTEM
8-30
A
EAS27340
EAS27330
(Gy) (Gy)
1 B/L W/R
W R
A B
L/Y
B/L W/R R W R/W
18 20 G/Y R/B W/Y
2 W W 3 32
W W B B (Gy) O O
17 B 19 G B 21 26
L B/L Y
W W W R
(B)
B R R G/Y Sb
B L/B L/Y P Gy
(B) B B/Y B
(B)
CIRCUIT DIAGRAM
B L/Y
L/B L L Sb
14 L/B 35
4 B P/W O/B R/B
B B L/B L Y
28 (B)
B B
25 (B)
15 16 G/B
23 24 B/L Br/W
R 29
B
ON Dg Br/W Ch 31
Br/R Br/R W P
Br
W/B W L O/R
OPEN 36 B/W B/L
R R L B/L B/W
B/L
FUEL INJECTION SYSTEM
G/Y Br W/Y L/B

G/B Br/R R/B
6
Br/R R R/W R/B (L)
Br/L B 37
R R/W
L/B B
8
Br/R L/R B/W
B/W B R/L 9
Y/L G/L R/B
10 Gy/G B B R/B G/W

Br/L R/Y
38 W L Gy/G B/L
R/G B B 77
R/W Lg Y/L (B)
(B)
11
Br/L Br
B
R/W R/B
8-31
R/Y R/Y
B B/W
L/R
R/B A R/B
Y/L R/Y
42 Br
R/G R/L L/B
Br/W 40
R/Y W/B P
R/W R/B L/R 41
Lg
R/W L/B W/B (B)

75 Br/W
B B G/L L Br/W
Y/L Y/L
78 B B L G/B
L
44 45 46 47
G/B Br/R Br/R G/B
B R/L B/W 48
Y/L 39
B B/L
B B/L B
Y/L B
B P B G/Y
B 76 L/B R/Y Br
R/L Dg Br/W Ch
(B) (B)
B
G Y G/Y B P
Ch Br/W Dg
Br R/Y L/B
B B
B B

B B
62 G Ch Dg Ch Dg
56 G Y Br Br Br Br
Gy
63 59
L/R 57 55 54 52 49
66 67 68 69 70 71 72 B B Br G/Y B Br G/Y
64 65 58 53 50
Ch B Dg B
G Y Y G
Gy
B B 51 51
B/L B B B
60 B
B B B
G/L Br Y/L B/L Gy B
B B
B B B B B
B
B Gy
B B
(B)
B B B/L
(B)

4. Backup fuse (immobilizer unit and meter
assembly)
5. Main switch
6. ECU fuse
7. Radiator fan motor fuse
9. Ignition fuse
10.Headlight fuse
12.Battery
13.Main fuse
17.Frame ground
18.Sidestand switch
19.Fuel pump
27.Throttle position sensor
28.Intake air pressure sensor
29.Intake air temperature sensor
30.Lean angle sensor
32.Ignition coil
33.Spark plug
34.ISC (idle speed control) unit
35.Fuel injector
36.Speed sensor
37.Air induction system solenoid
38.O2 sensor
42.Headlight relay
68.Engine trouble warning light
74.Radiator fan motor
75.Radiator fan motor relay
A. Wire harness
8-32
EAS27351
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
number 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 LCD. This
number 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
Flashing* when unable to start Operation stopped Cannot be operated
engine
Operated with substi-
tute characteristics in Can or cannot be oper-
Remains on Malfunction detected accordance with the ated depending on the
description of the mal- fault code
function
* The warning light flashes when any one of the following conditions is present and the start switch is
pushed:
Fuel injector
12: Crankshaft position sensor 39:
(open or short circuit)
Sidestand switch Lean angle sensor
19: 41:
(open circuit wire harness to ECU) (open or short circuit)
Lean angle sensor ECU internal malfunction
30: 50:
(latch up detected) (faulty ECU memory)
33: Faulty ignition
Checking the engine trouble warning light

The engine trouble warning light comes on for around 2 seconds after the main switch has been turned
to “ON” and it comes on when the start switch is being pushed. If the warning light does not come on
under these conditions, the warning light may be defective.
ECU detects an abnormal signal from a sensor

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 operating or stop operating, depending on the conditions.
8-33
EAS30580
5. Erase the malfunction history in the diagnos-
TROUBLESHOOTING METHOD
tic mode (Code No. D62). Refer to “SELF-DI-
AGNOSTIC FUNCTION AND DIAGNOSTIC
The engine operation is not normal and the
CODE TABLE” on page 9-5.
engine trouble warning light comes on.
1. Check: TIP
• Fault code number Turning the main switch to “OFF” will not erase
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ the malfunction history.
a. Check the fault code number displayed on
the multi-function meter.
The engine operation is not normal, but the
b. Identify the faulty system with the fault code
engine trouble warning light does not come
number.
on.
c. Identify the probable cause of the malfunc-
1. Check the operation of the following sensors
tion.
and actuators in the diagnostic mode. Refer
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
to “TROUBLESHOOTING DETAILS” on
2. Check and repair the probable cause of the page 8-37.
malfunction.
D01: Throttle position sensor signal (throttle
Fault code No. No fault code No. angle)
D30: ignition coil
Check and repair. Check and repair. D36: Injector
Refer to “TROUBLE-
SHOOTING DE- If a malfunction is detected in the sensors or
TAILS” on page 8-37. actuators, repair or replace all faulty parts.
Monitor the opera- If no malfunction is detected in the sensors
tion of the sensors
and actuators, check and repair the inner
and actuators in the
diagnostic mode. Re- parts of the engine.
fer to “TROUBLE-
SHOOTING
DETAILS” on page
8-37 and “SELF-DI-
AGNOSTIC FUNC-
TION AND
DIAGNOSTIC CODE
TABLE” on page 9-5.
3. Perform the reinstatement action for the fuel

injection system.
Refer to “Confirmation of service completion”
in the appropriate table in “TROUBLE-
SHOOTING DETAILS” on page 8-37.
4. Turn the main switch to “OFF”, and back to
“ON”, and then check that no fault code num-
ber is displayed.
TIP
If another fault code number is displayed, repeat
steps (1) to (4) until no fault code number is dis-
played.
8-34
EAS27441
DIAGNOSTIC MODE
It is only possible to monitor the sensor output data or check the activation of actuators by connecting
the FI diagnostic tool to the vehicle and setting the diagnostic mode.
TIP
The diagnostic mode can only be set using the FI diagnostic tool. The diagnostic mode cannot be set
using the meter.
FI diagnostic tool
90890-03182
YU-03182
Setting the diagnostic mode

1. Turn the main switch to “OFF”.
2. Disconnect the wire harness coupler from the fuel pump.
3. Disconnect the self-diagnosis signal coupler, and then connect the FI diagnostic tool “1” as shown.
4. While pressing the “MODE” button, turn the main switch to “ON”.
TIP
• “DIAG” appears on the LCD of the FI diagnostic tool. If “CO” appears on the LCD of the FI diagnostic
tool, press the “UP” button to select “DIAG”.
• The “POWER” LED (green) comes on.
5. Press the “MODE” button.
TIP
The diagnostic code number “D01” appears on the LCD of the FI diagnostic tool.
6. Select the diagnostic code number corresponding to the fault code number by pressing the “UP” and
“DOWN” buttons.
TIP
• The diagnostic code number appears on the LCD (01-70).
• To decrease the selected diagnostic code number, press the “DOWN” button. Press the “DOWN” but-
ton for 1 second or longer to automatically decrease the diagnostic code numbers.
• To increase the selected diagnostic code number, press the “UP” button. Press the “UP” button for 1
second or longer to automatically increase the diagnostic code numbers.
8-35
7. Check the operation of the sensor or actuator.

• Sensor operation
The data representing the operating conditions of the sensor appear on the LCD.
• Actuator operation
Press the “MODE” button.
8. Turn the main switch to “OFF” to cancel the diagnostic mode.
9. Disconnect the FI diagnostic tool and connect the self-diagnosis signal coupler.
TIP
Information about each diagnostic code number is organized in this manual as follows:
• If a diagnostic code number has a corresponding fault code number, the information is shown in
“TROUBLESHOOTING DETAILS”. (Refer to “TROUBLESHOOTING DETAILS” on page 8-37.)
• If a diagnostic code number does not have a corresponding fault code number, the information is
shown in “DIAGNOSTIC CODE TABLE”. (Refer to “SELF-DIAGNOSTIC FUNCTION AND DIAG-
NOSTIC CODE TABLE” on page 9-5.)
10.Connect the wire harness coupler to the fuel pump.
8-36
EAS27462
TROUBLESHOOTING DETAILS
This section describes the measures per fault code number displayed on the multi-function 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 have been completed, reset the multi-function
meter according to the “Confirmation of service completion”.
Fault code No.:
Fault code number displayed on the multi-function meter when the engine failed to work normally.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “SELF-DIAGNOS-
TIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 9-5.
Fault code No. 12
Crankshaft position sensor: no normal signals are received
Item
from the crankshaft position sensor.
Unable to start engine
Fail-safe system
Unable to drive vehicle
Diagnostic code No. —
FI diagnostic tool display —
Procedure —
Probable cause of mal- Confirmation of service
Item Maintenance job
function and check completion
1 Connection of crankshaft po- Improperly connected → Crank the engine.
sition sensor coupler. Connect the coupler secure- Fault code number is not dis-
Check the locking condition ly or replace the wire har- played → Service is finished.
of the coupler. ness. Fault code number is dis-
Disconnect the coupler and played → Go to item 2.
check the pins (bent or bro-
ken terminals and locking
condition of the pins).
2 Connection of wire harness Improperly connected → Crank the engine.
ECU coupler. Connect the coupler secure- Fault code number is not dis-
3 Wire harness continuity. Open or short circuit → Re- Crank the engine.
place the wire harness. Fault code number is not dis-
Between crankshaft position played → Service is finished.
sensor coupler and ECU Fault code number is dis-
coupler. played → Go to item 4.
black/blue–black/blue
white/red–white/red
8-37
Fault code No. 12

Crankshaft position sensor: no normal signals are received
Item
from the crankshaft position sensor.
4 Installed condition of crank- Improperly installed sensor Crank the engine.
shaft position sensor. → Reinstall or replace the Fault code number is not dis-
Check for looseness or sensor. played → Service is finished.
pinching. Refer to “STARTER Fault code number is dis-
Check the gap between the CLUTCH AND GENERA- played → Go to item 5.
crankshaft position sensor TOR” on page 5-41.
and the generator rotor.
5 Defective crankshaft posi- Check the crankshaft posi- Crank the engine.
tion sensor. tion sensor. Fault code number is not dis-
Refer to “CHECKING THE played → Service is finished.
CRANKSHAFT POSITION Fault code number is dis-
SENSOR” on page 8-92. played → Go to item 6.
Replace if defective.
6 Malfunction in ECU. Replace the ECU.
Fault code No. 13

Item Intake air pressure sensor: open or short circuit detected.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. D03
FI diagnostic tool display Displays the intake air pressure.
Operate the throttle while pulling the brake lever and pushing the
Procedure start switch “ ”. (If the display value changes, the performance is
OK.)
1 Connection of intake air Improperly connected → Turn the main switch to “ON”.
pressure sensor coupler. Connect the coupler secure- Fault code number is not dis-
2 Connection of wire harness Improperly connected → Turn the main switch to “ON”.
8-38
Fault code No. 13

Item Intake air pressure sensor: open or short circuit detected.
3 Connection of engine sub- Improperly connected → Turn the main switch to “ON”.
wire harness coupler. Connect the coupler secure- Fault code number is not dis-
Check the locking condition ly or replace the engine sub- played → Service is finished.
of the coupler. wire harness. Fault code number is dis-
4 Wire harness continuity. Open or short circuit → Re- Turn the main switch to “ON”.
Between intake air pressure played → Service is finished.
pink/white–pink/white
blue–blue
5 Installed condition of intake Improperly installed sensor Turn the main switch to “ON”.
air pressure sensor. → Reinstall or replace the Fault code number is not dis-
pinching. Fault code number is dis-
played → Go to item 6.
6 Defective intake air pressure Execute the diagnostic Turn the main switch to “ON”.
sensor. mode. (Code No. D03) Fault code number is not dis-
When engine is stopped: played → Service is finished.
Atmospheric pressure at the Fault code number is dis-
current altitude and weather played → Go to item 7.
conditions is indicated.
At sea level: Approx. 101 kPa
(757.6 mmHg, 29.8 inHg)
1000 m (3300 ft) above sea
level: Approx. 90 kPa (675.1
mmHg, 26.6 inHg)
mmHg, 23.6 inHg)
mmHg, 20.7 inHg)
When engine is cranking:
Make sure that the indication
value changes.
The value does not change
when engine is cranking. →
Check the intake air pressure
sensor.
INTAKE AIR PRESSURE
8-39
TIP
If fault code numbers “13” and “14” are both indicated, take the actions specified for fault code number
“13” first.
Fault code No. 14

