Yzf R15 Service PDF

2PLF8197E0.
book Page 1 Tuesday, April 22, 2014 1:46 PM
2014
SERVICE MANUAL
YZF-R15
2PK-F8197-E0
2PLF8197E0.book Page 1 Tuesday, April 22, 2014 1:46 PM
EAS00000
YZF-R15 (2PK1) 2014

SERVICE MANUAL
©2014 by Yamaha Indonesia Motor Manufacturing
First edition, May 2014
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Indonesia Motor Manufacturing
is expressly prohibited.
IMPORTANT
This manual was produced by the Yamaha Indonesia Motor Manufacturing 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, anyone who uses this book to perform maintenance and
repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to
repair these types of vehicle. Repair and maintenance work attempted by anyone without this
knowledge is likely to render the vehicle unsafe and unfit for use.
Yamaha Indonesia Motor Manufacturing is continually striving to improve all of its models. Modifica-
tions 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.
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 per-
sonal 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,

WARNING could 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.

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 sec-
tion title “1” is shown at the top of each page.
● Sub-section titles “2” appear in smaller print than the section title.
● To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of
each removal and disassembly section.
● Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a dis-
assembly step.
● Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
● A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names
of parts and notes in jobs, etc.
● Job “7” requiring more information (such as special tools and technical data) are described
sequentially.
CLUTCH CLUTCH
CLUTCH
Removing the clutch cover
REMOVING THE CLUTCH
1. Straighten the lock washer tab.
CHECKING THE FRICTION PLATES
The following procedure applies to all of the fric-
2
2. Loosen: tion plates.
• Clutch boss nut “1” 1. Check:
TIP • Friction plate
While holding the clutch boss “2” with the univer- Damage/wear Replace the friction plates
as a set.
3 sal clutch holder “3”, loosen the clutch boss nut.
2. Measure:
• Friction plate thickness
Clutch hub holder
Out of specification Replace the friction
YSST-733
plates as a set. 7
4 New 4
5
TIP
Measure the friction plate at four places.
LS
Friction plate 1 thickness
New 6 2.90–3.10 mm (0.114–0.122 in)
Wear limit
E 2.80 mm (0.110 in)
2.90–3.10 mm (0.114–0.122 in)
Wear limit
5 2 2.80 mm (0.110 in)
3 New REMOVING THE CLUTCH PUSH LEVER

1. Remove:
New LS
1 • Clutch push lever “1”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. Unhook the clutch push lever spring from the
(4)
5 LS
(4) clutch push lever “1”.
b. Turn the clutch push lever“1” 180° counter-
clockwise.
10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) c. Remove the coolant reservoir bolts.
T.
T.
T.
R.
R.
R.
d. Move the coolant reservoir“2” forward as

6 Order Job/Parts to remove Q’ty
Drain.
Remarks shown in the illustration.
e. Remove the clutch push lever“1”.
A B
Engine oil Refer to “CHANGING THE ENGINE OIL” on

page 3-12.
Right bottom cowling Refer to “GENERAL CHASSIS” on page

4-3.
1 Oil filter element cover 1
2 Oil filter element 1 2
3 Clutch cover 1 1 a b
4 Clutch cover gasket 1
A. Friction plate 1
5 Dowel pin 2
B. Friction plate 2
6 Oil seal 1 a. Gap between friction material segments on
For installation, reverse the removal proce- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ friction plate 1
dure. b. Gap between friction material segments on
friction plate 2
TIP
The gap “a” on friction plate 1 is smaller than the
gap “b” on friction plate 2.
5-39 5-42
SYMBOLS 1. Serviceable with engine mounted

The following symbols are used in this manual 2. Filling fluid
for easier understanding. 3. Lubricant
4. Special tool
TIP 5. Tightening torque
The following symbols are not relevant to 6. Wear limit, clearance
every vehicle. 7. Engine speed
8. Electrical data
9. Engine oil
1 2 3 10.Gear oil
11.Molybdenum disulfide oil
12.Brake fluid
13.Wheel bearing grease
14.Lithium-soap-based grease
4 5 6 15.Molybdenum disulfide grease
16.Silicone grease
17.Apply locking agent (LOCTITE®).
T.
18.Replace the part with a new one.

R.
7 8
9 10
E G
11 12
M BF
13 14
B LS
15 16
M S
17 18
LT New
TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC
2
PERIODIC CHECKS AND
CHK
ADJUSTMENTS ADJ 3
CHASSIS CHAS
4
ENGINE ENG
5
COOLING SYSTEM COOL
6
FUEL SYSTEM FI
7
– +
ELECTRICAL SYSTEM ELEC

8
TROUBLESHOOTING TRBL
SHTG 9
GEN
INFO
CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1

VEHICLE IDENTIFICATION NUMBER ..................................................... 1-1
MODEL LABEL.......................................................................................... 1-1
ENGINE SERIAL NUMBER ...................................................................... 1-1
FEATURES...................................................................................................... 1-2
OUTLINE OF THE FI SYSTEM ................................................................. 1-2
FI SYSTEM................................................................................................ 1-3
MULTI-FUNCTION DISPLAY.................................................................... 1-4
IMPORTANT INFORMATION ......................................................................... 1-5

PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-5
REPLACEMENT PARTS........................................................................... 1-5
GASKETS, OIL SEALS AND O-RINGS .................................................... 1-5
LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-5
BEARINGS AND OIL SEALS .................................................................... 1-6
CIRCLIPS .................................................................................................. 1-6
CHECKING THE CONNECTIONS .................................................................. 1-7
SPECIAL TOOLS ............................................................................................ 1-8

GEN
INFO
GEN
IDENTIFICATION INFO
IDENTIFICATION
GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is
stamped into the steering head pipe.
TIP
The vehicle identification number issued to
identify your motorcycle and may be used to
register your motorcycle with the licensing
authority in your area.
MODEL LABEL
The model label “1” is affixed to the frame
under the seat. This information will be needed
to order spare parts.
1
ENGINE SERIAL NUMBER

The engine serial number “1” is stamped into
the crankcase.
1-1
GEN
FEATURES INFO
FEATURES
OUTLINE OF THE FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti-
mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera-
ture. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the
combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet
used in the respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating
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 airfuel ratio can be achieved to accommodate the constant changes in the operating condi-
tions 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 man-
ner. To accommodate this need, this model has adopted an electronically controlled fuel injection
(FI) system, in place of the conventional carburetor system. This system can achieve an optimum
air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel
injection volume according to the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine
response, better fuel economy, and reduced exhaust emissions.
1 2 3 4 5,6 7 8
11 10 9
1. Engine trouble warning light
2. Spark plug
3. Ignition coil
4. Fuel pump
5. FID (fast idle solenoid)
6. Throttle body sensor assembly (consisting
of throttle position sensor, intake air pres-
sure sensor, intake air temperature sensor)
7. Lean angle sensor
8. ECU (engine control unit)
9. Crankshaft position sensor
10.Fuel injector
11.Coolant temperature sensor
1-2
GEN
FEATURES INFO
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains
the fuel pressure that is applied to the fuel injector at only 250 kPa (2.50 kg/cm², 36.3 psi). Accord-
ingly, 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, crankshaft position sensor, intake air pressure sensor, intake air tem-
perature sensor, lean angle sensor, coolant temperature 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 sup-
plied at all times in accordance with the driving conditions.
5 6
2
4
1 3
8
11 12
13
14
10
1. Fuel pump 11.Throttle body sensor assembly

2. Fuel injector 12.Intake air temperature sensor
3. Ignition coil 13.Throttle position sensor
4. Coolant temperature sensor 14.Intake air pressure sensor
6. Lean angle sensor A. Fuel system
7. Crankshaft position sensor B. Air system
8. FID (fast idle solenoid) C. Control system
9. Air filter case
10.Throttle body
1-3
GEN
FEATURES INFO
MULTI-FUNCTION DISPLAY To reset a tripmeter, select it by pushing the
“RESET/SELECT” button briefly (less than one
second), and then push the button for at least
three seconds while the selected tripmeter is
flashing. If you do not reset the fuel reserve
1 tripmeter manually, it will reset itself automati-
x 1000 r/min
cally and the display will return to the prior
mode after refueling and traveling 5 km (3 mi).
Fuel meter
2
1. Multi-function display
2. “RESET/SELECT” button
The multi-function display is equipped with the

following: 1 x 1000 r/min
• a speedometer (which shows the riding

speed)
• an odometer (which shows the total dis-
tance traveled) 1. Fuel meter
• two tripmeters (which show the distance
traveled since they were last set to zero) The fuel meter indicates the amount of fuel in
• a fuel reserve tripmeter (which shows the the fuel tank. The display segments of the fuel
distance traveled since the fuel level warn- meter disappear towards “E” (Empty) as the
ing light came on) fuel level decreases. When the last fuel meter
• a fuel meter segment starts flashing, refuel as soon as pos-
sible.
TIP
Be sure to turn the key to “ON” before using
the “RESET/ SELECT” button.
Odometer and trip meter modes

A brief push (less than one second) on the
“RESET/ SELECT” button switches the display
between the odometer mode “ODO” and the
tripmeter modes “TRIP 1” and “TRIP 2” in the
following order:
ODO → TRIP 1 → TRIP 2 → ODO
When approximately 1.9 L (0.50 US gal, 0.42
lmp.gal) of fuel remains in the fuel tank, the
odometer display will automatically change to
the fuel reserve tripmeter mode “F-TRIP” and
start counting the distance traveled from that
point, and the last segment of the fuel meter
will start flashing. In that case, pushing the
“RESET/SELECT” button switches the display
between the various tripmeter and odometer
modes in the following order:
F-TRIP → TRIP 1 → TRIP 2 → ODO →
F-TRIP
1-4
GEN
IMPORTANT INFORMATION INFO
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket sur-
faces, oil seal lips and O-rings must be
2. Use only the proper tools and cleaning cleaned.
equipment.” 2. During reassembly, properly oil all mating
Refer to “SPECIAL TOOLS” on page 1-8. parts and bearings and lubricate the oil seal
3. When disassembling, always keep mated lips with grease.
parts together. This includes gears, cylin-
ders, pistons and other parts that have
been “mated” through normal wear. Mated
parts must always be reused or replaced as
an assembly.
1. Oil
2. Lip
3. Spring
4. Grease
4. During disassembly, clean all of the parts LOCK WASHERS/PLATES AND COTTER
and place them in trays in the order of dis- PINS
assembly. This will speed up assembly and After removal, replace all lock washers/plates
allow for the correct installation of all parts. “1” and cotter pins. After the bolt or nut has
5. Keep all parts away from any source of fire. been tightened to specification, bend the lock
tabs along a flat of the bolt or nut.
REPLACEMENT PARTS
Use only genuine Yamaha parts for all
replacements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
1-5
GEN
IMPORTANT INFORMATION INFO
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.
NOTICE
Do not spin the bearing with compressed air
because this will damage the bearing surfaces.
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always 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.
1-6
GEN
CHECKING THE CONNECTIONS INFO
CHECKING THE CONNECTIONS Digital Circuit tester
CHECKING THE CONNECTIONS 90890-03174
Check the leads, couplers, and connectors for
stains, rust, moisture, etc. TIP
1. Disconnect: • If there is no continuity, clean the terminals.
• Lead • When checking the wire harness, perform
• Coupler steps (1) to (3).
• Connector • As a quick remedy, use a contact revitalizer
2. Check: available at most part stores.
• Lead
• Coupler
• Connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect
several times.
3. Check:
• All connections
Loose connection → Connect properly.
TIP
If the pin “1” on the terminal is flattened, bend it
up.
4. Connect:
• Lead
• Coupler
• Connector
TIP
Make sure all connections are tight.
5. Check:
• Continuity
(with the multimeter)
1-7
GEN
SPECIAL TOOLS INFO
EAS00027
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 inappropri-
ate 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.
Tool no. Tool name/Usage Illustration

Slide hammer bolt
90890-01085
These tools are used when removing
or installing the cam shafts.
Rotor holding tool
90890-01235 This tool is used to hold the AC

magneto rotor when removing or
installing the AC magneto rotor nut.
Ring nut wrench
90890-01268
This tool is used to loosen and tighten
the steering ring nut.
Tappet adjusting tool
90890-01311
This tool is necessary for adjusting
valve clearance.
Radiator cap tester
90890-01325
This tool is used for testing radiator
cap.
Radiator cap tester adapter
90890-01326
This tool is necessary for adapter
radiator cap tester.
T-handle 1
Shock absorber rod mounting 2
90890-01326
This tool is used for holding the
90890-01294
damper rod holder when removing or
installing the damper rod holder.
1-8
GEN
SPECIAL TOOLS INFO
Locknut wrench
90890-01348 This tool is used to loosen and tighten

the clutch carrier locknut of the
secondary sheave.
Flywheel puller
90890-01362
This tool is used for removing the AC
magneto rotor.
Fork seal driver weight 1
Fork seal driver attachment 2
90890-01184
90890-01186
This tool is used to install the oil seal.
Oil seal guide
90890-01384
This tool is used to install oil seals.

Steering nut wrench
90890-01403
This tool is used to loosen and tighten
the steering ring nut.
Sheave holder
90890-01701 This tool is used for holding the

primary sheave and secondary
sheave.
Thickness gauge
90890-03180
This tool is used to measure the valve
clearance.
Compression gauge
90890-03081
These tools are used to measure the
engine compression.
Digital tachometer
90890-06760
This tool is needed for detecting
engine rpm.
1-9
GEN
SPECIAL TOOLS INFO
Timing light
90890-03141
This tool is used for measuring mark at
AC magneto rotor.
Pocket tester
90890-03112
These instruments are invaluable for
checking the electrical system.
Valve lapper
90890-04101
This tool is used for lapping the valve.

Valve spring compressor
Valve spring compressor attachment
90890-04019 (ø19 mm)
90890-04108 These tools are used when removing
or installing the valve and the valve
spring.
Valve guide remover (ø4.5 mm)
90890-04116
This tool is needed to remove and
install the valve guide.
Valve guide installer (ø4.5 mm)
90890-04117
This tool is needed to install the valve
guide.
Valve guide reamer (ø5 mm)
90890-04099
This tool is needed to rebore the new
valve guide.
Ignition checker
90890-06754 This instrument is necessary for

checking the ignition system
components.
Yamaha bond No. 1215 (Three bond
No. 1215®)
90890-85505
This sealant (bond) is used for
crankcase mating surface, etc.
1-10
GEN
SPECIAL TOOLS INFO
Digital circuit tester
90890-03174
This instrument is necessary for
checking the electrical system.
Piston pin puller set
90890-01304
This tool is used for removing piston
pin.
Pressure gauge
90890-03153
This tool is needed to measure fuel
pressure.
Crankcase separating tool
90890-01135
This tool is necessary for separating
the crankcase.
Crankshaft installer pot
90890-01274
This tool is necessary for installing the
crankshaft.
Crankshaft installer bolt
90890-01275
crankshaft.
Adapter (M12)
90890-01278
crankshaft.
Crankshaft installer spacer
90890-04181
crankshaft.
1-11
GEN
SPECIAL TOOLS INFO
Cam chain sprocket holder
90890-04168
This tool is used for removing or
installing the camshaft sprocket.
Oil cap removal
90843-110A1
This tool is used for removing or
installing the oil cap.
Bearing puller attachment (ø32 mm)
90843-110A3
This tool is used for joining crankcase
separating tool.
YAMAHA DIAGNOSTIC TOOL
90890-03231
This tool is used for checking fault
diagnostic mode.
Fuel pressure adapter (ø6.3 mm)
90890-03227
This tool is used for measure fuel
pressure.
1-12
SPEC
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................ 2-2
CHASSIS SPECIFICATIONS .......................................................................... 2-9
ELECTRICAL SPECIFICATIONS ................................................................. 2-12
TIGHTENING TORQUES .............................................................................. 2-14

GENERAL TIGHTENING TORQUE SPECIFICATIONS ......................... 2-14
ENGINE TIGHTENING TORQUES .........................................................2-15
CHASSIS TIGHTENING TORQUES....................................................... 2-18
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-21

ENGINE ...................................................................................................2-21
CHASSIS................................................................................................. 2-23
LUBRICATION SYSTEM DIAGRAMS .......................................................... 2-25
COOLING SYSTEM DIAGRAMS .................................................................. 2-29
CABLE ROUTING ......................................................................................... 2-31

SPEC
GENERAL SPECIFICATIONS SPEC

GENERAL SPECIFICATIONS
SPECIFICATIONS
Model
Model 2PK1
Dimensions
Overall length 1975 mm (77.8 in)
Overall width 670 mm (26.4 in)
Overall height 1070 mm (42.1 in)
Seat height 800 mm (31.5 in)
Wheelbase 1345 mm (53.0 in)
Ground clearance 160 mm (6.30 in)
Minimum turning radius 2600 mm (102.4 in)
Weight
Curb weight 134 kg (296 Ib)
Maximum load (total weight of rider, passenger,
cargo and accessories) 192 kg (424 Ib)
2-1
ENGINE SPECIFICATIONS SPEC

ENGINE SPECIFICATIONS
Engine
Engine type Liquid cooled 4-stroke, SOHC
Displacement 149 cm³
Cylinder arrangement Single cylinder
Bore × stroke 57.0 × 58.7 mm (2.24 × 2.31 in)
Compression ratio 10.40 :1
Standard compression pressure (at sea level) 1350 kPa(13.5 kg/cm², 192 psi) at 500 r/min
Minimum–maximum 1170 – 1510 kPa(11.7 – 15.1 kg/cm²,
116 – 215 psi) at 500 r/min
Starting system Electric starter
Fuel
Recommended fuel Regular unleaded gasoline (Gasohol (E10)
acceptable)
Fuel tank capacity 12.0 L (3.17 US gal, 2.64 Imp.gal)
Fuel reserve amount 2.6 L (0.7 US gal, 0.5 Imp.gal)
Engine oil
Lubrication system Wet sump
Recommended brand: YAMALUBE
Type SAE 20W-40 or 20W-50
Recommended engine oil grade API service SE type or higher, JASO standard MA
Engine oil quantity
Total amount 1.15 L (1.22 US qt, 1.01 Imp.qt)
Without oil filter element replacement 0.95 L (1.00 US qt, 0.84 Imp.qt)
With oil filter element replacement 1.00 L (1.06 US qt, 0.88 Imp.qt)
Oil filter
Oil filter type Paper
Oil pump
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance Less than 0.15 mm (0.0059 in)
Limit 0.23 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing clearance 0.13-0.19 mm
Limit 0.26 mm (0.0102 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.05 - 0.11 mm (0.0020 - 0.0043 in)
Limit 0.18 mm (0.0071 in)
Rotor thickness 9.95 - 9.98 mm (0.3917 - 0.3929 in)
Relief valve operating pressure 39.2 - 78.4 kPa (0.39 - 0.78 kgf/cm²,
5.7 - 11.4 psi)
Pressure check location Check bolt on cylinder head body
Cooling system
Radiator capacity (including all routes) 0.59 L (0.62 US qt, 0.52 Imp.qt)
Radiator capacity 0.38 L (0.40 US qt, 0.33 Imp.qt)
Coolant reservoir capacity
(up to the maximum level mark) 0.25 L (0.26 US qt, 0.22 Imp.qt)
2-2

Radiator cap opening pressure 107.9 -137.3 kPa (1.08 - 1.37 kgf/cm²,
15.6 - 19.9 psi)
Valve relief pressure 4.9 kPa (0.05 kgf/cm², 0.7 psi)
Thermostat
Valve opening temperature 79.5-84.5 °C
Valve full open temperature 95.0 °C (203.00 °F)
Valve lift (full open) 3.0 mm (0.12 in)
Radiator core
Width 198.0 mm (7.80 in)
Height 128.0 mm (5.04 in)
Depth 24.0 mm (0.94 in)
Water pump
Water pump type Single section centrifugal pump
Reduction ratio 1/2 (0.500)
Spark plug(s)
Manufacturer/model NGK/CR9E
Spark plug gap 0.7–0.8 mm (0.028–0.031 in)
Cylinder head
Combustion chamber volume 9.90–10.50 cm³ (0.60–0.64 cu.in)
Warpage limit 0.05 mm (0.0020 in)
Camshaft
Drive system Chain drive (left)
Camshaft lobe dimensions
Intake A 30.225–30.325 mm (1.1900–1.1939 in)
Limit 0.030 mm (0.0011 in)
Intake B 25.127–25.227 mm (0.9893–0.9932 in)
Limit 0.030 mm (0.0011 in)
Exhaust A 30.232–30.332 mm (1.1902–1.1942 in)
Limit 0.030 mm (0.0011 in)
Exhaust B 25.065–25.165 mm (0.9868–0.9907 in)
Limit 0.030 mm (0.0011 in)
B
Camshaft runout limit 0.030 mm (0.0012 in)
2-3
Timing chain
Model/number of links DID SCR-0404 SV/96
Tensioning system Automatic
Rocker arm/rocker arm shaft

Rocker arm inside diameter 9.985–10.000 mm (0.3931–0.3937 in)
Limit 10.015 mm (0.3943 in)
Rocker arm shaft outside diameter 9.966–9.976 mm (0.3924–0.3928 in)
Limit 9.950 mm (0.3917 in)
Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.034 mm (0.0004–0.0013 in)
Limit 0.08 mm (0.0032 in)
Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.10–0.14 mm (0.0039–0.0055 in)
Exhaust 0.20–0.24 mm (0.0079–0.0094 in)
Valve dimensions
Valve head diameter A (intake) 19.40–19.60 mm (0.7638–0.7717 in)
Valve head diameter A (exhaust) 16.90–17.10 mm (0.6654–0.6732 in)
A
Valve face width B (intake) 1.538–2.138 mm (0.0606–0.0842 in)
Valve face width B (exhaust) 1.538–2.138 mm (0.0606–0.0842 in)
Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in)

Limit 1.6 mm (0.06 in)
Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)
Valve margin thickness D (intake) 0.50–0.90 mm (0.0197–0.0354 in)

Valve margin thickness D (exhaust) 0.50–0.90 mm (0.0197–0.0354 in)
Valve stem diameter (intake) 4.475–4.490 mm (0.1762–0.1768 in)

Limit 4.450 mm (0.1751 in)
Valve stem diameter (exhaust) 4.460–4.475 mm (0.1756–0.1762 in)
Limit 4.435 mm (0.1744 in)
Valve guide inside diameter (intake) 4.500–4.512 mm (0.1772–0.1776 in)
Limit 4.550 mm (0.1791 in)
Valve guide inside diameter (exhaust) 4.500–4.512 mm (0.1772–0.1776 in)
2-4

Limit 4.550 mm (0.1791 in)
Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in)
Limit 0.100 mm (0.0039 in)
Valve stem runout 0.010 mm (0.0004 in)
Cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in)

Cylinder head valve seat width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)
Valve spring
Free length (intake) 41.50 mm (1.63 in)
Limit 39.43 mm (1.5523 in)
Free length (exhaust) 41.50 mm (1.63 in)
Limit 39.43 mm (1.5523 in)
Installed length (intake) 35.30 mm (1.39 in)
Installed length (exhaust) 35.30 mm (1.39 in)
Spring rate K1 (intake) 24.51 N/mm
Spring rate K2 (intake) 36.36 N/mm
Spring rate K1 (exhaust) 24.51 N/mm
Spring rate K2 (exhaust) 36.36 N/mm
Installed compression spring force (intake) 135.10-166.90 N
Installed compression spring force (exhaust) 135.10-166.90 N
Spring tilt (intake) 1.4 mm (0.06 in)
Spring tilt (exhaust) 1.4 mm (0.06 in)
Winding direction (intake) Clockwise

Winding direction (exhaust) Clockwise
Cylinder
Bore 56.985–57.010 mm (2.2435–2.2445 in)
Taper limit 0.05 mm (0.0020 in)
Out of round limit 0.05 mm (0.0020 in)
Piston
Piston-to-cylinder clearance 0.015–0.025 mm (0.0006–0.0010 in)
Limit 0.15 mm (0.0059 in)
Diameter D 56.965–56.990 mm (2.2427–2.2437 in)
2-5

Height H 5.0 mm (0.20 in)
H
D
Offset 0.25 mm (0.0098 in)

Offset direction Intake side
Piston pin bore inside diameter 14.002–14.013 mm (0.5513–0.5517 in)
Limit 14.043 mm (0.5529 in)
Piston pin outside diameter 13.995–14.000 mm (0.5510–0.5512 in)
Limit 13.975 mm (0.5502 in)
Piston-pin-to-piston-pin-bore clearance 0.002–0.018 mm (0.0001–0.0007 in)
Limit 0.068 mm (0.0027 in)
Piston ring
Top ring
Ring type Barrel
Dimensions (B × T) 0.80 × 2.10 mm (0.03 × 0.08 in)
B
T
End gap (installed) 0.10–0.25 mm (0.0039–0.0098 in)

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

Limit 0.40 mm (0.0157 in)
Limit 0.100 mm (0.0039 in)
Oil ring
B
T

Connecting rod
Small end inside diameter 14.015–14.028 mm (0.5516–0.5523 in)
2-6
Crankshaft
Width A 47.95–48.00 mm (1.888–1.890 in)
Runout limit C 0.030 mm (0.0012 in)
Big end side clearance D 0.110–0.410 mm (0.0043–0.0161 in)
Big end radial clearance E 0.004–0.014 mm (0.0002–0.0006 in)
C C
E
D
Balancer
Balancer drive method Gear
Clutch
Clutch type Wet, multiple-disc
Clutch release method Inner push, cam push
Clutch lever free play 10.0–15.0 mm (0.39–0.59 in)
Friction plate 1 thickness 2.90–3.10 mm (0.114–0.122 in)
Wear limit 2.80 mm (0.1102 in)
Plate quantity 2 pcs
Friction plate 1 thickness 2.90–3.10 mm (0.114–0.122 in)
Wear limit 2.80 mm (0.1102 in)
Clutch plate thickness 1.85–2.15 mm (0.073–0.085 in)
Warpage limit 0.20 mm (0.0079 in)
Clutch spring free length 41.62 mm (1.64 in)
Minimum length 39.54 mm (1.56 in)
Spring quantity 4 pcs
Push rod bending limit 0.500 mm (0.0197 in)
Transmission
Transmission type Constant mesh 6-speed
Primary reduction system Helical gear
Primary reduction ratio 3.042 (73/24)
Final drive Chain
Secondary reduction ratio 3.133 (47/15)
Operation Left foot operation
Gear ratio
1st 2.833 (34/12)
2nd 1.875 (30/16)
3rd 1.364 (30/22)
4th 1.143 (24/21)
5th 0.957 (22/23)
6th 0.840 (21/25)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
2-7
Shifting mechanism
Shift mechanism type Shift drum and guide bar
Shift fork-L thickness 5.76–5.89 mm (0.2268–0.2319 in)
Shift fork-C, -R thickness 4.76–4.89 mm (0.187–0.193 in) × 2
Decompression device
Device type Auto decomp
Air filter
Air filter element Dry element
Fuel pump
Pump type Electrical
Model 2FB1
Output pressure 250.0 kPa (36.3 psi, 2.50 kgf/cm²)
Fuel injector
Model/quantity 1100–04460/1
Throttle body
Type/quantity AC28/1
ID mark 2PK1 00
Fuel injection sensor

Crankshaft position sensor resistance 248–372 Ω at 20 °C (68 °F)
Intake air pressure sensor output voltage 0.789–4.000 V at 20.00–101.32 kPa
Intake air temperature sensor resistance 2.51–2.78 kΩ at 20 °C (68 °F)
Coolant temperature sensor resistance 210–221 Ω at 80 °C (176 °F)
Idling condition
Engine idling speed 1300–1500 r/min
Water temperature 90.0 °C (194.00 °F) or more
Oil temperature 40.0–60.0 °C (104.00–140.00 °F)
Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)
2-8
CHASSIS SPECIFICATIONS SPEC

CHASSIS SPECIFICATIONS
Chassis
Frame type Diamond
Caster angle 26.00°
Trail 98 mm (3.9 in)
Front wheel
Wheel type Cast wheel
Rim size 17M/C × MT2.15
Rim material Aluminum
Wheel travel 130.0 mm (5.12 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Rear wheel
Wheel type Cast wheel
Rim size 17M/C × MT3.5
Rim material Aluminum
Wheel travel 105.0 mm (4.13 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Front tire
Type Tubeless
Size 90/80-17M/C 46P
Manufacturer/model IRC/NR67D
Wear limit (front) 0.8 mm (0.03 in)
Rear tire
Type Tubeless
Size 130/70-R17 62P
Manufacturer/model IRC/RX-01 R
Wear limit (rear) 1.0 mm (0.04 in)
Tire air pressure (measured on cold tires)

Front 200 kPa (2.00 kgf/cm², 29 psi)
Rear 225 kPa (2.25 kgf/cm², 33 psi)
Front brake
Type Single 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)
Brake disc deflection limit 0.15 mm (0.0059 in)
Brake pad lining thickness (inner) 5.3 mm (0.21 in)
Brake pad lining thickness (outer) 5.3 mm (0.21 in)
2-9

Master cylinder inside diameter 11.00 mm (0.43 in)
Caliper cylinder inside diameter 25.40 mm × 2 (1.00 in × 2)
Recommended fluid DOT 4
Rear brake
Type Single disc brake
Operation Right foot operation
Brake pedal position 44.0 mm (1.73 in)
Rear disc brake
Disc outside diameter × thickness 220.0 × 4.5 mm (8.66–0.18 in)
Brake disc thickness limit 4.0 mm (0.16 in)
Brake disc deflection limit 0.15 mm (0.0059 in)
Brake pad lining thickness (inner) 7.0 mm (0.28 in)
Brake pad lining thickness (outer) 7.0 mm (0.28 in)
Master cylinder inside diameter 12.7 mm (0.50 in)
Caliper cylinder inside diameter 32.00 mm (1.26 in)
Recommended fluid DOT 4
Steering
Steering bearing type Ball and angular bearing
Center to lock angle (left) 35.0°
Center to lock angle (right) 35.0°
No./size of steel balls
(Upper) 16 pcs
(Lower) 16 pcs
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 130.0 mm (5.12 in)
Fork spring free length 384.8 mm (15.15 in)
Limit 377.1 mm (14.85 in)
Collar length 88.0 mm (3.46 in)
Installed length 381.8 mm (15.03 in)
Spring rate K1 5.00 N/mm (0.51 kgf/mm, 28.55 lb/in)
Spring stroke K1 0.0–75.0 mm (0.00–2.95 in)
Inner tube outer diameter 33.0 mm (1.30 in)
Inner tube bending limit 0.2 mm (0.01 in)
Optional spring available No
Recommended oil Fork oil 10W or equivalent
Quantity 240.0 cm3 (8.11 US oz, 8.45 lmp.oz)
Level 126.0 mm (4.96 in)
Rear suspension
Type Swingarm (link suspension)
Spring/shock absorber type Coil spring/oil damper
Rear shock absorber assembly travel 50.0 mm (1.97 in)
2-10

Rear wheel travel 105.0 mm (4.13 in)
Spring free length 167.4 mm (6.59 in)
Installed length 154.8 mm (6.09 in)
Optional spring available No
Drive chain
Type/manufacturer 428VIX/DAIDO
Number of links 132
Drive chain slack 25.0–35.0 mm (0.98–1.38 in)
15-link length limit 191.5 mm (7.54 in)
2-11
ELECTRICAL SPECIFICATIONS SPEC

ELECTRICAL SPECIFICATIONS
Voltage
System voltage 12 V
Ignition system
Ignition system TCI (Transistorized coil ignition)
Advancer type Digital
Ignition timing (B.T.D.C.) 2.0 degree/1400 r/min
TCI
Pickup coil resistance 220–342 Ω
Engine control unit

Model/manufacturer 2PK0/YE
Ignition coil
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 2.16–2.64 Ω at 20 °C (68 °F)
Secondary coil resistance 8.64–12.96 kΩ at 20 °C (68 °F)
Spark plug cap

Material Resin
Resistance 5.0 kΩ
AC magneto
Standard output 14.0 V, 175 W@5000 r/min
Stator coil resistance 0.36–0.54 Ω at 20 °C (68 °F)
Rectifier/regulator
Regulator type Semi conductor-short circuit
Regulated voltage (DC) 14.0–15.0 V
Rectifier capacity (DC) 13.0 A
Battery
Model GTZ4V
Voltage, capacity 12 V, 3.0 Ah
Manufacturer PT. GS BATTERY
Ten hour rate amperage 0.35 A
Headlight
Bulb type Halogen bulb
Bulb voltage, wattage × quantity

Headlight 12 V, 35.0 W/35.0 W × 2
Auxiliary light 12 V, 5.0 W × 2
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 LED
2-12
ELECTRICAL SPECIFICATIONS SPEC
Indicator light
Neutral indicator light LED
Turn signal indicator light LED
High beam indicator light LED
Coolant temperature warning light LED
Fuel injection system warning light LED
Electric starting system

System type Constant mesh
Starter motor
Power output 0.20 kW
Armature coil resistance 0.0315–0.0385 Ω
Brush overall length 7.0 mm (0.28 in)
Limit 3.50 mm (0.14 in)
Brush spring force 3.92–5.88 N (400–600 gf, 14.11–21.17 oz)
Commutator diameter 17.6 mm (0.69 in)
Limit 16.6 mm (0.65 in)
Mica undercut (depth) 1.35 mm (0.05 in)
Starter relay
Amperage 180.0 A
Coil resistance 4.18–4.62 Ω at 20 °C (68 °F)
Horn
Horn type Plane
Quantity 1
Maximum amperage 1.5 A
Coil resistance 3.44–3.64 Ω
Turn signal relay