Intake air pressure sensor: hose system malfunction (clogged
Item
or detached hose).
Fail-safe system
FI diagnostic tool display Displays the intake air pressure.
Operate the throttle while pulling the brake lever and pushing the
Procedure start switch “ ”. (If the display value changes, the performance is
OK.)
1 Condition of intake air pres- Clogged or detached hose Start the engine and let it idle
sure sensor hose. → Repair or replace the sen- for approximately 5 seconds.
Check the intake air pressure sor hose. Fault code number is not dis-
sensor hose condition. played → Service is finished.
Fault code number is dis-
2 Defective intake air pressure Execute the diagnostic
sensor. mode. (Code No. D03)
When engine is stopped:
Atmospheric pressure at the
current altitude and weather
conditions is indicated.
At sea level: Approx. 101 kPa
(757.6 mmHg, 29.8 inHg)
mmHg, 26.6 inHg)
mmHg, 23.6 inHg)
mmHg, 20.7 inHg)
When engine is cranking:
Make sure that the indication
value changes.
The value does not change
when engine is cranking. →
Check the intake air pressure
sensor.
INTAKE AIR PRESSURE
8-40
Fault code No. 15

Item Throttle position sensor: open or short circuit detected.
Fail-safe system
Throttle position sensor signal
FI diagnostic tool display • 8–22 (fully closed position)
• 88–102 (fully open position)
• Check with throttle valve fully closed.
Procedure
• Check with throttle valve fully open.
1 Connection of throttle posi- Improperly connected → Turn the main switch to “ON”.
tion sensor coupler. Connect the coupler secure- Fault code number is not dis-
Between throttle position played → Service is finished.
yellow–yellow
blue–blue
5 Installed condition of throttle Improperly installed sensor Turn the main switch to “ON”.
position sensor. → Reinstall. Fault code number is not dis-
Check for looseness or Refer to “THROTTLE BODY” played → Service is finished.
pinching. on page 7-4. Fault code number is dis-
8-41
Fault code No. 15

Item Throttle position sensor: open or short circuit detected.
6 Throttle position sensor volt- Measure the throttle position Turn the main switch to “ON”.
age. sensor voltage. Fault code number is not dis-
blue–black/blue played → Service is finished.
Refer to “CHECKING THE Fault code number is dis-
THROTTLE POSITION played → Go to item 7.
7 Defective throttle position Check throttle position sen- Turn the main switch to “ON”.
sensor. sor signal. Fault code number is not dis-
Execute the diagnostic played → Service is finished.
mode. (Code No. D01) Fault code number is dis-
When the throttle valve is ful- played → Go to item 8.
ly closed:
A value of 8–22 is indicated.
When throttle valve is fully
open:
A value of 88–102 is indicat-
ed.
An indicated value is out of
the specified range → Re-
place the throttle position
sensor.
Fault code No. 16

Throttle position sensor: stuck throttle position sensor is de-
Item
tected.
Fail-safe system
Throttle position sensor signal
FI diagnostic tool display • 8–22 (fully closed position)
• 88–102 (fully open position)
• Check with throttle valve fully closed.
Procedure
• Check with throttle valve fully open.
1 Installed condition of throttle Improperly installed sensor Turn the main switch to “ON”
position sensor. → Reinstall. and then open and close the
Check for looseness or Refer to “THROTTLE BODY” throttle valve.
pinching. on page 7-4. Fault code number is not dis-
played → Service is finished.
8-42
Fault code No. 16

Throttle position sensor: stuck throttle position sensor is de-
Item
tected.
2 Defective throttle position Check throttle position sen- Turn the main switch to “ON”
sensor. sor signal. and then open and close the
Execute the diagnostic throttle valve.
mode. (Code No. D01) Fault code number is not dis-
When the throttle valve is ful- played → Service is finished.
ly closed: Fault code number is dis-
A value of 8–22 is indicated. played → Go to item 3.
When throttle valve is fully
open:
A value of 88–102 is indicat-
ed.
An indicated value is out of
the specified range → Re-
place the throttle position
sensor.
TIP
• If fault code numbers “15” and “16” are both indicated, take the actions specified for fault code number
“15” first.
“16” first.
Fault code No. 19

Sidestand switch: a break or disconnection of the blue/yellow
Item
lead of the ECU is detected.
Fail-safe system
Sidestand switch
FI diagnostic tool display • “ON” (sidestand retracted)
• “OFF” (sidestand extended)
Procedure Extend and retract the sidestand.
1 Connection of sidestand Improperly connected → Turn the main switch to “ON”,
switch coupler. Connect the coupler secure- and then extend and retract
Check the locking condition ly or replace the wire har- the sidestand.
of the coupler. ness. Fault code number is not dis-
Disconnect the coupler and played → Service is finished.
check the pins (bent or bro- Fault code number is dis-
ken terminals and locking played → Go to item 2.
8-43
Fault code No. 19

Sidestand switch: a break or disconnection of the blue/yellow
Item
lead of the ECU is detected.
2 Connection of wire harness Improperly connected → Turn the main switch to “ON”,
ECU coupler. Connect the coupler secure- and then extend and retract
Check the locking condition ly or replace the wire har- the sidestand.
3 Defective sidestand switch. Execute the diagnostic Turn the main switch to “ON”,
mode. (Code No. D20) and then extend and retract
Sidestand retracted: “ON” the sidestand.
Sidestand extended: “OFF” Fault code number is not dis-
Replace if defective. played → Service is finished.
Fault code No. 21

Item Coolant temperature sensor: open or short circuit detected.
Fail-safe system
FI diagnostic tool display Displays the coolant temperature.
Compare the actually measured coolant temperature with the FI
Procedure
diagnostic tool display value.
1 Connection of coolant tem- Improperly connected → Turn the main switch to “ON”.
perature sensor coupler. Connect the coupler secure- Fault code number is not dis-
8-44
Fault code No. 21

Item Coolant temperature sensor: open or short circuit detected.
Between coolant tempera- played → Service is finished.
ture sensor coupler and ECU Fault code number is dis-
green/red–green/red
5 Installed condition of coolant Improperly installed sensor Turn the main switch to “ON”.
temperature sensor. → Reinstall or replace the Fault code number is not dis-
6 Defective coolant tempera- Execute the diagnostic Turn the main switch to “ON”.
ture sensor. mode. (Code No. D06) Fault code number is not dis-
When engine is cold: played → Service is finished.
Displayed temperature is Fault code number is dis-
close to the ambient temper- played → Go to item 7.
ature.
The displayed temperature is
not close to the ambient tem-
perature → Check the cool-
ant temperature sensor.
COOLANT TEMPERATURE
Fault code No. 22

Item Intake air temperature sensor: open or short circuit detected.
Fail-safe system
FI diagnostic tool display Displays the intake air temperature.
Compare the actually measured air temperature with the FI diag-
Procedure
nostic tool display value.
8-45
Fault code No. 22

Item Intake air temperature sensor: open or short circuit detected.
1 Connection of intake air tem- Improperly connected → Turn the main switch to “ON”.
perature sensor coupler. Connect the coupler secure- Fault code number is not dis-
Between intake air tempera- played → Service is finished.
ture sensor coupler and ECU Fault code number is dis-
brown/white–brown/white
5 Installed condition of intake Improperly installed sensor Turn the main switch to “ON”.
air temperature sensor. → Reinstall or replace the Fault code number is not dis-
6 Defective intake air tempera- Execute the diagnostic Turn the main switch to “ON”.
ture sensor. mode. (Code No. D05) Fault code number is not dis-
When engine is cold: played → Service is finished.
Displayed temperature is Fault code number is dis-
close to the ambient temper- played → Go to item 7.
ature.
The displayed temperature is
not close to the ambient tem-
perature. → Check the intake
air temperature sensor.
INTAKE AIR PRESSURE
8-46
Fault code No. 24
Item O2 sensor: no normal signals are received from the O2 sensor.

Fail-safe system
Procedure —
1 Installed condition of O2 sen- Improperly installed sensor Start the engine, warm it up,
sor. → Reinstall or replace the and then race it, or execute
sensor. the diagnostic mode. (Code
No. D63)
Fault code number is not dis-
2 Connection of O2 sensor Improperly connected → Start the engine, warm it up,
coupler. Connect the coupler secure- and then race it, or execute
Check the locking condition ly or replace the wire har- the diagnostic mode. (Code
of the coupler. ness. No. D63)
Disconnect the coupler and Fault code number is not dis-
check the pins (bent or bro- played → Service is finished.
ken terminals and locking Fault code number is dis-
condition of the pins). played → Go to item 3.
3 Connection of wire harness Improperly connected → Start the engine, warm it up,
ECU coupler. Connect the coupler secure- and then race it, or execute
Check the locking condition ly or replace the wire har- the diagnostic mode. (Code
of the coupler. ness. No. D63)
4 Connection of engine sub- Improperly connected → Start the engine, warm it up,
wire harness coupler. Connect the coupler secure- and then race it, or execute
Check the locking condition ly or replace the engine sub- the diagnostic mode. (Code
of the coupler. wire harness. No. D63)
5 Wire harness continuity. Open or short circuit → Re- Start the engine, warm it up,
place the wire harness. and then race it, or execute
Between O2 sensor coupler the diagnostic mode. (Code
and ECU coupler. No. D63)
gray/green–gray/green Fault code number is not dis-
green/white–green/white played → Service is finished.
black/blue–black/blue Fault code number is dis-
red/black–red/black played → Go to item 6.
8-47
Fault code No. 24
Item O2 sensor: no normal signals are received from the O2 sensor.

6 Check fuel pressure. Refer to “CHECKING THE Start the engine, warm it up,
FUEL PRESSURE” on page and then race it, or execute
7-3. the diagnostic mode. (Code
No. D63)
7 Defective O2 sensor. Check the O2 sensor. Start the engine, warm it up,
Replace if defective. and then race it, or execute
Refer to “ENGINE REMOV- the diagnostic mode. (Code
AL” on page 5-2. No. D63)
Fault code No. 30

Item Latch up detected.
Fail-safe system
Lean angle sensor output voltage
FI diagnostic tool display • 0.4–1.4 (upright)
• 3.7–4.4 (overturned)
Remove the lean angle sensor and incline it more than 65 de-
Procedure
grees.
1 The vehicle has overturned. Raise the vehicle upright. Turn the main switch to “ON”,
then to “OFF”, and then back
to “ON”.
2 Installed condition of lean Check the installed direction Turn the main switch to “ON”,
angle sensor. and condition of the sensor. then to “OFF”, and then back
to “ON”.
8-48
Fault code No. 30

Item Latch up detected.
3 Defective lean angle sensor. Execute the diagnostic Turn the main switch to “ON”,
mode. (Code No. D08) then to “OFF”, and then back
Replace if defective. to “ON”.
Refer to “CHECKING THE Fault code number is not dis-
LEAN ANGLE SENSOR” on played → Service is finished.
page 8-92. Fault code number is dis-
Fault code No. 33

Ignition coil: open or short circuit detected in the primary lead
Item
of the ignition coil.
Fail-safe system
Actuates the ignition coil five times at one-second intervals.
Actuation
Illuminates the engine trouble warning light.
Check that a spark is generated five times.
Procedure
• Connect an ignition checker.
1 Connection of ignition coil Improperly connected → Start the engine and let it idle
coupler. Connect the coupler secure- for approximately 5 seconds.
Check the locking condition ly or replace the wire har- Fault code number is not dis-
of the coupler. ness. played → Service is finished.
Disconnect the coupler and Fault code number is dis-
check the pins (bent or bro- played → Go to item 2.
2 Connection of wire harness Improperly connected → Start the engine and let it idle
ECU coupler. Connect the coupler secure- for approximately 5 seconds.
3 Wire harness continuity. Open or short circuit → Re- Start the engine and let it idle
place the wire harness. for approximately 5 seconds.
Between ignition coil coupler Fault code number is not dis-
and ECU coupler. played → Service is finished.
orange–orange Fault code number is dis-
8-49
Fault code No. 33

Ignition coil: open or short circuit detected in the primary lead
Item
of the ignition coil.
4 Installed condition of ignition Improperly installed ignition Start the engine and let it idle
coil. coil → Reinstall or replace for approximately 5 seconds.
Check for looseness or the ignition coil. Fault code number is not dis-
pinching. played → Service is finished.
5 Defective ignition coil. Measure the primary coil re- Start the engine and let it idle
sistance of the ignition coil. for approximately 5 seconds.
Replace if out of specifica- Fault code number is not dis-
tion. played → Service is finished.
IGNITION COIL” on page played → Go to item 6.
8-91.
6 Malfunction in ECU. Execute the diagnostic
mode. (Code No. D30)
No spark → Replace the
ECU.
Fault code No. 37

Component other than ISC (idle speed control) unit is de-
A
fective (ISC operating sound is heard).
Item
Defective ISC (idle speed control) unit (ISC operating sound is
B
not heard).
Fail-safe system
Actuates and fully closes the ISC valve, then opens it to the stand-
Actuation by opening position when the engine is started.
This operation takes approximately 3 seconds until it is completed.
Procedure The ISC unit vibrates when the ISC valve operates.
1 Locate the malfunction. Execute the diagnostic ISC operating sound is heard
mode. (Code No. D54) → Go to item 2.
Fully closes the ISC (idle ISC operating sound is not
speed control) valve, and heard → Go to item 2 in sec-
then fully opens the valve. tion B for the defective ISC
(idle speed control) unit.
2 Incorrect speed sensor sig- Check the speed sensor. Start the engine and let it idle
nal. Execute the diagnostic for approximately 10 sec-
mode. (Code No. D07) onds.
Rotate the rear wheel by Fault code number is not dis-
hand and check that the indi- played → Service is finished.
cated value increases. Fault code number is dis-
Value does not increase → played → Go to item 3.
Go to fault code No. 42.
8-50
Fault code No. 37

Component other than ISC (idle speed control) unit is de-
A
fective (ISC operating sound is heard).
Item
Defective ISC (idle speed control) unit (ISC operating sound is
B
not heard).
3 Throttle valve does not fully Checking the throttle body. Start the engine and let it idle
close. Refer to “CHECKING THE for approximately 10 sec-
THROTTLE BODY” on page onds.
7-7. Fault code number is not dis-
Checking the throttle cable. played → Service is finished.
THROTTLE GRIP OPERA- played → Go to item 4.
TION” on page 3-24.
4 ISC valve is not moving cor- Replace the throttle body as- Start the engine and let it idle
rectly. sembly. for approximately 10 sec-
onds.
TIP
• Do not remove the ISC (idle speed control) valve.
“46” first.
“42” first.
Fault code No. 37

Component other than ISC (idle speed control) unit is defective
A
(ISC operating sound is heard).
Item
Defective ISC (idle speed control) unit (ISC operating
B
sound is not heard).
Fail-safe system
Actuates and fully closes the ISC valve, then opens it to the stand-
Actuation by opening position when the engine is started.
This operation takes approximately 3 seconds until it is completed.
Procedure The ISC unit vibrates when the ISC valve operates.
8-51
Fault code No. 37

A
Item
B
1 Locate the malfunction. Execute the diagnostic ISC operating sound is heard
mode. (Code No. D54) → Go to item 2 in section A
Fully closes the ISC (idle for the component other than
speed control) valve, and ISC (idle speed control) unit
then fully opens the valve. is defective.
ISC operating sound is not
heard → Go to item 2.
2 Connection of ISC (idle Improperly connected → Execute the diagnostic
speed control) unit coupler. Connect the coupler secure- mode. (Code No. D54)
Check the locking condition ly or replace the wire har- ISC operating sound is heard
of the coupler. ness. → Go to item 9.
Disconnect the coupler and ISC operating sound is not
check the pins (bent or bro- heard → Go to item 3.
3 Connection of wire harness Improperly connected → Execute the diagnostic
ECU coupler. Connect the coupler secure- mode. (Code No. D54)
Check the locking condition ly or replace the wire har- ISC operating sound is heard
of the coupler. ness. → Go to item 9.
4 Connection of engine sub- Improperly connected → Execute the diagnostic
wire harness coupler. Connect the coupler secure- mode. (Code No. D54)
Check the locking condition ly or replace the engine sub- ISC operating sound is heard
of the coupler. wire harness. → Go to item 9.
5 Wire harness continuity. Open or short circuit → Re- Execute the diagnostic
place the wire harness. mode. (Code No. D54)
Between ISC (idle speed ISC operating sound is heard
control) unit coupler and → Go to item 9.
ECU coupler. ISC operating sound is not
pink–pink heard → Go to item 6.
green/yellow–green/yellow
gray–gray
sky blue–sky blue
6 Installed condition of ISC Improperly installed ISC (idle Execute the diagnostic
(idle speed control) unit. speed control) unit → Rein- mode. (Code No. D54)
Check for looseness or stall the ISC (idle speed con- ISC operating sound is heard
pinching. trol) unit. → Go to item 9.
8-52
Fault code No. 37

A
Item
B
7 ISC valve is not moving cor- Replace the throttle body as- Execute the diagnostic
rectly. sembly. mode. (Code No. D54)
ISC operating sound is heard
→ Go to item 9.
9 Delete the fault code. Start the engine and let it idle
for approximately 10 sec-
onds.
Check that the fault code
number is not displayed.
TIP
• Do not remove the ISC (idle speed control) valve.
“46” first.
“42” first.
Fault code No. 39

Item Injector: open or short circuit detected.
Fail-safe system
Actuates injector five times at one-second intervals.
Actuation
Illuminates the engine trouble warning light.
Check that injector is actuated five times by listening for the oper-
Procedure
ating sound.
1 Connection of injector cou- Improperly connected → Execute the diagnostic
pler. Connect the coupler secure- mode. (Code No. D36)
Check the locking condition ly or replace the wire har- No operating sound → Go to
of the coupler. ness. item 2.
Disconnect the coupler and Operating sound → Go to
check the pins (bent or bro- item 7.
8-53
Fault code No. 39

Item Injector: open or short circuit detected.
2 Defective injector. Measure the injector resis- Execute the diagnostic
tance. mode. (Code No. D36)
Replace if out of specifica- No operating sound → Go to
tion. item 3.
Refer to “CHECKING THE Operating sound → Go to
FUEL INJECTOR” on page item 7.
7-7.
3 Connection of wire harness Improperly connected → Execute the diagnostic
ECU coupler. Connect the coupler secure- mode. (Code No. D36)
Check the locking condition ly or replace the wire har- No operating sound → Go to
of the coupler. ness. item 4.
4 Connection of engine sub- Improperly connected → Execute the diagnostic
wire harness coupler. Connect the coupler secure- mode. (Code No. D36)
Check the locking condition ly or replace the engine sub- No operating sound → Go to
of the coupler. wire harness. item 5.
5 Wire harness continuity. Open or short circuit → Re- Execute the diagnostic
place the wire harness. mode. (Code No. D36)
Between injector coupler and No operating sound → Go to
ECU coupler. item 6.
red/black–red/black Operating sound → Go to
orange/black–orange/black item 7.
7 Delete the fault code. Start the engine and let it idle
for approximately 5 seconds.
8-54
Fault code No. 41

Item Lean angle sensor: open or short circuit detected.
Fail-safe system
Lean angle sensor output voltage
FI diagnostic tool display • 0.4–1.4 (upright)
• 3.7–4.4 (overturned)
Remove the lean angle sensor and incline it more than 65 de-
Procedure
grees.
1 Connection of lean angle Improperly connected → Turn the main switch to “ON”,
sensor coupler. Connect the coupler secure- then to “OFF”, and then back
Check the locking condition ly or replace the wire har- to “ON”.
2 Connection of wire harness Improperly connected → Turn the main switch to “ON”,
ECU coupler. Connect the coupler secure- then to “OFF”, and then back
Check the locking condition ly or replace the wire har- to “ON”.
3 Wire harness continuity. Open or short circuit → Re- Turn the main switch to “ON”,
place the wire harness. then to “OFF”, and then back
Between lean angle sensor to “ON”.
coupler and ECU coupler. Fault code number is not dis-
yellow/green–yellow/green played → Service is finished.
blue–blue Fault code number is dis-
black/blue–black/blue played → Go to item 4.
4 Defective lean angle sensor. Execute the diagnostic Turn the main switch to “ON”,
mode. (Code No. D08) then to “OFF”, and then back
Replace if defective. to “ON”.
Refer to “CHECKING THE Fault code number is not dis-
LEAN ANGLE SENSOR” on played → Service is finished.
page 8-92. Fault code number is dis-
Fault code No. 42

Speed sensor: no normal signals are received from the speed
Item
sensor.
Fail-safe system
8-55
Fault code No. 42

Speed sensor: no normal signals are received from the speed
Item
sensor.
Front wheel speed pulse
FI diagnostic tool display
0–999
Check that the number increases when the front wheel is rotated.
Procedure The number is cumulative and does not reset each time the wheel
is stopped.
1 Connection of speed sensor Improperly connected → Turn the main switch to “ON”
coupler. Connect the coupler secure- and then rotate the front
Check the locking condition ly or replace the wire har- wheel a few turns by hand.
2 Connection of wire harness Improperly connected → Turn the main switch to “ON”
ECU coupler. Connect the coupler secure- and then rotate the front
Check the locking condition ly or replace the wire har- wheel a few turns by hand.
3 Wire harness continuity. Open or short circuit → Re- Turn the main switch to “ON”
place the wire harness. and then rotate the front
Between speed sensor cou- wheel a few turns by hand.
pler and ECU coupler. Fault code number is not dis-
white–white played → Service is finished.
blue–blue Fault code number is dis-
black/blue–black/blue played → Go to item 4.
4 Defective speed sensor. Check the installed condi- Turn the main switch to “ON”
tion of the speed sensor and and then rotate the front
for damage. wheel a few turns by hand.
Execute the diagnostic mode Fault code number is not dis-
(Code No. D07). played → Service is finished.
Front wheel stop: The pulse Fault code number is dis-
integrated value should be played → Go to item 5.
constant.
Rotate the front wheel a few
turns by hand and enter the
speed pulse: The pulse inte-
grated value will be added.
8-56
Fault code No. 43

Fuel system voltage: incorrect voltage supplied to the fuel in-
Item
jector and fuel pump.
Fail-safe system
Fuel system voltage (battery voltage)
FI diagnostic tool display
Approximately 12.0
Compare the actually measured battery voltage with the FI diag-
Procedure nostic tool display value. (If the actually measured battery voltage
is low, recharge the battery.)
1 Connection of wire harness Improperly connected → Start the engine and let it idle
ECU coupler. Connect the coupler secure- for approximately 5 seconds.
2 Wire harness continuity. Open or short circuit → Re- Start the engine and let it idle
place the wire harness. for approximately 5 seconds.
Between battery terminal Fault code number is not dis-
and ECU coupler. played → Service is finished.
red–red/white Fault code number is dis-
Fault code No. 44

EEPROM fault code number: an error is detected while reading
Item
or writing on EEPROM.
Fail-safe system
EEPROM fault code display
• 00 (no history)
• 01: CO adjustment value (history exists)
FI diagnostic tool display • 03: Immobilizer code (history exists)
• 04: ISC (idle speed control) unit learning values (history exists)
If there are multiple errors, they are displayed in two seconds in-
tervals.
Procedure —
8-57
Fault code No. 44

EEPROM fault code number: an error is detected while reading
Item
or writing on EEPROM.
1 Locate the malfunction. Execute the diagnostic —
mode. (Code No. D60)
00: Go to item 5.
01: Go to item 2.
03: Go to item 3.
04: Go to item 4.
2 “01” is indicated in diagnostic Change the CO concentra- Turn the main switch to “ON”.
mode (Code No. D60). EEP- tion, and rewrite in EE- Fault code number is not dis-
ROM data error for adjust- PROM. played → Service is finished.
ment of CO concentration. Refer to “ADJUSTING THE Fault code number is dis-
EXHAUST GAS VOLUME” played → Repeat item 1. If
on page 3-9. the same number is indicat-
After this adjustment is ed, go to item 5.
made, the memory is not re-
covered when the main
switch is turned to “OFF”.
3 “03” is indicated in diagnostic Turn the main switch to Turn the main switch to “ON”.
mode (Code No. D60). EEP- “OFF”. Fault code number is not dis-
ROM data error for immobi- played → Service is finished.
lizer code. Fault code number is dis-
played → Repeat item 1. If
the same number is indicat-
ed, go to item 5.
4 “04” is indicated in diagnostic Turn the main switch to “ON”, Turn the main switch to “ON”.
mode (Code No. D60). EEP- and then fully opens and Fault code number is not dis-
ROM data error for ISC (idle closes the throttle valve. played → Service is finished.
speed control) unit learning Turn the main switch to Fault code number is dis-
values. “OFF”. played → Repeat item 1. If
the same number is indicat-
ed, go to item 5.
Fault code No. 46

Item Charging voltage is abnormal.
Fail-safe system
Procedure —
8-58
Fault code No. 46

Item Charging voltage is abnormal.
1 Malfunction in charging sys- Check the charging system. Start the engine and let it idle
tem. Refer to “CHARGING SYS- for approximately 5 seconds.
TEM” on page 8-11. Fault code number is not dis-
Defective rectifier/regulator played → Service is finished.
or AC magneto → Replace. Fault code number is dis-
Defective connection in the played → Repeat the mainte-
charging system circuit → nance job.
Properly connect or replace
the wire harness.
Fault code No. 50