Relay type Condenser
Built-in, self-canceling device No
Turn signal blinking frequency 70–100 cycles/min
Wattage 10 W × 2 + LED 5mA
Fuel sender unit

Sender unit resistance (full) 10.0–14.0 Ω
Sender unit resistance (empty) 267.0–273.0 Ω
Starting circuit cut-off relay

Coil resistance 54.0–66.0 Ω
Diod Yes
Radiator fan
Running rpm 4800 r/min
Fuse
Main fuse 20.0 A
Spare fuse 20.0 A
2-13
TIGHTENING TORQUES SPEC

TIGHTENING TORQUES
GENERAL TIGHTENING TORQUE
SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch.
Tightening torque specifications for special com-
ponents or assemblies are provided for each
chapter of this manual. To avoid warpage, tight-
en multi-fastener assemblies in a crisscross pat-
tern and progressive stages until the specified
tightening torque is reached. Unless otherwise
specified, tightening torque specifications re-
quire clean, dry threads. Components should be
at room temperature.
A. Distance between flats

B. Outside thread diameter
General tightening
A (nut) B (bolt) torques
Nm m·kg ft·lb
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
2-14

ENGINE TIGHTENING TORQUES
Thread
Item Q’ty Tightening torque Remarks
size
Cylinder head bolt (Inside) M8 4 22 Nm (2.2 m·kg, 16 ft·lb) E
Cylinder head bolt (Chain side) M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) E
Spark plug M10 1 13 Nm (1.3 m·kg, 9.4 ft·lb)

Cylinder head cover bolt M6 5 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil check bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Exhaust pipe stud bolt M8 2 15 Nm (1.5 m·kg, 11 ft·lb)
Coolant drain bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Balancer driven gear nut M10 1 50 Nm (5.0 m·kg, 36 ft·lb)
Valve adjusting screw locknut M5 4 7 Nm (0.7 m·kg, 5.1 ft·lb)
Camshaft sprocket bolt M8 1 30 Nm (3.0 m·kg, 22 ft·lb)
Camshaft retainer bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Timing chain guide (intake side)
M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
bolt
Yamaha
bond
No.1215
Timing chain tensioner bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) (Three
Bond
No.1215
®)
Radiator bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Radiator fan bolt M6 2 8 Nm (0.8 m·kg, 5.8 ft·lb)
Coolant reservoir bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Water pump assembly bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Radiator hose clamp screw M6 4 1.8 Nm (0.18 m·kg, 1.3 ft·lb)
Water pump housing cover bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)
Impeller shaft retainer bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Thermostat cover bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil pump assembly screw M5 2 4 Nm (0.4 m·kg, 2.9 ft·lb)
Engine oil drain plug M35 1 32 Nm (3.2 m·kg, 23 ft·lb)
Oil filter element cover bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil baffle plate bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Intake manifold bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Fuel injector bolt M6 1 12 Nm (1.2 m·kg, 8.7 ft·lb)
Throttle body joint clamp screw M4 2 2 Nm (0.2 m·kg, 1.4 ft·lb)
Air filter case joint clamp screw M4 1 2 Nm (0.2 m·kg, 1.4 ft·lb)
Air filter case bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Resonator bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
2-15

Thread
size
Exhaust pipe nut M8 2 15 Nm (1.5 m·kg, 11 ft·lb)
Muffler bolt M8 2 20 Nm (2.0 m·kg, 14 ft·lb)
Muffler protector bolt M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)
Muffler end cap bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Muffler end cap bracket bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Crankcase bolt M6 13 10 Nm (1.0 m·kg, 7.2 ft·lb)
Generator cover bolt M6 7 10 Nm (1.0 m·kg, 7.2 ft·lb)
Clutch cover bolt M6 10 10 Nm (1.0 m·kg, 7.2 ft·lb)
Drive sprocket cover bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Starter clutch bolt M6 3 14 Nm (1.4 m·kg, 10 ft·lb) Stake.
Primary drive gear nut M12 1 60 Nm (6.0 m·kg, 43 ft·lb)
Clutch spring bolt M6 4 12 Nm (1.2 m·kg, 8.7 ft·lb)
Short clutch push rod locknut M6 1 8 Nm (0.8 m·kg, 5.8 ft·lb)
Clutch boss nut M14 1 70 Nm (7.0 m·kg, 50 ft·lb)
Clutch cable locknut M8 1 9 Nm (0.9 m·kg, 6.5 ft·lb)
Drive sprocket retainer bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Crankcase bearing retainer
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
screw
Shift drum segment screw M6 1 12 Nm (1.2 m·kg, 8.7 ft·lb)
Stopper lever bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Stator coil bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Crankshaft position sensor bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Generator rotor nut M12 1 70 Nm (7.0 m·kg, 50 ft·lb)
Neutral switch M10 1 3.5 Nm (0.35 m·kg, 2.5 ft·lb)
Starter motor bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Coolant temperature sensor M12 1 18 Nm (1.8 m·kg, 13 ft·lb)
O2 Sensor M12 1 25 Nm (2.5 m·kg, 18 ft·lb)
Speed Sensor M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
2-16

Cylinder head tightening sequence:
1 3
5
4 2
Generator cover tightening sequence:

1,6 7
5 8
4 9
3,11 2,10
Clutch cover tightening sequence:
6
1,7 8
9
5 9
4 10
2,12
3,13 11
Crankcase tightening sequence:
A B
15
1,7
8
16
9
6
10
2,13
5
4 11
3,14 12
A. Left crankcase
B. Right crankcase
2-17

CHASSIS TIGHTENING TORQUES
Thread
size
Upper bracket pinch bolt M8 2 21 Nm (2.1 m·kg, 15 ft·lb)
Lower bracket pinch bolt M10 2 28 Nm (2.8 m·kg, 20 ft·lb)
Lower ring nut M25 1 See TIP
Steering stem bolt M10 1 35 Nm (3.5 m·kg, 25 ft·lb)
Handlebar pinch bolt M8 2 23 Nm (2.3 m·kg, 17 ft·lb)
Handlebar bolt M6 2 13 Nm (1.3 m·kg, 9.4 ft·lb)
Front brake master cylinder
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
holder bolt
Throttle cable locknut M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Front upper cowling bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Bottom cowling bolt rear side M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)
Rearview mirror bolt M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)
Number plate bolt M6 2 4 Nm (0.4 m·kg, 2.9 ft·lb)
Meter assembly bracket bolt M8 2 33 Nm (3.3 m·kg, 24 ft·lb)
Front fender bolt (outside) M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Front fender bolt (inner side) M6 2 9 Nm (0.9 m·kg, 6.5 ft·lb)
Front wheel axle nut M12 1 60 Nm (6.0 m·kg, 43 ft·lb)
Front brake hose holder bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Speed sensor lead holder and
M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
front brake hose holder bolt
Front brake caliper bolt M10 2 35 Nm (3.5 m·kg, 25 ft·lb)
Front brake hose union bolt M10 2 30 Nm (3.0 m·kg, 22 ft·lb)
Speedometer cable holder bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Grip end bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Clutch lever holder bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Main switch screw M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Ignition coil bolt M6 2 9 Nm (0.9 m·kg, 6.5 ft·lb)
Engine mounting nut M10 3 49 Nm (4.9 m·kg, 35 ft·lb) E
Muffler bracket bolt M8 2 28 Nm (2.8 m·kg, 20 ft·lb)

Pivot shaft nut M12 1 70 Nm (7.0 m·kg, 50 ft·lb) LS
Rear shock absorber assembly

M10 1 44 Nm (4.4 m·kg, 32 ft·lb) LS
lower nut
M10 1 44 Nm (4.4 m·kg, 32 ft·lb)
upper nut
Relay arm and frame nut M10 1 44 Nm (4.4 m·kg, 32 ft·lb) LS
Connecting arm and relay arm

M10 1 44 Nm (4.4 m·kg, 32 ft·lb) LS
nut
Connecting arm and swingarm
M10 1 44 Nm (4.4 m·kg, 32 ft·lb) LS
nut
2-18

Thread
size
Rear wheel axle nut M14 1 90 Nm (9.0 m·kg, 65 ft·lb) LS
Drive chain case bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Drive chain protector bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Drive chain adjusting locknut M8 2 16 Nm (1.6 m·kg, 11 ft·lb)
Coolant reservoir bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Radiator hose clamp screw M6 4 1.8 Nm (0.18 m·kg, 1.3 ft·lb)
Radiator bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Battery box bolt M6 2 9 Nm (0.9 m·kg, 6.5 ft·lb)
Passenger seat lock nut M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Rider seat bolt M6 2 16 Nm (1.6 m·kg, 11 ft·lb)
Rear fender bolt M6 3 9 Nm (0.9 m·kg, 6.5 ft·lb)
Stay rear fender M6 2 9 Nm (0.9 m·kg, 6.5 ft·lb)
Stay 1 rear fender M4 2 0.4 Nm (0.04 m·kg, 0.29 ft·lb)
License plate light assembly bolt M6 2 9 Nm (0.9 m·kg, 6.5 ft·lb)
Rectifier/regulator bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Side cover bolt M6 6 7 Nm (0.7 m·kg, 5.1 ft·lb)
Fuel tank bracket bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Fuel tank bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)
Fuel pump retainer bolt M5 6 4.0 Nm (0.04 m·kg, 2.9 ft·lb)
Rear cowling bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Rear panel M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Rear brake hose union bolt M10 2 30 Nm (3.0 m·kg, 22 ft·lb)
Rear brake master cylinder bolt M8 2 23 Nm (2.3 m·kg, 17 ft·lb)
Rear brake master cylinder rod
M8 1 17 Nm (1.7 m·kg, 12 ft·lb)
locknut
Brake fluid reservoir bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Footrest plate 1 and plate 2 bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)
Shift arm bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Sidestand nut M10 1 44 Nm (4.4 m·kg, 32 ft·lb)
Rider footrest bracket bolt M10 2 45 Nm (4.5 m·kg, 32 ft·lb)
Passenger footrest bracket bolt M8 4 30 Nm (3.0 m·kg, 22 ft·lb)
Rear footrest hose holder bolt M6 1 11 Nm (1.1 m·kg, 8.0 ft·lb)
Horn bracket bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Front fork cap bolt M30 2 23 Nm (2.3 m·kg, 17 ft·lb)
Damper rod bolt (Front Fork) M10 2 30 Nm (3.0 m·kg, 22 ft·lb)
Brake lever bolt M6 1 6 Nm (0.6 m·kg, 4.3 ft·lb)
Brake lever nut M6 1 6 Nm (0.6 m·kg, 4.3 ft·lb)
2-19

Thread
size
Front brake disc bolt M8 5 23 Nm (2.3 m·kg, 17 ft·lb)
Front brake caliper bleed screw M7 1 6 Nm (0.6 m·kg, 4.3 ft·lb)
Rear wheel sprocket nut M8 6 43 Nm (4.3 m·kg, 31 ft·lb)
Rear brake disc bolt M8 5 23 Nm (2.3 m·kg, 17 ft·lb)
Rear brake caliper pin bolt M8 1 12 Nm (1.2 m·kg, 8.7 ft·lb)
Rear brake pad retaining nut M8 1 22 Nm (2.2 m·kg, 16 ft·lb)
Rear brake pad pin M10 1 17 Nm (1.7 m·kg, 12 ft·lb)
Rear brake caliper bleed screw M8 1 5 Nm (0.5 m·kg, 3.6 ft·lb)
Rear brake light switch bracket
M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
bolt
Upper panel bolt M5 6 1.5 Nm (0.15 m·kg, 1.1 ft·lb)
Front upper cowling bolt (front
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
side)
Front upper cowling bolt (rear
M5 6 1.5 Nm (0.15 m·kg, 1.1 ft·lb)
side)
Front lower cowling bolt (inner
M5 4 1.3 Nm (0.13 m·kg, 0.94 ft·lb)
side)
Front lower cowling bolt (outer
M5 2 1.5 Nm (0.15 m·kg, 1.1 ft·lb)
side)
Bottom cowling bolt (front side) M5 4 1.3 Nm (0.13 m·kg, 0.94 ft·lb)
Front bottom cowling M5 6 1.3 Nm (0.13 m·kg, 0.94 ft·lb)
Headlight and front cowling
M5 4 1.5 Nm (0.15 m·kg, 1.1 ft·lb)
assembly screw
Headlight assembly screw M5 5 0.8 Nm (0.08 m·kg, 0.58 ft·lb)
Meter screw M5 3 1.3 Nm (0.13 m·kg, 0.94 ft·lb)
Windshield screw M5 4 0.4 Nm (0.04 m·kg, 2.9 ft·lb)
Right handlebar switch screw M5 2 2.5 Nm (0.25 m·kg, 1.8 ft·lb)
Left handlebar switch screw M5 2 2.5 Nm (0.25 m·kg, 1.8 ft·lb)
Drive chain seal guard bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Lean angle sensor screw M4 2 0.7 Nm (0.07 m·kg, 0.51 ft·lb)
Passenger seat lock screw M5 2 3.8 Nm (0.8 m·kg, 2.8 ft·lb)
Rear cowling screw M6 2 1.8 Nm (0.18 m·kg, 1.3 ft·lb)
Rear brake pad pin cap M10 1 2.5 Nm (0.25 m·kg, 1.8 ft·lb)
TIP
• First, tighten the lower ring nut to approximately 55 Nm (5.5 m·kg, 40 ft·lb) with a torque wrench,
then loosen the lower ring nut completely.
• Retighten the lower ring nut to 22 Nm (2.2 m·kg, 16 ft ·lb) with a torque wrench.
2-20
LUBRICATION POINTS AND LUBRICANT TYPES SPEC

LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication point Lubricant
Oil seal lips LS
Bearings E
O-rings LS
Cylinder head bolt seats, cylinder head bolt threads and washers E
Water pump seal and impeller shaft LS
Connecting rod big end E
Crankshaft bearing inner surface M
Piston pin E
Cylinder inner surface, piston, ring grooves, and piston rings E
Balancer driven gear inner surface E
Camshaft lobes and camshaft O-ring M
Rocker arm rollers M
Decompression cam E
Valve stems and valve stem seals M
Valve stem ends M
Rocker arm shafts E
Rocker arm inner surface M
Decompression arm pivoting point M
Oil pump driven gear shaft E
Oil pump inner and outer rotor E
Fuel injector O-ring E
Starter clutch gear thrust surfaces and washer E
Starter clutch rollers and starter clutch gear boss E
Starter clutch idle gear shaft and starter clutch idle gear inner surface E
Starter clutch idle gear thrust surfaces and washer E
Clutch push lever E
Clutch plates and friction plates E
Primary driven gear inner surface E
Long clutch push rod E
Short clutch push rod E
Clutch push rod ball E
Clutch boss nut seat and clutch boss nut thread E
Main axle and pinion gears M
2-21

Drive axle and wheel gears M
Shift drum assembly E
Shift forks and shift fork guide bar E
Shift shaft E
Yamaha bond No.

Crankshaft position sensor/stator assembly lead grommet 1215 (Three Bond
No.1215®)
Yamaha bond No.
Crankcase mating surfaces 1215 (Three Bond
No.1215®)
Yamaha bond No.
Timing chain tensioner bolt threads 1215 (Three Bond
No.1215®)
2-22

CHASSIS

Speed sensor unit oil seal lip LS
Front wheel axle outer surface LS
Front wheel oil seal lip LS
Rear wheel axle outer surface LS
Rear wheel axle and nut thread LS
Rear wheel axle nut seat LS
Rear wheel drive hub oil seal lip LS
Rear wheel drive hub mating surface LS
Rear wheel oil seal lip LS
Brake lever pivot bolt outer surface S
Brake lever and master cylinder contact point S
Front brake caliper bracket boots inner surface S
Front brake caliper piston oil seal BF
Front brake caliper dust seal S
Rear brake caliper bracket boots inner surface S
Rear brake caliper piston oil seal BF
Rear brake caliper dust seal S
Rear brake master cylinder boot S
Rear brake master cylinder piston surface BF
Rear brake master cylinder rod and piston contact point S
Tube guide (throttle grip) inner surface and throttle cable LS
Clutch cable end at the clutch lever LS
Clutch lever pivoting point and metal-to-metal moving parts LS
Passenger footrest pivoting point and ball LS
Sidestand pivoting point and metal-to-metal moving parts LS
Sidestand spring-to-hook mating point LS
Shift pedal pivoting point and metal-to-metal moving parts LS
Rear brake pedal pivoting point and metal-to-metal moving parts LS
Steering bearings upper bearing cover lip LS
Steering head dust seal lip LS
Bolt outer surface (relay arm) LS
Nut seats (relay arm and swingarm) LS
2-23

Bolt and nut thread (relay arm and flame) LS
Bolt and nut thread (relay arm and connecting arm) LS
Bolt and nut thread (relay arm and rear shock absorber) LS
Bolt and nut thread (swingarm and connecting arm) LS
Oil seal lips (relay arm and swingarm) LS
Collars (relay arm and swingarm) LS
Pivot shaft outer surface LS
Pivot shaft and nut thread LS
Swingarm bushing outer surface LS
Swingarm dust cover lips LS
Seat lock moving parts LS
Engine mounting bolt threads E
2-24
LUBRICATION SYSTEM DIAGRAMS SPEC

LUBRICATION SYSTEM DIAGRAMS
2-25

1. Clutch push lever
2. Main axle
3. Drive axle
4. Crankshaft
5. Oil filter
6. Oil pump assembly
7. Oil strainer
A. To cylinder head
2-26
2-27

1. Camshaft
2. Crankshaft
2-28
COOLING SYSTEM DIAGRAMS SPEC

COOLING SYSTEM DIAGRAMS
1 2 3
7 5 1
2-29
COOLING SYSTEM DIAGRAMS SPEC

1. Coolant reservoir
2. Radiator inlet hose
3. Coolant reservoir hose
4. Radiator
5. Water pump
6. Radiator outlet hose
7. Water pump breather hose
2-30
CABLE ROUTING SPEC

CABLE ROUTING
18 19
20 23 28
17 27
22 24 26
29
21 25
A–A H–H L
C 6
A 7
1 5
B 2 3 4
H
F
E
G 8
D
C
F
E 9
D
B 0
39
34 37 38
31 40
35
30
36 42
33 41
32
N–N P–P Q
2-31
CABLE ROUTING SPEC

1. Tail assembly lead wire G. Wire lead shall be not put between fender and wire
2. Rectifier regulator assembly harness.
3. Throttle body assembly. H. Put the connected wire in the cover connector.
cover connector shall be assembled to the
4. Throttle cable 1 direction of drawing (The mating face is upturned).
5. Throttle cable 2
6. Pipe 2
7. Throttle cable 1
8. Throttle cable 2
9. Wire harness through guide
10. Rear stop switch
11. Starter motor lead wire
12. Negative battery lead
13. Starter relay lead wire
14. Relay assembly lead wire
15. Joint connector lead wire
16. Switch handle lead wire (Left side)
17. Switch handle lead wire (Right side)
18. Stop switch lead wire
19. Main switch lead wire
20. Cover 1
21. Speed sensor lead wire
22. Frame complete
23. Water temperature sensor lead wire
24. Pipe 2
25. Hose reserve
26. Cover side 2
27. Frame comp.
28. Stop switch assy.
29. Wire harness
30. Frame complete
31. Rear Stop switch lead wire
32. Starter Motor lead wire
33. Frame complete
34. Joint connector Lead wire
35. Rely assy. Lead wire
36. Tail Assy. Lead wire
38. Stop switch lead wire
39. Frame complete
41. Switch handle lead wire (Right side)
A. Clamp joint connector lead wire, Tail assy. Lead

wire to frame complete. Do not cut clamp set tip of
clamp in a under of motorcycle.
B. Set tip of “Clamp hose” in the right side of
motorcycle.
C. Clamp main switch lead wire, Stop switch lead
wire, handle switch lead wire, sensor speed lead
wire and cover 1. cut tip of clamp to be tip of length
5mm max.
D. Rear stop switch lead wire shall be out side of hose
reservoir.
E. Clamp wire harness, starter motor lead wire, rear
stop switch lead wire to frame comp. on white tape
do not cut clamp. set tip of clamp in a upper of
motorcycle.
F. Wire harness must not drop because of under side
of back stay of frame.
2-32
CABLE ROUTING SPEC
1 A 2 B 3 4 C 5
9 8 7
6
10
11
17 12
13
14
F
15
D
16
E
RR.
18
20
21
19 Cla
mp 90
i nt
his
are FR.
a
V–V M
2-33
CABLE ROUTING SPEC

1. Clutch cable
2. Guide, wire
3. Throttle cable 1
4. Throttle cable 2
5. Brake hose 1
6. Switch handle (Right side)
8. Clutch switch lead wire
9. Switch handle (Left side)
11. Clutch cable
12. Left side switch handle lead wire
13. Throttle cable 1
15. Cover radiator
16. Under Bracket
17. Sensor, speed lead wire
18. Rotation stopper
19. Grommet
20. Brake hose
21. Frame comp.
22. Cover radiator
23. Band, switch cord
24. Brake hose
A. Clutch cable, Throttle cable, Switch. handle lead

wire through guide wire.
B. Put throttle cable to outside of clutch cable.
C. Put throttle cable too outside of hose brake 1.
D. Wire Throttle through tunnel of cover, radiator.
E. The grommet of the “Brake hose 1” shall be fitted
between under bracket and holder brake hose.
F. Band switch cord, clamp hose brake to front fork
assy.
2-34
CABLE ROUTING SPEC
4
B 5
6
A
3
7
2
1
8
17 10
16
G C
12
13
15
D
E
11
14
23
24
Protector, wire harness development view
H
19 22
18
20
40
MI
N 21
J U–U
2-35
CABLE ROUTING SPEC

1. Throttle cable 1
2. Throttle cable 2
3. Clutch cable
4. Horn lead wire
5. Fuel hose
6. Fuel tank complete.
7. Fuel pump lead wire
8. Breather hose of tank recovery
9. Fuel drain pipe
10. Band
11. Relay assy.
12. Wire minus lead wire
13. Protector wire harness.
14. Neutral switch lead wire
15. Horn lead wire
16. Frame comp.
17. Guide
18. Hose (Radiator)
19. Clip
20. Horn lead.
21. Frame comp.
22. A Through hole
A. Put switch handle lead wire on front side of front

fork.
B. Clamp wire, throttle 1 and wire, throttle 2 with
clamp to frame.
C. Clamp ACM lead wire, Neutral switch lead wire,
wire minus lead to frame complete. Do not cut
clamp. Set tip of clamp in a backward of
motorcycle.
D. Pass through breather hose of tank, recovery
inside engine bracket.
E. Wire minus lead alongside the positioning pin.
F. Pass through breather hose of tank, recovery and
fuel drain pipe to the slit of guard, mud 1.
G. Clamp horn lead wire to guide on white tape. Do
not cut clamp.
H. Pass through breather hose and fuel drain pipe
inside engine bracket.
2-36
CABLE ROUTING SPEC
31 32
M
N T–T
33
36
26 34
35
27
30
29 28
D 2
3 4
C 5
B E 6 7 8
9
10
F G
A 11 12
1 23
24
22
21
25
20
19 H 14 13
I
16 15
K J 17
L
18
2-37
CABLE ROUTING SPEC

1. Front right turn signal light lead wire A. Fix meter harness, headlight lead wire, front right
2. O2 sensor lead wire turn signal light lead wire with clamp.
B. Clamp rectifier/regulator lead wire to meter
3. Horn lead wire harness lead and headlight lead wire, set tip of
4. Water temperature sensor lead wire clamp in a under motorcycles. Do not cut clamp.
5. Fan motor lead wire C. Fix meter harness, headlight lead wire, front right
6. Fuel pump lead wire turn signal light lead wire with clamp.
7. Injector lead wire D. Pass lead wire of fan motor and O2 sensor through
the hole of cover radiator.
8. Injector assy
E. Insert clamp (wire harness) into frame comp.
9. M.A.Q.S lead wire
F. Fix wire harness with clamp
10. FID lead wire
G. Clamp wire harness to frame comp. Do not cut
11. Wire harness clamp. No slack within the span illustrated by
12. Breather pipe of canister arrows when clamp the wire to the frame.
13. Fuel drain pipe H. Protector, wire harness should be located inside
14. Breather hose of tank, recovery the tank recovery fitting bolt and the wire minus
lead.
15. Fuel hose
I. Clamp ignition coil lead wire to frame comp on
16. Ignition coil lead wire white tape.
17. Ignition coil J. Clamp fuel pump lead wire with bracket coil with
18. Front left turn signal light lead wire clamp.
19. Head light lead wire K. Clamp throttle cable 1 and throttle cable 2 with
20. Meter harness clamp to frame.
21. Rectifier/regulator lead wire L. Fix front left turn signal light lead wire with clamp.
22. Rectifier/regulator assy M. Clamp headlight lead wire to stay 1 on white tape.
Do not cut clamp.
N. Clamp meter harness lead and headlight lead wire
24. Throttle cable 2 and rectifier/regulator lead wire to stay. Do not cut
25. Clutch cable clamp. No slack within the span illustrated by
26. Front left turn signal light lead wire arrows when clamp the wire to the frame.
27. Meter harness
28. Rectifier/regulator lead wire
29. Front right turn signal light lead wire
30. Head light lead wire
32. Stay 1
33. Stay 1
34. Meter harness
36. Rectifier/regulator lead wire
2-38
CABLE ROUTING SPEC
1 4 5 6 A
2 3 7 B
12
16 15 14 9
8
11 10
13
26
25 27
28
R
Hose clamp development view
17 31
19 30
20 32
18 21
24 22 33
29
23
E-E G-G
2-39
CABLE ROUTING SPEC

1. Starter motor lead wire A. Clamp cover connector to frame comp.
2. Wire plus lead B. Service tool lead wire should be located under the
3. Starter relay lead wire cover connector.
4. Starter relay
5. Joint connector lead wire
6. Cover connector
7. Cover connector (wire harness)
8. Rear right turn light signal lead wire
9. Rear left turn light signal lead wire
10. Licence light assy
11. Tail light unit assy lead wire
12. ECU
13. Seat lock wire
16. Wire minus lead
17. Wire plus lead
19. Band
20. Wire plus lead cover
22. Wire minus lead
23. Battery
24. Pad battery
25. Fuel drain pipe
27. Frame comp
28. A through hole
29. Fuel drain pipe
30. Clamp hose
31. Wire harness
32. Frame comp
2-40
CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENT
PERIODIC MAINTENANCE ............................................................................ 3-1

INTRODUCTION ....................................................................................... 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM ................................................................................ 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART ....................... 3-1
ENGINE ........................................................................................................... 3-4

ADJUSTING THE VALVE CLEARANCE .................................................. 3-4
ADJUSTING THE EXHAUST GAS VOLUME ........................................... 3-5
ADJUSTING THE ENGINE IDLING SPEED ............................................. 3-6
ADJUSTING THE THROTTLE GRIP FREE PLAY ................................... 3-8
CHECKING THE SPARK PLUG ............................................................... 3-9
CHECKING THE IGNITION TIMING ......................................................... 3-9
MEASURING THE COMPRESSION PRESSURE .................................. 3-10
CHECKING THE ENGINE OIL LEVEL....................................................3-11
CHANGING THE ENGINE OIL ...............................................................3-12
ADJUSTING THE CLUTCH LEVER FREE PLAY ...................................3-13
CLEANING THE AIR FILTER ELEMENT................................................3-14
CHECKING THE THROTTLE BODY JOINT AND AIR FILTER
CASE JOINT ..........................................................................................3-15
CHECKING THE FUEL LINE .................................................................. 3-15
CHECKING THE CYLINDER HEAD BREATHER HOSE ....................... 3-16
CHECKING THE EXHAUST SYSTEM....................................................3-16
CHECKING THE COOLANT LEVEL....................................................... 3-17
CHECKING THE COOLING SYSTEM ....................................................3-17
CHANGING THE COOLANT................................................................... 3-18
CHASSIS .......................................................................................................3-20
ADJUSTING THE REAR DISC BRAKE ..................................................3-20
CHECKING THE BRAKE FLUID LEVEL................................................. 3-20
CHECKING THE FRONT BRAKE PADS ................................................3-21
CHECKING THE REAR BRAKE PADS ..................................................3-21
CHECKING THE FRONT BRAKE HOSE................................................3-21
CHECKING THE REAR BRAKE HOSE ..................................................3-21
ADJUSTING THE REAR BRAKE LIGHT SWITCH ................................. 3-22
BLEEDING THE HYDRAULIC BRAKE SYSTEM ...................................3-22
ADJUSTING THE DRIVE CHAIN SLACK ............................................... 3-23
LUBRICATING THE DRIVE CHAIN ........................................................ 3-24
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-24
CHECKING THE FRONT FORK .............................................................3-25
CHECKING THE TIRES .......................................................................... 3-26
CHECKING THE WHEELS ..................................................................... 3-27
CHECKING AND LUBRICATING THE CABLES END ............................3-27
CHK
ADJ
LUBRICATING THE CLUTCH LEVER ....................................................3-27
LUBRICATING THE BRAKE LEVER ...................................................... 3-27
LUBRICATING THE PEDALS ................................................................. 3-28
LUBRICATING THE SIDESTAND...........................................................3-28
LUBRICATING THE REAR SUSPENSION............................................. 3-28
ELECTRICAL SYSTEM.................................................................................3-29
CHECKING AND CHARGING THE BATTERY .......................................3-29
CHECKING THE FUSE........................................................................... 3-29
REPLACING THE HEADLIGHT BULBS ................................................. 3-29
ADJUSTING THE HEADLIGHT BEAMS ................................................. 3-29
CHK
PERIODIC MAINTENANCE ADJ
PERIODIC CHECKS AND ADJUSTMENT
PERIODIC MAINTENANCE
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
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

TIP
 The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.
 From 16000 km, repeat the maintenance intervals starting from 4000 km.
 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and tech-
nical skills.
EAU46932
ODOMETER READING (whichever comes first)

1000 km 4000 km 7000 km 10000 km 13000 km ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
or or or or or CHECK
1 month 4 months 7 months 10 months 13 months
• Check fuel hoses for cracks or

1 * Fuel line √ √ √ √ √
damage.
• Check condition.
√ √
2 Spark plug • Clean and regap.
• Replace. √ √
• Check valve clearance.
3 * Valves Every 10000 km (6000 mi)
• Adjust.
4 * Fuel injection • Check engine idle speed. √ √ √ √ √
GENERAL MAINTENANCE AND LUBRICATION CHART

• Clean. √ √ √ √ √ √
1 Air filter element
• Replace. Every 10000 km (6200 mi)
• Check battery voltage.
2 * Battery √ √ √ √ √ √
• Change battery if necessary.
• Check operation.
3 Clutch √ √ √ √ √
• Adjust.
• Check operation, fluid level and
√ √ √ √ √ √
4 * Front brake vehicle for fluid leakage.
• Replace brake pads. Whenever worn to the limit
• Check operation, fluid level and
√ √ √ √ √ √
5 * Rear brake vehicle for fluid leakage.
• Replace brake pads. Whenever worn to the limit
• Check for cracks or damage.
• Check for correct routing and √ √ √ √ √
6 * Brake hose clamping.
• Replace. Every 4 years
7 * Wheels • Check runout and for damage. √ √ √ √
• Check tread depth and for dam-
age.
8 * Tires • Replace if necessary. √ √ √ √ √
• Check air pressure.
• Correct if necessary.
3-1
CHK
• Check bearings for looseness or

9 * Wheel bearings √ √ √ √
damage.
• Check operation and for exces-
√ √ √ √
sive play.
10 * Swingarm
• Lubricate with lithium-soap-
Every 24000 km (14000 mi)
based grease.
• Check chain slack, alignment and
condition.
Every 500 km (300 mi) and after washing the motorcycle, riding in the rain or
11 Drive chain • Adjust and lubricate chain with a
riding in wet areas
special O-ring chain lubricant
thoroughly.
• Check bearing play and steering
√ √ √ √ √
for roughness.
12 * Steering bearings
• Lubricate with lithium-soap-
Every 24000 km (14000 mi)
based grease.
• Make sure that all nuts, bolts and
13 * Chassis fasteners √ √ √ √ √
screws are properly tightened.
Brake lever pivot
14 • Lubricate with silicone grease. √ √ √ √ √
shaft
Brake pedal pivot
shaft
Clutch lever pivot
shaft
Shift pedal pivot • Lubricate with lithium-soap-
17 √ √ √ √ √ √
shaft based grease.
18 Sidestand • Lubricate with lithium-soap- √ √ √ √ √ √
based grease.
• Check operation and for oil leak-
19 * Front fork √ √ √ √
age.
Shock absorber as- • Check operation and shock ab-
20 * √ √ √ √
sembly sorber for oil leakage.
• Change.
21 Engine oil • Check oil level and vehicle for oil √ √ √ √ √ √
leakage.
Engine oil filter ele-
22 • Replace. √ √ √
ment
• Check coolant level and vehicle
√ √ √ √ √
23 * Cooling system for coolant leakage.
• Change coolant. Every 3 years
Front and rear
24 * • Check operation. √ √ √ √ √ √
brake switches
Moving parts and
25 • Lubricate. √ √ √ √ √
cables
• Check throttle grip free play, and
26 * Throttle grip √ √ √ √ √
adjust if necessary.
• Lubricate cable and grip housing.
Lights, signals and • Check operation.
27 * √ √ √ √ √ √
switches • Adjust headlight beam.
3-2
CHK
TIP
 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
 Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder and caliper, and change the brake
fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-3
CHK
ENGINE ADJ
ENGINE Valve clearance (cold)
ADJUSTING THE VALVE CLEARANCE Intake
0.10-0.14 mm (0.0039-0.0055 in)
The following procedure applies to all of the
Exhaust
valves. 0.20-0.24 mm (0.0079-0.0094 in)
TIP
o Valve clearance adjustment should be made on a cold engine, at room temperature.
● Valve clearance adjustment should be made ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

on a cold engine, at room temperature. a. Turn the crankshaft counterclockwise.
● When the valve clearance is to be measured b. Align the “I” mark “a” on the generator rotor
or adjusted, the piston must be at top dead with the stationary pointer “b” on the genera-
center (TDC) on the compression stroke. tor cover.
1. Remove:
• Front cowlings
Refer to “GENERAL CHASSIS” on b
page 4-1.
• Passenger and rider seat
Refer to “GENERAL CHASSIS” on
page 4-1.
• Fuel tank a
Refer to “FUEL TANK” on page 7-1.
2. Disconnect:
c. Check that the cam lobes are positioned as
• Spark plug cap
shown in the illustration.
• Cylinder head cover
• Cylinder head cover gasket
Refer to “CYLINDER HEAD” on page 5-6.
TIP
When removing the cylinder head cover, lift it
out from between the frame tubes.
4. Remove:
• Timing mark accessing screw “1”
• Crankshaft end accessing screw “2”
(With center plug spanner “3”)
d. Measure the valve clearance with a feeler
gauge “1”.
1 Out of specification → Adjust.
Thickness gauge
90843-11002
2
3
5. Measure: 1
• Valve clearance
Out of specification → Adjust.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-4
CHK
ENGINE ADJ
6. Adjust: 7. Install:
• Valve clearance • All removed parts
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “1”. TIP
For installation, reverse the removal procedure.
b. Insert a feeler gauge “2” between the end of
the adjusting screw and the valve tip.
ADJUSTING THE EXHAUST GAS VOLUME
1 TIP
Be sure to set the CO density level to standard,
and then adjust the exhaust gas volume.
2 1. Remove:
page 4-1.
2. Set the main switch to “OFF”.
c. Turn the adjusting screw “3” in direction “a” 3. Disconnect:
or “b” until the specified valve clearance is • Self-diagnosis signal connector “1”
obtained. 4. Connect:
Direction “a” • FI diagnostic tool “2” to self-diagnosis sig-
Valve clearance is increased. nal connector.
Direction “b”
Valve clearance is decreased. FI diagnostic tool
90890-03215
Tappet adjusting tool

90890-01311
Six piece tappet set 2
YM-A5970
a
3 b 3
1
5. While pressing the “MODE” button “1”, turn
the main switch to “ON”.
TIP
● “DIAG” appears on the LCD “2” of the FI
d. Hold the adjusting screw to prevent it from diagnostic tool.
moving and tighten the locknut to specifica- ● “POWER” LED (Green) “3” comes on.
tion.
Valve adjusting screw locknut
7 Nm (0.7 m·kg, 5.1 ft·lb)
T.
R.
e. Measure the valve clearance again.

f. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance adjust-
ment steps until the specified clearance is
obtained.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-5
CHK
ENGINE ADJ
6. Press the “UP” button “4” to select the CO 15.Install:
adjustment mode “CO” or the diagnostic • Passenger and rider seat
mode “DIAG”. Refer to “GENERAL CHASSIS” on
page 4-1.
3 ADJUSTING THE ENGINE IDLING SPEED
FI Diagnostic Tool
2 TIP
DIAG Prior to adjusting the engine idling speed, the
air filter element should be clean, and the
engine should have adequate compression.
4 1
1. Start the engine and let it warm up for sev-
eral minutes.
7. After selecting “CO”, press the “MODE” but- 2. Remove:
ton. • Passenger and rider seat
8. Check that “C1” appears on the LCD of the Refer to “GENERAL CHASSIS” on
FI diagnostic tool, and then press the page 4-1.
“MODE” button.
3. Set the main switch to “OFF”.
9. Start the engine.
4. Disconnect:
NOTICE • Self-diagnosis signal connector “1”
Perform the adjustment after the battery has
been sufficiently charged.
1
FI Diagnostic Tool
1400rpm
C1 : -10
10.Change the CO adjustment volume by 5. Connect:

pressing the “UP” and “DOWN” buttons. • FI diagnostic tool wire “1” to Self-diagnosis
signal connector “2” coupler.
TIP
The CO adjustment volume and engine idling FI diagnostic tool
speed appears on the LCD of the FI diagnostic 90890-03215
tool.
● To decrease the CO adjustment volume,
press the “DOWN” button. 2

● To increase the CO adjustment volume,
press the “UP” button.