Faulty ECU memory. (When this malfunction is detected in the
Item ECU, the fault code number might not appear on the multi-
function meter.)
Fail-safe system
Procedure —
1 Malfunction in ECU. Replace the ECU. Turn the main switch to “ON”.
Fault code No. 61

Item ISC (idle speed control) unit: open or short circuit detected.
Fail-safe system
Procedure —
1 Connection of ISC (idle Improperly connected → Turn the main switch to “ON”.
speed control) unit coupler. Connect the coupler secure- Fault code number is not dis-
8-59
Fault code No. 61

Item ISC (idle speed control) unit: open or short circuit detected.
Between ISC (idle speed played → Service is finished.
control) unit coupler and Fault code number is dis-
ECU coupler. played → Go to item 5.
pink–pink
green/yellow–green/yellow
gray–gray
sky blue–sky blue
5 Defective ISC (idle speed Execute the diagnostic Turn the main switch to “ON”.
control) unit. mode. (Code No. D54). Fault code number is not dis-
ISC (idle speed control) played → Service is finished.
valve operating sound is not Fault code number is dis-
heard. → Replace the throt- played → Go to item 6.
tle body assembly.
TIP
Do not remove the ISC (idle speed control) valve.
Fault code No. Er-1

ECU (engine control unit) internal malfunction (output signal
Item error): signals cannot be transmitted between the ECU and the
multi-function meter.
Fail-safe system
Procedure —
8-60
Fault code No. Er-1

Item error): signals cannot be transmitted between the ECU and the
multi-function meter.
1 Connection of meter assem- Improperly connected → Turn the main switch to “ON”.
bly coupler. Connect the coupler secure- Fault code number is not dis-
Between meter coupler and played → Service is finished.
ECU coupler. Fault code number is dis-
yellow/blue–yellow/blue played → Go to item 4.
4 Defective meter assembly. Replace the meter assembly. Turn the main switch to “ON”.
Fault code No. Er-2

Item error): no signals are received from the ECU within the speci-
fied duration.
Fail-safe system
Procedure —
8-61
Fault code No. Er-2

Item error): no signals are received from the ECU within the speci-
fied duration.
Fault code No. Er-3

Item
error): data from the ECU cannot be received correctly.
Fail-safe system
Procedure —
8-62
Fault code No. Er-3

Item
error): data from the ECU cannot be received correctly.
Fault code No. Er-4

ECU (engine control unit) internal malfunction (input signal er-
Item
ror): non-registered data has been received from the meter.
Fail-safe system
Procedure —
8-63
Fault code No. Er-4

ECU (engine control unit) internal malfunction (input signal er-
Item
ror): non-registered data has been received from the meter.
8-64
A
EAS27560
EAS27550
(Gy) (Gy)
1 B/L W/R
W R
A B
L/Y
B/L W/R R W R/W
18 20 G/Y R/B W/Y
2 W W 3 32
W W B B (Gy) O O
17 B 19 G B 21 26
L B/L Y
W W W R
(B)
B R R G/Y Sb
B L/B L/Y P Gy
(B) B B/Y B
(B)
CIRCUIT DIAGRAM
B L/Y
L/B L L Sb
14 L/B 35
4 B P/W O/B R/B
B B L/B L Y
28 (B)
B B
25 (B)
15 16 G/B
23 24 B/L Br/W
R 29
FUEL PUMP SYSTEM

B
ON Dg Br/W Ch 31
Br/R Br/R W P
Br
W/B W L O/R
OPEN 36 B/W B/L
R R L B/L B/W
G/Y Br W/Y L/B B/L
G/B Br/R R/B
6
Br/R R R/W R/B (L)
Br/L B 37
R R/W
L/B B
8
Br/R L/R B/W
B/W B R/L 9
Y/L G/L R/B
10 Gy/G B B R/B G/W

Br/L R/Y
38 W L Gy/G B/L
R/G B B 77
R/W Lg Y/L (B)
(B)
11
Br/L Br
B
R/W R/B
8-65
R/Y R/Y
B B/W
L/R
R/B A R/B
Y/L R/Y
42 Br
R/G R/L L/B
Br/W 40
R/Y W/B P
R/W R/B L/R 41
Lg
R/W L/B W/B (B)

75 Br/W
B B G/L L Br/W
Y/L Y/L
78 B B L G/B
L
44 45 46 47
G/B Br/R Br/R G/B
B R/L B/W 48
Y/L 39
B B/L
B B/L B
Y/L B
B P B G/Y
B 76 L/B R/Y Br
R/L Dg Br/W Ch
(B) (B)
B
G Y G/Y B P
Ch Br/W Dg
Br R/Y L/B
B B
B B

B B
62 G Ch Dg Ch Dg
56 G Y Br Br Br Br
Gy
63 59
L/R 57 55 54 52 49
66 67 68 69 70 71 72 B B Br G/Y B Br G/Y
64 65 58 53 50
Ch B Dg B
G Y Y G
Gy
B B 51 51
B/L B B B
60 B
B B B
G/L Br Y/L B/L Gy B
B B
B B B B B
B
B Gy
B B
(B)
B B B/L
(B)
FUEL PUMP SYSTEM
FUEL PUMP SYSTEM
5. Main switch
6. ECU fuse
9. Ignition fuse
12.Battery
13.Main fuse
17.Frame ground
19.Fuel pump
8-66
FUEL PUMP SYSTEM
EAS27570
TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
1. Storage box
2. Leg shield

(Main, ECU, and ignition)
ES” on page 8-85.
OK ↓
page 8-85.
OK ↓
OK ↓
4. Check the fuel pump operation. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump.
PRESSURE” on page 7-3.
OK ↓
5. Check the entire fuel pump system NG →
page 8-65.
OK ↓
Replace the ECU.
8-67
FUEL PUMP SYSTEM
8-68
A
EAS27650
EAS27640
(Gy) (Gy)
1 B/L W/R
W R
A B
L/Y
B/L W/R R W R/W
18 20 G/Y R/B W/Y
2 W W 3 32
W W B B (Gy) O O
17 B 19 G B 21 26
L B/L Y
W W W R
(B)
B R R G/Y Sb
B L/B L/Y P Gy
(B) B B/Y B
(B)
CIRCUIT DIAGRAM
B L/Y
L/B L L Sb
14 L/B 35
4 B P/W O/B R/B
B B L/B L Y
28 (B)
B B
25 (B)
15 16 G/B
23 24 B/L Br/W
R 29
B
5
IMMOBILIZER SYSTEM
Dg Br/W Ch (G) Br/W Br/W A Br/W Y/G B/Y

ON 31
Br/R Br/R W P
Br
W/B W L O/R
OPEN 36 B/W B/L
R R L B/L B/W
G/Y Br W/Y L/B B/L
G/B Br/R R/B
6
Br/R R R/W R/B (L)
Br/L B 37
R R/W
L/B B
8
Br/R L/R B/W
B/W B R/L 9
Y/L G/L R/B
10 Gy/G B B R/B G/W

Br/L R/Y
38 W L Gy/G B/L
R/G B B 77
R/W Lg Y/L (B)
(B)
11
Br/L Br
B
R/W R/B
8-69
R/Y R/Y
B B/W
L/R
R/B A R/B
Y/L R/Y
42 Br
R/G R/L L/B
Br/W 40
R/Y W/B P
R/W R/B L/R 41
Lg
R/W L/B W/B (B)

75 Br/W
B B G/L L Br/W
Y/L Y/L
78 B B L G/B
L
44 45 46 47
G/B Br/R Br/R G/B
B R/L B/W 48
Y/L 39
B B/L
B B/L B
Y/L B
B P B G/Y
B 76 L/B R/Y Br
R/L Dg Br/W Ch
(B) (B)
B
G Y G/Y B P
Ch Br/W Dg
Br R/Y L/B
B B
B B

B B
62 G Ch Dg Ch Dg
56 G Y Br Br Br Br
Gy
63 59
L/R 57 55 54 52 49
66 67 68 69 70 71 72 B B Br G/Y B Br G/Y
64 65 58 53 50
Ch B Dg B
G Y Y G
Gy
B B 51 51
B/L B B B
60 B
B B B
G/L Br Y/L B/L Gy B
B B
B B B B B
B
B Gy
B B
(B)
B B B/L
(B)
IMMOBILIZER SYSTEM
IMMOBILIZER SYSTEM
4. Backup fuse (immobilizer unit and meter

assembly)
5. Main switch
6. ECU fuse
9. Ignition fuse
12.Battery
13.Main fuse
17.Frame ground
62.Immobilizer system indicator light
77.Immobilizer unit
8-70
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 is 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
replaced.
Therefore, always use a standard key for driving. (See NOTICE.)
TIP
Each standard key is registered during production, therefore re-registering at purchase is not neces-
sary.
ECA37P1038
NOTICE
• 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.
TIP
Each standard key is registered during production, therefore re-registering at purchase is not neces-
sary.
8-71
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.
TIP
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.
8-72
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.
TIP
Do not start the engine with a standard key that has not been registered. If the main switch is turned to
“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 8-75.)
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.
TIP
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.
TIP
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”.
TIP
When the indicator light goes off, the registration is complete.
6. Check that the engine can be started with the two registered standard keys.
8-73
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.
8-74
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, ECU, and backup)
ES” on page 8-85.
OK ↓
page 8-85.
OK ↓
OK ↓
NG →
4. Check the entire immobilizer sys-
tem wiring. Properly connect or replace the wire har-
page 8-69.
OK ↓
• Check the condition each of the im-
mobilizer system circuits.
Refer to “SELF-DIAGNOSIS FAULT
CODE INDICATION” on page 8-75.
EAS27720
SELF-DIAGNOSIS FAULT CODE INDICATION

When a system malfunction occurs, the fault code number is indicated in the LCD display of the meter
assembly and the immobilizer system indicator light flashes at the same time. The pattern of flashing
also shows the fault code.
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.
8-75
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 Register another
UNIT tion malfunction. attempted to be regis- standard key.
tered two consecutive
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
8-76
IMMOBILIZER SYSTEM
a. Light on
b. Light off
8-77
IMMOBILIZER SYSTEM
8-78
ELECTRICAL COMPONENTS
EAS27970
4 5 6 7
8
3
9
2
1
32 10
31 11
12
14
13
30
29 15
28
16
27
26 17
18
25 19
24 20
23 22 21
8-79
1. Battery
2. Diode
3. Fuse box
6. Main switch/immobilizer unit
8. Fuel pump
9. Ignition coil
10. Fuel injector
11. Intake air temperature sensor
12. Intake air pressure sensor
15. Air induction system solenoid
17. Stator coil
19. O2 sensor
20. Sidestand switch
23. Radiator fan motor
24. Horn
25. Speed sensor
27. Headlight relay
29. Turn signal relay
30. Air temperature sensor
31. Main fuse
32. Starter relay
8-80
EAS27980
CHECKING THE SWITCHES
1 2 3 4
L/W W/Y Dg Br/W Ch R Br/L Br/R Br/R
ON
OFF
OPEN R
LOCK
Br/L
P
Dg Br/W Ch
L/W W/Y G/Y Br
G/Y Br
5 7 9 10
L/B G Y Ch Br/W Dg
B
B
6 8 (B)
R/Y Y P B
G/Y Br
Y G P B G/Y
Dg Br/W Ch L/B R/Y Br
8-81
1. Start switch
2. Hazard switch
4. Main switch
5. Dimmer switch
6. Pass switch
7. Turn signal switch
8. Horn switch
10. Sidestand switch
8-82
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
NOTICE
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
YU-03112-C
TIP
• Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back and forth between the switch positions a few times.
The switches and their terminal connections are illustrated as in the following example of the main
switch.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in the
top row.
The continuity (i.e., a closed circuit) between switch terminals at a given switch position is indicated by
“ ”. There is continuity between red, brown/blue, and brown/red when the switch is turned to
“ON” and between red and brown/red when the switch is turned to “ ”.
b
R Br/L Br/R
ON
OFF
a OPEN
LOCK
P
R
Br/R
Br/L
8-83
EAS27990 EWA37P1018
CHECKING THE BULBS AND BULB WARNING

SOCKETS Since headlight bulbs get extremely hot,
TIP keep flammable products and your hands
Do not check any of the lights that use LEDs. away from them until they have cooled
down.
Check each bulb and bulb socket for damage or
ECA37P1039
wear, proper connections, and also for continuity
NOTICE
between the terminals.
Damage/wear → Repair or replace the bulb, • Be sure to hold the socket firmly when re-
bulb socket or both. moving the bulb. Never pull the lead, other-
Improperly connected → Properly connect. wise it may be pulled out of the terminal in
No continuity → Repair or replace the bulb, bulb the coupler.
socket or both. • Avoid touching the glass part of a headlight
bulb to keep it free from oil, otherwise the
Types of bulbs transparency of the glass, the life of the
The bulbs used on this vehicle are shown in the bulb, and the luminous flux will be adverse-
illustration. ly affected. If the headlight bulb gets soiled,
• Bulbs “a” and “b” are used for the headlights thoroughly clean it with a cloth moistened
and usually use a bulb holder that must be de- with alcohol or lacquer thinner.
tached before removing the bulb. The majority 2. Check:
of these types of bulbs can be removed from • Bulb (for continuity)
their respective socket by turning them coun- (with the pocket tester)
terclockwise. No continuity → Replace.
• Bulbs “c” are used for turn signal and tail/brake
lights and can be removed from the socket by Pocket tester
pushing and turning the bulb counterclockwise. 90890-03112
YU-03112-C
TIP
Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to terminal
“1” and the negative tester probe to terminal
“2”, and check the continuity.
b. Connect the positive tester probe to terminal
“1” and the negative tester probe to terminal
“3”, and check the continuity.
c. If either of the readings indicate no continuity,
replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the condition of the bulbs

bulbs.
1. Remove:
• Bulb
8-84
Checking the condition of the bulb sockets 3. Replace:

The following procedure applies to all of the bulb • Blown fuse
sockets. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1. Check: a. Turn the main switch to “OFF”.
• Bulb socket (for continuity) b. Install a new fuse of the correct amperage
(with the pocket tester) rating.
No continuity → Replace. c. Set on the switches to verify if the electrical
circuit is operational.
Pocket tester d. If the fuse immediately blows again, check
90890-03112 the electrical circuit.
YU-03112-C Amperage
Fuses Q’ty
rating
TIP Main 30.0 A 1
Check each bulb socket for continuity in the Headlight 20.0 A 1
same manner as described in the bulb section,
Signaling system 10.0 A 1
however, note the following.
Ignition 10.0 A 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a good bulb into the bulb socket. Turn signal/hazard 10.0 A 1
b. Connect the pocket tester probes to the re- ECU 10.0 A 1
spective leads of the bulb socket.
Backup (immobilizer
c. Check the bulb socket for continuity. If any of 10.0 A 1
and meter assembly)
the readings indicate no continuity, replace
the bulb socket. Radiator fan motor 7.5 A 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Spare 30.0 A 1
EAS28000 Spare 20.0 A 1
CHECKING THE FUSES
Spare 10.0 A 1
The following procedure applies to all of the fus-
es. Spare 7.5 A 1
ECA1SD1017
EWA13310
NOTICE
WARNING
To avoid a short circuit, always turn the main
Never use a fuse with an amperage rating
switch to “OFF” when checking or replacing
other than that specified. Improvising or us-
a fuse.
ing a fuse with the wrong amperage rating
1. Remove: may cause extensive damage to the electri-
• Fuse box cover and/or front cowling cal system, cause the lighting and ignition
Refer to “GENERAL CHASSIS” on page 4-1. systems to malfunction and could possibly
2. Check: cause a fire.
• Fuse
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and 4. Install:
check the continuity. • Fuse box cover and/or front cowling
TIP Refer to “GENERAL CHASSIS” on page 4-1.
Set the pocket tester selector to “Ω × 1”. EAS28030
CHECKING AND CHARGING THE BATTERY

EWA13290
Pocket tester WARNING
90890-03112
Analog pocket tester Batteries generate explosive hydrogen gas
YU-03112-C and contain electrolyte which is made of poi-
sonous and highly caustic sulfuric acid.
b. If the pocket tester indicates “∞”, replace the Therefore, always follow these preventive
fuse. measures:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-85
• Wear protective eye gear when handling or 2. Disconnect:

working near batteries. • Battery leads
• Charge batteries in a well-ventilated area. (from the battery terminals)
• Keep batteries away from fire, sparks or ECA13640
open flames (e.g., welding equipment, NOTICE

lighted cigarettes). First, disconnect the negative battery lead
• DO NOT SMOKE when charging or han- “1”, and then the positive battery lead “2”.
dling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN. 2
• 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.
• Eyes — Flush with water for 15 minutes and
get immediate medical attention. 3. Remove:
INTERNAL • Battery
• Drink large quantities of water or milk fol- 4. Check:
lowed with milk of magnesia, beaten egg or • Battery charge
vegetable oil. Get immediate medical atten- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
tion. a. Connect a pocket tester to the battery termi-
ECA13661 nals.
NOTICE • Positive tester probe →
• This is a VRLA (Valve Regulated Lead Acid) positive battery terminal
battery. Never remove the sealing caps be- • Negative tester probe →
cause the balance between cells will not be negative battery terminal
maintained and battery performance will
deteriorate. TIP
• Charging time, charging amperage and • The charge state of a VRLA (Valve Regulated
charging voltage for a VRLA (Valve Regu- Lead Acid) battery can be checked by measur-
lated Lead Acid) battery are different from ing its open-circuit voltage (i.e., the voltage
those of conventional batteries. The VRLA when the positive battery terminal is discon-
(Valve Regulated Lead Acid) battery should nected).
be charged according to the appropriate • No charging is necessary when the open-cir-
charging method. If the battery is over- cuit voltage equals or exceeds 12.8 V.
charged, the electrolyte level will drop con- b. Check the charge of the battery, as shown in
siderably. Therefore, take special care the charts and the following example.
when charging the battery.
Example
TIP Open-circuit voltage = 12.0 V
Since VRLA (Valve Regulated Lead Acid) bat- Charging time = 6.5 hours
teries are sealed, it is not possible to check the Charge of the battery = 20–30%
charge state of the battery by measuring the
specific gravity of the electrolyte. Therefore, the
charge of the battery has to be checked by mea-
suring the voltage at the battery terminals.
1. Remove:
• Upper panel
• Battery cover
8-86
• When charging a battery, be sure to remove

it from the vehicle. (If charging has to be
done with the battery mounted on the vehi-
cle, disconnect the negative battery lead
from the battery terminal.)
• To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
• Before removing the battery charger lead
clips from the battery terminals, be sure to
A. Open-circuit voltage (V) turn off the battery charger.
B. Charging time (hours) • Make sure the battery charger lead clips are
C. Relationship between the open-circuit voltage in full contact with the battery terminal and
and the charging time at 20 °C (68 °F) that they are not shorted. A corroded bat-
D. These values vary with the temperature, the tery charger lead clip may generate heat in
condition of the battery plates, and the the contact area and a weak clip spring may
electrolyte level.
cause sparks.
• If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the bat-
tery cool before reconnecting it. Hot
batteries can explode!
• As shown in the following illustration, the
open-circuit voltage of a VRLA (Valve Reg-
ulated Lead Acid) battery stabilizes about
30 minutes after charging has been com-
pleted. Therefore, wait 30 minutes after
A. Open-circuit voltage (V) charging is completed before measuring
B. Charging condition of the battery (%) the open-circuit voltage.
C. Ambient temperature 20 °C (68 °F)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Charge:
• Battery
(refer to the appropriate charging method)
EWA13300
WARNING
Do not quick charge a battery.
ECA1SD1018
NOTICE
A. Open-circuit voltage (V)
• Never remove the VRLA (Valve Regulated B. Time (minutes)
Lead Acid) battery sealing caps. C. Charging
• Do not use a high-rate battery charger D. Ambient temperature 20 °C (68 °F)
since it forces a high-amperage current E. Check the open-circuit voltage.
into the battery quickly and can cause bat-
tery overheating and battery plate damage. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• If it is impossible to regulate the charging Charging method using a variable-current
current on the battery charger, be careful (voltage) charger
not to overcharge the battery. a. Measure the open-circuit voltage prior to
charging.
8-87
TIP c. Make sure that the current is higher than the

Voltage should be measured 30 minutes after standard charging current written on the bat-
the engine is stopped. tery.
TIP
b. Connect a charger and ammeter to the bat-
If the current is lower than the standard charging
tery and start charging.
current written on the battery, this type of battery
TIP charger cannot charge the VRLA (Valve Regu-
Set the charging voltage to 16–17 V. If the set- lated Lead Acid) battery. A variable voltage
ting is lower, charging will be insufficient. If too charger is recommended.
high, the battery will be over-charged.
d. Charge the battery until the battery’s charg-
c. Make sure that the current is higher than the ing voltage is 15 V.
standard charging current written on the bat- TIP
tery.
Set the charging time at 20 hours (maximum).
TIP
If the current is lower than the standard charging e. Measure the battery open-circuit voltage after
current written on the battery, set the charging leaving the battery unused for more than 30
voltage adjust dial at 20–24 V and monitor the minutes.
amperage for 3–5 minutes to check the battery. 12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
• Standard charging current is reached Under 12.0 V --- Replace the battery.
Battery is good.
• Standard charging current is not reached ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Replace the battery. 6. Install:
• Battery
d. Adjust the voltage so that the current is at the
7. Connect:
standard charging level.
• Battery leads
e. Set the time according to the charging time
(to the battery terminals)
suitable for the open-circuit voltage. ECA13630
f. If charging requires more than 5 hours, it is NOTICE

advisable to check the charging current after First, connect the positive battery lead “1”,
a lapse of 5 hours. If there is any change in and then the negative battery lead “2”.
the amperage, readjust the voltage to obtain
the standard charging current.
g. Measure the battery open-circuit voltage after 1
leaving the battery unused for more than 30
minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery. 2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Charging method using a constant volt- 8. Check:
age charger • Battery terminals
a. Measure the open-circuit voltage prior to Dirt → Clean with a wire brush.
charging. Loose connection → Connect properly.
9. Lubricate:
TIP
• Battery terminals
Voltage should be measured 30 minutes after
the engine is stopped. Recommended lubricant
Dielectric grease
b. Connect a charger and ammeter to the bat-
tery and start charging. 10.Install:
• Battery cover
8-88
• Upper panel 4. Negative tester probe

EAS28040
Result
CHECKING THE RELAYS Continuity
Check each switch for continuity with the pocket (between “3” and “4”)
tester. If the continuity reading is incorrect, re-
place the relay. Headlight relay
Pocket tester 3
90890-03112
Analog pocket tester 4 +
YU-03112-C
2 1
1. Disconnect the relay from the wire harness.
2. Connect the pocket tester (Ω × 1) and battery W/B R/Y
L/B
(12 V) to the relay terminal as shown.
R/Y
Check the relay operation.
1. Positive battery terminal
Starting circuit cut-off relay 2. Negative battery terminal
3. Positive tester probe
4 4. Negative tester probe
1
Result
Continuity
+ 2 3 (between “3” and “4”)
L/Y G/Y
R/B W/Y Radiator fan motor relay
3
1. Positive battery terminal 4 +
2. Negative battery terminal
3. Positive tester probe 2
4. Negative tester probe
1
G/B R/B
Result L
Continuity R/W
(between “3” and “4”)
Starter relay 2. Negative battery terminal
3
4. Negative tester probe
R
Result
R Continuity
B L/B (between “3” and “4”)
R
1 2
4
2. Negative battery terminal
8-89
EAS37P1082
CHECKING THE TURN SIGNAL/HAZARD Pocket tester

RELAY 90890-03112
1. Check: Analog pocket tester
• Turn signal/hazard relay input voltage YU-03112-C
Out of specification → The wiring circuit from
the main switch to the turn signal/hazard re- • Positive tester probe →
lay coupler is faulty and must be repaired. brown/white “1”
• Negative tester probe →
Turn signal/hazard relay input ground
voltage
DC 12 V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the
turn signal/hazard relay terminal as shown.
Pocket tester
L/R
90890-03112
YU-03112-C
• Positive tester probe → b. Turn the main switch to “ON”.

blue/red “1” c. Measure the turn signal/hazard relay output
• Negative tester probe → voltage.
ground ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28050
CHECKING THE DIODE

1. Check:
• Diode
Pocket tester
L/R 90890-03112
YU-03112-C
b. Turn the main switch to “ON”. TIP

c. Measure the turn signal/hazard relay input The pocket tester and the analog pocket tester
voltage. readings are shown in the following table.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check: Continuity
• Turn signal/hazard relay output voltage Positive tester probe →
Out of specification → Replace. blue/black “1”
Negative tester probe →
Turn signal/hazard relay output black “2”
voltage No continuity
DC 12 V Positive tester probe →
black “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Negative tester probe →
a. Connect the pocket tester (DC 20 V) to the blue/black “1”
turn signal/hazard relay terminal as shown.
8-90
Primary coil resistance