FI Diagnostic
POWER
11.Release the “DOWN” and “UP” buttons to

Warning
Tool
execute the selection.

12.Set the main switch to “OFF” to cancel the
mode.
13.Disconnect:
• FI diagnostic tool 1
14.Connect:
• Self-diagnosis signal connector
3-6
CHK
ENGINE ADJ
6. Attach positive terminal clip “1” of diagnostic
tool “2” to positive of battery and negative
terminal clip “3” of diagnostic tool to negative
of battery.
NOTICE
Ensure the connection is made only when
the main switch is in OFF position.
(a) (b)
2 TIP
Preferably set the RPM on lower side of specifi-
1 cation.
Engine RPM
3 1400 rpm
WARNING
7. Start the engine and diagnostic tool will show
the RPM of engine and coolant temperature. Never adjust RPM by Screw at Pulley “1”
Engine RPM Coolant Temp
FI Diagnostic Tool
0
1350rpm 90 C
NOTICE
9. After adjusting the RPM to specification stop
Check the RPM when coolant temp is at the engine.
90°C. 10.Disconnect:
• FI disconnect tool wire “1”
Engine idling speed
1300-1500 r/min
1
8. If RPM is not as per specification then adjust
through idle RPM adjusting Screw.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the RPM adjusting screw “1” in direction
“a” or “b” until the specified engine idling speed
is obtained.
Direction “a”
Engine idling speed is increased.
Direction “b”
Engine idling speed is decreased.
3-7
CHK
ENGINE ADJ
11.Connect: 3. Lift the fuel tank. (Do not disconnect the fuel
• Self-diagnosis signal connector “1” hose and fuel pump coupler.)
4. Adjust:
1 • Throttle grip free play (at the end of the
throttle grip)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Throttle body end
a. Loosen the locknut “1” on the throttle cable.
b. Turn the adjusting nut “2” in direction “a” or
9
“b” until the specified throttle grip free play is

obtained.
Direction “a”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Throttle grip free play is increased.
12.Install: Direction “b”
• Passenger and rider seat Throttle grip free play is decreased.
page 4-1.
13.Adjust:
• Throttle grip free play
Refer to “ADJUSTING THE THROTTLE
GRIP FREE PLAY” on page 3-8.
Throttle grip free play (at the 1
(b)
inner edge of the throttle grip)
3.0-5.0 mm (0.12-0.20 in)
(a)
ADJUSTING THE THROTTLE GRIP FREE 2
PLAY c. Tighten the locknut.
TIP
Throttle cable locknut
Prior to adjusting the throttle grip free play, the 7 Nm (0.7 m·kg, 5.1 ft·lb)
engine idling speed should be adjusted.
T.
R.
TIP
1. Check:
If the specified throttle grip free play cannot be
• Throttle grip free play “a”
obtained on the throttle body end of the cable,
use the adjusting nut on the handlebar end.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Handlebar end
a. Slide back the rubber cover “1” at the throttle
a cable.
b. Loosen the locknut “2”.
c. Turn the adjusting nut “3” in direction “a” or
“b” until the specified throttle grip free play is
obtained.
Throttle grip free play (at the
inner edge of the throttle grip) Direction “a”
3.0-5.0 mm (0.12-0.20 in) Throttle grip free play is increased.
Direction “b”
2. Remove: Throttle grip free play is decreased.
• Right side cover
page 4-1.
3-8
CHK
ENGINE ADJ
5. Check:
• Electrodes “1”
Damage/wear → Replace the spark plug.
• Insulator “2”
Abnormal color → Replace the spark plug.
(a) Normal color is medium-to-light tan.
6. Clean:
• Spark plug
(with a spark plug cleaner or wire brush)
2 3
(b) 1 7. Measure:
d. Tighten the locknut. • Spark plug gap “a”
e. Slide the rubber cover to its original position. (with a wire thickness gauge)
Out of specification → Regap.
WARNING
Spark plug gap
After adjusting the throttle grip free play,
0.7-0.8 mm (0.028-0.031 in)
start the engine and turn the handlebar to
the right or left to ensure that this does not
cause the engine idling speed to change.
5. Install:
• Fuel tank
Refer to “FUEL TANK” on page 7-1. 2
6. Install:
• Right side covers 1
page 4-1. 8. Install:
• Spark plug
CHECKING THE SPARK PLUG
1. Remove: Spark plug
• Right front cowlings 13 Nm (1.3 m·kg, 9.4 ft·lb)
T.
R.

TIP
page 4-1.
Before installing the spark plug, clean the spark
2. Disconnect: and gasket surface.
• Spark plug cap
3. Remove: 9. Connect:
• Spark plug • Spark plug cap
10.Install:
NOTICE
• Right front cowlings
Before removing the spark plug, blow away Refer to “GENERAL CHASSIS” on
any dirt accumulated in the spark plug well page 4-1.
with compressed air to prevent it from fall-
ing into the cylinder. CHECKING THE IGNITION TIMING
4. Check: TIP
• Spark plug type Prior to checking the ignition timing, check the
Incorrect → Change. wiring connections of the entire ignition system.
Make sure all connections are tight and free of
Manufacturer/model corrosion.
NGK/CR9E
1. Remove:
page 4-1.
3-9
CHK
ENGINE ADJ
2. Remove: 6. Remove:
• Timing mark accessing screw “1” • Digital tachometer
3. Lift the fuel tank. (Do not disconnect the fuel • Timing light
hose and fuel pump coupler.) 7. Install:
Refer to “FUEL TANK” on page 7-1. • Fuel tank
4. Connect: Refer to “FUEL TANK” on page 7-1.
• Timing light “1” 8. Install:
• Digital tachometer • Timing mark accessing screw
Timing light 9. Install:
90843-08H09 • Passenger and rider seat
page 4-1.
MEASURING THE COMPRESSION

PRESSURE
TIP
Insufficient compression pressure will result in a
loss of performance.
1
1. Measure:
• Valve clearance
5. Check: Refer to “ADJUSTING THE VALVE
• Ignition timing CLEARANCE” on page 3-4.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2. Start the engine, warm it up for several min-
a. Start the engine, warm it up for several minutes, and then turn it off.
utes, and then let it run at the specified
engine idling speed. 3. Remove:
Engine idling speed Refer to “GENERAL CHASSIS” on
1300-1500 r/min page 4-1.
b. Check that the stationary pointer “a” on the Refer to “GENERAL CHASSIS” on
generator cover is within the firing range “b” page 4-1.
on the generator rotor.
4. Disconnect:
Incorrect firing range → Check the ignition
system. • Spark plug cap “1”
a
1
b
5. Remove:
TIP
• Spark plug
The ignition timing is not adjustable.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-10
CHK
ENGINE ADJ
NOTICE d. If the compression pressure is below the
minimum specification, pour a teaspoonful of
Before removing the spark plug, use com-
engine oil into the spark plug bore and mea-
pressed air to blow away any dirt accumu-
sure again.
lated in the spark plug well to prevent it from
Refer to the following table.
falling into the cylinder.
Compression pressure (with oil applied into
6. Install: the cylinder)
• Extension “1”
Reading Diagnosis
• Compression gauge “2”
Higher than without Piston ring(s) wear or
Compression gauge oil damage → Repair.
90890-03081 Piston, valves,
cylinder head gasket
Same as without oil
2 or piston possibly
defective → Repair.
1 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Remove:
• Compression gauge
• Extension
9. Install:
• Spark plug
Spark plug
7. Measure: 13 Nm (1.3 m·kg, 9.4 ft·lb)
• Compression pressure
T.
R.
Out of specification → Refer to steps (c) 10.Connect:

and (d). • Spark plug cap
Standard compression pressure 11.Install:
(at sea level) • Right front cowlings
1350 kPa (13.5 kg/cm ², 192 psi) Refer to “GENERAL CHASSIS” on
Minimum-maximum page 4-1.
1170 -1510 kPa (11.7 -15.1 kg/cm², • Passenger and rider seat
116 -216 psi) Refer to “GENERAL CHASSIS” on
page 4-1.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “ON”. CHECKING THE ENGINE OIL LEVEL
b. With the throttle wide open, crank the engine 1. Stand the vehicle on a level surface.
until the reading on the compression gauge TIP
stabilizes. TIP
● Place the vehicle on a suitable stand.

c. If the compression pressure is above the ● Make sure the vehicle is upright.
maximum specification, check the cylinder
head, valve surfaces and piston crown for 2. Start the engine, warm it up for several min-
carbon deposits. utes, and then turn it off.
Carbon deposits → Eliminate. 3. Check:
• Engine oil level
The engine oil level should be between the
minimum level mark “a” and maximum
level mark “b”.
Below the minimum level mark → Add the
recommended engine oil to the proper
level.
3-11
CHK
ENGINE ADJ
TIP
TIP
4. Remove:
● Before checking the engine oil level, wait a • Engine oil filler cap (dipstick) “1”
few minutes until the oil has settled. • Engine oil drain plug “2”
● Do not screw the engine oil filler cap (dip- • O-ring “3”
stick) “1” in when checking the oil level. • Spring “4”
• Engine oil strainer “5”
1 NOTICE
NOTICE
• When removing the engine oil drain bolt,

the O-ring, compression spring, and oil
strainer will fall out. Take care not to lose
these parts.
b
a
Type
SAE 20W-40 or 20W-50 1
Recommended engine oil grade
API service SE type or higher,
JASO standard MA
NOTICE
• Engine oil also lubricates the clutch and
the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives or use engine
oils with a grade of “CD” or higher and do
not use oils labeled “ENERGY CONSERV- 5
4
ING II”.
• Do not allow foreign materials to enter the 3
2
crankcase. 2
4. Start the engine, warm it up for several min- a
utes, and then turn it off. 5. Drain:
5. Check the engine oil level again. • Engine oil
TIP
(completely from the crankcase)
Before checking the engine oil level, wait a few 6. If the oil filter element is also to be replaced,
minutes until the oil has settled. perform the following procedure.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHANGING THE ENGINE OIL a. Remove the oil filter element cover “1” by
removing the bolts “2”.
1. Remove:
• Bottom cowlings
1
page 4-1. 2
utes, and then turn it off.
3. Place a oil pan “a” under the engine oil drain
bolt to collect the used oil.
3-12
CHK
ENGINE ADJ
b. Remove and replace the oil filter element “3” 13. Check:
and new O-ring “4”. • Engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL” on page 3-11.
New 3
14. Check:
• Engine oil pressure
New 4
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slightly loosen the oil check bolt “1”.
c. Install the oil filter element cover by installing

the bolts, then tightening them to the speci-
fied torque.
Oil filter element cover bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
1
R.
TIP
Make sure that the O-ring is properly seated. b. Start the engine and keep it idling until
engine oil starts to seep from the oil check
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ bolt. If no engine oil comes out after one
7. Check: minute, turn the engine off so that it will not
• Engine oil strainer seize.
Dirt → Clean. c. Check the engine oil passages, the oil filter
element and the oil pump for damage or
8. Install: leakage.
• Engine oil strainer
• Spring d. Start the engine after solving the problem(s)
and check the engine oil pressure again.
• O-ring New
• Engine oil drain plug e. Tighten the oil check bolt to specification.
Engine oil drain plug Oil check bolt

32 Nm (3.2 m·kg, 23 ft·lb) 7 Nm (0.7 m·kg, 5.1 ft·lb)
T.
R.
T.
R.
9. Fill: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Crankcase 15.Install:
(with the specified amount of the recom- • Bottom cowlings
mended engine oil) • Right front cowlings
Engine oil quantity page 4-1
Total amount
1.15 L (1.22 US qt, 1.01 Imp.qt) ADJUSTING THE CLUTCH LEVER FREE
Without oil filter element
PLAY
replacement
0.95 L (1.00 US qt, 0.84 Imp.qt) 1. Check:
With oil filter element replace- • Clutch lever free play “a”
ment Out of specification → Adjust.
1.00 L (1.06 US qt, 0.88 Imp.qt)
Clutch lever free play
10.Install: 10.0-15.0 mm (0.39-0.59 in)
• Engine oil filler cap (dipstick)
12. Check:
• Engine
(for engine oil leaks)
3-13
CHK
ENGINE ADJ
1
a (a)
(b)
2
2. Adjust:
• Clutch lever free play
c. Tighten the locknut at the crankcase.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Handlebar end
CLEANING THE AIR FILTER ELEMENT
a. Slide back the rubber cover “1” at the clutch
TIP
lever.
There is a check hose “1” at the bottom of the
b. Loosen the locknut “2”. air filter case. If dust and/or water collects in this
c. Turn the adjusting bolt “3” in direction “a” or hose, clean the air filter element and air filter
“b” until the specified clutch lever free play is case.
obtained.
Direction “a”
Clutch lever free play is increased.
Direction “b”
Clutch lever free play is decreased.
1
1
3
2 (a)
1. Remove:
page 4-1.
(b) 2. Remove:
• Fuel tank
3. Remove:
d. Tighten the locknut. • Air filter case cover “1” by removing the
e. Slide the rubber cover to its original position. screw “2” and then pull the air filter ele-
ment “3”
TIP
If the specified clutch lever free play cannot be 3
obtained on the handlebar end of the cable, use
the adjusting nut on the engine end.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Engine end
a. Loosen the locknut “1” at the crankcase.
b. Turn the adjusting nut “2” in direction “a” or
“b” until the specified clutch lever free play is 3
obtained.
Direction “a”
Clutch lever free play is increased.
Direction “b”
Clutch lever free play is decreased.
3-14
CHK
ENGINE ADJ
4. Lightly tap the air filter element to remove the • Right side cover
most of the dust and dirt. Refer to “GENERAL CHASSIS” on
5. Clean: page 4-1.
• Air filter element “1” 2. Check:
Apply compressed air to the inner side of • Throttle body joint “1”
the air filter element. • Air filter case joint “2”
Cracks/damage → Replace.
1
6. Check:
• Air filter element
Damage → Replace.
3. Install:
7. Install: • Right side cover
• Air filter element Refer to “GENERAL CHASSIS” on
• Air filter case cover by installing the screws page 4-1.
(along with the gaskets) • Front cowlings
NOTICE page 4-1.
Never operate the engine without the air fil- • Passenger and rider seat
ter element installed. Unfiltered air will Refer to “GENERAL CHASSIS” on
cause rapid wear of engine parts and may page 4-1.
damage the engine. Operating the engine
CHECKING THE FUEL LINE
without the air filter element will also affect
throttle body tuning, leading to poor engine 1. Remove:
performance and possible overheating. • Passenger and rider seat
TIP page 4-1.
• Fuel tank
When installing the air filter element into the air
filter case cover make sure the air filter element
is properly installed in the air filter case to pre- 2. Check:
vent any air leaks. • Fuel hose “1”
8. Install: Loose connection → Connect properly.
• Fuel tank
• Passenger and rider seat 1
page 4-1.
CHECKING THE THROTTLE BODY JOINT

AND AIR FILTER CASE JOINT
1. Remove:
• Passenger and rider seat TIP
Refer to “GENERAL CHASSIS” on Before removing the fuel hose, place a few regs
page 4-1. in the area under where it will be removed.
• Front cowlings
page 4-1.
3-15
CHK
ENGINE ADJ
3. Install: CHECKING THE EXHAUST SYSTEM
• Fuel tank 1. Check:
Refer to “FUEL TANK” on page 7-1. • Muffler “1”
• Passenger and rider seat Cracks/damage → Replace.
Refer to “GENERAL CHASSIS” on • Exhaust pipe gasket “2”
page 4-1.
Exhaust gas leaks → Replace.
CHECKING THE CYLINDER HEAD 2. Check:
BREATHER HOSE Tightening torque
1. Remove: • Muffler nuts “3”
• Passenger and rider seat • Muffler bolts “4'”
Refer to “GENERAL CHASSIS” on Muffler nut
page 4-1. 15 Nm (1.5 m·kg, 11 ft·lb)
• Left front cowlings
T.
R.
Muffler bolt
Refer to “GENERAL CHASSIS” on 20 Nm (2.0 m·kg, 14 ft·lb)
page 4-1.
• Left side cover
page 4-1.
• Fuel tank
2. Check: 2 (2)
4
• Cylinder head breather hose “1”
Loose connection → Connect properly.
NOTICE 1
Make sure the cylinder head breather hose
is routed correctly. CHECKING THE COOLANT LEVEL
1. Stand the vehicle on a level surface.
TIP TIP
● Place the vehicle on a suitable stand.

1
● Make sure the vehicle is upright position.
2. Check:
• Coolant level in the coolant reservoir
The coolant level should be between the
maximum level mark “a” and minimum
level mark “b”.
3. Install: Below the minimum level mark → Add the
• Fuel tank recommended coolant to the proper level.
Refer to “FUEL TANK” on page 7-1. TIP
• Left side cover
TIP
To access the coolant reservoir cap “1”, remove

Refer to “GENERAL CHASSIS” on the left side cover. Refer to “GENERAL CHAS-
page 4-1.
SIS” on page 4-1.
page 4-1.
page 4-1.
3-16
CHK
ENGINE ADJ
2. Check:
• Radiator “1”
a • Radiator inlet hose “2”
• Radiator outlet hose “3”
b • Coolant reservoir hose “4”
• Water pump breather hose “5”
Refer to “RADIATOR” on page 6-1.
4
1 1 5
3
WARNING 2
Remove only the coolant reservoir cap,
never attempt to remove the radiator cap 3. Install:
when the engine the hot. • Left front cowlings
NOTICE
page 4-1.
NOTICE
• Left side cover
• Adding water instead of coolant lowers the Refer to “GENERAL CHASSIS” on
antifreeze content of the coolant. If water page 4-1.
is used instead of coolant, check and, if • Passenger and rider seat
necessary, correct the antifreeze concen- Refer to “GENERAL CHASSIS” on
tration of the coolant. page 4-1.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
4. Check:
• Coolant level
TIP
TIP
Before checking the coolant level, wait a few

minutes until it settles.
CHECKING THE COOLING SYSTEM

1. Remove:
page 4-1.
• Left side cover
page 4-1.
page 4-1.
3-17
CHK
ADJ
CHANGING THE COOLANT • Coolant reservoir cap “3”
1. Remove:
• Right front cowlings. 3
page 4-1.
2. Remove: 2
• Radiator cap “1”
1
1
7. Drain:
• Coolant
(from the coolant reservoir)
8. Install:
• Coolant reservoir
9. Connect:
WARNING • Coolant reservoir hose
A hot radiator is under pressure. Therefore, 10.Install:
do not remove the radiator cap when the • Coolant drain bolt “1”
engine is hot. Scalding hot fluid and steam (along with the copper washer “2” New )
may be blown out, which could cause seri-
ous injury. When the engine has cooled, 2
open the radiator cap as follows:
1
Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap coun-
terclockwise toward the detent to allow any
residual pressure to escape. When the hiss-
ing sound has stopped, press down on the
radiator cap and turn it counterclockwise to Coolant drain bolt
7 Nm (0.7 m·Kg, 5.1 ft·lb)
remove.
T.
R.
3. Remove: 11.Fill:
• Coolant drain bolt “1” • Cooling system
(along with the copper washer) (with the specified amount of the recom-
mended coolant)
Recommended antifreeze
High-quality ethylene glycol
1
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Radiator capacity (including all
routes)
0.59 L (0.62 US qt, 0.52 Imp.qt)
4. Drain: Radiator capacity
• Coolant 0.38 L (0.40 US qt, 0.33 Imp.qt)
(from the engine and radiator) Coolant reservoir capacity (up
5. Disconnect: to the maximum level mark)
• Coolant reservoir hose “1” 0.25 L (0.26 US qt, 0.22 Imp.qt)
6. Remove:
• Coolant reservoir “2”
3-18
CHK
ENGINE ADJ
Handling notes for coolant 17.Install:
Coolant is potentially harmful and should be • Right front cowlings
handled with special care. Refer to “GENERAL CHASSIS” on
page 4-1.
WARNING
• If coolant splashes in your eyes, thor-
oughly wash them with water and consult
a doctor.
• If coolant splashes on your clothes,
quickly wash it away with water and then
with soap and water.
• If coolant is swallowed, induce vomiting
and get immediate medical attention.
NOTICE
NOTICE
• Adding water instead of coolant lowers the

antifreeze content of the coolant. If water
is used instead of coolant, check and, if
necessary, correct the antifreeze concen-
tration of the coolant.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
• If coolant comes into contact with painted
surfaces, immediately wash them with
water.
• Do not mix different types of antifreeze.
12.Install:
• Radiator cap
13.Fill:
• Coolant reservoir
(with the recommended coolant to the
maximum level mark “a”)
14.Install:
• Coolant reservoir cap
15.Start the engine, warm it up for several min-
16.Check:
• Coolant level
Refer to “CHECKING THE COOLANT
LEVEL” on page 3-16.
TIP
Before checking the coolant level, wait a few
minutes until the coolant has settled.
3-19
CHK
CHASSIS ADJ
CHASSIS WARNING
ADJUSTING THE REAR DISC BRAKE A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
1. Check:
system. Before the vehicle is operated, the
• Brake pedal position air must be removed by bleeding the brake
(distance “a” from the center of the rider system. Air in the brake system will consid-
footrest to the center of the brake pedal) erably reduce braking performance.
NOTICE
Brake pedal position
44.0 mm (1.73 in) After adjusting the brake pedal position,
make sure there is no brake drag.
e. Install the pin, washer, and cotter pin.

WARNING
Always use a new cotter pin.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a
3. Adjust:
• Brake light switch
Refer to “ADJUSTING THE REAR BRAKE
2. Adjust: LIGHT SWITCH” on page 3-22.
• Brake pedal position CHECKING THE BRAKE FLUID LEVEL
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1. Stand the vehicle on a level surface.
a. Loosen the locknut “1”.
b. Remove the cotter pin “2”, washer “3”, and TIP
pin “4”. ● Place the vehicle on a suitable stand.
c. Turn the adjusting nut “5” in direction “a” or ● Make sure the vehicle is upright.
“b” until the specified brake pedal position is
obtained. 2. Check:
• Brake fluid level
Direction “a” Below the minimum level mark “a” → Add
Brake pedal is raised. the recommended brake fluid to the proper
Direction “b” level.
Brake pedal is lowered.
Recommended fluid
DOT 4
a b a
1
5
3
4
2
d. Tighten the locknut to specification. B
Locknut
17 Nm (1.7 m·kg, 12 ft·lb)
T.
R.
UPPER
LOW ER a
A. Front brake
B. Rear brake
3-20
CHK
CHASSIS ADJ
WARNING CHECKING THE FRONT BRAKE HOSE
WARNING
• Use only the designated brake fluid. Other 1. Check:

brake fluids may cause the rubber seals to • Brake hose “1”
deteriorate, causing leakage and poor Cracks/damage/wear → Replace.
brake performance. 2. Check:
• Refill with the same type of brake fluid that • Front brake hose holder “2”
is already in the system. Mixing brake flu- Loose connection → Tighten the holder
ids may result in a harmful chemical reac- bolt.
tion, leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water Lowe
r
will significantly lower the boiling point of

the brake fluid and could cause vapor lock.
NOTICE
1
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately. 2
TIP 3. Hold the vehicle upright and apply the front
In order to ensure a correct reading of the brake brake several times.
fluid level, make sure the top of the brake fluid 4. Check:
reservoir is horizontal. • Brake hose
Brake fluid leakage → Replace the dam-
CHECKING THE FRONT BRAKE PADS aged hose.
The following procedure applies to all of the Refer to “FRONT BRAKE” on page 4-18.
brake pads.
1. Operate the brake. CHECKING THE REAR BRAKE HOSE
2. Check: 1. Check:
• Front brake pad • Brake hoses “1”
Wear indicator grooves “a” have almost Cracks/damage/wear → Replace.
disappeared → Replace the brake pads as 2. Check:
a set. • Rear brake hose holder “2”
Refer to “FRONT BRAKE” on page 4-18.
Loose connection → Tighten the holder
a bolt.
Loose or open holder → Fasten properly.
1 UP
PE
R
LO
WE
R
CHECKING THE REAR BRAKE PADS

brake pads.
1. Operate the brake.
2. Check:
• Rear brake pad
Wear indicator groove “a” has almost disap- 2
peared → Replace the brake pads as a set. 3. Hold the vehicle upright and apply the rear
Refer to “REAR BRAKE” on page 4-30. brake several times.
a 4. Check:
• Brake hoses
Brake fluid leakage → Replace the dam-
aged hose.
Refer to “REAR BRAKE” on page 4-30.
3-21
CHK
CHASSIS ADJ
ADJUSTING THE REAR BRAKE LIGHT ● When bleeding the hydraulic brake system,
SWITCH make sure there is always enough brake
TIP fluid before applying the brake. Ignoring this
The rear brake light switch is operated by precaution could allow air to enter the
movement of the brake pedal. The rear brake hydraulic brake system, considerably length-
light switch is properly adjusted when the brake ening the bleeding procedure.
light comes on just before the braking effect ● If bleeding is difficult, it may be necessary to
starts. let the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
1. Check: bubbles in the hose have disappeared.
• Rear brake light operation timing
Incorrect → Adjust. 1. Bleed:
2. Adjust: • Hydraulic brake system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Rear brake light operation timing
a. Fill the brake fluid reservoir to the proper
a. Hold the main body “1” of the rear brake light level with the recommended brake fluid.
switch so that it does not rotate and turn the b. Install the diaphragm (brake master cylinder
adjusting nut “2” in direction “a” or “b” until reservoir or brake fluid reservoir).
the rear brake light comes on at the proper
c. Connect a clear plastic hose “1” tightly to the
time.
bleed screw “2”.
Direction “a”
Brake light comes on sooner. A
Direction “b”
Brake light comes on later.
2
1
1
b
a
A. Front
B. Rear
2
d. Place the other end of the hose into a con-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ tainer.
e. Slowly apply the brake several times.
BLEEDING THE HYDRAULIC BRAKE
f. Fully pull the brake lever or fully press down
SYSTEM
the brake pedal and hold it in position.
WARNING g. Loosen the bleed screw.
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.
• brake operation is faulty.
TIP
TIP
● Be careful not to spill any brake fluid or allow

the brake master cylinder reservoir or brake
fluid reservoir to overflow.
3-22
CHK
CHASSIS ADJ
TIP 3. Check:
Loosening the bleed screw will release the • Drive chain slack “a”
pressure and cause the brake lever to contact Out of specification → Adjust.
the throttle grip or the brake pedal to fully
extend.
h. Tighten the bleed screw and then release

the brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air bub-
bles have disappeared from the brake fluid in
the plastic hose.
j. Tighten the bleed screw to specification.
Front brake caliper bleed screw
6 Nm (0.6 m·kg, 4.3 ft·lb) Drive chain slack
T.
25.0–35.0 mm (0.98–1.37 in)

R.
Rear brake caliper bleed screw

5 Nm (0.5 m·kg, 3.6 ft·lb)
TIP
k. Fill the brake fluid reservoir to the proper Measure the drive chain slack halfway between
level with the recommended brake fluid. the drive axle and the rear wheel axle.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-20. 4. Adjust:
• Drive chain slack
WARNING
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
After bleeding the hydraulic brake system, a. Loosen the axle nut “1”and the drive chain
check the brake operation. slack adjusting locknut “2” on each side of
the swingarm.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ADJUSTING THE DRIVE CHAIN SLACK

2
TIP
The drive chain slack must be checked at the
tightest point on the chain.
1
NOTICE
A drive chain that is too tight will overload
the engine and other vital parts, and one
b. To tighten the drive chain, turn the drive
that is too loose can skip and damage the chain slack adjusting bolt “1” on each side of
swingarm or cause an accident. Therefore, the swingarm in direction “a”. To loosen the
keep the drive chain slack within the speci- drive chain, turn the adjusting bolt on each
fied limits. side of the swingarm in direction “b”, and
then push the rear wheel forward.
WARNING 1 3
(b)
Securely support the vehicle so that there is
no danger of it falling over.
TIP
Both wheels should be on the ground without a (a)
2
rider on the vehicle.
2. Turn the rear wheel several times and find

the tightest position on the drive chain.
3-23
CHK
CHASSIS ADJ
NOTICE CHECKING AND ADJUSTING THE
STEERING HEAD
Improper drive chain slack will overload the
engine as well as other vital parts of the 1. Stand the vehicle on a level surface.
motorcycle and can lead to chain slippage WARNING
or breakage.
Securely support the vehicle so that there is
To prevent this from occurring, keep the
no danger of it falling over.
drive chain slack within the specified limits.
TIP
TIP
Place the vehicle on a suitable stand so that the
Using the alignment marks “2” on each side of
front wheel is elevated.
the swingarm, make sure that both drive chain
pullers are in the same position for proper wheel 2. Check:
alignment. • Steering head
Grasp the bottom of the front fork legs and
c. Tighten the axle nut, then the drive chain gently rock the front fork.
slack adjuster locknuts “3” to their specified Binding/looseness → Adjust the steering
torques. head.
Tightening torques:
Axle nut:
90 Nm (9.0 m·kgf, 65 ft·lbf)
Locknut:
16 Nm (1.6 m·kgf, 11 ft·lbf)
d. Make sure that the drive chain pullers are in

the same position, the drive chain slack is
correct, and the drive chain moves smoothly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Remove:
LUBRICATING THE DRIVE CHAIN • Upper bracket
The drive chain consists of many interacting Refer to “STEERING HEAD” on page 4-54.
parts. If the drive chain is not maintained prop- 4. Adjust:
erly, it will wear out quickly. Therefore, the drive • Steering head
chain should be serviced, especially when the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
vehicle is used in dusty areas. a. Remove the lock washer “1”, the upper ring
This vehicle has a drive chain with small rubber nut “2”, and the rubber washer “3”.
O-rings between each side plate. Steam clean-
ing, high-pressure washing, certain solvents,
and the use of a coarse brush can damage
these O-rings. Therefore, use only chain clean-
ing solvent to the drive chain and thoroughly
lubricate it with chain lubricant that is suitable
for O-ring chains.
Do not use any other lubricants on the drive
chain since they may contain solvents that
could damage the O-rings.
Recommended lubricant b. Tighten the lower ring nut “4” with a steering
Chain lubricant nut wrench “5”.
suitable for O-ring chains
TIP
Set the torque wrench at a right angle to the
steering nut wrench.
3-24
CHK
CHASSIS ADJ
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Steering nut wrench
5. Install:
90890-01403
• Upper bracket
Refer to “STEERING HEAD” on page 4-54.
Lower ring nut (initial tightening CHECKING THE FRONT FORK
torque)
T.
R.
55 Nm (5.5 m·kg, 40 ft·lb)

WARNING
c. Loosen the lower ring nut “4” completely, WARNING
and then tighten it to specification with a Securely support the vehicle so that there is
steering nut wrench. no danger of it falling over.
WARNING 2. Check:
• Inner tube
Do not overtighten the lower ring nut. Damage/scratches → Replace.
• Oil seal
Lower ring nut (final tightening Oil leakage → Replace.
torque) 3. Hold the vehicle upright and apply the front
T.
brake.
R.
22 Nm (2.2 m·kg, 16 ft·lb)

4. Check:
d. Check the steering head for looseness or • Front fork operation
binding by turning the front fork all the way in Push down hard on the handlebar several
both directions. If any binding is felt, remove times and check if the front fork rebounds
the lower bracket and check the upper and smoothly.
lower bearings. Rough movement → Repair.
Refer to “STEERING HEAD” on page 4-54. Refer to “FRONT FORK” on page 4-46.
e. Install the rubber washer “3”.
f. Install the upper ring nut “2”.
g. Finger tighten the upper ring nut “2”, and
then align the slots of both ring nuts. If nec-
essary, hold the lower ring nut and tighten
the upper ring nut until their slots are aligned.
TIP
Make sure the lock washer tabs “a” sit correctly
in the ring nut slots “b”.
3-25
CHK
CHASSIS ADJ
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Check:
• Tire pressure
Out of specification → Regulate.
1. Tire tread depth

2. Side wall
3. Wear indicator
Wear limit (front)

1.0 mm (0.04 in)
Wear limit (rear)
1.0 mm (0.04 in)
WARNING
• The tire pressure should only be checked
WARNING
and regulated when the tire temperature
• Do not use a tubeless tire on a wheel
equals the ambient air temperature.
designed only for tube tires to avoid tire
• The tire pressure must be adjusted
failure and personal injury from sudden
according to the total weight (including deflation.
cargo, rider, passenger and accessories) • When using a tube tire, be sure to install
and the anticipated riding speed. the correct tube.
• Operation of an overloaded vehicle could • Always replace a new tube tire and a new
cause tire damage, an accident or an tube as a set.
injury. • To avoid pinching the tube, make sure the
NEVER OVERLOAD THE VEHICLE. wheel rim band and tube are centered in
the wheel groove.
• Patching a punctured tube is not recom-
Tire air pressure (measured on
mended. If it is absolutely necessary to
cold tires)
Front do so, use great care and replace the tube
200 kPa (2.00 kgf/cm², 29 psi) as soon as possible with a good quality
Rear replacement.
225 kPa (2.25 kgf/cm², 33 psi)
Maximum load (total weight of
A B
rider, passenger, cargo and
accessories)
194 kg (428 lb)
SUITABLE FOR
WARNING TUBELESS TIRES
It is dangerous to ride with a worn-out tire.