1 2.16–2.64 Ω
L/B ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the ignition coil connectors from
B the ignition coil terminals.
b. Connect the pocket tester (Ω × 1) to the igni-
2 tion coil as shown.
Pocket tester
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 90890-03112
a. Disconnect the diode from the wire harness. Analog pocket tester
b. Connect the pocket tester (Ω × 1) to the diode YU-03112-C
terminals as shown.
c. Check the diode for continuity. • Positive tester probe →
d. Check the diode for no continuity. red/black “1”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Negative tester probe →
EAS28060
orange “2”
CHECKING THE SPARK PLUG CAP
1. Check:
• Spark plug cap resistance
Resistance
10.0 kΩ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the spark plug cap from the spark
plug lead.
b. Connect the pocket tester (Ω × 1k) to the c. Measure the primary coil resistance.
spark plug cap as shown. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Pocket tester 2. Check:

90890-03112 • Secondary coil resistance
Analog pocket tester Out of specification → Replace.
YU-03112-C
Secondary coil resistance
8.64–12.96 kΩ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the igni-
tion coil.
b. Connect the pocket tester (Ω × 1k) to the ig-
nition coil as shown.
Pocket tester
90890-03112
c. Measure the spark plug cap resistance. YU-03112-C
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28090
• Positive tester probe →
CHECKING THE IGNITION COIL red/black “1”
1. Check: • Negative tester probe →
• Primary coil resistance Spark plug lead “2”
8-91
e. Crank the engine by pushing the start switch

“ ” and gradually increase the spark gap un-
til a misfire occurs.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28120
CHECKING THE CRANKSHAFT POSITION

SENSOR
1. Disconnect:
• Crankshaft position sensor coupler
(from the wire harness)
c. Measure the secondary coil resistance. 2. Check:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Crankshaft position sensor resistance
EAS28930 Out of specification → Replace the crank-
CHECKING THE IGNITION SPARK GAP shaft position sensor/stator assembly.
1. Check:
• Ignition spark gap Crankshaft position sensor resis-
Out of specification → Perform the ignition tance
system troubleshooting, starting with step 5. 228–342 Ω
Refer to “TROUBLESHOOTING” on page
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
8-3. a. Connect the pocket tester (Ω × 100) to the
crankshaft position sensor coupler as shown.
Minimum ignition spark gap
6.0 mm (0.24 in) Pocket tester
90890-03112
TIP Analog pocket tester
If the ignition spark gap is within specification, YU-03112-C
the ignition system circuit is operating normally.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the spark red “1”
plug. • Negative tester probe →
white “2”
b. Connect the ignition checker “1” as shown.
Ignition checker
90890-06754
Oppama pet-4000 spark checker
YM-34487
R W
1 2
b. Measure the crankshaft position sensor re-

sistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28130
CHECKING THE LEAN ANGLE SENSOR

2. Spark plug cap 1. Remove:
• Lean angle sensor
c. Turn the main switch to “ON”. 2. Check:
d. Measure the ignition spark gap “a”. • Lean angle sensor output voltage
8-92
EWA13810
Lean angle sensor output voltage WARNING

Less than 65°: 0.4–1.4 V • A wire that is used as a jumper lead must
More than 65°: 3.7–4.4 V have at least the same capacity of the bat-
tery lead, otherwise the jumper lead may
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the test harness-lean angle sensor burn.
(6P) “1” to the lean angle sensor and wire • This check is likely to produce sparks,
harness as shown. therefore, make sure no flammable gas or
b. Connect the pocket tester (DC 20 V) to the fluid is in the vicinity.
test harness-lean angle sensor (6P).
Test harness- lean angle sensor

(6P)
90890-03209
YU-03209
Pocket tester
90890-03112
YU-03112-C
• Positive tester probe → b. Check the starter motor operation.

yellow/green (wire harness color) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Negative tester probe → EAS28150
black/blue (wire harness color) CHECKING THE STATOR COIL

1. Disconnect:
• Stator coil coupler
(from the wire harness)
2. Check:
65 65 • Stator coil resistance
shaft position sensor/stator assembly.
Stator coil resistance

0.232–0.348 Ω
c. Turn the main switch to “ON”. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Connect the digital circuit tester to the stator
d. Turn the lean angle sensor to 65°.
coil coupler as shown.
e. Measure the lean angle sensor output volt-
age. Digital circuit tester
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 90890-03174
EAS28940 Model 88 Multimeter with ta-
CHECKING THE STARTER MOTOR chometer
OPERATION YU-A1927
1. Check:
• Starter motor operation • Positive tester probe →
Does not operate → Perform the electric white “1”
starting system troubleshooting, starting with • Negative tester probe →
step 4. white “2”
Refer to “TROUBLESHOOTING” on page
8-9. • Positive tester probe →
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
white “1”
a. Connect the positive battery terminal “1” and • Negative tester probe →
starter motor lead “2” with a jumper lead “3”. white “3”
8-93
• Positive tester probe → d. Measure the charging voltage.

white “2” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Negative tester probe → EAS28370
white “3” CHECKING THE AIR INDUCTION SYSTEM

SOLENOID
1. Check:
• Air induction system solenoid resistance
Solenoid resistance
18–22 Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the air induction system solenoid
coupler from the air induction system sole-
b. Measure the stator coil resistance. noid.
b. Connect the pocket tester (Ω × 1) to the air in-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
duction system solenoid terminal as shown.
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 Air induction system solenoid terminal “1”
14 V at 5000 r/min • Negative tester probe →
Air induction system solenoid terminal “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the engine tachometer to the spark
plug lead.
b. Connect the pocket tester (DC 20 V) to the 2 1
battery as shown.
Pocket tester
90890-03112
YU-03112-C

positive battery terminal “1” c. Measure the air induction system solenoid re-
• Negative tester probe → sistance.
negative battery terminal “2”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28230
CHECKING THE FUEL SENDER

1. Remove:
• Fuel pump
(from the fuel tank)
2. Check:
• Fuel sender resistance
Out of specification → Replace the fuel send-
er.
c. Start the engine and let it run at approximate-

ly 5000 r/min.
8-94
The warning light comes on for a few sec-

Sender unit resistance (full) onds, then goes off → The warning light is
10.0–12.0 Ω OK.
Sender unit resistance (empty) The warning light does not come on → Re-
137.0–143.0 Ω
place the meter assembly.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
All LCD segments of the fuel meter “2” and
a. Connect the pocket tester (Ω × 10) to the fuel the fuel level warning light “1” flash (malfunc-
sender terminal as shown. tion detected in fuel sender) → Replace the
fuel pump assembly.
Pocket tester
CLOCK
90890-03112
YU-03112-C
OUT TEMP
1
• Positive tester probe → 2 1/2
°C
green “1”
• Negative tester probe → TRIP 1
black “2”
EAS28240
2 1 CHECKING THE SPEED SENSOR
1. Check:
• Speed sensor output voltage
G B Out of specification → Replace.
R/B B/Y
Output voltage reading cycle
0.6 V to 4.8 V to 0.6 V to 4.8 V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b. Move the fuel sender float to minimum “3” a. Connect the test harness-speed sensor (3P)
and maximum “4” level position. “1” to the speed sensor coupler and wire har-
ness as shown.
b. Connect the pocket tester (DC 20 V) to the
test harness-speed sensor (3P).
4
Test harness- speed sensor (3P)
90890-03208
YU-03208
3 Pocket tester
90890-03112
YU-03112-C
c. Measure the fuel sender resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Positive tester probe →
EAS29040 white (wire harness color)
CHECKING THE FUEL LEVEL WARNING • Negative tester probe →
LIGHT black/blue (wire harness color)
This model is equipped with a self-diagnosis de-
vice for the fuel level detection circuit.
1. Check:
• Fuel level warning light “1”
(Turn the main switch to “ON”.)
8-95
• Never subject the coolant temperature sen-

sor to strong shocks. If the coolant temper-
ature sensor is dropped, replace it.
2. Check:
• Coolant temperature sensor resistance
1
Coolant temperature sensor re-
sistance
2.32–2.59 kΩ at 20 °C (68 °F)
c. Turn the main switch to “ON”. 310–326 Ω at 80 °C (176 °F)
d. Elevate the front wheel and slowly rotate it.
e. Measure the voltage of white and black/blue. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1k × 100) to
With each full rotation of the front wheel, the
the coolant temperature sensor terminals as
voltage reading should cycle from 0.6 V to 4.8
shown.
V to 0.6 V to 4.8 V.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Pocket tester
EAS28250 90890-03112
CHECKING THE RADIATOR FAN MOTOR Analog pocket tester
1. Check: YU-03112-C
• Radiator fan motor
Faulty/rough movement → Replace. b. Immerse the coolant temperature sensor “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ in a container filled with coolant “2”.
a. Disconnect the radiator fan motor coupler TIP
from the wire harness. Make sure the coolant temperature sensor ter-
b. Connect the battery (DC 12 V) as shown. minals do not get wet.
red “1” c. Place a thermometer “3” in the coolant.
black “2”
3
1
d. Heat the coolant or let it cool down to the

specified temperatures.
e. Measure the coolant temperature sensor re-
c. Check the radiator fan motor movement. sistances.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28260 3. Install:
CHECKING THE COOLANT TEMPERATURE • Coolant temperature sensor
SENSOR
1. Remove: Coolant temperature sensor
• Coolant temperature sensor 18 Nm (1.8 m·kgf, 13 ft·lbf)
T.
R.
Refer to “CYLINDER HEAD” on page 5-15.

EWA14130 EAS28300
WARNING CHECKING THE THROTTLE POSITION

• Handle the coolant temperature sensor SENSOR
with special care. 1. Check:
• Throttle position sensor
8-96
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the test harness- TPS 5RU (3P) “1” Throttle position sensor voltage
to the throttle position sensor and wire har- (closed position)
ness as shown. 0.40–0.90 V
b. Connect the digital circuit tester (DCV) to the (yellow–black/blue)
test harness- TPS 5RU (3P).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Test harness- TPS 5RU (3P) EAS28410
90890-03230 CHECKING THE INTAKE AIR PRESSURE

Digital circuit tester SENSOR
90890-03174 1. Check:
Model 88 Multimeter with ta- • Intake air pressure sensor output voltage
chometer Out of specification → Replace.
YU-A1927
Intake air pressure sensor output
• Positive tester probe → voltage
blue (wire harness color) 3.57–3.71 V
black/blue (wire harness color) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the test harness-TPS (3P) “1” to the
atmospheric pressure sensor and wire har-
ness as shown.
1 b. Connect the digital circuit tester (DCV) to the
test harness-TPS (3P).
Test harness- TPS (3P)

90890-03204
YU-03204
Pocket tester
90890-03112
c. Measure the throttle position sensor voltage. YU-03112-C
Out of specification → Replace or repair the
wire harness. • Positive tester probe →
pink/white (wire harness color)
Throttle position sensor voltage
5V
black/blue (wire harness color)
(blue–black/blue)
d. Connect the digital circuit tester to the test

harness- TPS 5RU (3P).
yellow (wire harness color)
1
black/blue (wire harness color)
e. While slowly opening the throttle, check that

the throttle position sensor voltage is in-
creased.
Voltage does not change or it changes c. Turn the main switch to “ON”.
abruptly → Replace the throttle position sen- d. Measure the intake air pressure sensor out-
sor. put voltage.
Out of specification (closed position) → Re- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
place the throttle position sensor.
8-97
EAS28420 EAS37P1083
CHECKING THE INTAKE AIR CHECKING THE AIR TEMPERATURE

TEMPERATURE SENSOR SENSOR
1. Remove: 1. Remove:
• Intake air temperature sensor • Air temperature sensor
(from the air filter case) EWA37P1017
EWA14110 WARNING
WARNING • Handle the air temperature sensor with
• Handle the intake air temperature sensor special care.
with special care. • Never subject the air temperature sensor to
• Never subject the intake air temperature strong shocks. If the air temperature sen-
sensor to strong shocks. If the intake air sor is dropped, replace it.
temperature sensor is dropped, replace it. 2. Check:
2. Check: • Air temperature sensor resistance
• Intake air temperature sensor resistance Out of specification → Replace.
Air temperature sensor resis-
Intake air temperature sensor re- tance
sistance 12.09 kΩ at 20 °C (68 °F)
2.21–2.69 kΩ 4.16 kΩ at 50 °C (122 °F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1k) to the in- a. Connect the pocket tester (Ω × 1k) to the air
take air temperature sensor terminal as temperature 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
b. Immerse the air temperature sensor “1” in a
b. Immerse the intake air temperature sensor container filled with water “2”.
“1” in a container filled with water “2”. TIP
TIP Make sure that the air temperature sensor termi-
Make sure that the intake air temperature sensor nals do not get wet.
terminals do not get wet. c. Place a thermometer “3” in the water.
c. Place a thermometer “3” in the water.
B
3 1 3 B
2
2
d. Heat the water or let it cool down to the spec-

d. Heat the water or let it cool down to the specified temperatures.
ified temperature. e. Measure the air temperature sensor resis-
e. Measure the intake air temperature sensor tance.
resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-98
EAS1SD1038
CHECKING THE FUEL INJECTOR Pocket tester

1. Check: 90890-03112
• Fuel injector resistance Analog pocket tester
Out of specification → Replace the fuel injec- YU-03112-C
tor.
Resistance pink “1”
12.0 Ω • Negative tester probe →
green/yellow “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the fuel injector coupler from wire
harness. gray “3”
b. Connect the pocket tester (Ω × 1) to the fuel • Negative tester probe →
injector coupler as shown. sky blue “4”
Pocket tester
90890-03112
4 2
YU-03112-C
G/Y Sb
• Positive tester probe
blue “1” P Gy
• Negative tester probe
yellow “2” 3 1
1 2 c. Measure the ISC unit resistance.