When the tire tread reaches the wear limit,
replace the tire immediately.
2. Check:
A. Tire
• Tire surfaces
B. Wheel
Damage/wear → Replace the tire.
Tube wheel Tube tire only
Tubeless wheel Tubeless tire
3-26
CHK
CHASSIS ADJ
WARNING CHECKING THE WHEELS
After extensive tests, the tires listed below The following procedure applies to both of the
have been approved by Yamaha Motor Co., wheels.
Ltd. for this model. The front and rear tires 1. Check:
should always be by the same manufac- • Wheel
turer and of the same design. No guarantee Damage/out-of-round → Replace.
concerning handling characteristics can be
given if a tire combination other than one WARNING
approved by Yamaha is used on this vehi- Never attempt to make any repairs to the
cle. wheel.
TIP
Front tire After a tire or wheel has been changed or
Size
replaced, always balance the wheel.
90/80–17M/C 46P
Manufacturer/model
IRC/NR67D CHECKING AND LUBRICATING THE
CABLES END
Rear tire inner and outer cables.
Size
130/70–R17M/C 62P WARNING
Manufacturer/model
Damaged outer cable may cause the cable
IRC/RX-01R
to corrode and interfere with its movement.
Replace damaged outer cable and inner
WARNING
cables as soon as possible.
New tires have a relatively low grip on the
road surface until they have been slightly 1. Check:
worn. Therefore, approximately 100 km • Outer cable
should be traveled at normal speed before Damage → Replace.
any high-speed riding is done. 2. Check:
• Cable operation
TIP
Rough movement → Lubricate cable end/
For tires with a direction of rotation mark “1”:
Replace.
• Install the tire with the mark pointing in the
direction of wheel rotation. Recommended lubricant
• Align the mark “2” with the valve installation Lithium-soap-based grease
point.
LUBRICATING THE CLUTCH LEVER
Lubricate the pivoting point and metal-to-metal
moving parts of the lever.
Recommended lubricant
Lithium-soap-based grease
LUBRICATING THE BRAKE LEVER

moving parts of the lever.
Silicone grease
3-27
CHK
ELECTRICAL SYSTEM ADJ
LUBRICATING THE PEDALS
moving parts of the pedals.
LUBRICATING THE SIDESTAND

moving parts of the sidestand.
LUBRICATING THE REAR SUSPENSION

moving parts of the rear suspension.
3-28
CHK
ELECTRICAL SYSTEM WARNING
Since the headlight bulb gets extremely
CHECKING AND CHARGING THE hot, keep flammable products and your
BATTERY hands away from the bulb until it has
Refer to “ELECTRICAL COMPONENTS” on cooled down.
page 8-57.
5. Install:
• Headlight bulb New
CHECKING THE FUSE
Secure the new headlight bulb with the
Refer to “ELECTRICAL COMPONENTS” on
headlight bulb holder.
page 8-57.
NOTICE
REPLACING THE HEADLIGHT BULBS
Avoid touching the glass part of the head-
The following procedure applies to both of the light bulb to keep it free from oil, otherwise
headlight bulbs. the transparency of the glass, the life of the
1. Disconnect: bulb and the luminous flux will be
• Headlight coupler “1” adversely affected. If the headlight bulb
2. Remove: gets soiled, throughly clean it with a cloth
• Headlight bulb cover “2” moistened with alcohol or lacquer thinner.
1 6. Attach:
• Headlight bulb holder
7. Install:
• Headlight bulb cover
8. Connect:
2 • Headlight coupler
ADJUSTING THE HEADLIGHT BEAMS

3. Detach: headlights.
• Headlight bulb holder “1”
1. Adjust:
• Headlight beam (vertically)
1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw “1” in direction “a”
or “b”.
Direction “a”
Headlight beam is raised.
Direction “b”
Headlight beam is lowered.
4. Remove:
• Headlight bulb “1”
3-29
CHK
A
1
a 1
b
b
a
B
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1
b
A. Left headlight
B. Right headlight
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
• Headlight beam (horizontally)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw “1” in direction “a”
or “b”.
Left headlight
Direction “a”
Headlight beam moves to the right.
Direction “b”
Headlight beam moves to the left.
1
a
Right headlight
Direction “a”
Headlight beam moves to the left.
Direction “b”
Headlight beam moves to the right.
3-30
CHAS
CHAPTER 4
GENERAL CHASSIS
GENERAL CHASSIS....................................................................................... 4-1

INSTALLING THE AIR FILTER CASE ...................................................... 4-5
FRONT WHEEL............................................................................................... 4-6

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

REMOVING THE REAR WHEEL (DISC) ................................................4-16
DISASSEMBLING THE REAR WHEEL ..................................................4-16
CHECKING THE REAR WHEEL.............................................................4-16
CHECKING THE REAR WHEEL DRIVE HUB ........................................ 4-16
CHECKING AND REPLACING THE REAR WHEEL SPROCKET ......... 4-16
ASSEMBLING THE REAR WHEEL ........................................................ 4-17
ADJUSTING THE REAR WHEEL STATIC BALANCE............................4-17
INSTALLING THE REAR WHEEL (DISC)............................................... 4-17
FRONT BRAKE ............................................................................................. 4-18

INTRODUCTION ..................................................................................... 4-23
CHECKING THE FRONT BRAKE DISC ................................................. 4-23
REPLACING THE FRONT BRAKE PADS ..............................................4-24
REMOVING THE FRONT BRAKE CALIPER .......................................... 4-25
DISASSEMBLING THE FRONT BRAKE CALIPER ................................ 4-25
CHECKING THE FRONT BRAKE CALIPER .......................................... 4-25
ASSEMBLING THE FRONT BRAKE CALIPER ...................................... 4-26
INSTALLING THE FRONT BRAKE CALIPER ........................................ 4-26
REMOVING THE FRONT BRAKE MASTER CYLINDER ....................... 4-27
CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 4-27
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ...................4-27
INSTALLING THE FRONT BRAKE MASTER CYLINDER...................... 4-28
REAR BRAKE ............................................................................................... 4-30

INTRODUCTION ..................................................................................... 4-35
CHECKING THE REAR BRAKE DISC....................................................4-35
REPLACING THE REAR BRAKE PADS................................................. 4-35
REMOVING THE REAR BRAKE CALIPER ............................................ 4-36
DISASSEMBLING THE REAR BRAKE CALIPER .................................. 4-36
CHECKING THE REAR BRAKE CALIPER ............................................. 4-37
CHECKING THE REAR BRAKE CALIPER BRACKET ........................... 4-37
ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-37
INSTALLING THE REAR BRAKE CALIPER ........................................... 4-37
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-39
CHAS
CHECKING THE REAR BRAKE MASTER CYLINDER ..........................4-39
ASSEMBLING THE REAR BRAKE MASTER CYLINDER...................... 4-39
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-39
HANDLEBARS ..............................................................................................4-41
REMOVING THE HANDLEBARS ...........................................................4-43
CHECKING THE HANDLEBARS ............................................................ 4-43
INSTALLING THE HANDLEBARS .......................................................... 4-43
FRONT FORK................................................................................................ 4-46

REMOVING THE FRONT FORK LEGS ..................................................4-49
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-49
CHECKING THE FRONT FORK LEGS ..................................................4-50
ASSEMBLING THE FRONT FORK LEGS ..............................................4-50
INSTALLING THE FRONT FORK LEGS ................................................4-53
STEERING HEAD..........................................................................................4-54
REMOVING THE LOWER BRACKET..................................................... 4-56
CHECKING THE STEERING HEAD ....................................................... 4-56
INSTALLING THE STEERING HEAD ..................................................... 4-56
REAR SHOCK ABSORBER ASSEMBLY ....................................................4-58

REMOVING THE REAR SHOCK ABSORBER ASSEMBLY...................4-59
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ...................4-59
CHECKING THE CONNECTING ARMS AND RELAY ARM .................. 4-59
INSTALLING THE RELAY ARM.............................................................. 4-59
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY .................4-59
SWINGARM...................................................................................................4-61
REMOVING THE SWINGARM................................................................ 4-63
CHECKING THE SWINGARM ................................................................ 4-63
INSTALLING THE SWINGARM .............................................................. 4-63
CHAIN DRIVE................................................................................................ 4-64

REMOVING THE DRIVE CHAIN BY USING CHAIN CUTTER...............4-65
CHECKING THE DRIVE CHAIN .............................................................4-65
CHECKING THE DRIVE SPROCKET..................................................... 4-66
CHECKING THE REAR WHEEL SPROCKET ........................................ 4-66
CHECKING THE REAR WHEEL DRIVE HUB ........................................ 4-66
INSTALLING THE DRIVE CHAIN BY USING CHAIN RIVETING TOOL 4-66
CLEANING AND LUBRICATING THE DRIVE CHAIN ............................4-68
GENERAL CHASSIS CHAS

GENERAL CHASSIS
GENERAL CHASSIS
Removing the seats, and battery
16 Nm (1.6 m • kg, 11 ft • Ib)

T .R
1.3 Nm (0.13 m • kg, 0.94 ft • Ib)

.
T .R
.
1
3
4 2
6
5 7
9
Order Job/Parts to remove Q’ty Remarks

1 Passenger seat 1
2 Cover, side 6 / Cover seat lock 1
3 Cable, seat lock 1
4 Rider Seat 1
5 Battery band 1
6 Battery rubber cover 1
7 Negative battery lead 1 Disconnect.
8 Positive battery lead 1 Disconnect.
9 Battery 1
For installation, reverse the removal
procedure.
4-1
Removing the rear side cowlings

7 Nm (0.7 m • kg, 5.1 ft • Ib)
T .R
.
1.5 Nm (0.15 m • kg, 1.1 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T .R
T .R
.
5 3
2
1.5 Nm (0.15 m • kg, 1.1 ft • Ib)

T .R
.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T .R
.

Passenger seat / cover, seat lock / rider Refer to ““GENERAL CHASSIS” on
seat page 4-1.
1 Left side cover 1
2 Right side cover 1
3 Rear panel 1
4 Left rear cowling 1
5 Right rear cowling 1
procedure.
4-2

Removing the front cowlings and headlight assembly
2 1.5 Nm (0.15 m • kg, 1.1 ft • Ib)
T.R
.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.R
.
5 A
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.R
.
1.5 Nm (0.15 m • kg, 1.1 ft • Ib)
T.R
.
6 1
D
8
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.R
.
12 B
3
9 C
13 (3)
A 11
(4) 7
D
B 14
(4) 4
C
15
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.R
16
.
1.3 Nm (0.13 m • kg, 0.94 ft • Ib)

T.R
.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.R
.
1.5 Nm (0.15 m • kg, 1.1 ft • Ib)

0.4 Nm (0.004 m • kg, 0.29 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.R
.
T.R
T.R
.

1 Left upper panel 1
2 Right upper panel 1
3 Left front upper cowling 1
4 Left front lower cowling 1
5 Right front upper cowling 1
6 Right front lower cowling 1
7 Left bottom cowling 1
8 Right bottom cowling 1
9 Front bottom cowling 1
10 Licence Plate 1
11 Left rearview mirror 1
12 Right rearview mirror 1
13 Bracket, Licence plate 1
14 Windshield 1
15 Headlight inner panel 1
16 Headlight assembly 1
procedure.
4-3

Removing the air filter case
New
New
6
7
2 Nm (0.2 m • kg, 1.4 ft • Ib)

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

T.R
.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

4
T.R
.

Passenger and rider seat / side covers Refer to “Removing the passenger and rider
seat, battery and rear cowlings”.
Fuel tank 1 Refer to “FUEL TANK” on page 7-1.
1 Air filter case cover 1
2 Air filter element 1
3 Air filter case joint clamp screw 1 Loosen.
4 Cylinder head breather hose 1 Disconnect.
5 Air filter case silencer 1
6 Air filter case 1
procedure.
4-4

INSTALLING THE AIR FILTER CASE
1. Install:
• Air filter case joint clamp
TIP
Align the projection “a” on the air filter case
with the slot “b” in the air filter case joint clamp.
4-5
FRONT WHEEL CHAS

FRONT WHEEL
Removing the front wheel and brake disc
7 Nm (0.7 m • kg, 5.1 ft • Ib)

1
T.R
.
35 Nm (3.5 m • kg, 25 ft • Ib)

T.R
.
23 Nm (2.3 m • kg, 17 ft • Ib)

T.R
.
2
LS
(4) LT
6
3
60 Nm (6.0 m • kg, 43 ft • Ib)

T.R
.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.R
.

1 Front brake hose holder 1
2 Front brake caliper 1
3 Front wheel axle nut 1
4 Front wheel axle 1
5 Front wheel 1
6 Collar 1
7 Brake disc 1
8 Collar 2 1
procedure.
4-6
FRONT WHEEL CHAS

Disassembling the front wheel
LS
New 1
2
3
4

1 Oil seal 1
2 Wheel bearing 1
3 Spacer 1
4 Wheel bearing 1
For assembly, reverse the disassembly
procedure.
4-7
FRONT WHEEL CHAS

REMOVING THE FRONT WHEEL (DISC) c. Remove the wheel bearings with bearing
1. Stand the vehicle on a level surface. puller.
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
2. Elevate:
• Front wheel
TIP
Place the vehicle on a suitable stand so that
the front wheel is elevated.
3. Remove:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Front brake caliper
CHECKING THE FRONT WHEEL
TIP
Do not squeeze the brake lever when remov- 1. Check:
ing the front brake caliper. • Front wheel axle
Roll the wheel axle on a flat surface.
4. Remove: Bends → Replace.
• Front wheel axle nut
• Front wheel axle WARNING
• Front wheel Do not attempt to straighten a bent wheel
• Speed sensor axle.
• Collar
DISASSEMBLING THE FRONT WHEEL

1. Remove:
• Oil seal
• Wheel bearings
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside of the front wheel hub.

b. Remove the oil seal “1” with a flat-head 2. Check:
screwdriver. • Tire
• Front wheel
TIP
Damage/wear → Replace.
To prevent damaging the wheel, place a rag
Refer to “CHECKING THE TIRES” on
“3” between the oil seal remover and the wheel
page 3-26 and “CHECKING THE
surface.
WHEELS” on page 3-27.
3. Measure:
• Radial wheel runout “1”
• Lateral wheel runout “2”
Over the specified limits → Replace.
Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
4-8
FRONT WHEEL CHAS
4
3
2
1
c. Install the spacer.

d. Install the new wheel bearing (left side).
4. Check: TIP
• Spacer Place a suitable washer “1” between the
Damage/wear → Replace. socket “2” and the bearing so that both the
inner race “3” and outer race “4” are pressed at
5. Check: the same time, and then press the bearing until
• Wheel bearings the inner race makes contact with the spacer
Front wheel turns roughly or is loose → “5”.
Replace the wheel bearings.
• Oil seal
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
ADJUSTING THE FRONT WHEEL STATIC
ASSEMBLING THE FRONT WHEEL BALANCE
1. Install: TIP
• Wheel bearings New ● After replacing the tire, wheel or both, the
• Oil seal New front wheel static balance should be
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
adjusted.
a. Install the new wheel bearing (right side). ● Adjust the front wheel static balance with
the brake discs installed.
b. Install the new oil seal (right side)
NOTICE 1. Remove:
• Balancing weight(s)
Do not contact the wheel bearing inner race
“1” or balls “2”. Contact should be made 2. Find:
only with the outer race “3”. • Front wheel's heavy spot
TIP
TIP Place the front wheel on a suitable balancing
Use bearing punch “4” that matches the diam- stand.
eter of the wheel bearing outer race.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Spin the front wheel.
b. Wheel the front wheel stops, put an “X1”.
4-9
FRONT WHEEL CHAS

3. Check:
• Front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the front wheel and make sure it stays
at each position shown.
c. Turn the front wheel 90 so that the “X1”

mark is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X2” mark at
the bottom of the wheel. b. If the front wheel does not remain stationary
at all of the positions, rebalance it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
INSTALLING THE FRONT WHEEL (DISC)

1. Install:
• Front brake disc
Front brake disc bolt
23 Nm (2.3 m·kg, 17 ft·lb)
T.
R.
LOCTITE®
f. Repeat steps (c) through (e) several times TIP

until all the marks come to rest at the same Tighten the brake disc bolts in stages and in a
spot. crisscross pattern.
g. The spot where all the marks come to rest
is the front wheel's heavy spot “X”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TIP
Start with the lightest weight.
a. 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 DISC” on page 4-23.
3. Lubricate:
• Front wheel axle
• Oil seal lip
b. If the heavy spot does not stay in that posi- Recommended lubricant
tion, install a heavier weight. Lithium-soap-based grease
c. Repeat steps (b) and (c) until the front
wheel is balanced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-10
FRONT WHEEL CHAS

4. Tighten:
• Front wheel axle nut
Front wheel axle nut
59 Nm (5.9 m·kg, 43 ft·lb)
T.
R.
WARNING
WARNING
Make sure the brake hose is routed prop-

erly.
NOTICE
After tightening the wheel axle nut, push
down hard on the handlebar(s) several
times and check if the front fork rebounds
smoothly.
4-11
CHAS
REAR WHEEL
Removing the rear wheel
90 Nm (9.0 m • kg, 65 ft • lb)
T.R
.
13
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
14
1
2
15
8
9
10
3 10 Nm (1.0 m • kg, 7.2 ft • Ib)

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

T.
R.
5
12
7 Nm (0.7 m • kg, 5.1 ft • Ib)
4
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib) 11

T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.

1 TIP
the rear wheel is elevated.
1 Brake hose clamp 2
2 Rear fender Comp. 1
3 Protector chain 1
4 Plate 1 1
5 Case chain 1
6 Rear wheel axle nut 1 Remove.
4-12
CHAS
Removing the rear wheel

90 Nm (9.0 m • kg, 65 ft • lb)
T.R
.
13
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
14
1
2
15
8
9
10
3 10 Nm (1.0 m • kg, 7.2 ft • Ib)

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

T.
R.
5
12
7 Nm (0.7 m • kg, 5.1 ft • Ib)
4
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib) 11

T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.

7 Drive chain adjusting bolt 2
8 Drive chain adjusting locknut 2 Loosen.
9 Washer 1 Tighten.
10 Drive chain puller (RH) 1
11 Rear wheel axle 1
12 Drive chain puller (LH) 1
13 Rear wheel 1
14 Collar wheel 1
15 Collar sprocket axle 1
procedure.
4-13
CHAS
Removing the brake disc and rear wheel sprocket
23 Nm (2.3 m • kg, 17 ft • Ib)

T.R
.
LT
(5)
43 Nm (4.3 m • kg, 31 ft • Ib)
T.R
.
1
6
7
4 (6)
LS 5 New 3
LS
2

1 Rear brake disc 1
2 Rear wheel sprocket 1
3 Oil seal 1
4 Bearing 1
5 Rear wheel drive hub 1
6 Collar 1
7 Rear wheel drive hub damper 4
procedure.
4-14
CHAS
Disassembling the rear wheel
New
LS
3
4
2
1

1 Wheel bearing 1
2 Spacer 1
3 Oil seal 1
4 Wheel bearing 1
procedure.
4-15
CHAS
REMOVING THE REAR WHEEL (DISC) 2. Check:
1. Stand the vehicle on a level surface. • Tire
• Rear wheel
WARNING Damage/wear → Replace.
Securely support the vehicle so that there Refer to ““CHECKING THE TIRES” on
is no danger of it falling over. page 3-26 and “” on page 4-13.
2. Elevate: 3. Measure:
• Rear wheel • Radial wheel runout
TIP • Lateral wheel runout
Place the vehicle on a suitable stand so that Refer to “CHECKING THE FRONT
the rear wheel is elevated. WHEEL” on page 4-8.
Radial wheel runout limit
3. Loosen: 1.0 mm (0.04 in)
• Rear wheel axle Lateral wheel runout limit
• Drive chain adjusting locknut 0.5 mm (0.02 in)
• Drive chain adjusting bolt
CHECKING THE REAR WHEEL DRIVE HUB
4. Remove: 1. Check:
• Rear wheel axle nut • Rear wheel drive hub
• Rear wheel axle Cracks/damage → Replace.
• Drive chain pullers • Rear wheel drive hub dampers
• Collars Damage/wear → Replace.
• Rear wheel
• Rear brake caliper CHECKING AND REPLACING THE REAR
TIP WHEEL SPROCKET
● Push the rear wheel forward and remove 1. Check:
the drive chain from the rear wheel • Rear wheel sprocket
sprocket. More than 1/4 tooth “a” wear → Replace
● Do not depress the brake pedal when the rear wheel sprocket.
removing the rear wheel. Bent teeth → Replace the rear wheel
sprocket.
DISASSEMBLING THE REAR WHEEL
1. Remove:
• Oil seal
• Wheel bearings
Refer to “DISASSEMBLING THE
FRONT WHEEL” on page 4-8.
CHECKING THE REAR WHEEL

1. Check: b. Correct
• Rear wheel axle
1. Drive chain roller
• Rear wheel
• Wheel bearings 2. Rear wheel sprocket
• Oil seal
2. Replace:
• Rear wheel sprocket
WHEEL” on page 4-8.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-16
CHAS
a. Remove the self-locking nuts and the rear INSTALLING THE REAR WHEEL (DISC)
wheel sprocket. 1. Install:
b. Clean the rear wheel drive hub with a clean • Rear brake disc
cloth, especially the surfaces that contact
the sprocket. Rear brake disc bolt
c. Install the new rear wheel sprocket. 23 Nm (2.3 m·kg, 17 ft·lb)
T.
R.
LOCTITE®
Rear wheel sprocket self-locking
nut TIP
T.
R.
43 Nm (4.3 m·kg, 31 ft·lb) Tighten the brake disc bolts in stages and in a
crisscross pattern.
TIP
Tighten the self-locking nuts in stages and in a
crisscross pattern.
2. Check:
• Rear brake disc
Refer to “CHECKING THE REAR
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Lubricate:
ASSEMBLING THE REAR WHEEL • Rear wheel axle
• Contact surface of rear wheel hub and
1. Install: rear wheel
• Wheel bearings • Oil seal lips
Refer to “ASSEMBLING THE FRONT
WHEEL” on page 4-9. Recommended lubricant
ADJUSTING THE REAR WHEEL STATIC
4. Adjust:
BALANCE
• Drive chain slack
TIP Refer to “ADJUSTING THE DRIVE
● After replacing the tire, wheel or both, the CHAIN SLACK” on page 3-23.
rear wheel static balance should be
adjusted. Drive chain slack
● Adjust the rear wheel static balance with the 25.0-35.0 mm (0.98-1.38 in)
brake disc and rear wheel drive hub
installed.
1. Adjust:
• Rear wheel static balance
Refer to “ADJUSTING THE FRONT
WHEEL STATIC BALANCE” on page 4-9.
4-17
FRONT BRAKE CHAS

FRONT BRAKE
Removing the front brake pads
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.R
.
2
3
2
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.R
.
5
7
4
8
6 35 Nm (3.5 m • kg, 25 ft • Ib)

T.R
.

2 Front brake caliper bolt 2
4 Brake pad clip 2
5 Brake pad pin 1
6 Front brake pad 2
7 Brake pad spring 1
8 Brake pad support (Clip) 1
procedure.
4-18
FRONT BRAKE CHAS

Removing the front brake master cylinder
1.5 Nm (0.15 m • kg, 1.1 ft • Ib)
T.R
.
30 Nm (3.0 m • kg, 22 ft • Ib)
T.R
.
1
6 New
2
4 5
3
7
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.R
10
.
S
8
S
6 Nm (0.6 m • kg, 4.3 ft • Ib)

T.R
.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.R
.

Brake fluid Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-22.
1 Brake master cylinder reservoir cap 1
2 Brake master cylinder reservoir diaphragm 1
holder
3 Brake master cylinder reservoir diaphragm 1
4 Front brake light switch 1
5 Brake hose union bolt 1
6 Copper washer 2
7 Front brake hose 1
8 Brake lever 1
9 Front brake master cylinder holder 1
10 Front brake master cylinder 1
procedure.
4-19
FRONT BRAKE CHAS

Disassembling the front brake master cylinder
4 New
3
2 New
1

1 Dust boot 1
2 Circlip 1
3 Washer 1
4 Brake master cylinder kit 1
5 Brake master cylinder body 1
procedure.
4-20
FRONT BRAKE CHAS

Removing the front brake caliper
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
1
5
4
2
New 3
6
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
R.
35 Nm (3.5 m • kg, 25 ft • Ib)

T.R
.

Brake fluid Drain.
3 Copper washer 2
4 Front brake hose 1
5 Front brake caliper bolt 2
procedure.
4-21
FRONT BRAKE CHAS

Disassembling the front brake caliper
6 Nm (0.6 m • kg, 4.3 ft • Ib)

10
T.
R.
1
1
2 7
9 New
4 8 New
S
S
7
9 New
6 BF
8 New
5
3

1 Brake pad clip 2
2 Brake pad pin 1
3 Front brake pad 2
5 Brake caliper bracket 1
6 Brake pad support 1
7 Brake caliper piston 2
8 Brake caliper piston dust seal 2
9 Brake caliper piston seal 2
10 Bleed screw 1
procedure.
4-22
FRONT BRAKE CHAS

INTRODUCTION ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. Place the vehicle on a suitable stand so
WARNING that the front wheel is elevated.
Disc brake components rarely require dis- b. Before measuring the front brake disc
assembly. Therefore, always follow these deflection, turn the handlebar to the left or
preventive measures: right to ensure that the front wheel is sta-
● Never disassemble brake components
tionary.
unless absolutely necessary.
● If any connection on the hydraulic brake
c. Remove the brake caliper.
system is disconnected, the entire brake d. Hold the dial gauge at a right angle against
system must be disassembled, drained, the brake disc surface.
cleaned, properly filled, and bled after e. Measure the deflection 0.75 mm (0.008 in)
reassembly. below the edge of the brake disc.
● Never use solvents on internal brake ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
components.
4. Measure:
● Use only clean or new brake fluid for
cleaning brake components. • Brake disc thickness
● Brake fluid may damage painted sur-
Measure the brake disc thickness at a
faces and plastic parts. Therefore, few different locations.
always clean up any spilt brake fluid Out of specification → Replace.
immediately.
● Avoid brake fluid coming into contact
with the eyes as it can cause serious
injury.
● FIRST AID FOR BRAKE FLUID ENTER-
ING THE EYES:
● Flush with water for 15 minutes and get
immediate medical attention.
CHECKING THE FRONT BRAKE DISC

1. Remove:
• Front wheel Brake disc thickness limit
Refer to “FRONT WHEEL” on page 4-6. 3.5 mm (0.14 in)
2. Check:
• Brake disc 5. Adjust:
Damage/galling → Replace. • Brake disc deflection
3. Measure: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Brake disc deflection a. Remove the brake disc.