Out of specification → Replace the throttle
L Y body.
Resistance
27–33 Ω
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS37P1084
CHECKING THE V-BELT REPLACEMENT

c. Measure the fuel injector resistance.
INDICATOR RESET COUPLER
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1. Remove:
EAS37P1085
• V-belt replacement indicator reset coupler
CHECKING THE ISC (IDLE SPEED 2. Check:
CONTROL) UNIT • V-belt replacement indicator reset coupler for
TIP continuity
Do not remove the ISC unit completely from the Out of specification → Replace the V-belt re-
throttle body. placement indicator coupler.
1. Check: Continuity
• ISC unit Positive tester probe → black
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ “1”
a. Disconnect the ISC unit coupler from the ISC Negative tester probe → black
unit. “2”
b. Connect the pocket tester (Ω × 10) to the ter- Continuity
minals of the ISC unit. Positive tester probe → black
“2”
Negative tester probe → black
“1”
8-99
1 2
B B
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1) to the V-
belt replacement indicator reset coupler ter-
minals.
Pocket tester
90890-03112
YU-03112-C
b. Check the V-belt replacement indicator reset

coupler for continuity.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-100
8-101
TROUBLESHOOTING
TROUBLESHOOTING.....................................................................................9-1
GENERAL INFORMATION ....................................................................... 9-1
STARTING FAILURE/HARD STARTING.................................................. 9-1
INCORRECT ENGINE IDLING SPEED .................................................... 9-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ........................... 9-2
FAULTY CLUTCH .....................................................................................9-2
OVERHEATING ........................................................................................9-2
OVERCOOLING........................................................................................9-3
POOR BRAKING PERFORMANCE.......................................................... 9-3
FAULTY FRONT FORK LEGS..................................................................9-3
UNSTABLE HANDLING ............................................................................9-3
FAULTY LIGHTING OR SIGNALING SYSTEM ........................................ 9-3
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE............9-5
9
TROUBLESHOOTING
EAS28450
Electrical system
TROUBLESHOOTING 1. Battery
EAS28460
• Discharged battery
GENERAL INFORMATION • Faulty battery
TIP 2. Fuse(s)
• Blown, damaged or incorrect fuse
The following guide for troubleshooting does not
• Improperly installed fuse
cover all the possible causes of trouble. It should
3. Spark plug
be helpful, however, as a guide to basic trouble-
• Incorrect spark plug gap
shooting. Refer to the relative procedure in this
• Incorrect spark plug heat range
manual for checks, adjustments, and replace-
• Fouled spark plug
ment of parts.
• Worn or damaged electrode
EAS28480
• Worn or damaged insulator
STARTING FAILURE/HARD STARTING • Faulty spark plug cap
4. Ignition coil
Engine • Cracked or broken ignition coil body
1. Cylinder and cylinder head • Broken or shorted primary or secondary coils
• Loose spark plug • Faulty spark plug lead
• Loose cylinder head or cylinder 5. Ignition system
• Damaged cylinder head gasket • Faulty ECU
• Damaged cylinder gasket • Faulty crankshaft position sensor
• Worn or damaged cylinder • Broken generator rotor woodruff key
• Incorrect valve clearance 6. Switches and wiring
• Improperly sealed valve • Faulty main switch
• Incorrect valve-to-valve-seat contact • Broken or shorted wiring
• Incorrect valve timing • Faulty front, rear or both brake light switches
• Faulty valve spring • Faulty start switch
• Seized valve • Faulty sidestand switch
2. Piston and piston ring(s) • Improperly grounded circuit
• Improperly installed piston ring • Loose connections
• Damaged, worn or fatigued piston ring 7. Starting system
• Seized piston ring • Faulty starter motor
• Seized or damaged piston • Faulty starter relay
3. Air filter • Faulty starting circuit cut-off relay
• Improperly installed air filter • Faulty starter clutch
• Clogged air filter element EAS28500
4. Crankcase and crankshaft INCORRECT ENGINE IDLING SPEED
• Improperly assembled crankcase
• Seized crankshaft Engine
1. Cylinder and cylinder head
Fuel system • Incorrect valve clearance
1. Fuel tank • Damaged valve train components
• Empty fuel tank 2. Air filter
• Clogged fuel tank cap breather hole • Clogged air filter element
• Deteriorated or contaminated fuel
• Clogged or damaged fuel hose Fuel system
2. Fuel pump 1. Throttle body
• Faulty fuel pump • Damaged or loose throttle body joint
• Clogged fuel pump filter • Improperly adjusted engine idling speed
3. Throttle body • Improper throttle grip free play
• Deteriorated or contaminated fuel
• Sucked-in air
9-1
TROUBLESHOOTING
Electrical system Poor starting performance

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

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

1. Fuel pump 1. Clogged coolant passages
• Faulty fuel pump 2. Cylinder head and piston
• Heavy carbon buildup
EAS28580
FAULTY CLUTCH 3. Engine oil

• Incorrect oil level
Engine operates but vehicle will not move • Incorrect oil viscosity
1. V-belt • Inferior oil quality
• Bent, damaged or worn V-belt
• Slipping V-belt Cooling system
2. Primary pulley cam and primary pulley slid- 1. Coolant
er(s) • Low coolant level
• Damaged or worn primary pulley cam 2. Radiator
• Damaged or worn primary pulley slider • Damaged or leaking radiator
3. Clutch spring • Faulty radiator cap
• Damaged clutch spring • Bent or damaged radiator fin
4. Transmission gear(s) 3. Water pump
• Damaged transmission gear • Damaged or faulty water pump
4. Thermostat
Clutch slips • Thermostat stays closed
1. Clutch shoe spring(s) 5. Hose(s) and pipe(s)
• Damaged, loose or worn clutch shoe spring • Damaged hose
2. Clutch shoe(s) • Improperly connected hose
• Damaged or worn clutch shoe • Damaged pipe
3. Primary sliding sheave • Improperly connected pipe
• Seized primary sliding sheave
9-2
TROUBLESHOOTING
Fuel system • Bent or damaged damper rod

1. Throttle body • Incorrect oil viscosity
• Damaged or loose throttle body joint • Incorrect oil level
2. Air filter
EAS28670
• Clogged air filter element UNSTABLE HANDLING
1. Handlebar
Chassis • Bent or improperly installed handlebar
1. Brake(s) 2. Steering head components
• Dragging brake • Improperly installed lower handlebar holder
• Improperly installed lower bracket
Electrical system
(improperly tightened ring nut)
1. Spark plug
• Bent steering stem
• Incorrect spark plug gap
• Damaged ball bearing or bearing race
• Incorrect spark plug heat range
3. Front fork leg(s)
2. Ignition system
• Uneven oil levels (both front fork legs)
• Faulty ECU
• Unevenly tensioned fork spring (both front
EAS28610 fork legs)
OVERCOOLING • Broken fork spring
• Bent or damaged inner tube
Cooling system • Bent or damaged outer tube
1. Thermostat 4. Swingarm
• Thermostat stays open • Worn bearing or bushing
EAS28620
• Bent or damaged swingarm
POOR BRAKING PERFORMANCE 5. Rear shock absorber assembly(-ies)
• Worn brake pad • Faulty rear shock absorber spring
• Worn brake disc • Leaking oil
• 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
FAULTY FRONT FORK LEGS 8. Frame

• Bent frame
Leaking oil • Damaged steering head pipe
• Bent, damaged or rusty inner tube • Improperly installed bearing race
• 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
• Loose damper rod bolt • Wrong headlight bulb
• Damaged damper rod bolt copper washer • Too many electrical accessories
• Cracked or damaged front fork cap bolt O-ring • Hard charging
• Incorrect connection
Malfunction • Improperly grounded circuit
• Bent or damaged inner tube • Poor contacts (main switch)
• Bent or damaged outer tube • Burnt-out headlight bulb
• Damaged fork spring
• Worn or damaged outer tube bushing
9-3
TROUBLESHOOTING
Headlight bulb burnt out

• Wrong headlight bulb
• Faulty battery
• Faulty rectifier/regulator
• Improperly grounded circuit
• Faulty main switch
• Headlight bulb life expired
Tail/brake light does not come on

• Wrong tail/brake light LED
• Too many electrical accessories
Turn signal does not come on

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

• Faulty turn signal switch
• Incorrect turn signal light bulb
Turn signals remain lit

Turn signal flashes quickly

• Incorrect turn signal light bulb
Horn does not sound

• Damaged or faulty horn
• Faulty horn switch
• Faulty battery
• Faulty wire harness
9-4
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
EAS1SD1039

Self-diagnostic function table
Fault Reference
Item
code No. pages
Crankshaft position sensor: no normal signals are received from the
12 8-37
crankshaft position sensor.
13 Intake air pressure sensor: open or short circuit detected. 8-38
Intake air pressure sensor: hose system malfunction (clogged or de-
14 8-40
tached hose).
15 Throttle position sensor: open or short circuit detected. 8-41
16 Throttle position sensor: stuck throttle position sensor is detected. 8-42
Sidestand switch: a break or disconnection of the blue/yellow lead of
19 8-43
the ECU is detected.
21 Coolant temperature sensor: open or short circuit detected. 8-44
22 Intake air temperature sensor: open or short circuit detected. 8-45
24 O2 sensor: no normal signals are received from the O2 sensor. 8-47
30 Latch up detected. 8-48
Ignition coil: open or short circuit detected in the primary lead of the
33 8-49
ignition coil.
Component other than ISC (idle speed control) unit is defective (ISC
8-50
operating sound is heard).
37
Defective ISC (idle speed control) unit (ISC operating sound is not
8-51
heard).
39 Injector: open or short circuit detected. 8-53
41 Lean angle sensor: open or short circuit detected. 8-55
42 Speed sensor: no normal signals are received from the speed sensor. 8-55
Fuel system voltage: incorrect voltage supplied to the fuel injector and
43 8-57
fuel pump.
EEPROM fault code number: an error is detected while reading or
44 8-57
writing on EEPROM.
46 Charging voltage is abnormal. 8-58
Faulty ECU memory. (When this malfunction is detected in the ECU,
50 8-59
the fault code number might not appear on the multi-function meter.)
Immobilizer unit: Code cannot be transmitted between the key and the
51 8-75
immobilizer unit.
Immobilizer unit: Codes between the key and immobilizer unit do not
52 8-75
match.
Immobilizer unit: Codes cannot be transmitted between the ECU and
53 8-75
the immobilizer unit.
Immobilizer unit: Codes transmitted between the ECU and the immo-
54 8-75
bilizer unit do not match.
55 Immobilizer unit: Key code registration malfunction. 8-75
56 ECU: Unidentified code is received. 8-75
9-5
Fault Reference
Item
code No. pages
61 ISC (idle speed control) unit: open or short circuit detected. 8-59
Communication error with the meter
Fault Reference
Item
code No. pages
ECU (engine control unit) internal malfunction (output signal error):
Er-1 signals cannot be transmitted between the ECU and the multi-function 8-60
meter.
ECU (engine control unit) internal malfunction (output signal error): no
Er-2 8-61
signals are received from the ECU within the specified duration.
ECU (engine control unit) internal malfunction (output signal error):
Er-3 8-62
data from the ECU cannot be received correctly.
ECU (engine control unit) internal malfunction (input signal error):
Er-4 8-63
non-registered data has been received from the meter.
Diagnostic code: sensor operation table
Diagnostic
Item Meter display Procedure
code No.
D01 Throttle position sensor
signal
• Fully closed position 8–22 Check with throttle valve
fully closed.
• Fully open position 88–102 Check with throttle valve
fully open.
D03 Intake air pressure Displays the intake air Operate the throttle while
pressure. pulling the brake lever and
pushing the start switch
“ ”. (If the display value
changes, the perfor-
mance is OK.)
D05 Intake air temperature Displays the intake air Compare the actually
temperature. measured air temperature
with the meter display val-
ue.
D06 Coolant temperature When engine is cold: Dis- Compare the actually
plays temperature closer measured coolant temper-
to air temperature. ature with the meter dis-
When engine is hot: Dis- play value.
plays current coolant tem-
perature.
D07 Front wheel speed pulse Front wheel speed pulse Check that the number in-
0–999 creases when the front
wheel is rotated. The num-
ber is cumulative and
does not reset each time
the wheel is stopped.
9-6
Diagnostic
code No.
D08 Lean angle sensor Lean angle sensor output Remove the lean angle
voltage sensor and incline it more
• Upright 0.4–1.4 than 65 degrees.
• Overturned 3.7–4.4
D09 Fuel system voltage Approximately 12.0 Compare the actually
(battery voltage) measured battery voltage
with the meter display val-
ue. (If the actually mea-
sured battery voltage is
low, recharge the battery.)
D20 Sidestand switch Extend and retract the sid-
• Stand retracted ON estand.
• Stand extended OFF

D60 EEPROM fault code dis- —
play
• No history 00
• No malfunctions detect-
ed (If the self-diagnosis
fault code 44 is indicat-
ed, the ECU is defec-
tive.)
• History exists 01(Data error for CO ad-
justment value)
03 (Data error for immobi-
lizer code)
04 (Data error for ISC (idle
speed control) unit learn-
ing values)
D61 Malfunction history code —
display
• No history 00
• History exists Fault codes 12–61
• (If more than one code
number is detected, the
display alternates every
two seconds to show all
the detected code num-
bers.
When all code numbers
are shown, the display
repeats the same pro-
cess.)
9-7
Diagnostic
code No.
D62 Malfunction history code
erasure
• No history 00 —
• History exists • Displays the total num- To erase the history, push
ber of malfunctions, in- the start switch “ ”.
cluding the current
malfunction, that have
occurred since the histo-
ry was last erased. (For
example, if there have
been three malfunc-
tions, “03” is displayed.)
D70 Control number 0–254 [-] —
Diagnostic code: actuator operation table

Diagnostic
Item Actuation Procedure
code No.
D30 Ignition coil Actuates the ignition coil Check that a spark is gen-
five times at one-second erated five times.
intervals. • Connect an ignition
Illuminates the engine checker.
trouble warning light.
D36 Injector Actuates the injector five Check that injector is actu-
times at one-second inter- ated five times by listening
vals. for the operating sound.
Illuminates the engine
D48 Air induction system sole- Actuates the air induction Check that the air induc-
noid system solenoid five times tion system solenoid is ac-
at one-second intervals. tuated five times by
Illuminates the engine listening for the operating
trouble warning light. sound.
D51 Radiator fan motor relay Actuates the radiator fan Check that the radiator fan
motor relay five times at motor relay is actuated
five-second intervals. Illu- five times by listening for
minates the engine trouble the operating sound.
warning light.
D52 Headlight relay Actuates the headlight re- Check that the headlight
lay five times at five-sec- relay is actuated five times
ond intervals. Illuminates by listening for the operat-
the engine trouble warning ing sound.
light.
D54 ISC (idle speed control) Actuates and fully closes The ISC unit vibrates
unit the ISC valve, then opens when the ISC valve oper-
it to the standby opening ates.
position when the engine
is started.
This operation takes ap-
proximately 3 seconds un-
til it is completed.
9-8
Diagnostic
Item Actuation Procedure
code No.
D57 Grip warmer (option) Turns on the grip warmers. Check that the grip warm-
Illuminates the engine ers become warm.
9-9
9-10
EAS28740
57. Headlight EAS28750
WIRING DIAGRAM 58. Auxiliary light COLOR CODE

YP400R 2013 59. License plate light B Black
1. Crankshaft position sensor 60. V-belt replacement indicator re- Br Brown
2. AC magneto set coupler Ch Chocolate
61. Meter assembly Dg Dark green
G Green
4. Backup fuse (immobilizer unit 62. Immobilizer system indicator
Gy Gray
and meter assembly) light L Blue
5. Main switch 63. Multi-function meter Lg Light green
6. ECU fuse 64. Speedometer O Orange
7. Radiator fan motor fuse 65. Tachometer P Pink
8. Turn signal/hazard fuse 66. Engine oil change indicator R Red
9. Ignition fuse 67. V-belt replacement indicator Sb Sky blue
10. Headlight fuse 68. Engine trouble warning light W White
11. Signaling system fuse 69. Meter light Y Yellow
12. Battery 70. High beam indicator light B/L Black/Blue
71. Right turn signal indicator light B/W Black/White
13. Main fuse
B/Y Black/Yellow
14. Starter relay 72. Left turn signal indicator light
Br/L Brown/Blue
15. Starter motor 73. Air temperature sensor Br/R Brown/Red
16. Diode 74. Radiator fan motor Br/W Brown/White
17. Frame ground 75. Radiator fan motor relay G/B Green/Black
18. Sidestand switch 76. Self-diagnosis signal coupler G/L Green/Blue
19. Fuel pump 77. Immobilizer unit G/R Green/Red
20. Fuel sender 78. Anti-theft alarm (OPTION) G/W Green/White
21. Starting circuit cut-off relay A. Wire harness G/Y Green/Yellow
22. Right handlebar switch B. Engine sub-wire harness Gy/G Gray/Green
L/B Blue/Black
23. Start switch
L/R Blue/Red
24. Hazard switch L/W Blue/White
25. Front brake light switch L/Y Blue/Yellow
26. Coolant temperature sensor O/B Orange/Black
27. Throttle position sensor O/R Orange/Red
28. Intake air pressure sensor O/W Orange/White
29. Intake air temperature sensor P/B Pink/Black
30. Lean angle sensor P/W Pink/White
31. ECU (engine control unit) R/B Red/Black
32. Ignition coil R/G Red/Green
33. Spark plug R/L Red/Blue
R/W Red/White
R/Y Red/Yellow
35. Fuel injector W/B White/Black
36. Speed sensor W/R White/Red
37. Air induction system solenoid W/Y White/Yellow
38. O2 sensor Y/G Yellow/Green
39. Auxiliary DC jack Y/L Yellow/Blue
40. Horn
42. Headlight relay
43. Left handlebar switch
44. Dimmer switch
45. Pass switch
46. Turn signal switch
47. Horn switch
49. Right tail/brake light assembly
50. Right rear turn signal light
51. Tail/brake light
52. Left tail/brake light assembly
53. Left rear turn signal light
54. Right front turn signal light
55. Left front turn signal light
56. Headlight assembly
YP400R 2013 YP400R 2013 YP400R 2013 YP400R 2013 YP400R 2013
WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO
A
G/R Y Gy/G L B/L Y/L R/W W R/B G/B G/Y G/B P B O/B O P O/B R/B Y Y R/B O/B P
(Gy) (Gy)
1 B/L W/R
W R
A B
L/Y
B/L W/R R W R/W
(B) B R/B L/Y G/Y
W W R B
18 R/B G 20 G/Y R/B W/Y
G/R B/L B/L R/B
32
2 W W 3
W W B
17 B
B 19 G B 21 (Gy) 26 O O
L B/L Y
W W W R
(B)
B R R G/Y Sb
L/Y
W W W
13
B L/B
27 G/Y A G/Y G/Y
34
P Gy
W W W
(B)
12 (B) B B/Y B
B/L Y Gy Gy A Gy Gy (B)
B L/Y
L/B L L Sb
4 B
14 L/B
P/W
35 O/B R/B
L/B
R/L R B
B B L/B 22 W/Y 28 L L A L R/B L Y
(B)
B B
25 (B)
15 16 23 24 G/B
R 29 B/L Br/W

5 B
Br/R Br/R
ON Dg Br/W Ch (G) Br/W Br/W A Br/W Y/G 31 B/Y
W P
Br
OPEN
W/B W L O/R 36 B/W B/L
R R LOCK
Ch Br/W Dg
Dg Ch Br G/Y 30 L
Y/G L/Y Br/R
B/L B/W

G/Y Br W/Y L/B B/L
G/B Br/R R/B
6
Br/R R R/W R/B (L)
Br/L B 37
R R/W
L/B B
8
Br/R L/R B/W
B/W B R/L
Br/L
9 R/B
Y/L G/L R/B G/W G/W A G/W G/W B B R/B
10 Gy/G
38 B B R/B G/W
R/G B B 77 Br/L R/Y W L Gy/G B/L
R/W Lg Y/L (B)

11 (B)
Br/L Br
B
R/W R/B R/Y R/Y
B B/W
L/R
R/B A R/B
Y/L R/Y
42 L/B
Br
R/G R/L Br/W 40
Lg
R/W R/B
R/Y W/B
L/R 41 P
R/W 75 L/B W/B (B)

Br/W
B B G/L L Br/W
78 B B
Y/L Y/L
L G/B
L
44 45 46 47
B R/L B/W 48 G/B Br/R Br/R G/B
B Y/L Y/L R Br
B
P/B
B/L
39 P/B Br
B B/L B
Y/L B
B
B
B/W
R/L
76 Y/L L R 74 Y G
Dg Br/W Ch
P B G/Y
L/B R/Y Br
(B)
(B) (B)
B
G Y G/Y B P
Ch Br/W Dg
Br R/Y L/B
B B
B B

B B
62 G B L/R B Br B G/Y G/Y

Gy
59 56 G Y Br Br Ch Dg Br Ch Br Dg
63
L/R 57 55 54 52 49
66 67 68 69 70 71 72 B B Br G/Y B Br G/Y
64 65 58 53 50
Ch B Dg B
G Y Y G
Gy
B B 51 51
B/L B 60 B B B

B B B
G/L Br Y/L B/L Gy B
B B
B B B B B
B
B Gy
B B
(B)
B B B/L
(B)
YP400R 2013 YP400R 2013 YP400R 2013 YP400R 2013 YP400R 2013
WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO
A
(Gy) (Gy)
1
A B
(B)
18 20 32
2 3
17 19 21 (Gy) 26
(B) A 33
(B)
(B) A
13 27 A
34
(B)
12 (B) A (B)
(L) A A
4 14 35
22 28 A
(B)
A (B)
A
25 (B)
15 16 23 24
29
A
5
ON
(G) A 31
OFF
OPEN 36
LOCK 30
P
6
(L)
37
7 A
8
A
9
A
10 38
77
(B)
11 (B)
A
42
40
41
75 (B)
43
78
44 45 46 47
48
39
76 74 (B)
(B) (B)
61
62 56
63 59
57 55 54 52 49
66 67 68 69 70 71 72
64 65 58 53 50
51 51
60
73
(B)
(B)

Yamaha Xmax

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Yamaha Xmax

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2013

IMPORTANT MANUAL INFORMATION

A WARNING indicates a hazardous situation which, if not avoided, could

A NOTICE indicates special precautions that must be taken to avoid

TIP A TIP provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Gear oil

Filling fluid Molybdenum disulfide oil

Lubricant Brake fluid

Special tool B Wheel bearing grease

Tightening torque LS Lithium-soap-based grease

Wear limit, clearance M Molybdenum disulfide grease

Engine speed S Silicone grease

Electrical data Apply locking agent (LOCTITE®).

Engine oil New Replace the part with a new one.

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

IMPORTANT INFORMATION ......................................................................... 1-8

BASIC SERVICE INFORMATION.................................................................1-10

SPECIAL TOOLS .......................................................................................... 1-15

VEHICLE IDENTIFICATION NUMBER

OUTLINE OF THE FI SYSTEM

1. Air temperature sensor 13. Ignition coil

1. Fuel pump 14. Intake air pressure sensor

1. V-belt replacement indicator “V-BELT”

3. And then, connect the V-belt replacement re-

Ambient temperature display

1. Ambient temperature display

PREPARATION FOR REMOVAL AND

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS

BASIC SERVICE INFORMATION

NOTICE Checking the electrical system

Intake air temperature sensor re-

FI diagnostic tool 3-9, 8-34

Steering nut wrench 3-16, 4-61

Damper rod holder 4-54, 4-56

Fork seal driver weight 4-56

Fork seal driver attachment (ø38) 4-56

Compression gauge 5-1

Yamaha bond No. 1215 5-14, 5-46,

Valve spring compressor 5-20, 5-25

Valve spring compressor attachment 5-20, 5-25

Valve guide remover (ø5) 5-22

Valve guide reamer (ø5) 5-22

Piston pin puller set 5-28

Rotor holding tool 5-35, 5-39,

Sheave holder 5-35, 5-40,

Locknut wrench 5-35, 5-39

Sheave fixed block 5-36, 5-39

Oil seal guide (ø41) 5-38

Flywheel puller 5-44

Flywheel puller attachment 5-44

Digital circuit tester 5-52, 8-93,

Radiator cap tester 6-2

Radiator cap tester adapter 6-2

Middle driven shaft bearing driver 6-8

Mechanical seal installer 6-8

Pressure gauge 7-3

Ignition checker 8-92

Test harness- lean angle sensor (6P) 8-93

Test harness- speed sensor (3P) 8-95