Out of specification → Correct the brake b. Rotate the brake disc by one bolt hole.
disc deflection or replace the brake disc. c. Install the brake disc.
Fixed screw Fixed screw
Front brake disc bolt
23 Nm (2.3 m·kg, 17 ft·lb)
T.
R.
Arm LOCTITE®
TIP
Tighten the brake disc bolts in stages and in a
crisscross pattern.
Center position
Magnet stand
Brake disc deflection limit

0.15 mm (0.006 in)
4-23
FRONT BRAKE CHAS

2. Install:
• Brake pad support
• Brake pad spring
• Brake pads
TIP
Always replace the brake pads, brake pad
spring, and brake pad support as a set.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose “1” tightly to
the bleed screw “2”. Put the other end of
d. Measure the brake disc deflection. the hose into an open container.
e. If out of specification, repeat the adjust-
ment steps until the brake disc deflection is
within specification.
f. If the brake disc deflection cannot be
brought within specification, replace the 2
brake disc. 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
• Front wheel
Refer to “FRONT WHEEL” on page 4-6.
b. Loosen the bleed screw and push the
REPLACING THE FRONT BRAKE PADS brake caliper pistons into the brake caliper
with your fingers.
TIP c. Tighten the bleed screw.
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas- Front brake caliper bleed screw
semble the brake caliper. 6 Nm (0.6 m·kg, 4.3 ft·lb)
T.
R.
1. Measure: d. Install the brake pad support, brake pad

• Brake pad wear limit “a” spring, and brake pads.
Out of specification → Replace the brake ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
pads as a set. 3. Install:
Brake pad lining thickness • Brake pad pin
(inner) • Brake pad clips
5.3 mm (0.21 in) • Front brake caliper
Limit
0.8 mm (0.03 in) Front brake caliper bolt
Brake pad lining thickness 35 Nm (3.5 m·kg, 25 ft·lb)
T.
R.
(outer)
5.3 mm (0.21 in) 4. Check:
Limit • Brake fluid level
0.8 mm (0.03 in) Below the minimum level mark “a” → Add
the recommended brake fluid to the
proper level.
a Refer to “CHECKING THE BRAKE
FLUID LEVEL” on page 3-20.
4-24
FRONT BRAKE CHAS

a ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose
joint opening “a” to force out the pistons
from the brake caliper.
WARNING
● Cover the brake caliper piston with a
5. Check: rag. Be careful not to get injured when
• Brake lever operation the piston is expelled from the brake
Soft or spongy feeling → Bleed the brake caiper.
system. ● Never try to pry out the brake caliper pis-
• Refer to “BLEEDING THE HYDRAULIC ton.
a
REMOVING THE FRONT BRAKE CALIPER
TIP
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:
• Brake hose union bolt “1”
• Copper washers “2”
• Brake hose “3”
TIP b. Remove the brake caliper piston seals and
Put the end of the brake hose into a container dust seals.
and pump out the brake fluid carefully. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE FRONT BRAKE CALIPER
Recommended brake component

replacement schedule
3 Brake pads If necessary
1
Piston seals Every two years
Piston dust seals Every two years
Brake hose Every four years
2
Every two years and
DISASSEMBLING THE FRONT BRAKE Brake fluid whenever the brake
CALIPER is disassembled
• Brake caliper pistons “1” • Brake caliper pistons “1”
• Brake caliper piston dust seals “2” Rust/scratches/wear → Replace the
• Brake caliper piston seals “3” brake caliper pistons.
• Brake caliper cylinders “2”
Scratches/wear → Replace the brake
caliper assembly.
• Brake caliper body “3”
1 Cracks/damage → Replace the brake
3 caliper assembly.
2 • Brake fluid delivery passages
1 (brake caliper body)
Obstruction → Blow out with compressed
3 air.
4-25
FRONT BRAKE CHAS

WARNING NOTICE
WARNING
Whenever a brake caliper is disassembled, When installing the brake hose onto the
replace the brake caliper piston dust seals brake caliper “1”, make sure the brake pipe
and piston seals. “a” touches the projection “b” on the brake
caliper.
3
b
2 2
a
1
1
2. Check:
• Brake caliper bracket
2. Remove:
• Brake caliper
ASSEMBLING THE FRONT BRAKE CALIPER 3. Install:
• Brake pad spring
WARNING • Brake pads
● Before installation, all internal brake • Brake caliper
components should be cleaned and • Front brake hose holder
lubricated with clean or new brake fluid. Front brake caliper bolt
● Never use solvents on internal brake 35 Nm (3.5 m·kg, 25 ft·lb)
components as they will cause the brake
T.
R.
Front brake hose holder bolt

caliper dust seals and piston seals to 7 Nm (0.7 m·kg, 5.1 ft·lb)
swell and distort.
● Whenever a brake caliper is disassem- Refer to “REPLACING THE FRONT
bled, replace the brake caliper piston BRAKE PADS” on page 4-24.
dust seals and piston seals.
4. Fill:
• Brake master cylinder reservoir
Recommended fluid (with the specified amount of the
DOT 4 recommended brake fluid)
INSTALLING THE FRONT BRAKE CALIPER Recommended fluid

1. Install: DOT 4
• Brake caliper “1”
(temporarily) WARNING
• Copper washers ● Use only the designated brake fluid.
• Brake hose Other brake fluids may cause the rubber
• Brake hose union bolt seals to deteriorate, causing leakage
and poor brake performance.
Brake hose union bolt ● Refill with the same type of brake fluid
30 Nm (3.0 m·kg, 22 ft·lb) that is already in the system. Mixing
T.
R.
brake fluids may result in a harmful

WARNING chemical reaction, leading to poor brake
Proper brake hose routing is essential to performance.
insure safe vehicle operation. Refer to ● When refilling, be careful that water does
“CABLE ROUTING” on page 2-31. not enter the brake master cylinder res-
ervoir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
4-26
FRONT BRAKE CHAS

NOTICE
up any spilt brake fluid immediately.
5. Bleed:
• Brake system
6. Check:
• Brake fluid level 2. Remove:
Below the minimum level mark “a” → Add • Brake hose union bolt
the recommended brake fluid to the • Copper washers
proper level.
TIP
Refer to “CHECKING THE BRAKE
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
a
CHECKING THE FRONT BRAKE MASTER
CYLINDER
1. Check:
• Brake master cylinder
Damage/scratches/wear → Replace.
• Brake fluid delivery passages
(brake master cylinder body)
7. Check: air.
• Brake lever operation
2. Check:
Soft or spongy feeling → Bleed the brake
system.
Cracks/damage → Replace the brake
master cylinder.
REMOVING THE FRONT BRAKE MASTER
diaphragm
CYLINDER
TIP 3. Check:
Before removing the front brake master cylin- • Brake hose
der, drain the brake fluid from the entire brake Cracks/damage/wear → Replace.
system.
ASSEMBLING THE FRONT BRAKE
1. Disconnect: MASTER CYLINDER
• Front brake light switch “1”
WARNING
TIP
● Before installation, all internal brake
Push the fastener to remove the front brake
components should be cleaned and
light switch from the brake master cylinder.
lubricated with clean or new brake fluid.
● Never use solvents on internal brake
components.
Recommended fluid
DOT 4
4-27
FRONT BRAKE CHAS

INSTALLING THE FRONT BRAKE MASTER
CYLINDER a 1 New
1. Install: 3
• Brake master cylinder “1”
• Brake master cylinder holder “2” 2
Front brake master cylinder

holder bolt 75–850
T.
R.
7 Nm (0.7 m·kg, 5.1 ft·lb)
TIP 3. Fill:
● Install the brake master cylinder holder with • Brake master cylinder reservoir
the “UP” mark facing up. (with the specified amount of the
● Align the end of the brake master cylinder recommended brake fluid)
holder with the punch mark “a” on the han-
dlebar. Recommended fluid
● First, tighten the upper bolt, then the lower DOT 4
bolt.
WARNING
● Use only the designated brake fluid.
1 Other brake fluids may cause the rubber
seals to deteriorate, causing leakage
● Refill with the same type of brake fluid
that is already in the system. Mixing
UP
chemical reaction, leading to poor brake
a 2 performance.
● When refilling, be careful that water does
not enter the brake master cylinder res-
2. Install: ervoir. Water will significantly lower the
• Copper washers “1” New boiling point of the brake fluid and could
• Brake hose “2” cause vapor lock.
• Brake hose union bolt “3”
• Front brake light switch NOTICE
Brake hose union bolt Brake fluid may damage painted surfaces
30 Nm (3.0 m·kg, 22 ft·lb) and plastic parts. Therefore, always clean
T.
R.

WARNING
4. Bleed:
Proper brake hose routing is essential to
• Brake system
insure safe vehicle operation. Refer to
“CABLE ROUTING” on page 2-31.
TIP 5. Check:
● Install the brake hose to the front brake • Brake fluid level
master cylinder within the angle shown in Below the minimum level mark “a” → Add
the illustration. the recommended brake fluid to the
● While holding the brake hose, tighten the proper level.
brake hose union bolt as shown. Refer to “CHECKING THE BRAKE
● Turn the handlebar to the left and right to FLUID LEVEL” on page 3-20.
make sure the brake hose does not touch
other parts (e.g., wire harness, cables, and
leads). Correct if necessary.
4-28
CHAS
6. Check:
• Brake lever operation
system.
4-29
REAR BRAKE CHAS

REAR BRAKE
Removing the seats, and battery
17 Nm (1.7 m • kg, 12 ft • Ib) 5 Nm (0.5 m • kg, 3.6 ft • Ib)

T.R
.
T.R
.
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.R
.
1
S
2
S
LT
4
LT

1 Screw plug 1
2 Brake pad pin 1
3 Rear brake pad 2
procedure.
4-30
REAR BRAKE CHAS

Removing the rear brake master cylinder
4
2
30 Nm (3.0 m • kg, 22 ft • Ib) 5
T.R
.
7
8
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.R
.
9 New
10
11 1
9 New
New
LT
23 Nm (2.3 m • kg, 17 ft • Ib) LT 10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.R
.
T.R
.

Right side covers Refer to “GENERAL CHASSIS” on page 4-1.
Brake fluid Drain.
1 Footrest plate 1
2 Brake fluid reservoir assembly 1
3 Brake fluid reservoir cap 1
4 Brake fluid reservoir diaphragm holder 1
5 Brake fluid reservoir diaphragm 1
6 Brake fluid reservoir 1
7 Brake fluid reservoir hose 1
9 Copper washer 2
10 Rear brake hose 1
11 Rear brake master cylinder 1
procedure.
4-31
REAR BRAKE CHAS

Disassembling the rear brake master cylinder
3
1
New
BF New
S
2 New
17 Nm (1.7 m • kg, 12 ft • Ib)

T.R
.

1 Brake hose joint 1
2 Brake master cylinder kit 1
3 Brake master cylinder body 1
procedure.
4-32
REAR BRAKE CHAS

Removing the rear brake caliper
1 4
2
New

Brake fluid Drain.
Rear wheel Refer to “” on page 4-13.
2 Copper washer 2
3 Rear brake hose 1
4 Rear brake caliper 1
procedure.
4-33
REAR BRAKE CHAS

Disassembling the rear brake caliper
17 Nm (1.7 m • kg, 12 ft • Ib) 5 Nm (0.5 m • kg, 3.6 ft • Ib)

T.R
.
T.R
.
9
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.R
.
1
S
2
S
LT
4
5 LT
6
7
New S
8 22 Nm (2.2 m • kg, 16 ft • Ib)

T.R
.

1 Screw plug 1
2 Brake pad pin 1
3 Rear brake pad 2
5 Brake caliper piston 1
6 Brake caliper piston dust seal 1
7 Brake caliper piston seal 1
8 Brake caliper bracket 1
9 Bleed screw 1
procedure.
4-34
REAR BRAKE CHAS

INTRODUCTION
Brake disc thickness limit
WARNING 4.0 mm (0.16 in)
Disc brake components rarely require dis-
5. Adjust:
assembly. Therefore, always follow these
• Brake disc deflection
preventive measures:
● Never disassemble brake components
unless absolutely necessary.
● If any connection on the hydraulic brake Rear brake disc bolt
system is disconnected, the entire brake 23 Nm (2.3 m·kg, 17 ft·lb)
T.
system must be disassembled, drained,
R.
LOCTITE®
cleaned, properly filled, and bled after
reassembly. 6. Install:
● Never use solvents on internal brake • Rear wheel
components. Refer to “” on page 4-13.
● Use only clean or new brake fluid for
cleaning brake components. REPLACING THE REAR BRAKE PADS
● Brake fluid may damage painted sur- TIP
faces and plastic parts. Therefore, When replacing the brake pads, it is not neces-
always clean up any spilt brake fluid sary to disconnect the brake hose or disas-
immediately. semble the brake caliper.
● Avoid brake fluid coming into contact
with the eyes as it can cause serious 1. Remove:
injury. • Rear wheel
● FIRST AID FOR BRAKE FLUID ENTER- Refer to “” on page 4-13.
ING THE EYES: • Brake caliper
● Flush with water for 15 minutes and get Refer to “REMOVING THE REAR
immediate medical attention. BRAKE CALIPER” on page 4-36.
• Brake pad
CHECKING THE REAR BRAKE DISC Refer to “DISASSEMBLING THE REAR
BRAKE CALIPER” on page 4-36.
1. Remove:
• Rear wheel 2. Measure:
Refer to “” on page 4-13. • Brake pad wear limit “a”
Out of specification → Replace the brake
2. Check:
pads as a set.
• Brake disc
Damage/galling → Replace. Brake pad lining thickness
3. Measure: (inner)
• Brake disc deflection 7.0 mm (0.28 in)
Out of specification → Correct the brake Limit
disc deflection or replace the brake disc. 1.5 mm (0.06 in)
Brake pad lining thickness
(outer)
BRAKE DISC” on page 4-23. 7.0 mm (0.28 in)
Brake disc deflection limit Limit
0.10 mm (0.0039 in) 1.5 mm (0.06 in)
4. Measure:
• Brake disc thickness
Measure the brake disc thickness at a
few different locations.
Out of specification → Replace. 3. Install:
Refer to “CHECKING THE FRONT • Brake pad spring
BRAKE DISC” on page 4-23. • Brake pads
4-35
REAR BRAKE CHAS

TIP Refer to “CHECKING THE BRAKE
Always replace the brake pads, and brake pad FLUID LEVEL” on page 3-20.
spring as a set.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose “1” tightly to
the bleed screw “2”. Put the other end of
the hose into an open container.
UPPER
L OW E R a
5. Check:
• Brake pedal operation
system.
b. Loosen the bleed screw and push the REMOVING THE REAR BRAKE CALIPER
brake caliper pistons into the brake caliper TIP
with your finger. Before removing the brake caliper, drain the
c. Tighten the bleed screw. brake fluid from the entire brake system.
Bleed screw 1. Remove:

5 Nm (0.5 m·kg, 3.6 ft·lb) • Brake hose union bolt “1”
T.

R.
d. Install a new brake pad shim “3” onto each • Brake hose “3”
new brake pad “4”.
3
e. Install new brake pads and a new brake
pad spring “5”.
1 2 32
TIP
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Remove:
3. Install: • Rear wheel
• Brake pad pin Refer to “” on page 4-13.
• Screw plug • Brake caliper
Refer to “REMOVING THE REAR
Brake pad pin BRAKE CALIPER” on page 4-36.
17 Nm (1.7 m·kg, 12 ft·lb)
T.
R.
DISASSEMBLING THE REAR BRAKE

4. Check: CALIPER
• Brake fluid level 1. Remove:
Below the minimum level mark “a” → Add • Brake caliper piston “1”
the recommended brake fluid to the • Brake caliper piston dust seal “2”
proper level. • Brake caliper piston seal “3”
4-36
REAR BRAKE CHAS

• Brake caliper cylinder “2”
Scratches/wear → Replace the brake
caliper assembly.
• Brake caliper body “3”
Cracks/damage → Replace the brake
3
caliper assembly.
2
1 • Brake fluid delivery passages
(brake caliper body)
air.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose 3
joint opening “a” to force out the piston
from the brake caliper. 2 1
WARNING
● Cover the brake caliper piston with a rag.
Be careful not to get injured when the
piston is expelled from the brake caliper.
● Never try to pry out the brake caliper pis-
ton. WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seal
a and piston seal.
CHECKING THE REAR BRAKE CALIPER

BRACKET
1. Check:
• Rear brake caliper bracket
ASSEMBLING THE REAR BRAKE CALIPER

b. Remove the brake caliper piston seal and
dust seal. WARNING
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
● Before installation, all internal brake
CHECKING THE REAR BRAKE CALIPER components should be cleaned and
Recommended brake component ● Never use solvents on internal brake
replacement schedule components as they will cause the brake
Brake pads If necessary caliper piston dust seal and piston seal
Piston seals Every two years to swell and distort.
● Whenever a brake caliper is disassem-
Piston dust seals Every two years bled, replace the brake caliper piston
Brake hose Every four years dust seal and piston seal.
Every two years and
Brake fluid whenever the brake
is disassembled Recommended fluid
DOT 4
1. Check:
• Brake caliper piston “1” INSTALLING THE REAR BRAKE CALIPER
Rust/scratches/wear → Replace the 1. Install:
brake caliper piston. • Brake pad spring
4-37
REAR BRAKE CHAS

• Brake pads WARNING
• Brake pad retaining bolt
● Use only the designated brake fluid.
Refer to “REPLACING THE REAR
Other brake fluids may cause the rubber
BRAKE PADS” on page 4-35.
Rear brake pad retaining bolt and poor brake performance.
17 Nm (1.7 m·kg, 12 ft·lb) ● Refill with the same type of brake fluid
T.

R.
2. Install: brake fluids may result in a harmful

• Brake caliper “1” chemical reaction, leading to poor brake
• Rear wheel performance.
Refer to “” on page 4-13. ● When refilling, be careful that water does
• Copper washers New not enter the brake fluid reservoir. Water
• Brake hose “2” will significantly lower the boiling point
• Brake hose union bolt “3” of the brake fluid and could cause vapor
lock.
Brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb) NOTICE
T.
R.

WARNING
Proper brake hose routing is essential to up any spilt brake fluid immediately.
“CABLE ROUTING” on page 2-31. 4. Bleed:
• Brake system
NOTICE Refer to “BLEEDING THE HYDRAULIC
When installing the brake hose onto the BRAKE SYSTEM” on page 3-22.
brake caliper, be sure to position the brake 5. Check:
pipe “a” into the slot “b” in the brake cali- • Brake fluid level
per. Below the minimum level mark “a” → Add
proper level.
a b Refer to “CHECKING THE BRAKE
a b
3 1 b2
UPPER
Recommended fluid L OW E R a
DOT 4
3. Fill: 6. Check:
• Brake fluid reservoir • Brake pedal operation
(with the specified amount of the Soft or spongy feeling → Bleed the brake
recommended brake fluid) system.
4-38
REAR BRAKE CHAS

REMOVING THE REAR BRAKE MASTER ASSEMBLING THE REAR BRAKE MASTER
CYLINDER CYLINDER
TIP
WARNING
Before removing the rear brake master cylin-
der, drain the brake fluid from the entire brake ● Before installation, all internal brake
system. components should be cleaned and
1. Remove: ● Never use solvents on internal brake
• Brake hose union bolt “1” components.
Recommended fluid
TIP DOT 4
To collect any remaining brake fluid, place a
container under the master cylinder and the INSTALLING THE REAR BRAKE MASTER
end of the brake hose. CYLINDER
1. Install:
• Copper washers “2” New
3 • Brake hose union bolt “3”
1
WARNING
Proper brake hose routing is essential to
2 “CABLE ROUTING” on page 2-31.
NOTICE
CHECKING THE REAR BRAKE MASTER When installing the brake hose onto the
brake master cylinder, make sure the brake
CYLINDER
pipe touches the projection “a” as shown.
1. Check:
• Brake master cylinder
Damage/scratches/wear → Replace the
brake master cylinder assembly.
• Brake fluid delivery passages
(brake master cylinder body) 1
3
air.
New
2. Check:
2
• Brake master cylinder kit
Damage/scratches/wear → Replace the
brake master cylinder kit.
3. Check: 2. Fill:
• Brake fluid reservoir • o Brake fluid reservoir
Cracks/damage → Replace the reservoir (with the specified amount of the
tank. recommended brake fluid)
• Brake fluid reservoir diaphragm
Cracks/damage → Replace the brake Recommended fluid
DOT 4
fluid reservoir diaphragm.
4. Check:
• Brake hoses
Cracks/damage/wear → Replace the
brake hose.
4-39
REAR BRAKE CHAS

WARNING
WARNING
Brake pedal position
● Use only the designated brake fluid. 44.0 mm (1.73 in)
Other brake fluids may cause the rubber
● Refill with the same type of brake fluid
chemical reaction, leading to poor brake
performance.
● When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point
of the brake fluid and could cause vapor
lock.
NOTICE
3. Bleed:
• Brake system
4. Check:
• Brake fluid level
Below the minimum level mark “a” → Add
proper level.
Refer to “CHECKING THE BRAKE
UPPER
LOWER a
5. Check:
• Brake pedal operation
system.
6. Adjust:
• Brake pedal position
Refer to “ADJUSTING THE REAR DISC
BRAKE” on page 3-20.
4-40
HANDLEBARS CHAS
HANDLEBARS
Removing the handlebars

7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.R
.
1 2 LS LS
8
9 7 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.R
.
3 5
17
5 4
6 15
7 Nm (0.7 m • kg, 5.1 ft • Ib) 16
T.R
.
13 Nm (1.3 m • kg, 9.4 ft • Ib)

T.R
.
18 18 22 LS
19 12 14
19 11
20
LS
21
20 LS
13
10
2.5 Nm (0.25 m • kg, 1.8 ft • Ib)
T.R
.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.R
.
23 Nm (2.3 m • kg, 17 ft • Ib)

T.R
.

1 Left grip end 1
2 Left handlebar weight 1
3 Handlebar grip 1
4 Clutch switch coupler 1 Disconnect.
5 Left handlebar switch 1
6 Clutch switch 1
7 Clutch cable 1 Disconnect.
8 Clutch lever 1
9 Clutch lever holder 1
10 Right grip end 1
11 Right handlebar weight 1
12 Right handlebar switch 1
13 Throttle cable 1 Disconnect.
14 Throttle grip 1
15 Spacer 1
16 Front brake master cylinder holder 1
4-41
HANDLEBARS CHAS
Removing the handlebars
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.R
.
1 2 LS LS
8
9 7 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.R
.
3 5
17
5 4
6 15
7 Nm (0.7 m • kg, 5.1 ft • Ib) 16
T.R
.
13 Nm (1.3 m • kg, 9.4 ft • Ib)

T.R
.
18 18 22 LS
19 12 14
19 11
20
LS
21
20 LS
13
10
2.5 Nm (0.25 m • kg, 1.8 ft • Ib)
T.R
.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.R
.
23 Nm (2.3 m • kg, 17 ft • Ib)

T.R
.

17 Front brake master cylinder 1
18 Plug 2
19 Handlebar bolt 2
20 Handlebar pinch bolt 2
21 Left handlebar 1
22 Right handlebar 1
procedure.
4-42
HANDLEBARS CHAS
REMOVING THE HANDLEBARS ● Align the end of the brake master cylinder
1. Stand the vehicle on a level surface. holder with the punch mark “a” on the han-
dlebar.
WARNING ● First, tighten the upper bolt, then the lower
Securely support the vehicle so that there bolt.
2. Remove: 1
• Handlebar grip “1”
TIP
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the a
grip off the handlebar.
2
3. Install:
• Spacer “1”
• Throttle grip “2”
• Throttle cables
• Right handlebar switch “3”
TIP
● Be sure to position the spacer between the
front brake master cylinder and the right
handlebar switch.
CHECKING THE HANDLEBARS ● Lubricate the end of the throttle cables and
1. Check: the inside of the throttle grip with a thin coat
• Left handlebar of the lithium-soap-based grease, and then
• Right handlebar install the throttle grip onto the right handle-
Bends/cracks/damage → Replace bar.
● Route the throttle cables through the slots in
WARNING the throttle grip, and then install the cables.
Do not attempt to straighten a bent handle- ● Align the projection “a” on the right handle-
bar as this may dangerously weaken it. bar switch with the hole “b” in the right han-
dlebar.
INSTALLING THE HANDLEBARS
a
WARNING b 3
WARNING
Securely support the vehicle so that there 2

2. Install:
• Front brake master cylinder “1”
• Front brake master cylinder holder “2” 1 3
Front brake master cylinder 4. Install:
holder bolt • Right handlebar weight
T.
R.
7 Nm (0.7 m·kg, 5.1 ft·lb) • Right grip end “1”

TIP TIP
TIP
● Install the brake master cylinder holder with There should be 0.4-2.0 mm (0.02-0.08 in) of
the “UP” mark facing up. clearance “a” between the throttle grip and the
right grip end.
4-43
HANDLEBARS CHAS
8. Install:
• Left handlebar switch “1”
TIP
Align the projection “a” on the left handlebar
switch with the hole “b” in the left handlebar.
1 a
b
5. Install:
• Clutch lever holder “1”
Clutch lever holder bolt
7 Nm (0.7 m·kg, 5.1 ft·lb)
T.
R.
1
TIP
Align the end of the clutch lever holder with the 9. Connect:
punch mark “a” on the left handlebar. • Clutch switch coupler
10. Install:
a • Handlebar grip “1”
• Left handlebar weight
• Left grip end “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of rubber adhesive onto
the end of the left handlebar.
b. Slide the handlebar grip over the end of the
left handlebar.
1 c. Wipe off any excess rubber adhesive with a
6. Install: clean rag.
• Clutch lever WARNING
• Clutch switch “1” Do not touch the handlebar grip until the
TIP rubber adhesive has fully dried.
Align the projection “a” on the clutch switch
with the slit “b” in the clutch lever holder. TIP
There should be 0.4-2.0 mm (0.02-0.08 in) of
clearance “a” between the handlebar grip and
the left grip end.
a
1
b
7. Connect:
• Clutch cable 11. Check:
• Cable routing
TIP
Lubricate the end of the clutch cable with a thin
coat of lithium-soap-based grease.
4-44
HANDLEBARS CHAS
TIP
Make sure the main switch lead, brake hose,
throttle cable, clutch cable, and handlebar
switch leads are routed properly. Refer to
“CABLE ROUTING” on page 2-31.
12. Adjust:
Refer to “ADJUSTING THE CLUTCH
LEVER FREE PLAY” on page 3-13.

10.0-15.0 mm (0.39-0.59 in)
13.Adjust:
3.0-5.0 mm (0.12-0.20 in)
4-45
FRONT FORK CHAS

FRONT FORK
Removing the front fork legs

23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
21 Nm (2.1 m • kg, 15 ft • Ib)
T.R
.
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
3
2
28 Nm (2.8 m • kg, 20 ft • Ib)
T.
R.
4
6
5
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
9 Nm (0.9 m • kg, 6.5 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
T.
R.
R.

The following procedure applies to both of
the front fork legs.
Front wheel Refer to “FRONT WHEEL” on page 4-6.
1 Front fender
2 Cap bolt cover
3 Handlebar pinch bolt Loosen.
4 Cap bolt Loosen.
5 Upper bracket pinch bolt Loosen.
6 Lower bracket pinch bolt Loosen.
7 Front fork leg
procedure.
4-46
FRONT FORK CHAS

Disassembling the front fork legs
1
2 New
3 13
4
5
14
7 New
8 New
6
15 New
16 New
11
17
12
10 New
9
LT 23 Nm (2.3 m • kg, 17 ft • Ib)

T.R
.

The following procedure applies to both of
the front fork legs.
1 Cap bolt 1
2 O-ring 1
3 Plate 1
4 Spacer 1
5 Washer 1
6 Fork spring 1
7 Dust seal 1
8 Oil seal clip 1
9 Damper rod bolt 1
10 Copper washer 1
11 Damper rod 1
12 Rebound spring 1
13 Inner tube 1
14 Oil flow stopper 1
15 Oil seal 1
16 Outer tube bushing 1
4-47
FRONT FORK CHAS

Disassembling the front fork legs
1
2 New
3 13
4
5
14
7 New
8 New
6
15 New
16 New
11
17
12
10 New
9
LT 23 Nm (2.3 m • kg, 17 ft • Ib)

T.R
.

17 Outer tube 1
procedure.
4-48
FRONT FORK CHAS

REMOVING THE FRONT FORK LEGS
front fork legs.
WARNING
2. Remove
• Cap bolt cover
2. Remove:
3. Loosen:
• Dust seal “1”
• Handlebar pinch bolt “1”
• Oil seal clip “2”
• Cap bolt “2”
(with a flat-head screwdriver)
• Upper bracket pinch bolt “3”
• Lower bracket pinch bolt “4” NOTICE
WARNING Do not scratch the inner tube.
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
1
3
1
3. Remove:
• Oil seal “1”
4. Remove:
• Damper rod bolt “1”
• Damper rod
TIP
4 While holding the damper rod with the damper
rod holder “2” and T-handle “3”, loosen the
damper rod bolt.
T-handler
90890-01326
4. Remove:
• Front fork leg
DISASSEMBLING THE FRONT FORK LEGS 1

The following procedure applies to both of the 2
front fork legs.
1. Drain:
• Fork oil
TIP 3
Stroke the inner tube several times while
draining the fork oil.
4-49
FRONT FORK CHAS

CHECKING THE FRONT FORK LEGS WARNING
front fork legs. ● Make sure the oil levels in both front fork
1. Check: legs are equal.
• Inner tube ● Uneven oil levels can result in poor han-
• Outer tube dling and a loss of stability.
Bends/damage/scratches → Replace. TIP
WARNING ● When assembling the front fork leg, be sure
to replace the following parts:
Do not attempt to straighten a bent inner
- Outer tube bushing
tube as this may dangerously weaken it.
- Oil seal
2. Measure: - Dust seal
• Spring free length “a” - Oil seal clip
Out of specification → Replace. - O-ring (Cap bolt)
● Before assembling the front fork leg, make
Fork spring free length sure all of the components are clean.
384.8 mm (15.15 in)
Limit 1. Install:
377.1 mm (14.85 in) • Damper rod “1”
• Rebound spring “2”
NOTICE
Allow the damper rod to slide slowly down
the inner tube “3” until it protrudes from
the bottom of the inner tube. Be careful not
to damage the inner tube.
2 1
3
3. Check:
• Damper rod
Obstruction → Blow out all of the oil
passages with compressed air.
• Oil flow stopper 2. Lubricate:
Damage → Replace. • Inner tube's outer surface
4. Check:
Recommended oil
• Cap bolt O-ring
Fork oil 10W or equivalent
NOTICE
When disassembling and assembling the
front fork leg, do not allow any foreign
material to enter the front fork.
ASSEMBLING THE FRONT FORK LEGS

front fork legs.
4-50
FRONT FORK CHAS

3. Install: 7. Install:
• Inner tube “1” • Oil seal “1” New
(into outer tube “2”) (with the Fork seal driver weight “2”)
• Oil flow stopper “3”
NOTICE
Make sure the numbered side of the oil seal
faces up.
TIP
● Before installing the oil seal, lubricate its
lips with lithium-soap-based grease.
1 ● Lubricate the outer surface of the inner tube
with fork oil.
3 ● Before installing the oil seal, cover the top
2 of the front fork leg with a plastic bag to pro-
tect the oil seal during installation.
4. Install:
• Copper washer New
• Damper rod bolt
5. Tighten:
• Damper rod bolt “1”
Damper rod bolt
23 Nm (2.3 m·kg, 17 ft·lb)
T.
R.
LOCTITE®
TIP
While holding the damper rod with the damper
rod holder “2” and T-handle “3”, tighten the
damper rod bolt.
T-handler
90890-01326
1 8. Install:
2
• Oil seal clip “1” New
TIP
Adjust the oil seal clip so that it fits into the
outer tube's groove.
3
6. Install:
• Outer tube bushing “1”
New
2 New
New 1
4-51
FRONT FORK CHAS

9. Install: 12. Before measuring the fork oil level, wait
• Dust seal “1” New ten minutes until the oil has settled and the
(with the fork seal driver weight “2”) air bubbles have dispersed.
TIP
Be sure to bleed the front fork leg of any resid-
ual air.
13. Measure:
• Front fork leg oil level “a”
(from the top of the inner tube, with the
inner tube fully compressed and without
the fork spring)
Out of specification → Correct.
10. Fill: Level

126.0 mm (4.96 in)
• Front fork leg
(with the specified amount of the
recommended fork oil)
Recommended oil
Fork oil 10W or equivalent.
Quantity
240.0 cm³ (8.12 US oz, 8.47
Imp.oz)
NOTICE
● Be sure to use the recommended fork
oil. Other oils may have an adverse
effect on front fork performance. 14. Install:
● When disassembling and assembling • Fork spring “1”
the front fork leg, do not allow any for- • Washer “2”
eign material to enter the front fork. • Spacer
• Plate
11. After filling the front fork leg, slowly stroke • Cap bolt
the inner tube “1” up and down (at least (along with the O-ring) New
ten times) to distribute the fork oil.
TIP
TIP
Be sure to stroke the inner tube slowly
● Install the spring with the larger pitch “a”
because the fork oil may spurt out.
facing up.
● Before installing the cap bolt, lubricate its
O-ring with grease.
● Temporarily tighten the cap bolt.
2
a
1
4-52
FRONT FORK CHAS

INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the 3
front fork legs.
1. Install:
• Front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts. 2
TIP 4
Make sure the inner tube is flush with the top
of the handlebar.
2. Tighten:
• Lower bracket pinch bolt “1”
Lower bracket pinch bolt
30 Nm (3.0 m·kg, 22 ft·lb)
T.
R.
• Upper bracket pinch bolt “2”

Upper bracket pinch bolt
21 Nm (2.1 m·kg, 15 ft·lb)
T.
R.
• Cap bolt “3”

Cap bolt
13 Nm (1.3 m·kg, 9.4 ft·lb)
T.
R.
• Handlebar pinch bolt “4”

Handlebar pinch bolt
23 Nm (2.3 m·kg, 17 ft·lb)
T.
R.
1. Install:
• Cap bolt cover
WARNING
Make sure the brake hose, clutch cable,
and leads are routed properly.
4-53
STEERING HEAD CHAS

STEERING HEAD
Removing the lower bracket

35 Nm (3.5 m • kg, 25 ft • Ib)
T .R
.
3
4
16
14 5
LS
6
17
7
LS 8
LT
New 18 9
10 LT
11
7 Nm (0.7 m • kg, 5.1 ft • Ib) 12
T.R
.
13
15
2 1
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
1st 55 Nm (5.5 m • kg, 40 ft • lb)

T.
2nd 22 Nm (2.2 m • kg, 16 ft • lb)

R.

Upper panels Refer to “GENERAL CHASSIS” on page 4-
1.
Front fork legs Refer to “FRONT FORK” on page 4-46.
Handlebars Refer to “HANDLEBARS” on page 4-41.
1 Speed sensor lead holder 1
3 Steering stem bolt 1
4 Upper bracket 1
5 Mainswitch 1
6 Lock washer 1
7 Upper ring nut 1
8 Rubber washer 1
9 Lower ring nut 1
10 Lower bracket 1
11 Bearing cover 1
12 Upper bearing inner race 1
4-54
STEERING HEAD CHAS

Removing the lower bracket
35 Nm (3.5 m • kg, 25 ft • Ib)
T .R
.
3
4
16
14 5
LS
6
17
7
LS 8
LT
New 18 9
10 LT
11
7 Nm (0.7 m • kg, 5.1 ft • Ib) 12
T.R
.
13
15
2 1
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
1st 55 Nm (5.5 m • kg, 40 ft • lb)

T.
2nd 22 Nm (2.2 m • kg, 16 ft • lb)

R.

13 Upper bearing 1
14 Lower bearing 1
15 Upper bearing outer race 1
16 Lower bearing outer race 1
17 Lower bearing inner race 1
18 Dust seal 1
procedure.
* Removing and installing the ignition lock screw by using special tool [(Main switch steering lock
(T-30)].
4-55
STEERING HEAD CHAS

REMOVING THE LOWER BRACKET b. Remove the bearing race from the lower
1. Stand the vehicle on a level surface. bracket with a floor chisel “2” and hammer.
c. Install a new dust seal and new bearing
WARNING races.
is no danger of it falling over. NOTICE
If the bearing races are not installed prop-
2. Remove: erly, the steering head pipe could be dam-
• Lock washer aged.
• Upper ring nut
• Rubber washer TIP
• Lower ring nut “1” ● Always replace the bearings and bearing
• Lower bracket races as a set.
TIP ● Whenever the steering head is disassem-
Remove the lower ring nut with the steering bled, replace the dust seal.
nut wrench “2”.
Steering nut socket

90890-01403
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
CHECKING THE STEERING HEAD

1. Wash:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Bearings
• Bearing races 4. Check:
• Upper bracket
Recommended cleaning solvent • Lower bracket
Kerosene (along with the steering stem)
Bends/cracks/damage → Replace.
2. Check:
• Bearings INSTALLING THE STEERING HEAD
• Bearing races
1. Lubricate:
Damage/pitting → Replace.
• Upper bearing
3. Replace: • Lower bearing
• Bearings • Bearing races
• Bearing races
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Recommended lubricant
a. Remove the bearing races from the steer- Lithium-soap-based grease
ing head pipe with a long rod “1” and ham-
mer.
4-56
STEERING HEAD CHAS

2. Install:
• Lower ring nut
• Rubber washer
• Upper ring nut
• Lock washer
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-24.
3. Install:
• Upper bracket
• Washer
• Steering stem bolt
TIP
Temporarily tighten the steering stem bolt.
4. Install:
• Front fork legs
Refer to “INSTALLING THE FRONT
FORK LEGS” on page 4-53.
TIP
Temporarily tighten the upper and lower
bracket pinch bolts.
5. Tighten:
• Steering stem bolt
Steering stem bolt
35 Nm (3.5 m·kg, 25 ft·lb)
4-57
REAR SHOCK ABSORBER ASSEMBLY CHAS

EAS23160
REAR SHOCK ABSORBER ASSEMBLY

Removing the rear shock absorber assembly
44 Nm (4.4 m • kg, 32 ft • Ib)
T.
R.
5
LS
5
7
7 6
4
LS 2 4
LS
10 New
8 9
11
10 New 3 1
LS
2 11
New 10
44 Nm (4.4 m • kg, 32 ft • Ib)
T.
R.
LS 9
3 11 10 New
New 10 LS
1

Side Cover (L/H and R/H) Refer to “GENERAL CHASSIS” on
page 4-1.
1 Connecting arm nut/rear bolt 1/1
2 Connecting arm nut/front bolt 1/1
3 Connecting arm 2
4 Rear shock absorber assembly lower nut/bolt 1/1
5 Rear shock absorber assembly upper nut/bolt 1/1
6 Rear shock absorber assembly 1
7 Relay arm nut/bolt 1/1
8 Relay arm 1
9 Spacer 3
10 Oil seal 6
11 Bearing 3
procedure.
4-58

REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY Recommended lubricant
WARNING 2. Install:
• Bearing “1”
(to the relay arm)
• Oil seal “2”
TIP (to the relay arm)
Oil seal installed depth “a”
the rear wheel is elevated. 0.5 mm (0.02 in)
CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY
2 a 2
1. Check: 3
• Rear shock absorber rod
Bends/damage → Replace the rear
shock absorber assembly. 5
• Rear shock absorber
5 1
Oil leaks → Replace the rear shock
absorber assembly. 4
• Spring A B
Damage/wear → Replace the rear shock
absorber assembly. a
2 2
• Bushing
Damage/wear → Replace the rear shock
absorber assembly.
• Bolts
Bends/damage/wear → Replace.
CHECKING THE CONNECTING ARMS AND

a
RELAY ARM
1. Check:
• Connecting arms 3. Rear shock absorber assembly
• Relay arm 4. Relay arm
Damage/wear → Replace. 5. Connecting arm
2. Check: A. Left side
• Bearings B. Right side
• Oil seals
Damage/pitting → Replace. INSTALLING THE REAR SHOCK
3.Check: ABSORBER ASSEMBLY
• Spacers 1. Install:
Damage/scratches → Replace. • Rear shock absorber assembly
• Relay arm “1”
INSTALLING THE RELAY ARM
TIP
1. Lubricate: Install the relay arm as shown in the illustra-
• Spacers tion.
• Oil seals
• Bearings
4-59
FWD
2. Tighten:
• Rear shock absorber assembly upper nut
upper nut
T.
R.
44 Nm (4.4 m kg, 32 ft·lb)
• Relay arm nut

Relay arm nut
44 Nm (4.4 m kg, 32 ft·lb)
T.
R.
• Rear shock absorber assembly lower nut

lower nut
T.
R.
44 Nm (4.4 m kg, 32 ft·lb)
3. Install:
• Connecting arms
TIP
When installing the connecting arms, lift up the
swingarm.
4. Tighten:
• Connecting arm nuts
Connecting arm nut
44 Nm (4.4 m kg, 32 ft·lb)
T.
R.
4-60
SWINGARM CHAS
SWINGARM
Removing the swingarm

70Nm (7.0 m • kg, 50 ft • Ib)
T.
R.
3
LS
11
10
LS
7 New
69
11
8
7 New
LS
9 5 1
7 Nm (0.7 m • kg, 5.1 ft • Ib) 16Nm (1.6 m • kg, 11 ft •Ib)

T.
1
T.
R.
R.

Rear shock absorber assembly/Relay arm Refer to “REAR SHOCK ABSORBER
ASSEMBLY” on page 4-58.
Drive chain Refer to “CHAIN DRIVE” on page 4-64.
1 Drive chain adjusting bolt/locknut 2/2
2 Pivot shaft nut 1
3 Pivot shaft 1
4 Swingarm 1
5 Drive chain seal guide 1
6 Spacer 1
7 Oil seal 2
8 Bearing 1
4-61
SWINGARM CHAS
Removing the swingarm
70Nm (7.0 m • kg, 50 ft • Ib)

T.
R.
3
LS
11
10
LS
7 New
69
11
8
7 New
LS
9 5 1
7 Nm (0.7 m • kg, 5.1 ft • Ib) 16Nm (1.6 m • kg, 11 ft •Ib)

T.
1
T.
R.
R.

9 Dust cover 2
10 Spacer 1
11 Bearing 2
procedure.
4-62
SWINGARM CHAS
REMOVING THE SWINGARM • Spacers
1. Stand the vehicle on a level surface. • Dust covers
• Pivot shaft
WARNING
Securely support the vehicle so that there Recommended lubricant
is no danger of it falling over. Lithium-soap-based grease
TIP 2. Install:
Place the vehicle on a suitable stand so that • Bearings “1”
the rear wheel is elevated.
Bearing installed depth “a”
0.5 -1.5 mm (0.02-0.06 in)
CHECKING THE SWINGARM
1. Check:
• Swingarm
Bends/cracks/damage - Replace.
a 1 2 1 a
2. Check:
• Pivot shaft
Roll the pivot shaft on a flat surface. A B
Bends → Replace.
WARNING
Do not attempt to straighten a bent pivot
shaft. 2. Swingarm
A. Left side
B. Right side
3. Install:
• Rear shock absorber assembly
• Relay arm
• Connecting arms
• Rear wheel
Refer to “REAR SHOCK ABSORBER
ASSEMBLY” on page 4-58 and “” on
page 4-13.
3. Wash: 4. Adjust:
• Pivot shaft • Drive chain slack
• Dust covers Refer to “ADJUSTING THE DRIVE
• Spacers CHAIN SLACK” on page 3-23.
Recommended cleaning solvent Drive chain slack

Kerosene 25.0- 35.0 mm (0.98-1.37 in)
4. Check:
• Dust covers
• Spacers
• Oil seals
• Bearings
Damage/pitting → Replace.
INSTALLING THE SWINGARM

1. Lubricate:
• Bearings
4-63
CHAIN DRIVE CHAS

CHAIN DRIVE
Removing the drive chain
4
5 New
3
2 56
New
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

Lose the drive chain adjusting locknut and
wheel axle nut and push the wheel forward.
1 Drive sprocket cover 1
2 Drive chain 1
3 Chain Joint 1
4 Chain link 1
5 O-ring 4
6 Outer plate 1
procedure.
4-64
CHAIN DRIVE CHAS

REMOVING THE DRIVE CHAIN BY USING 3. By holding the clamping “1”, tighten the
CHAIN CUTTER pressure bolt “2” to remove the link pin “3”.
1 3
WARNING
TIP 2
the rear wheel is elevated. TIP
Do ensure that link pin is coming out while
a. Loosen the axle nut and drive chain slack tightening the pressure bolt.
adjuster locknut on each side of the swing-
arm. CHECKING THE DRIVE CHAIN
• Remove the drive chain sprocket cover 1. Measure:
• 15-link section “a” of the drive chain
Drive chain cutter & riveting tool
90890-01550 Out of specification → Replace the drive
chain.
1. Install pressure bolt “1” and cutter pin to “2”
15-link length limit
to clamp holder “3”.
191.5 mm (7.54 in)
2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the length “a” between the inner
sides of the pins and the length “b”
between the outer sides of the pins on a
3 15-link section of the drive chain as shown
in the illustration.
1
2. Attach Clamp “1” and clamp holder “2”
assembly on drive chain “3”.
TIP
During assembly clamp holder locking screw
should be tight on “A” position.
3
b. Calculate the length “c” of the 15-link sec-
A
tion of the drive chain using the following
formula.
Drive chain 15-link section length “c” =
(length “a” between pin inner sides + length
“b” between pin outer sides)/2
TIP
2 1
TIP
● When measuring a 15-link section of the

drive chain, make sure that the drive chain
is taut.
● Perform this procedure 2-3 times, at a dif-
ferent location each time.
4-65
CHAIN DRIVE CHAS
b. Correct
1. Drive chain roller
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Drive chain sprocket
2. Check:
• Drive chain CHECKING THE REAR WHEEL SPROCKET
Stiffness → Clean and lubricate or Refer to “CHECKING AND REPLACING THE
replace. REAR WHEEL SPROCKET” on page 4-16.
CHECKING THE REAR WHEEL DRIVE HUB

Refer to “CHECKING THE REAR WHEEL
DRIVE HUB” on page 4-16.
INSTALLING THE DRIVE CHAIN BY USING

CHAIN RIVETING TOOL
1. Install Cutter pin “1” with pressure bolt on
clamp holder “2”.
Drive chain cutter & riveting tool
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 90890-01550
3. Check:
• O-rings “1”
Damage → Replace the drive chain. 1
1
• Drive chain rollers “2”
Damage/wear → Replace the drive chain.
• Drive chain side plates “3”
Damage/wear → Replace the drive chain.
Cracks → Replace the drive chain. 2
2. Lubricate:
• Drive chain
• Chain link
• O-ring
Chain lubricant
CHECKING THE DRIVE SPROCKET suitable for O-ring chains
1. Check: 3. Install new chain link “1” with O-rings “2”
• Drive sprocket and fix on drive chain “3”
More than 1/4 tooth “a” wear → Replace
the drive chain sprockets as a set.
Bent teeth → Replace the drive chain
sprockets as a set.
4-66
CHAS
TIP
1 2 During flaring, Ensure Cutter pin is in line with
3
chain link pin.
A B
4. Install O-rings “1” and outer plate “2” with-

joint “3”.
3
1
A : Rivet “1st” point
1 B : Rivet “2nd” point
2 2 IMPORTANT :
1. Remove the special tool and measure flar-
TIP ing size of riveted pins, it should be 4.75
5. During installation of outer plate “1” +0.2 mm.
remember “writing side DID” should be out-
ward. Flaring size of riveted pins
4.75 + 0.2mm (0.177 + 0.007 in)
DID
6. Attach pressure plate “1” with pressure bolt

holder set “2” and screw it for locking.
● Install pressure plate as shown in illustra- 8. Tighten the axle nut, and then tighten the
tion and fixing of link plate in drive chain. chain adjuster locknuts to the specified
torque.
2
A Tightening torque :
Axle nut:
90 Nm (9.0 m kgf, 65 ft lbf)
Looknut:
16 Nm (1.6 m kgf, 12 ft lbf)
1 9. Install:
TIP • Drive chain sprocket cover
Clamp holder locking screw should be set on TIP
“A” position. Be sure not to pinch the neutral switch lead
when installing the drive sprocket cover.
7. After installing the joint plate “1” from spe-
cial tool, remove pressure plate and adjust 10. Adjust:
the clamp to 'B' position and screw in the • Drive chain slack
pressure bolt for flaring of rivet of both the Refer to “ADJUSTING THE DRIVE
link pins by tightening the pressure bolt.
CHAIN SLACK” on page 3-23.
4-67
CHAIN DRIVE CHAS
Drive chain slack

25.0-35.0 mm (0.98-1.37 in)
NOTICE
A drive chain that is too tight will overload
the engine and other vital parts, and one
that is too loose can skip and damage the
swingarm or cause an accident. Therefore,
keep the drive chain slack within the speci-
fied limits.
NOTICE
CLEANING AND LUBRICATING THE DRIVE ● This motorcycle has a drive chain with
CHAIN small rubber O-rings “1” between the
1. Stand the vehicle on a level surface. drive chain side plates. Never use high-
pressure water or air, steam, gasoline,
WARNING certain solvents (e.g., benzine), or a
Securely support the vehicle so that there coarse brush to clean the drive chain.
is no danger of it falling over. High-pressure methods could force dirt
or water into the drive chain's internals,
TIP and solvents will deteriorate the O-rings.
Place the vehicle on a suitable stand so that A coarse brush can also damage the O-
the rear wheel is elevated. rings. Therefore, use only chain cleaning
solvent to clean the drive chain.
2. Clean:
• Drive chain 3. Lubricate:
a. Remove all deposits of dust, soil, mud, oil • Drive chain
etc. during washing and dry it with air blow.
Spray the chain cleaning solvent and wait 5 Recommended lubricant
minutes to remove grease deposition. Chain lubricant
suitable for O-ring chains
a. Spray the lubricant inside the chain

between inner/outer plates roller and
bushes as shown in illustration.
TIP
● Shake the cleaner well before use
● During washing of vehicle, never use kero-
sene, petrol or any other solvent for clean-
ing.
b. After spraying wait for 15 minutes.
b. Wipe the drive chain with a clean cloth. c. Wipe the drive chain with a clean cloth.
4-68
ENG
CHAPTER 5
ENGINE
ENGINE REMOVAL ........................................................................................ 5-1

INSTALLING THE ENGINE....................................................................... 5-5
INSTALLING THE SHIFT ARM ................................................................. 5-5
CYLINDER HEAD............................................................................................ 5-6

REMOVING THE CYLINDER HEAD......................................................... 5-8
CHECKING THE CYLINDER HEAD ......................................................... 5-9
CHECKING THE CAMSHAFT SPROCKET AND TIMING CHAIN GUIDE5-10
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-10
CAMSHAFT ...................................................................................................5-11
REMOVING THE ROCKER ARMS AND CAMSHAFT............................5-12
CHECKING THE CAMSHAFT................................................................. 5-12
CHECKING THE DECOMPRESSION SYSTEM.....................................5-13
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........5-13
INSTALLING THE CAMSHAFT AND ROCKER ARMS ..........................5-14
INSTALLING THE CYLINDER HEAD ..................................................... 5-14
VALVES AND VALVE SPRINGS.................................................................. 5-17

REMOVING THE VALVES ......................................................................5-18
CHECKING THE VALVES AND VALVE GUIDES .................................. 5-18
CHECKING THE VALVE SEATS ............................................................ 5-20
CHECKING THE VALVE SPRINGS........................................................ 5-21
INSTALLING THE VALVES ....................................................................5-22
CYLINDER AND PISTON.............................................................................. 5-24

REMOVING THE PISTON ......................................................................5-25
CHECKING THE CYLINDER AND PISTON ........................................... 5-25
CHECKING THE PISTON RINGS...........................................................5-26
CHECKING THE PISTON PIN ................................................................ 5-27
INSTALLING THE PISTON AND CYLINDER .........................................5-27
GENERATOR AND STARTER CLUTCH...................................................... 5-29

REMOVING THE GENERATOR .............................................................5-31
REMOVING THE STARTER CLUTCH ................................................... 5-31
CHECKING THE STARTER CLUTCH ....................................................5-31
INSTALLING THE STARTER CLUTCH ..................................................5-32
INSTALLING THE GENERATOR............................................................ 5-32
ELECTRIC STARTER ...................................................................................5-34

CHECKING THE STARTER MOTOR ..................................................... 5-36
ASSEMBLING THE STARTER MOTOR ................................................. 5-37
ENG
CLUTCH ........................................................................................................ 5-38
REMOVING THE CLUTCH ..................................................................... 5-41
REMOVING THE CLUTCH PUSH LEVER ............................................. 5-41
CHECKING THE FRICTION PLATES..................................................... 5-41
CHECKING THE CLUTCH PLATES ....................................................... 5-42
CHECKING THE CLUTCH SPRINGS..................................................... 5-42
CHECKING THE CLUTCH HOUSING ....................................................5-42
CHECKING THE CLUTCH BOSS ...........................................................5-43
CHECKING THE PRESSURE PLATE ....................................................5-43
CHECKING THE CLUTCH PUSH LEVER AND SHORT
CLUTCH PUSH ROD ............................................................................. 5-43
CHECKING THE PRIMARY DRIVE GEAR ............................................. 5-43
CHECKING THE PRIMARY DRIVEN GEAR .......................................... 5-43
INSTALLING THE CLUTCH ....................................................................5-43
OIL PUMP...................................................................................................... 5-46

CHECKING THE OIL PUMP ................................................................... 5-48
ASSEMBLING THE OIL PUMP ...............................................................5-48
INSTALLING THE OIL PUMP ................................................................. 5-49
SHIFT SHAFT................................................................................................ 5-50

CHECKING THE SHIFT SHAFT .............................................................5-51
CHECKING THE STOPPER LEVER ...................................................... 5-51
INSTALLING THE SHIFT SHAFT ...........................................................5-51
BALANCER GEAR........................................................................................5-52
REMOVING THE PRIMARY DRIVE GEAR AND BALANCER GEARS.. 5-54
CHECKING THE BALANCER GEARS AND PRIMARY DRIVE GEAR .. 5-54
ASSEMBLING THE BALANCER DRIVEN GEAR ...................................5-54
INSTALLING THE PRIMARY DRIVE GEAR AND BALANCER GEARS 5-54
CRANKCASE ................................................................................................ 5-56

SEPARATING THE CRANKCASE .......................................................... 5-59
REMOVING THE CRANKCASE BEARING ............................................ 5-59
CHECKING THE CRANKCASE .............................................................. 5-59
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE ............. 5-60
CHECKING THE OIL STRAINER ...........................................................5-60
CHECKING THE BEARINGS AND OIL SEAL ........................................ 5-60
INSTALLING THE BEARING RETAINER ............................................... 5-60
ASSEMBLING THE CRANKCASE.......................................................... 5-60
CRANKSHAFT ..............................................................................................5-62
REMOVING THE CRANKSHAFT ...........................................................5-63
CHECKING THE CRANKSHAFT ............................................................ 5-63
INSTALLING THE CRANKSHAFT .......................................................... 5-63
ENG
TRANSMISSION............................................................................................5-65
CHECKING THE SHIFT FORKS.............................................................5-68
CHECKING THE SHIFT DRUM ASSEMBLY .......................................... 5-68
CHECKING THE TRANSMISSION .........................................................5-68
CHECKING THE CLUTCH PUSH RODS ............................................... 5-69
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ..............................5-69
INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY ......5-69
ENG
ENGINE REMOVAL ENG

ENGINE
ENGINE REMOVAL
Removing the muffler
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.R
.
LT
2
2 New
LT
5
(2)
20 Nm (2.0 m • kg, 14 ft • Ib)

T.R
.
LT
7 Nm (0.7 m • kg, 5.1 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 15 Nm (1.5 m • kg, 11 ft • Ib)
T.R
T.R
T.R
.
.
.

Refer to “GENERAL CHASSIS” on page 4-
Right cowlings/Right bottom cowling
1.
1 Muffler end cap 1
2 Muffler mounting bolt 2
3 Muffler protector 1
4 Muffler 1
5 Exhaust pipe gasket 1
procedure
5-1
ENGINE REMOVAL ENG
Disconnecting the leads and couplers
2
3
9 Nm (0.9 m • kg, 6.5 ft • Ib)

T.R
.
6
7
9
LT
4 Nm (0.4 m • kg, 2.9 ft • Ib) 4
T.R
.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.R
.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.R
.
3.5 Nm (0.35 m • kg, 2.5 ft • Ib)

T.R
.

NOTICE
First, disconnect the negative battery
lead, and then the positive battery lead.
Refer to “CHECKING AND CHARGING THE

Negative battery lead/Positive battery lead
BATTERY” on page 8-63.
Drain.
page 3-12.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-18.
Passenger and rider seat/Side covers Refer to “GENERAL CHASSIS” on page 4-
Front bottom cowling/Air filter case 1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Throttle body/Intake manifold Refer to “THROTTLE BODY” on page 7-4.
Water pump breather hose/Radiator outlet
hose/Radiator inlet hose/Radiator
Drive sprocket cover/Drive sprocket Refer to “CHAIN DRIVE” on page 4-64.
5-2
ENGINE REMOVAL ENG
Disconnecting the leads and couplers
2
3
9 Nm (0.9 m • kg, 6.5 ft • Ib)

T.R
.
6
7
9
LT
4 Nm (0.4 m • kg, 2.9 ft • Ib) 4
T.R
.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.R
.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.R
.
3.5 Nm (0.35 m • kg, 2.5 ft • Ib)

T.R
.

1 Spark plug cap 1 Disconnect.
2 Coolant temperature sensor coupler 1 Disconnect.
3 Stator coil coupler/Crankshaft position 1/1 Disconnect.
sensor coupler
4 Neutral switch connector 1 Disconnect.
5 Starter motor lead 1 Disconnect.
6 Clutch cable 1 Disconnect.
7 Negative battery lead 1 Disconnect.
8 Shift arm 1
procedure.
5-3
ENGINE REMOVAL ENG
Removing the engine
49 Nm (4.9 m • kg, 35 ft • Ib)

T.R
4
.
28 Nm (2.8 m • kg, 20 ft • Ib)

T.R
.
1 3
E
4
E 2
5
3
49 Nm (4.9 m • kg, 35 ft • Ib)

T.R
.

TIP
Place a suitable stand under the engine.
1 Muffler bracket 1
2 Engine mounting bolt/nut (front side) 1/1
3 Engine mounting bolt/nut (rear lower side) 1/1
4 Engine mounting bolt/nut (rear upper side) 1/1
5 Engine 1
procedure.
5-4
ENGINE REMOVAL ENG

INSTALLING THE ENGINE INSTALLING THE SHIFT ARM
1. Install: 1. Install:
• Engine “1” • Shift arm “1”
• Engine mounting bolt (rear upper side) “2” TIP
• Engine mounting nut (rear upper side) “3” Make sure that the distances “a” and “b”
• Engine mounting bolt (rear lower side) “4” between the center of the shift shaft “2” and the
• Engine mounting nut (rear lower side) “5” center of the shift pedal “3” are within specifica-
• Engine mounting bolt (front side) “6” tion.
• Engine mounting nut (front side) “7”
TIP Shift pedal distance “a”
● Lubricate the engine mounting bolt threads 12.0 mm (0.47 in) or less
with engine oil. Shift pedal distance “b”
● Do not fully tighten the bolts and nuts. 13.0 mm (0.51 in) or less
Shift arm bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
2
R.
3
1 2
a
4 b
3
6
5
2. Tighten:
• Engine mounting nut (rear upper side)
Engine mounting nut (rear upper

side)
T.
R.
49 Nm (4.9 m·kg, 35 ft·lb)
• Engine mounting nut (rear lower side)
Engine mounting nut (rear lower

side)
T.
R.
49 Nm (4.9 m·kg, 35 ft·lb)
• Engine mounting nut (front side)
Engine mounting nut (front side)

49 Nm (4.9 m·kg, 35 ft·lb)
T.
R.
5-5
CYLINDER HEAD ENG

CYLINDER HEAD
Removing the cylinder head
9
10

Passenger and rider seat/Front cowlings/ Refer to “GENERAL CHASSIS” on page 4-
Air filter case 1.
Throttle body/Intake manifold Refer to “THROTTLE BODY” on page 7-4.
Thermostat/Coolant temperature sensor Refer to “THERMOSTAT” on page 6-4.
Water pump Refer to “WATER PUMP” on page 6-6.
Radiator Refer to “RADIATOR” on page 6-1.
Muffler Refer to “ENGINE REMOVAL” on page 5-1.
Disconnect.
Clutch cable
Refer to “CLUTCH” on page 5-38.
1 Spark plug cap 1
2 Spark plug 1
3 Crankshaft end accessing screw 1
4 Timing mark accessing screw 1
5 Engine mounting bolt/nut (front side) 1/1
* YAMAHA BOND NO. 1215
5-6
CYLINDER HEAD ENG
Removing the cylinder head
9
10

6 Cylinder head cover 1
7 Cylinder head cover gasket 1
8 Dowel pin 1
9 Timing chain tensioner 1
10 Timing chain tensioner gasket 1
11 Camshaft sprocket 1
12 Decompression cam 1
13 Cylinder head 1
14 Cylinder head gasket 1
15 Dowel pin 2
16 Timing chain guide (exhaust side) 1
procedure.
* YAMAHA BOND NO. 1215
5-7
CYLINDER HEAD ENG

REMOVING THE CYLINDER HEAD
1. Remove:
• Passenger and rider seat.
• Side covers and cowlings. b
• Spark plug using a spark plug spanner “1”
• Coolant drain bolt and radiator cap, then
drain the coolant from cylinder.
• Radiator hoses and radiator fan coupler,
then drain the coolant from radiator. a
• Radiator from chassis.
• Water pump assembly from cylinder head
with its ‘O’ ring.
d
c
1
ZAUE0100
2. Remove: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Crank shaft end accessing screw “1” and 2. Loosen:

timing mark accessing screw “2” with its • Camshaft sprocket bolt “1”
cap ‘O’ ring. TIP
3. Remove: While holding the generator rotor nut with a
• Cylinder head cover by removing the bolt wrench “2”, loosen the camshaft sprocket bolt.
in crisscross pattern.
• Retract chain tensioner to loss the tension
• Cylinder head cover along with its gasket.
by using the small screwdriver.
1. Align:
• “I” mark “a” on the generator rotor (with
the stationary pointer “b” on the generator
cover)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1
a. Turn the crankshaft counterclockwise. 2

b. When the piston is at TDC on the compres-
sion stroke, align the “I” mark “c” on the
camshaft sprocket with the stationary
pointer “d” on the cylinder head.
3. Remove:
• Camshaft sprocket by removing the bolts
• Decompression cam
NOTICE
Be careful about bolt falling into the crank-
case.
TIP
To prevent the timing chain from falling into the
crankcase, fasten it with a steel wire “1”.
5-8
CYLINDER HEAD ENG
• Timing chain tensioner by removing 2 • Cylinder head
allen bolts with their washers Damage/scratches → Replace.
• Cylinder head • Cylinder head water jacket
TIP Mineral deposits/rust → Eliminate.
● Loosen the bolts in the proper sequence as 3. Measure:
shown. • Cylinder head warpage
● Loosen each bolt 1/2 of a turn at a time. After Out of specification → Resurface the
all of the bolts are fully loosened, remove cylinder head.
bolts 1, 2, 4, and 6, and then remove the cyl-
inder head with bolts 3 and 5 installed in the Warpage limit
0.03 mm (0.0012 in)
bolt holes.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straight edge “1” and a thickness
6 4 gauge “2” across the cylinder head.
2
1
3 5
CHECKING THE CYLINDER HEAD

1. Eliminate:
• Combustion chamber carbon deposits b. Measure the warpage.
(with a rounded scraper) c. If the limit is exceeded, resurface the cylin-
TIP der head as follows.
Do not use a sharp instrument to avoid damag- d. Place a 400–600 grit wet sandpaper on the
ing or scratching: surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
● Spark plug bore threads
● Valve seats TIP
To ensure an even surface, rotate the cylinder
head several times.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-9
CYLINDER HEAD ENG

CHECKING THE CAMSHAFT SPROCKET b. Remove the screwdriver and slowly release
AND TIMING CHAIN GUIDE the timing chain tensioner rod.
1. Check: c. Make sure that the timing chain tensioner
rod comes out of the timing chain tensioner
• Camshaft sprocket
housing smoothly. If there is rough move-
More than 1/4 tooth wear “a”→ Replace ment, replace the timing chain tensioner.
the camshaft sprocket, timing chain and
crankshaft as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. 1/4 tooth
b. Correct
1. Timing chain roller
2. Camshaft sprocket
2. Check:
• Timing chain guide (exhaust side)
CHECKING THE TIMING CHAIN

TENSIONER
1. Check:
• Timing chain tensioner
Cracks/damage/rough movement→
Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Lightly press the timing chain tensioner rod
into the timing chain tensioner housing by
hand.
TIP
While pressing the timing chain tensioner rod,
wind it clockwise with a thin screwdriver “1” until
it stops.
5-10
CAMSHAFT ENG
CAMSHAFT
Removing the rocker arms and camshaft
1 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
1
2
2 5
M
M
1 2
1 2 6 E
M 7 E
4
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
E New
M
3
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.

Cylinder head Refer to “CYLINDER HEAD” on page 5-6.
1 Locknut 4
2 Adjusting screw 4
3 Camshaft retainer 1
4 Rocker arm shaft 2
5 Intake rocker arm 1
6 Exhaust rocker arm 1
7 Camshaft 1
procedure.
5-11
CAMSHAFT ENG
REMOVING THE ROCKER ARMS AND
Camshaft lobe dimensions
CAMSHAFT Intake A
1. Loosen: 30.225–30.325 mm (1.1900–1.1939 in)
• Locknut “1” Limit
• Valve clearance adjusting screw “2” 30.125 mm (1.1860 in)
Intake B
25.127–25.227 mm (0.9893–0.9932 in)
2
Limit
25.027 mm (0.9853 in)
Exhaust A
30.232–30.332 mm (1.1902–1.1942 in)
1 Limit
30.132 mm (1.1863 in)
Exhaust B
25.065–25.165 mm (0.9869–0.9907 in)
Limit
2. Remove: 24.965 mm (0.9829 in)
• Rocker arm shaft and rocker arm
• Camshaft “1”
TIP
Screw 8-mm (0.31-in) bolt “2” into the threaded
end of the camshaft and then pull out the cam-
shaft.
Slide hammer bolt

90890-01085
T.
R.
3. Check:
CHECKING THE CAMSHAFT • Camshaft oil passage
1. Check: Obstruction → Blow out with compressed
• Camshaft lobes air.
Blue discoloration/pitting/scratches →
Replace the camshaft.
2. Measure:
• Camshaft lobe dimensions “a” and “b”
Out of specification → Replace the
camshaft.
5-12
CAMSHAFT ENG
CHECKING THE DECOMPRESSION CHECKING THE ROCKER ARMS AND
SYSTEM ROCKER ARM SHAFTS
1. Check: The following procedure applies to all of the
• Decompression system rocker arms and rocker arm shafts.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1. Check:
a. Check the decompression system with the • Rocker arm
camshaft sprocket and the decompression Damage/wear → Replace.
cam installed to the camshaft.
2. Check:
b. Check that the decompression lever “1” • Rocker arm shaft
moves smoothly.
Blue discoloration/excessive wear/pitting/
c. Without operating the decompression lever, scratches → Replace or check the
check that the decompression cam “2”
lubrication system.
projects from the camshaft (exhaust cam)
as shown in the illustration “A”. 3. Measure:
d. Move the decompression lever “1” in the • Rocker arm inside diameter “a”
direction of the arrow shown and check that Out of specification → Replace.
the decompression cam does not project
from the camshaft (exhaust cam) as shown Rocker arm inside diameter
in the illustration “B”. 9.985–10.000 mm (0.3931–0.3937 in)
Limit
10.015 mm (0.3943 in)
1
A
2
4. Measure:
• Rocker arm shaft outside diameter “a”
Out of specification → Replace.
Rocker arm shaft outside

diameter
9.966–9.976 mm (0.3924–0.3928 in)
Limit
9.935 mm (0.3911 in)
B 2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Calculate:
• Rocker-arm-to-rocker-arm-shaft
clearance
5-13
CAMSHAFT ENG
TIP
Calculate the clearance by subtracting the 1
rocker arm shaft outside diameter from the
rocker arm inside diameter.

defective part(s).
Rocker-arm-to-rocker-arm-shaft
clearance
0.009–0.034 mm (0.0004–0.0013 in)
Limit
0.074 mm (0.0029 in)
4. Install:
• Rocker arms (Inlet and exhaust)
INSTALLING THE CAMSHAFT AND
• Rocker arm shafts “1”
ROCKER ARMS
TIP
1. Lubricate: ● Make sure that the cutout “a” in each rocker
• Rocker arms arm shaft is facing downward as shown in
• Rocker arm shafts the illustration.
● Make sure the rocker arm shafts (intake and
exhaust) are completely pushed into the cyl-
Rocker arm inner surface
Molybdenum disulfide oil inder head.
Rocker arm shaft
Engine oil 1
2. Lubricate: 1 a
• Camshaft
Camshaft
Molybdenum disulfide grease
Camshaft bearing
Engine oil
3. Install: INSTALLING THE CYLINDER HEAD

• Camshaft “1” 1. Install:
TIP
• Cylinder head
Make sure that the camshaft projections “a” and TIP
hole “b” are positioned as shown in the illustra- Pass the timing chain through the timing chain
tion. cavity.
2. Tighten:
b • Cylinder head bolts “1”
Cylinder head bolt

22 Nm (2.2 m·kg, 16 ft·lb)
T.
R.
1
• Cylinder head bolts “2”
a
Cylinder head bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
TIP
TIP
Before installing the camshaft fix the “O” ring “1” ● Lubricate the cylinder head bolts and wash-
ers with engine oil.
as shown in the illustration.
5-14
CAMSHAFT ENG
● Tighten the cylinder head bolts in the proper NOTICE
tightening sequence as shown and torque
them in two stages. Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
2 valve timing.
1 3
e. While holding the camshaft, temporarily
5
tighten the camshaft sprocket bolt.
1 f. Remove the steel wire from the timing
chain.
6 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 2 4. Install:
2 • Timing chain tensioner gasket New
3. Install: • Timing chain tensioner by installing the
• Camshaft sprocket bolts
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise. a. Apply sealant to the timing chain tensioner
b. Align the “I” mark “a” on the generator rotor bolt threads.
with the stationary pointer “b” on the genera-
tor cover. Yamaha bond No. 1215
(Three Bond No.1215®)
c. Align the “I” mark “c” on the camshaft
sprocket with the stationary pointer “d” on
the cylinder head. b. While lightly pressing the timing chain ten-
sioner rod by hand, turn the tensioner rod
d. Install the timing chain onto the camshaft fully clockwise with a thin screwdriver “1”.
sprocket, and then install the camshaft
sprocket onto the camshaft. c. With the timing chain tensioner rod turned
all the way into the timing chain tensioner
housing (with the small screwdriver still
installed), install the gasket and the timing
b chain tensioner “2” onto the cylinder block.
d. Tighten the timing chain tensioner bolts “3”
to the specified torque.
Timing chain tensioner bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
a
T.
R.
TIP
When installing the camshaft sprocket, be sure
to keep the timing chain as tight as possible on
the exhaust side.
5-15
CAMSHAFT ENG
1 c
7. Tighten:
• Camshaft sprocket bolt
2 Camshaft sprocket bolt
30 Nm (3.0 m·kg, 22ft·lb)
3 T.
R.
NOTICE
1 Be sure to tighten the camshaft sprocket
bolt to the specified torque to avoid the
possibility of the bolt coming loose and
damaging the engine.
e. Remove the screwdriver, make sure the tim-
ing chain tensioner rod releases, and then 8. Install:
install the timing chain tensioner cap. • Water pump assembly with its new ‘O’
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ring and tighten the water pump housing
5. Turn: bolts with specified tightening torque.
• Crankshaft (several turns
Water pump bolt
counterclockwise)
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
6. Check:
R.
• “I” mark “a” • Radiator and radiator hoses. Fill the

Align the “I” mark on the generator rotor coolant to the radiator.
with the stationary pointer “b” on the • Crankshaft end accessing screw and
generator cover. Timing mark accessing screw with its new
• “I” mark “c” ‘O’ ring
Align the “I” mark on the camshaft • Side panel and cowlings
sprocket with the stationary pointer “d” on Refer to “GENERAL CHASSIS” on page 4-
the cylinder head. 1.
Out of alignment → Correct. • Rider and passenger seat
Refer to the installation steps above. Refer to “GENERAL CHASSIS” on page 4-
1.
9. Measure:
b • Valve clearance
Refer to “ADJUSTING THE VALVE
CLEARANCE” on page 3-4.
a Valve clearance (cold)

Intake
0.10–0.14 mm (0.0039–0.0055 in)
Exhaust
0.20–0.24 mm (0.0079–0.0094 in)
5-16
VALVES AND VALVE SPRINGS ENG

VALVES AND VALVE SPRINGS
Removing the valves and valve springs
1
2
1
3
6 New
2
3
M
7
New 6
7 8
M
M
8
M 5
7 8
3 6 New
2
1
5
1 7 8
6 New
2 3
M
4 4
M

Rocker arms/Camshaft Refer to “CAMSHAFT” on page 5-11.
1 Valve cotter 8
2 Upper spring seat 4
3 Valve spring 4
4 Intake valve 2
5 Exhaust valve 2
6 Valve stem seal 4
7 Lower spring seat 4
8 Valve guide 4
procedure.
5-17

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

GUIDES
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ valves and valve guides.
2. Remove: 1. Measure:
• Valve cotters “1” • Valve-stem-to-valve-guide clearance
TIP Out of specification → Replace the valve
Remove the valve cotters by compressing the guide.
valve spring with the valve spring compressor
“2” and valve spring compressor attachment • Valve-stem-to-valve-guide clearance =
“3”. Valve guide inside diameter “a” -
Valve stem diameter “b
Valve spring compressor
90890-04019
90890-04108
5-18

2. Eliminate:
Valve-stem-to-valve-guide
• Carbon deposits
clearance (intake)
0.010–0.037 mm (0.0004–0.0015 in) (from the valve face and valve seat)
Limit 3. Check:
0.080 mm (0.0032 in) • Valve face
Valve-stem-to-valve-guide Pitting/wear → Grind the valve face.
clearance (exhaust) • Valve stem end
0.025–0.052 mm (0.0010–0.0020 in) Mushroom shape or diameter larger than
Limit the body of the valve stem → Replace the
0.100 mm (0.0039 in) valve.
4. Measure:
• Valve margin thickness D “a”
Out of specification → Replace the valve.
Valve margin thickness D (intake)

0.50–0.90 mm (0.0197–0.0354 in)
Valve margin thickness D (exhaust)
0.50–0.90 mm (0.0197–0.0354 in)
5. Measure:
• Valve stem runout
Out of specification → Replace the valve.
Valve and valve guide clearance = a-b
TIP
● When installing a new valve, always replace
the valve guide.
● If the valve is removed or replaced, always
replace the valve stem seal.
Valve stem runout

0.010 mm (0.0004 in)
5-19

CHECKING THE VALVE SEATS 4. Lap:
The following procedure applies to all of the • Valve face
valves and valve seats. • Valve seat
1. Eliminate: TIP
• Carbon deposits After replacing the cylinder head or replacing
(from the valve face and valve seat) the valve and valve guide, the valve seat and
2. Check: valve face should be lapped.
• Valve seat ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Pitting/wear → Replace the cylinder head. a. Apply a coarse lapping compound “a” to the
3. Measure: valve face.
• Valve seat width C “a”
Out of specification → Replace the NOTICE
cylinder head. Do not let the lapping compound enter the
gap between the valve stem and the valve
Valve seat width C (intake) guide.
0.90–1.10 mm (0.0354–0.0433 in)
Valve seat width C (exhaust)
0.90–1.10 mm (0.0354–0.0433 in)
b. Apply molybdenum disulfide oil onto the

valve stem.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply Mechanic’s blueing dye (Dykem) “b”
onto the valve face.
c. Install the valve into the cylinder head.

d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all of
b. Install the valve into the cylinder head. the lapping compound.
c. Press the valve through the valve guide and TIP
onto the valve seat to make a clear impres- For the best lapping results, lightly tap the valve
sion. seat while rotating the valve back and forth
d. Measure the valve seat width. between your hands.
TIP
Where the valve seat and valve face contacted
one another, the blueing will have been
removed.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-20

Free length (intake)
41.71 mm(1.64 in)
Limit
39.62mm (1.56 in)
Free length (exhaust)
41.71mm(1.64 in)
Limit
39.62 mm (1.56 in)
e. Apply a fine lapping compound to the valve

face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) “b”
onto the valve face.
2. Measure:
• Compressed valve spring force “a”
Out of specification → Replace the valve
spring.
Installed compression spring

force (intake)
140.00-162.00 N (14.28-16.52 kgf,
31.47-36.42 lbf)
h. Install the valve into the cylinder head. Installed compression spring
i. Press the valve through the valve guide and force (exhaust)
onto the valve seat to make a clear impres- 140.00-162.00 N (14.28-16.52 kgf,
sion. 31.47-36.42 lbf)
j. Measure the valve seat width “c” again. If Installed length (intake)
the valve seat width is out of specification, 35.30 mm (1.39 in)
reface and lap the valve seat. Installed length (exhaust)
35.30 mm (1.39 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE VALVE SPRINGS

The following procedure applies to all of the b. Installed length
valve springs.
3. Measure:
1. Measure: • Valve spring tilt “a”
• Valve spring free length “a” Out of specification → Replace the valve
Out of specification → Replace the valve spring.
spring.
5-21

• Valve “3”
Spring tilt (intake)
• Valve spring “4”
1.4 mm (0.06 in)
Spring tilt (exhaust) • Upper spring seat “5”
1.4 mm (0.06 in) (into the cylinder head)
TIP
● Make sure each valve is installed in its origi-
nal place.
● Install the valve springs with the larger pitch
“a” facing up.
New
INSTALLING THE VALVES

valves and related components.
1. Deburr:
• Valve stem end
(with an oil stone)
New
b. Smaller pitch
4. Install:
• Valve cotters “1”
2. Lubricate:
• Valve stem “1” TIP
• Valve stem seal “2” New Install the valve cotters by compressing the
(with the recommended lubricant) valve spring with the valve spring compressor
“2”.
Molybdenum disulfide oil Valve spring compressor
90890-04019
90890-04108
3. Install:
• Lower spring seat “1”
• Valve stem seal “2” New
5-22
5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
NOTICE
Hitting the valve tip with excessive force
could damage the valve.
5-23
CYLINDER AND PISTON ENG

CYLINDER AND PISTON
Removing the cylinder and piston
8 E
9
6
E
1 5
E
New 4 4 New
New
2 New
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.

1 Cylinder 1
2 Cylinder gasket 1
3 Dowel pin 2
4 Piston pin clip 2
5 Piston pin 1
6 Piston 1
7 Top ring 1
8 2nd ring 1
9 Oil ring 1
procedure.
5-24

REMOVING THE PISTON CHECKING THE CYLINDER AND PISTON
• Piston pin clips “1” • Piston wall
• Piston pin “2” • Cylinder wall
• Piston “3” Vertical scratches → Replace the
cylinder, and replace the piston and piston
NOTICE rings as a set.
Do not use a hammer to drive the piston 2. Measure:
pin out. • Piston-to-cylinder clearance
TIP ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
● Before removing the piston pin clip, cover a. Measure cylinder bore “C” with the cylinder
the crankcase opening with a clean rag to bore gauge “1”.
prevent the piston pin clip from falling into
the crankcase.
● Before removing the piston pin, deburr the 1
piston pin clip groove and the piston pin bore
area.
Guide plate
Guide head
2 1 TIP
Measure cylinder bore “C” by taking side-to-side
and front-to-back measurements of the cylinder.
Then, find the average of the measurements.
3
Bore
2. Remove: 56.985–57.010 mm
• Top ring (2.2435–2.2445 in)
• 2nd ring Taper limit
• Oil ring 0.05 mm (0.0020 in)
TIP Out of round limit
When removing a piston ring, open the end gap 0.05 mm (0.0020 in)
with your fingers and lift the other side of the
ring over the piston crown. Cylinder bore “C” = D1 -D2 (Maximum diameter)
“T” = maximum of D1 or D2 - maximum of D5

or D6
“R” = maximum of D1, D3 or D5 - minimum of

D2, D4 or D6
5-25

b. If out of specification, replace the cylinder, CHECKING THE PISTON RINGS
and replace the piston and piston rings as a 1. Measure:
set.
• Piston ring side clearance
c. Measure piston skirt diameter D “a” with the Out of specification → Replace the piston
micrometer.
and piston rings as a set.
TIP
Before measuring the piston ring side clear-
ance, eliminate any carbon deposits from the
piston ring grooves and piston rings.
Piston ring
Top ring
Ring side clearance
0.030–0.065 mm
(0.0012–0.0026 in)
d. 5.0 mm (0.20 in) from the bottom edge of the Limit
piston
0.100 mm (0.0039 in)
2nd ring
Piston Ring side clearance
Diameter D 0.020–0.055 mm
56.965–56.990 mm (0.0008–0.0022 in)
(2.2427– 2.2437 in) Limit
0.100 mm (0.0039 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”
Piston-to-cylinder clearance
0.015-0.025 mm (0.0005-0.0009 in)
Limit
0.15 mm (0.0059 in) 2. Install:
• Piston ring
f. If out of specification, replace the cylinder, (into the cylinder)
and replace the piston and piston rings as a
set. TIP
Level the piston ring into the cylinder with the
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
piston crown.
a. 40 mm (1.57 in)
5-26

3. Measure: 3. Measure:
• Piston ring end gap • Piston pin bore diameter “b”
Out of specification → Replace the piston Out of specification → Replace the piston.
ring.
Piston pin bore inside diameter
TIP 14.002–14.013 mm
The oil ring expander spacer end gap cannot be (0.5513–0.5517 in)
measured. If the oil ring rail gap is excessive, Limit
replace all three piston rings. 14.043 mm (0.5529 in)
Piston ring
Top ring
End gap (installed)
0.10–0.25 mm (0.0039–0.0098 in)
Limit
0.40 mm (0.0157 in)
2nd ring
End gap (installed)
0.10–0.25 mm (0.0039–0.0098 in)
Limit
0.40 mm (0.0157 in)
Oil ring 4. Calculate:
End gap (installed)
• Piston-pin-to-piston-pin-bore clearance
0.20–0.70 mm (0.0079–0.0276 in)
Out of specification → Replace the piston
pin and piston as a set.
CHECKING THE PISTON PIN
1. Check: • Piston-pin-to-piston-pin-bore clearance =
• Piston pin Piston pin bore diameter “b” -
Blue discoloration/grooves → Replace the Piston pin outside diameter “a”
piston pin and then check the lubrication
system. Piston-pin-to-piston-pin-bore
2. Measure: clearance
• Piston pin outside diameter “a” 0.002–0.018 mm
Out of specification → Replace the piston (0.0001–0.0007 in)
pin. Limit
0.068 mm (0.0027 in)
Piston pin outside diameter
13.995–14.000 mm INSTALLING THE PISTON AND CYLINDER
(0.5510–0.5512 in)
Limit 1. Install:
13.975 mm (0.5502 in) • Oil ring expander “1”
• Lower oil ring rail “2”
• Upper oil ring rail “3”
• 2nd ring “4”
• Top ring “5”
TIP
Be sure to install the piston rings so that the
manufacturer marks or numbers face up.
5-27
e a
120
5
c
4 120 120
3 90
1
d 45 b
2 A 45
a. Top ring
2. Install: b. Upper oil ring rail
• Piston “1” c. Oil ring expander
• Piston pin “2” d. Lower oil ring rail
• Piston pin clips “3” New e. 2nd ring
A. Exhaust side
TIP
● Apply engine oil to the piston pin. 5. Install:
● Make sure the punch mark “a” on the piston • Dowel pins
points towards the exhaust side of the cylin- • Cylinder gasket New
der. TIP
● Before installing the piston pin clips, cover ● While compressing the piston rings with one
the crankcase opening with a clean rag to hand, install the cylinder with the other hand.
prevent the clips from falling into the crank- ● Pass the timing chain and timing chain guide
case. (intake side) through the timing chain cavity.
1
a 3 New
1
3. Lubricate:
• Piston
• Piston rings
• Cylinder
(with the recommended lubricant)
Engine oil
4. Offset:
• Piston ring end gaps
5-28
GENERATOR AND STARTER CLUTCH ENG

GENERATOR AND STARTER CLUTCH
Removing the stator coil, generator rotor, and starter clutch

1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.R
.
2
6 New
7 1 m • kg, 7.2 ft • Ib)

10 Nm (1.0
T.R
.
LT
L
LT
11 8
9
3 LS
13 L
LT
14 New
E
16 E
18 15
12 5 LS
New
E (3)
E 4
New 17 New
(7)
14 Nm (1.4 m • kg, 10 ft • Ib)
T.R
.
19
E 10 Nm (1.0 m • kg, 7.2 ft • Ib)
10
T.R
.
70 Nm (7.0 m • kg, 50 ft • lb)

T.R
.

Drain.
page 3-12.
Left bottom cowling/Left side cover Refer to “GENERAL CHASSIS” on page 4-
1.
Drive sprocket cover Refer to “CHAIN DRIVE” on page 4-64.
1 Stator coil coupler 1 Disconnect.
2 Crankshaft position sensor coupler 1 Disconnect.
3 Neutral switch connector 1 Disconnect.
4 Cowling bracket 1
5 Generator cover 1
6 Generator cover gasket 1
7 Dowel pin 2
8 Crankshaft position sensor 1
9 Stator coil 1
10 Generator rotor 1
11 Woodruff key 1
5-29
Removing the stator coil, generator rotor, and starter clutch

1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.R
.
2
6 New
7 1 m • kg, 7.2 ft • Ib)

10 Nm (1.0
T.R
.
LT
L
LT
11 8
9
3 LS
13 L
LT
14 New
E
16 E
18 15
12 5 LS
New
E (3)
E 4
New 17 New
(7)
14 Nm (1.4 m • kg, 10 ft • Ib)
T.R
.
19
E 10 Nm (1.0 m • kg, 7.2 ft • Ib)
10
T.R
.
70 Nm (7.0 m • kg, 50 ft • lb)

T.R
.

12 Starter clutch gear 1
13 Bearing 1
14 Washer 1
15 Starter clutch idle gear shaft 1
16 Washer 1
17 Circlip 1
18 Starter clutch idle gear 1
19 Starter clutch assembly 1
procedure.
5-30

REMOVING THE GENERATOR
1. Remove:
• Generator rotor nut “1”
• Washer 1
TIP 2
● While holding the generator rotor “2” with the
sheave holder “3”, loosen the generator rotor
nut.
● Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder REMOVING THE STARTER CLUTCH

90890-01701 1. Remove:
• Starter clutch bolts “1”
TIP
1 ● While holding the generator rotor “2” with the
sheave holder “3”, remove the starter clutch
bolts.
3
● Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder
90890-01701
2
2. Remove:
• Generator rotor “1” 1
(with the flywheel puller “2” by sheave
holder “3”)
• Woodruff key
NOTICE
To protect the end of the crankshaft, place 3 2
an appropriate sized socket between the
flywheel puller set center bolt and the
crankshaft. CHECKING THE STARTER CLUTCH
1. Check:
TIP
• Starter clutch rollers “1”
Make sure the flywheel puller is centered over
• Starter clutch spring caps “2”
the generator rotor.
• Starter clutch springs “3”
Damage/wear → Replace the starter
Flywheel puller
clutch assembly.
90890-01362
1 2 3
2
3
3
2 1
5-31

2. Check:
• Starter clutch idle gear New
• Starter clutch gear 1
Burrs/chips/roughness/wear → Replace
the defective part(s).
3. Check:
• Starter clutch gear contacting surfaces
Damage/pitting/wear → Replace the
starter clutch gear. 3 2
4. Check:
• Starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a
a. Install the starter clutch gear “1” onto the
starter clutch and hold the generator rotor. a
b. When turning the starter clutch gear clock-
wise “A”, the starter clutch and the starter
clutch gear should engage, otherwise the
starter clutch is faulty and must be replaced. a
c. When turning the starter clutch gear coun-
terclockwise “B”, it should turn freely, other-
wise the starter clutch is faulty and must be
INSTALLING THE GENERATOR
replaced.
1. Install:
A 1 • Woodruff key
• Generator rotor
• Washer
B • Generator rotor nut
TIP
● Clean the tapered portion of the crankshaft
and the generator rotor hub.
● When installing the generator rotor, make
sure the woodruff key is properly sealed in
the keyway of the crankshaft.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Tighten:
INSTALLING THE STARTER CLUTCH
• Generator rotor nut “1”
1. Install:
• Starter clutch assembly Generator rotor nut
• Starter clutch bolts “1” New 70 Nm (7.0 m·kg, 50 ft·lb)
T.
R.
Starter clutch bolt TIP

14 Nm (1.4 m·kg, 10 ft·lb) ● While holding the generator rotor “2” with the
T.
R.
magneto holder “3” and bush “4”, tighten the

TIP generator rotor nut.
● While holding the generator rotor “2” with the ● Do not allow the magneto holder to touch the
sheave holder “3”, tighten the starter clutch projection on the generator rotor.
bolts.
● Do not allow the sheave holder to touch the Sheave holder
projection on the generator rotor. 90890-01701
● Stake the end “a” of each starter clutch bolt.
Sheave holder
90890-01701
5-32
2
3. Apply:
• Sealant
(onto the crankshaft position sensor/stator
assembly lead grommet)
Yamaha bond No. 1215

(Three Bond No.1215®)
4. Install:
• Generator cover
Generator cover bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
TIP
Tighten the generator cover bolts in the proper
tightening sequence as shown.
1,6 7
5 8
4 9
3,11 2,10
5-33
ELECTRIC STARTER ENG

ELECTRIC STARTER
Removing the starter motor
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.R
.
2
New
LS

Refer to “GENERAL CHASSIS” on page 4-
Right front cowlings/Right bottom cowling
1.
1 Starter motor 1
2 Starter motor lead 1 Disconnect.
procedure.
5-34
Disassembling the starter motor
5
4 6
2 New
3
6
5

1 Starter motor yoke 1
2 O-ring 1
3 Commutator 1
4 Starter motor front cover/brush holder set 1
5 Brush 2
6 Brush spring 2
procedure.
5-35

CHECKING THE STARTER MOTOR
Multimeter
1. Check:
INS-003
• Commutator
Dirt → Clean with 600 grit sandpaper.
Armature coil
2. Measure: Commutator resistance “1”
• Commutator diameter “a” 0.0315.0.0385 Ω
Out of specification → Replace the starter Insulation resistance “2”
motor. Above 1 MΩ at 20°C (68°F)
Limit b. If any resistance is out of specification,

16.6 mm (0.65 in) replace the starter motor.
3. Measure: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Mica undercut “a”
5. Measure:
Out of specification → Scrape the mica to
• Brush length “a”
the proper measurement with a hacksaw
Out of specification → Replace the starter
blade that has been grounded to fit the
motor front cover/brush holder set.
commutator.
Mica undercut (depth) Limit

1.35 mm (0.05 in) 3.50 mm (0.14 in)
TIP
The mica of the commutator must be undercut
to ensure proper operation of the commutator.
6. Measure:
4. Measure:
• Brush spring force
• Armature assembly resistances
Out of specification → Replace the brush
(commutator and insulation)
springs as a set.
Out of specification → Replace the starter
motor.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Brush spring force
a. Measure the armature assembly resis- 3.92-5.88 N (400-600 gf, 14.11-
tances with the multimeter. 21.17 oz)
5-36

7. Check:
• Gear teeth
Damage/wear → Replace the starter
motor.
8. Check:
• Bearing
• Oil seal
• Damage/wear →Replace the starter
motor front cover/brush holder set.
ASSEMBLING THE STARTER MOTOR

1. Install:
• Starter motor front cover/brush holder set
“1”
• Starter motor yoke “2”
TIP
Align the marks “a” on the starter motor yoke
and starter motor front cover/brush holder set.
5-37
CLUTCH ENG
CLUTCH
Removing the clutch cover
5
New 4
LS
New 6
2
5
3 New
New LS
1
(4) (4)
LS
10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
T.
T.
R.
R.
R.

Engine oil Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-12.
Right bottom cowling Refer to “GENERAL CHASSIS” on page 4-
1.
1 Oil filter element cover 1
2 Oil filter element 1
3 Clutch cover 1
4 Clutch cover gasket 1
5 Dowel pin 2
6 Oil seal 1
procedure.
5-38
CLUTCH ENG
Removing the clutch
70 Nm (7.0 m • kg, 50 ft • lb)
T.
R.
12 Nm (1.2 m • kg, 8.7 ft • Ib) 11 New
T.
R.
8 Nm (0.8 m • kg, 5.8 ft • Ib)

T.
R.
E
10
3 6
12
4
5
1 7
17
8
9
(4) 8 16
2 9 15
E
(4) 8
7 13
14
E E

1 Locknut 1
2 Clutch spring 4
3 Pressure plate 1
4 Short clutch push rod 1
5 Clutch push rod holder 1
6 Ball 1
7 Friction plate 1 2
8 Clutch plate 3
9 Friction plate 2 2
10 Clutch boss nut 1
11 Lock washer 1
12 Clutch boss 1
13 Thrust washer 1
14 Clutch housing 1
15 Conical spring washer 1
16 Ball 1
17 Long clutch push rod 1
procedure.
5-39
CLUTCH ENG
Removing the clutch push lever
E
3
4 New
9 Nm (0.9 m • kg, 6.5 ft • Ib)
LS
T.R
.
E
1
5 New
6

Passenger and rider seat/Left front Refer to “GENERAL CHASSIS” on page 4-
cowlings/Left bottom cowling 1.
Pressure plate Refer to “Removing the clutch”.
1 Clutch cable Disconnect.
2 Clutch push lever
3 Clutch push lever spring
4 Circlip
5 Oil seal
6 Bearing
procedure.
5-40
CLUTCH ENG
REMOVING THE CLUTCH CHECKING THE FRICTION PLATES
1. Straighten the lock washer tab. The following procedure applies to all of the fric-
2. Loosen: tion plates.
• Clutch boss nut “1” 1. Check:
TIP • Friction plate
While holding the clutch boss “2” with the uni- Damage/wear → Replace the friction
versal clutch holder “3”, loosen the clutch boss plates as a set.
nut. 2. Measure:
• Friction plate thickness
Universal clutch holder Out of specification → Replace the friction
90890-04086 plates as a set.
TIP
Measure the friction plate at four places.
1
2.90–3.10 mm (0.114–0.122 in)
Wear limit
2 2.80 mm (0.110 in)
3 2.90–3.10 mm (0.114–0.122 in)
Wear limit
2.80 mm (0.110 in)
REMOVING THE CLUTCH PUSH LEVER

1. Remove:
• Clutch push lever “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Unhook the clutch push lever spring from
the clutch push lever “1”.
b. Turn the clutch push lever “1” 180° counter-
clockwise.
c. Remove the coolant reservoir bolts. A B
d. Move the coolant reservoir “2” forward as
shown in the illustration.
e Remove the clutch push lever “1”.
a b
2
A. Friction plate 1
1 B. Friction plate 2
a. Gap between friction material segments on
friction plate 1
b. Gap between friction material segments on
friction plate 2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TIP
The gap “a” on friction plate 1 is smaller than
the gap “b” on friction plate 2.
5-41
CLUTCH ENG
CHECKING THE CLUTCH PLATES CHECKING THE CLUTCH SPRINGS
The following procedure applies to all of the The following procedure applies to all of the
clutch plates. clutch springs.
1. Check: 1. Check:
• Clutch plate • Clutch spring
Damage → Replace the clutch plates as a Damage → Replace the clutch springs as
set. a set.
2. Measure: 2 Measure:
• Clutch plate thickness • Clutch spring free length “a”
(with a vernier caliper “1”) Out of specification → Replace the clutch
springs as a set.
Clutch spring free length

41.62 mm (1.64 in)
Minimum length
39.54 mm (1.56 in)
3. Measure:
• Clutch plate warpage
(with a surface plate and feeler gauge “1”)
Out of specification → Replace the clutch
plates as a set.
Feeler gauge set

YSST-715 CHECKING THE CLUTCH HOUSING
1. Check:
TIP • Clutch housing dogs “1”
Measure the warpage of the clutch plate at four Damage/pitting/wear → Deburr the clutch
places with feeler gauge. housing dogs or replace the clutch
housing.
Clutch plate thickness
TIP
1.45-1.75 mm (0.057–0.069 in)
Warpage limit Pitting on the clutch housing dogs will cause
0.20 mm (0.0079 in) erratic clutch operation.
2. Check:
• Bearing
Damage/wear → Replace the bearing and
clutch housing.
5-42
CLUTCH ENG
CHECKING THE CLUTCH BOSS CHECKING THE PRIMARY DRIVEN GEAR
1. Check: 1. Check:
• Clutch boss splines • Primary driven gear “1”
Damage/pitting/wear → Replace the Damage/wear → Replace the primary
clutch boss. drive gear and clutch housing as a set.
TIP Excessive noise during operation →
Pitting on the clutch boss splines will cause Replace the primary drive gear and clutch
erratic clutch operation. housing as a set.
INSTALLING THE CLUTCH

CHECKING THE PRESSURE PLATE
1. Install:
1. Check:
• Conical spring washer “1”
• Pressure plate
Cracks/damage → Replace. TIP
Install the conical spring washer in a way that its
CHECKING THE CLUTCH PUSH LEVER outer diameter should be butting on the clutch
AND SHORT CLUTCH PUSH ROD housing as shown in the illustration.
1. Check:
• Clutch push lever 1
• Short clutch push rod
Damage/wear → Replace the defective
part(s).
CHECKING THE PRIMARY DRIVE GEAR

1. Remove:
• Primary drive gear
Refer to “BALANCER GEAR” on page 5-
52. 2. Install:
2. Check: • Clutch housing
• Primary drive gear • Thrust washer
Damage/wear → Replace the primary
TIP
drive gear and clutch housing as a set.
● Lubricate the clutch housing with engine oil
Excessive noise during operation →
and install on the main shaft.
Replace the primary drive gear and clutch
housing as a set.
3. Install:
Refer to “BALANCER GEAR” on page 5-
52.
5-43
CLUTCH ENG
3. Install: 7. Lubricate:
• Clutch boss “1” • Friction plates
• Lock washer “2” New • Clutch plates
• Clutch boss nut “3” (with the recommended lubricant)
TIP
● Lubricate the clutch boss nut threads and Engine oil
lock washer mating surfaces with engine oil.
● Align the notch “a” in the lock washer with a 8. Install:
low rib “b” on the clutch boss. • Bearing
• Oil Seal
New 2 • Circlip
1
• Clutch push lever spring
• Clutch push lever
b
9. Install:
3 • Friction plate 1
• Clutch plates
a • Friction plate 2
• Clutch plates
• Friction plate 2
4. Tighten: • Clutch plates
• Friction plate 1
• Clutch boss nut “1”
TIP
Clutch boss nut First install a friction plate and then alternate
70 Nm (7.0 m·kg, 50 ft·lb) between a clutch plate and friction plate.
T.
R.
TIP 10. Install:

While holding the clutch boss “2” with the uni- • Long push rod
versal clutch holder “3”, tighten the clutch boss • Ball
nut. • Pressure plate
• Clutch springs “1”
Universal Clutch holder • Clutch spring bolts “2”
90890-04086
Clutch spring bolt
12 Nm (1.2 m·kg, 8.7 ft·lb)
T.
R.
1
TIP
Tighten the clutch spring bolts in stages and in
a crisscross pattern.
2
3
1
2
5. Bend the lock washer tab along a flat side of
the nut.
6. Check:
• Rotate the clutch boss and check for the
free rotation
11. Adjust:
• Clutch mechanism free play
5-44
CLUTCH ENG
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 12. Install:
a. Check that the projection “a” on the clutch • Oil seal (clutch cover) “1”
push lever “1” aligns with the mark “b”
shown on the crankcase in the illustration by Installed depth of oil seal “a”
pushing the clutch push lever manually in 35.9–36.4 mm (1.413–1.433 in)
direction “c” until it stops.
1
a
c
b a
1
13. Install:
• Gasket
• Clutch cover
b. If the projection “a” is not aligned with the Clutch cover bolt
mark “b”, align them as follows: 10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
• Loosen the locknut “2”.

• With the clutch push lever fully pushed in TIP
direction “c”, turn the short clutch push rod Tighten the clutch cover bolts in the proper
“3” in or out until the projection “a” aligns tightening sequence as shown.
with the mark “b”.
• Hold the short clutch push rod to prevent it
6
from moving, and then tighten the locknut 9
8
1,7
to specification.
5 9
Short clutch push rod locknut
8 Nm (0.8 m·kg, 5.8 ft·lb)
T.
R.
4 10
2,12
3,13 11
2
14. Adjust:
Refer to “ADJUSTING THE CLUTCH
LEVER FREE PLAY” on page 3-13.

3 10.0–15.0 mm (0.39–0.59 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-45
OIL PUMP ENG

OIL PUMP
Removing the oil pump
4 Nm (0.4 m • kg, 2.9 ft • Ib)

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

T.
R.

Clutch housing Refer to “CLUTCH” on page 5-38.
Balancer drive gear Refer to “BALANCER GEAR” on page 5-52.
1 Oil baffle plate 1
2 Oil pump assembly 1
3 Oil pump drive gear
procedure
5-46
OIL PUMP ENG
Disassembling the oil pump
1
E

1 Oil pump housing cover 1
2 Pin 1
3 Oil pump driven gear 1
4 Oil pump inner rotor 1
5 Oil pump outer rotor 1
6 Oil pump housing 1
procedure
5-47
OIL PUMP ENG

CHECKING THE OIL PUMP
Inner-rotor-to-outer-rotor-tip
1. Check: clearance
• Oil pump drive gear Less than 0.15 mm (0.0059 in)
• Oil pump driven gear Limit
• Oil pump housing 0.23 mm (0.0091 in)
• Oil pump housing cover Outer-rotor-to-oil-pump-hous-
Cracks/damage/wear → Replace the ing
defective part(s). clearance
2. Measure: 0.13.0.18 mm (0.0051.0.0071 in)
Limit
• Inner-rotor-to-outer-rotor-tip clearance
0.25 mm (0.0098 in)
“a” Oil-pump-housing-to-inner-and-
• Outer-rotor-to-oil-pump-housing outer-rotor clearance
clearance “b” 0.06.0.11 mm (0.0024.0.0043 in)
• . Oil-pump-housing-to-inner-rotor-and- Limit
outerrotor clearance “c” 0.18 mm (0.0071 in)
Out of specification → Replace the oil
pump. 3. Check:
• Oil pump operation
Rough movement → Repeat steps (1)
and (2) or replace the defective part(s).
ASSEMBLING THE OIL PUMP

1. Lubricate:
• Oil pump inner rotor
• Oil pump outer rotor
• Oil pump driven gear
(with the recommended lubricant)
1. Inner rotor Engine oil
2. Outer rotor
3. Oil pump housing 2. Install:
• Oil pump outer rotor
• Oil pump inner rotor “1”
• Oil pump driven gear
• Pin “2”
TIP TIP:
When installing the inner rotor, align the pin “2”

in the oil pump shaft with the groove “a” in the
inner rotor “1”.
5-48
OIL PUMP ENG
1
2
a
3. Check:
• Oil pump operation
• Refer to “CHECKING THE OIL PUMP”
on page 5-48.
INSTALLING THE OIL PUMP

1. Install:
• Oil pump assembly
Oil pump assembly screw

4 Nm (0.4 m·kg, 2.4 ft·lb)
T.
R.
NOTICE
NOTICE:
After tightening the screws, make sure the oil

pump turns smoothly.
5-49
SHIFT SHAFT ENG

SHIFT SHAFT
Removing the shift shaft and stopper lever
6 New
LS
New 2
E 3
LT
4
5
1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

Shift arm Refer to “ENGINE REMOVAL” on page 5-1.
Oil baffle plate Refer to “OIL PUMP” on page 5-46.
1 Shift shaft 1
2 Clip 1
3 Shift shaft spring 1
4 Stopper lever 1
5 Stopper lever spring 1
6 Oil seal 1
procedure
5-50
SHIFT SHAFT ENG

CHECKING THE SHIFT SHAFT
1. Check:
• Shift shaft
Bends/damage/wear → Replace.
• Shift shaft spring
3
CHECKING THE STOPPER LEVER
1. Check: 2 1
• Stopper lever
Bends/damage →Replace. TIP 3. Tighten the stopper lever bolt “1”
Roller turns roughly → Replace the TIP
stopper lever. Apply locking agent (LOCTITE R) to the threads
• Stopper lever spring off the oil stopper lever bolt.
INSTALLING THE SHIFT SHAFT

1. Install:
• Oil seal “1” New
(to the left crankcase “2”)
Installed depth “a”

0.0.5 mm (0.0.02 in)
1
4. Install:
2 • Shift shaft “1”
TIP TIP
Hook the end of the shift shaft spring onto the

New 1 shift shaft spring stopper “2”
2. Install:
• Stopper lever “1”
• Stopper lever spring “2”
TIP
TIP
● Install the stopper lever spring as shown in 2

the illustration.
1
● Hook the ends of the stopper lever spring
onto the stopper lever and the crankcase
boss “3”.
● Mesh the stopper lever with the shift drum
segment assembly.
5-51
BALANCER GEAR ENG

BALANCER GEAR
Removing the primary drive gear and balancer gears
5
14 12
4 10
11
3 13
1 16
15
60 Nm (6.0 m • kg, 43 ft • Ib)
T.R
.
E
9
8
50 Nm (5.0 m • kg, 36 ft • Ib)
T.R
.
7 New
2

1 Primary drive gear nut 1
2 Balancer driven gear nut 1
3 Washer 1
4 Primary drive gear 1
5 Balancer drive gear 1
6 Straight key 1
7 Lock washer 1
8 Balancer driven gear plate 1 1
9 Balancer driven gear assembly 1
10 Straight key 1
11 Balancer driven gear plate 1
12 Spacer 1
13 Balancer driven gear 1
14 Buffer boss 1
15 Spring 1
5-52
BALANCER GEAR ENG
Removing the primary drive gear and balancer gears
5
14 12
4 10
11
3 13
1 16
15
60 Nm (6.0 m • kg, 43 ft • Ib)
T.R
.
E
9
8
50 Nm (5.0 m • kg, 36 ft • Ib)
T.R
.
7 New
2

16 Dowel pin 4
procedure
5-53
BALANCER GEAR ENG

REMOVING THE PRIMARY DRIVE GEAR 2. Check:
AND BALANCER GEARS • Primary drive gear
1. Loosen: Refer to “CHECKING THE PRIMARY
• Primary drive gear nut “1” DRIVEN GEAR” on page 5-43.
TIP
TIP ASSEMBLING THE BALANCER DRIVEN
Place an aluminum plate “a” between the bal- GEAR
ancer drive gear “2” and the balancer driven
gear “3”, and then loosen the primary drive gear 1. Assemble:
nut. • Buffer boss “1”
• Balancer driven gear “2”
TIP TIP
2 Align the punch mark “a” on the buffer boss with

the punch mark “b” on the balancer driven gear.
3
1
1
a
2. Straighten the lock washer tab.

b a 2
3. Loosen:
Balancer driven gear nut “1”
TIP
INSTALLING THE PRIMARY DRIVE GEAR
AND BALANCER GEARS
TIP
Place an aluminum plate “a” between the bal-

ancer drive gear “2” and the balancer driven 1. Install:
gear “3”, and then loosen the balancer driven • Balancer driven gear “1”
gear nut. • Lock washer New
• Balancer drive gear “2”
a • Washer “3”
2
• Balancer driven gear nut
• Primary drive gear nut
1 TIP TIP
● Align the punch mark “a” on the balancer

drive gear “2” with the punch mark “b” on
3 the balancer driven gear “1”.
● Be sure to install the washer so that its
sharp edge “c” is facing the primary drive
gear.
CHECKING THE BALANCER GEARS AND
PRIMARY DRIVE GEAR
2
1. Check:
• Balancer drive gear 1
• Balancer driven gear
• Buffer boss
• Springs
• Dowel pins
• Cracks/damage/wear → Replace the a b
defective part(s).
5-54
BALANCER GEAR ENG
2. Tighten:
Balancer driven gear nut “1”
Primary drive gear nut “2”
Balancer driven gear nut

50 Nm (5.0 m kg, 36 ft·lb)
T.
R.
Primary drive gear nut

60 Nm (6.0 m kg, 43 ft·lb)
TIP
TIP
● Place an aluminum plate “a” between the

balancer drive gear “3” and the balancer
driven gear “4”, and then tighten the bal-
ancer driven gear nut.
● Place an aluminum plate “b” between the
balancer drive gear “3” and the balancer
driven gear “4”, and then tighten the primary
drive gear nut.
1
a
b
3
2
1
3. Bend the lock washer tab along a flat side of

the nut.
5-55
CRANKCASE ENG
CRANKCASE
Separating the crankcase
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.R
.
8 New 10 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.R
.
9 8 New
12
11
3
2
6
1
5
11
New 7
LS
4
New
32 Nm (3.2 m • kg, 23 ft • Ib)

T.R
17 Nm (1.7 m • kg, 12 ft • Ib)

.
T.R
.

T.R
T.R
.

Engine Refer to “ENGINE REMOVAL” on page 5-1.
Refer to “CYLINDER AND PISTON” on
Cylinder/Piston
page 5-24.
Oil pump assembly Refer to “OIL PUMP” on page 5-46.
Shift shaft Refer to “SHIFT SHAFT” on page 5-50.
Refer to “ELECTRIC STARTER” on page 5-
Starter motor
34.
Balancer gears Refer to “BALANCER GEAR” on page 5-52.
Crankshaft Refer to “GENERATOR AND STARTER
CLUTCH” on page 5-29.
1 Timing chain guide (intake side) 1
2 Timing chain guard 1
3 Timing chain 1
4 Engine oil drain plug 1
5 Spring 1
5-56
CRANKCASE ENG
Separating the crankcase

10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.R
.
8 New 10 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.R
.
9 8 New
12
11
3
2
6
1
5
11
New 7
LS
4
New
32 Nm (3.2 m • kg, 23 ft • Ib)

T.R
17 Nm (1.7 m • kg, 12 ft • Ib)

.
T.R
.

T.R
T.R
.

6 Engine oil strainer
7 Neutral switch
8 Circlip
9 Spacer
10 Right crankcase
11 Dowel pin
12 Left crankcase
procedure
5-57
CRANKCASE ENG
Removing the oil seal and bearings
3 E
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.R
.
3 E
2
3
3
LT
3 3 M
1 New
E LS

Crankshaft/Balancer Refer to “CRANKSHAFT” on page 5-62.
Transmission Refer to “TRANSMISSION” on page 5-65.
1 Oil seal 1
2 Bearing retainer 1
3 Bearing 7
procedure
5-58
CRANKCASE ENG
SEPARATING THE CRANKCASE NOTICE
NOTICE
1. Remove: Tap on one side of the crankcase with a soft-

• Crankcase bolts face hammer. Tap only on reinforced portions of
TIP the crankcase, not on the crankcase mating
TIP
Loosen each bolt 1/4 of a turn at a time, in surfaces. Work slowly and carefully and make
stages and in a crisscross pattern. After all of sure the crankcase halves separate evenly.
the bolts are fully loosened, remove them.
REMOVING THE CRANKCASE BEARING
A 1. Remove:
• Drive axle bearing with help of a bearing
puller “1”.
Bearing remover kit

KLK 31-3
2. Remove:
B
• Main axle bearing
• Crank shaft bearing
• Balancer bearing
• The following 3 bearing from RHS crank-
case from the other side with a help bear-
ing punch and suitable attachment “1”.
3. Remove:
• Right crankcase
Bearing remover kit

A. Right crankcase KLK 31-3
B. Left crankcase
2. Turn: 4. Remove:
• Shift drum segment The following bearing from LHS of crankcase
• Drive axel bearing
TIP
TIP
• Balancer bearing
Turn the shift drum segment “1” to the position (with a help of bearing punch and suitable
shown in the illustration. In this position, the attachment “1”).
shift drum segment teeth will not contact the
crankcase during crankcase separation. CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a
mild solvent.
1 2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:
• Crankcase
• Cracks/damage → Replace.
• Oil delivery passages
air.
3. Remove:
• Right crankcase
5-59
CRANKCASE ENG
CHECKING THE TIMING CHAIN AND TIMING
CHAIN GUIDE Bearing retainer screw
7 Nm (0.7 m·kg, 5.1 ft·lb)
1. Check:
T.
R.
LOCTITER®
• Timing chain
• Damage/stiffness → Replace the timing
chain and camshaft sprocket as a set.
a
2. Check: ASSEMBLING THE CRANKCASE

• Timing chain guide (intake side) 1. Thoroughly clean all the gasket mating sur-
Damage/wear → Replace. faces & crankcase mating surface with a flat
scaper “1”.
CHECKING THE OIL STRAINER
NOTICE
1. Check: Notice
• Oil strainer Do not use a screw driver or any sharp instru-

Damage → Replace. ments for removing the gasket.
Contaminants → Clean with solvent.
CHECKING THE BEARINGS AND OIL SEAL

1. Check:
• Bearings
Clean and lubricate the bearings, and then
rotate the inner race with your finger.
Rough movement → Replace.
• Oil seal
INSTALLING THE BEARING RETAINER 2. Apply:

• Sealant
1. Install: (onto the crankcase mating surfaces)
• Bearing retainer “1”
TIP Yamaha bond No. 1215
(Three Bond No.1215 ®)
TIP
● Install the bearing retainer “1” with its “OUT”

mark “a” facing outward.
TIP
● Apply locking agent (LOCTITER®) to the TIP
Do not allow any sealant to come into contact

threads of the bearing retainer screw.
with the oil gallery.
5-60
CRANKCASE ENG
3. Install:
• Right crankcase
TIP
Right crankcase
TIP
Turn the shift drum segment “1” to the position

shown in the illustration. In this position, the
shift drum segment teeth will not contact the
crankcase during crankcase installation.
4. Install:
• Crankcase bolts
Crankcase bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
TIP
TIP
Tighten each bolt 1/4 of a turn at a time, in

stages and in the proper sequence as shown.
• M6 . ~ 70 mm : “8.10”, “12”
• M6 . ~ 55 mm : “15”, “16”
• M6 . ~ 45 mm : “1.6”, “11”
A 1,7
8
9
6 10
2,13
5
4 11
3,14 12
15
B
16
A. Left crankcase
B. Right crankcase
5-61
CRANKSHAFT ENG
CRANKSHAFT
Removing the crankshaft and balancer
LS
LS
New
New

Separate.
Crankcase
Refer to “CRANKCASE” on page 5-56
1 Balancer 1
2 Crankshaft 1
procedure
5-62
CRANKSHAFT ENG
REMOVING THE CRANKSHAFT
A
1. Remove:
• Crankshaft “1” D
TIP
● Remove the crankshaft with the crankcase
removing tool “2”.
● Make sure the crankcase separating tool is
centered over the crankshaft.
C C
NOTICE 2. Measure:
● To protect the end of the crankshaft, • Big end side clearance
place an appropriate sized socket Out of specification → Replace the
between the crankcase separating tool crankshaft.
bolt and the crankshaft.
● Do not tap on the crankshaft. Big end side clearance D
0.110–0.410 mm
(0.0043–0.0161 in)
Crankshaft separating tool
90890-01135 3. Measure:
• Crankshaft width
crankshaft.
2
Width A
47.95–48.00 mm (1.888–1.890 in)
4. Check:
• Crankshaft sprocket
Damage/wear → Replace the crankshaft.
1 • Bearing
Cracks/damage/wear → Replace the
CHECKING THE CRANKSHAFT crankshaft.
1. Measure: 5. Check:
• Crankshaft runout • Crankshaft journal
Out of specification → Replace the Scratches/wear → Replace the
crankshaft, bearing or both. crankshaft.
• Crankshaft journal oil passage
TIP Obstruction → Blow out with compressed
Turn the crankshaft slowly. air.
Runout limit C INSTALLING THE CRANKSHAFT

0.030 mm (0.0012 in)
1. Install:
• Crankshaft “1”
TIP
Install the crankshaft with the crankshaft
installer pot “2”, crankshaft installer bolt “3”,
adapter (M12) “4”, and spacer (crankshaft
installer) “5”.
5-63
CRANKSHAFT ENG
Crankshaft installer pot
90890-01274
Crankshaft installer bolt
90890-01275
Adapter (M12)
90890-01278
Spacer (crankshaft installer)
90890-04081
1
2
5
4
3
NOTICE
To avoid scratching the crankshaft and to
ease the installation procedure, lubricate
the oil seal lips with lithium-soap-based
grease and each bearing with engine oil.
TIP
Hold the connecting rod at top dead center
(TDC) with one hand while turning the nut of the
crankshaft installer bolt with the other. Turn the
crankshaft installer bolt until the crankshaft bot-
toms against the bearing.
5-64
TRANSMISSION ENG
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
4
8
E
5 6
E
E
1
3
2

Separate.
Crankcase
Refer to “CRANKCASE” on page 5-56
1 Shift fork guide bar 1
2 Spring 2
3 Shift drum assembly 1
4 Shift fork-R 1
5 Shift fork-C 1
6 Shift fork-L 1
7 Drive axle assembly 1
8 Main axle assembly 1
9 Long clutch push rod 1
procedure
5-65
TRANSMISSION ENG
Disassembling the main axle

1 2nd pinion gear 1
2 6th pinion gear 1
3 3rd/4th pinion gear 1
4 Circlip 1
5 Toothed washer 1
6 5th pinion gear 1
7 Main axle/1st pinion gear 1
procedure
5-66
TRANSMISSION ENG
Disassembling the drive axle

1 Washer 1
2 2nd wheel gear 1
3 6th wheel gear 1
4 Washer 1
5 1st wheel gear 1
6 Spacer 1
7 5th wheel gear 1
8 Circlip 1
9 Toothed washer 1
10 4th wheel gear 1
11 3rd wheel gear 1
12 Drive axle 1
procedure
5-67
TRANSMISSION ENG
CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY
The following procedure applies to all of the 1. Check:
shift forks. • Shift drum groove
1. Check: Damage/scratches/wear → Replace the
• Shift fork cam follower “1” shift drum assembly.
• Shift fork pawl “2” • Shift drum segment “1”
Bends/damage/scoring/wear → Replace Damage/wear → Replace the shift drum
the shift fork. assembly.
• Shift drum bearing “2”
Damage/pitting → Replace the shift drum
assembly.
2. Check:
• Shift fork guide bar
Roll the shift fork guide bar on a flat
surface.
Bends → Replace. CHECKING THE TRANSMISSION
1. Measure:
WARNING • Main axle runout
Do not attempt to straighten a bent shift fork (with a centering device and dial gauge
guide bar. “1”)
Out of specification → Replace the main
axle.
Main axle runout limit

0.08 mm (0.0032 in)
3. Check:
• Shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift
forks and shift fork guide bar as a set.
2. Measure:
• Drive axle runout
(with a centering device and dial gauge
“1”)
Out of specification → Replace the drive
axle.
Drive axle runout limit

0.08 mm (0.0032 in)
5-68
TRANSMISSION ENG
ASSEMBLING THE MAIN AXLE AND DRIVE
AXLE
1. Install:
• Toothed washer “1”
• Circlip “2” New
TIP TIP
● Be sure to install the circlip so that its sharp

edge “a” is facing away from the toothed
washer and gear.
3. Check: ● Be sure the circlip ends “b” are positioned at
• Transmission gears the axle spline groove “c”.
Blue discoloration/pitting/wear → Replace
the defective gear(s). b
• Transmission gear dogs New 2
Cracks/damage/rounded edges →
Replace the defective gear(s).
a 1 c
2. Install:
• 2nd pinion gear “1”
TIP TIP
Press the 2nd pinion gear into the main axle “2”,
as shown in the illustration.
4. Check:
Installed depth “a”
• Transmission gear engagement 106.85.107.05 mm
(each pinion gear to its respective wheel (4.207.4.215in)
gear)
Incorrect → Reassemble the transmission
axle assemblies.
5. Check: a
• Transmission gear movement
Rough movement → Replace the
defective part(s).
CHECKING THE CLUTCH PUSH RODS

2
1. Check:
• Long clutch push rod 1
Cracks/damage/wear → Replace the long
clutch push rod. INSTALLING THE SHIFT FORKS AND
2. Measure: SHIFT DRUM ASSEMBLY
• Push rod bending limit
Out of specification → Replace the long 1. Install:
clutch push rod. • Shift fork-L “1”
• Shift fork-C “2”
Push rod bending limit • Shift fork-R “3”
0.500 mm (0.0197 in) • Shift drum assembly “4”
• Springs
• Shift fork guide bar “5”
5-69
TRANSMISSION ENG
TIP
TIP
The embossed marks on the shift forks should

face towards the right side of the engine and be
in the following sequence: “R”, “C”, “L”.
2
4
1
2. Check:
• Transmission
Rough movement → Repair.
TIP
TIP
● Apply engine oil to each gear and bearing

thoroughly.
● Before assembling the crankcase, make
sure that the transmission is in neutral and
that the gears turn freely.
5-70
COOL
CHAPTER 6
COOLING SYSTEM
RADIATOR ...................................................................................................... 6-1

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

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

DISASSEMBLING THE WATER PUMP.................................................... 6-8
CHECKING THE WATER PUMP .............................................................. 6-8
ASSEMBLING THE WATER PUMP.......................................................... 6-8
INSTALLING THE WATER PUMP ............................................................ 6-9
COOL
RADIATOR COOL
COOLING SYSTEM
RADIATOR
Removing the radiator

7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.R
.
8 Nm (0.8 m • kg, 5.8 ft • Ib) 2
13 5 T.R
.
12
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.R
.
1.8 Nm (0.18 m • kg, 1.3 ft • Ib) 1
9
T.R
.
8 11
6 4
10
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.R
.
1.8 Nm (0.18 m • kg, 1.3 ft • Ib)

T.R
.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.R
.
Order Job name/Parts name Q’ty Remarks

Passenger and rider seat/Side covers/ Refer to “GENERAL CHASSIS” on page 4-1
Front cowlings/Bottom cowlings
Coolant Drain.
Refer to “CHANGING THE COOLANT” on
page 3-18.
Air filter case Refer to “GENERAL CHASSIS” on page 4-
1.
1 Coolant reservoir breather hose 1
2 Coolant reservoir hose 1
3 Coolant reservoir cap 1
4 Coolant reservoir 1
5 Radiator fan motor coupler 1 Disconnect.
6 Water pump breather hose 1
7 Radiator outlet hose 1
8 Radiator inlet hose 1
9 Radiator cap 1
6-1
RADIATOR COOL
Removing the radiator

7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.R
.
8 Nm (0.8 m • kg, 5.8 ft • Ib) 2
13
T.R
5
.
12
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.R
.
1.8 Nm (0.18 m • kg, 1.3 ft • Ib) 1
9
T.R
.
8 11
6 4
10
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.R
.
1.8 Nm (0.18 m • kg, 1.3 ft • Ib)

T.R
.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.R
.

10 Radiator 1
11 Radiator fan 1
12 Throttle cables (throttle body end) 2 Disconnect.
13 Radiator cover 1
procedure
6-2
RADIATOR COOL
CHECKING THE RADIATOR
1. Check:
• Radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the
radiator.
Damage → Repair or replace.
TIP
Straighten any flattened fins with a thin, flat-
head screwdriver.
b. Apply the specified pressure for ten sec-
onds and make sure there is no drop in
pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Radiator fan
Damage → Replace.
Malfunction → Check and repair.
INSTALLING THE RADIATOR

2. Check: 1. Fill:
• Radiator hoses • Cooling system
Cracks/damage → Replace. (with the specified amount of the
3. Measure: recommended coolant)
• Radiator cap opening pressure Refer to “CHANGING THE COOLANT”
Below the specified pressure → Replace on page 3-18.
the radiator cap. 2. Check:
• Cooling system
Radiator cap opening pressure Leaks → Repair or replace any faulty
107.9—137.3 kPa
part.
(1.08—1.37 kgf/cm²,
15.6-19.9 psi) 3. Measure:
• Radiator cap opening pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Below the specified pressure → Replace
a. Install the radiator cap tester “1” and radia- the radiator cap.
tor cap tester adapter “2” to the radiator Refer to “CHECKING THE RADIATOR”
cap “3”. on page 6-3.
4. Adjust:
Radiator cap tester • Throttle grip free play
90890-01325
Radiator cap tester adapter
90890-01352
3.0—5.0 mm (0.12—0.20 in)
6-3
THERMOSTAT COOL
THERMOSTAT
Removing the thermostat
1.8 Nm (0.18 m • kg, 1.3 ft • Ib)
T.R
.
1
3
4
New
18 Nm (1.8 m • kg, 13 ft • Ib)

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

Coolant Drain.
page 3-18.
Passenger and rider seat/Right front Refer to “GENERAL CHASSIS” on page 4-
cowlings 1.
1 Radiator inlet hose 1
2 Coolant temperature sensor coupler 1 Disconnect.
3 Coolant temperature sensor 1
4 Washer 1
5 Thermostat cover 1
6 Thermostat 1
procedure.
6-4
THERMOSTAT COOL
CHECKING THE THERMOSTAT 2. Check:
1. Check: • Thermostat cover
• Thermostat Cracks/damage → Replace.
Does not open at 79.5—84.5°C (175.0— 3. Check:
184.0°F) → Replace. • Radiator inlet hose
INSTALLING THE THERMOSTAT

1. Install:
• Thermostat cover
• Thermostat
TIP
Install the thermostat with its breather hole “a”
facing up.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Suspend the thermostat “1” in a container
“2” filled with water.
b. Slowly heat the water “3”.
c. Place a thermometer “4” in the water.
d. While stirring the water, observe the ther-
mostat and thermometer's indicated tem-
perature.
2. Install:
• Copper washer
4 • Coolant temperature sensor
Coolant temperature sensor

3 18 Nm (1.8 m·kg, 13 ft·lb)
T.
R.
1
2 NOTICE
Use extreme care when handling the cool-
ant temperature sensor. Replace any part
that was dropped or subjected to a strong
impact.
3. Fill:
• Cooling system
recommended coolant)
Refer to “CHANGING THE COOLANT”
82 95 on page 3-18.
(179.6 203
4. Check:
A. Fully closed • Cooling system
B. Fully open Leaks → Repair or replace any faulty
part.
TIP
If the accuracy of the thermostat is in doubt, 5. Measure:
replace it. A faulty thermostat could cause seri- • Radiator cap opening pressure
ous overheating or overcooling. Below the specified pressure → Replace
the radiator cap.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Refer to “CHECKING THE RADIATOR”
on page 6-3.
6-5
WATER PUMP COOL

WATER PUMP
Removing the water pump
LS
New
1 New
LS
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.R
.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.R
1.8 Nm (0.18 m • kg, 1.3 ft • Ib)

.
T.R
.

It is not necessary to remove the water
pump unless the coolant level is extremely
low or the coolant contains engine oil.
Left front cowlings/Bottom cowlings Refer to “GENERAL CHASSIS” on page 4-
1.
Coolant Drain.
page 3-18.
1 Radiator outlet hose 1
2 Water pump breather hose 1
3 Cylinder head breather hose 1 Disconnect.
4 Radiator bolt (lower) 1
5 Water pump assembly 1
procedure.
6-6
WATER PUMP COOL
Disassembling the water pump

10 Nm (1.0 m • kg, 7.2 ft • Ib)
4
T.
R.
7 New
10 New 8
LT
9 New
New 5
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
11
12
LS
3 New
2
1 10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

1 Radiator bracket 1
2 Water pump housing cover 1
3 Water pump housing cover gasket 1
4 Impeller shaft retainer 1
5 Impeller shaft 1
6 Water pump housing plate 1
7 Water pump housing gasket 1
8 O-ring 1
9 Water pump seal 1
10 Bearing 1
11 O-ring 1
12 Water pump housing 1
procedure.
* Remove the bearing from water pump by using special tool (Water pump bearing remover YSST-723)
6-7
WATER PUMP COOL

DISASSEMBLING THE WATER PUMP NOTICE
1. Remove: Never lubricate the water pump seal surface
• Water pump seal “1” with oil or grease.
TIP
TIP
Remove the water pump seal from the inside of
Install the water pump seal with the mechanical
the water pump housing “2”.
seal installer “3” and middle driven shaft bearing
driver “4” to the specified depth as shown in the
illustration.
Mechanical seal installer

90890-04145
2
A
1
4
3
2. Remove:
• Bearing “1”
1 New
TIP
2
Remove the bearing from the outside of the
water pump housing “2”.
A. Push down
1
2
CHECKING THE WATER PUMP a. 0-0.5 mm (0.0.02 in)

2. Lubricate:
1. Check:
• Water pump seal lip
• Water pump housing cover
• Water pump housing
Cracks/damage → Replace. Recommended lubricant
• Impeller shaft Lithium-soap-based grease
Cracks/damage/wear → Replace.
• Bearing 3. Install:
Rough movement → Replace. • Water pump housing gasket “1”
• Radiator outlet hose • Water pump housing plate “2”
Cracks/damage → Replace. • Impeller shaft
• Impeller shaft retainer “3”
ASSEMBLING THE WATER PUMP
1. Install:
• Water pump seal “1” New
(into the water pump housing “2”)
6-8
WATER PUMP COOL

Refer to “CHANGING THE COOLANT”
Impeller shaft retainer bolt on page 3-18.
10 Nm (10. m·kg, 7.2 ft·lb)
3. Check:
T.
R.
LOCTITER®
• Cooling system
TIP
Leaks → Repair or replace the faulty part.
● Before installing the impeller shaft retainer, 4. Measure:
lubricate the slit on the impeller shaft end • Radiator cap opening pressure
with a thin coat of lithium-soap-based Below the specified pressure → Replace
grease. the radiator cap.
● Install the water pump housing gasket, water Refer to “CHECKING THE RADIATOR”
pump housing plate, and impeller shaft on page 6-3.
retainer as shown in the illustration.
● After installation, check that the impeller
shaft rotates smoothly.
New
1
2
3
INSTALLING THE WATER PUMP

1.Install:
• Water pump assembly “1”
• O-rings “2” New
TIP
● Align the projection “a” on the impeller shaft
with the slit “b” on the camshaft sprocket
bolt.
● Lubricate the O-rings with a thin coat of lithi-
umsoap-based grease.
b
1
2 New
2. Fill:
• Cooling system
recommended coolant)
6-9
COOL
6-10
FI
CHAPTER 7
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
CHECKING THE ROLLOVER VALVE ...................................................... 7-2
INSTALLING THE FUEL TANK................................................................. 7-3
CHECKING THE FUEL PRESSURE ........................................................ 7-3
THROTTLE BODY........................................................................................... 7-5

REMOVING THE THROTTLE BODY........................................................ 7-6
CHECKING THE FUEL INJECTOR .......................................................... 7-6
CHECKING THE THROTTLE BODY ........................................................ 7-6
INSTALLING THE THROTTLE BODY ...................................................... 7-6
FI
FUEL TANK FI
FUEL SYSTEM
FUEL TANK
Removing the fuel tank

10 Nm (1.0 m • kg, 7.2 ft • lb)
T
.R
.
New
11
6
7
10
3 1 8
2
1
4
4 Nm (0.4 m • kg, 2.9 ft • lb)
.R
.
10 Nm (1.0 m • kg, 7.2 ft • lb)

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

Passenger and rider seat Refer to “GENERAL CHASSIS” on page 1.
1 Fuel pump couplers 1 Disconnect.
2 Fuel tank breather hose 2 Disconnect.
3 Fuel hose 1 Disconnect.
4 Rollover valve hose 1 Disconnect.
5 Fuel tank 1
6 Fuel tank bracket 1
7 Rubber damper 1
8 Fuel pump bracket 1
9 Fuel pump gasket 1
10 Fuel pump 1
11 Fuel pump retainer 1
procedure.
7-1
FUEL TANK FI
REMOVING THE FUEL TANK CHECKING THE FUEL PUMP BODY
1. Extract the fuel in the fuel tank through the 1. Check:
fuel tank cap with a pump. • Fuel pump body
2. Disconnect: Obstruction → Clean.
• Roll over valve hose Cracks/damage → Replace the fuel
• Fuel pump coupler pump.
• Fuel tank breather hose
3. Disconnect: INSTALLING THE FUEL PUMP
• Fuel hose
1. Install:
WARNING • Fuel pump gasket “1” New
Cover fuel hose connections with a cloth • Fuel pump “2”
when disconnecting them. Residual pres- • Fuel pump retainer
sure in the fuel lines could cause fuel to
spurt out when removing the hoses. Fuel pump bolt
4 Nm (0.4 m·kg, 2.9 ft·lb)
TIP
● To remove the fuel hose from the fuel TIP
pump, slide the fuel hose connector cover ● Do not damage the installation surfaces of
“1” on the end of the hose in the direction of the fuel tank when installing the fuel pump.
the arrow shown, and then remove the ● Always use a new fuel pump gasket.
hose. ● Install the fuel pump gasket with its lip “a”
● Remove the fuel hose manually without facing downward.
using any tools. ● Align the projection “b” on the fuel pump
● Before removing the hose, place a few rags with the slot in the fuel pump retainer.
in the area under where it will be removed. ● Tighten the fuel pump bolts in the proper
tightening sequence as shown.
1 a
4
1
FWD
4. Remove: 3 2
• Fuel tank
TIP
Do not set the fuel tank down on the installa-
CHECKING THE ROLLOVER VALVE
tion surface of the fuel pump. Be sure to lean
the fuel tank against a wall or the like. 1. Check:
• Rollover valve
Damage/faulty → Replace.
REMOVING THE FUEL PUMP TIP
1. Remove: ● Check that air flows smoothly only in the
• Fuel pump direction of the arrow shown in the illustra-
tion.
NOTICE ● The rollover valves must be in an upright
● Do not drop the fuel pump or give it a position when checking the airflow.
strong shock.
● Do not touch the base section of the fuel
sender.
7-2
FUEL TANK FI
2. Connect:
• Fuel tank breather hose
• Fuel pump coupler
CHECKING THE FUEL PRESSURE

1. Check:
• Fuel pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove:
Refer to “GENERAL CHASSIS” on page 1.
Remove:
• Fuel tank front mounting bolt
Refer to “FUEL TANK” on page 1.
b. Lift the front of the fuel tank.
c. Disconnect the fuel tank breather hose.
d. Disconnect the fuel hose “1” from the fuel
pump “2”.
WARNING
Cover fuel hose connections with a cloth
when disconnecting them. Residual pres-
INSTALLING THE FUEL TANK
spurt out when removing the hoses.
1. Connect:
• Fuel hose
NOTICE 2
When installing the fuel hose, make sure that it
is securely connected, and that the fuel hose 1
connector cover on the fuel hose is in the cor-
rect position, otherwise the fuel hose will not
be properly installed.
TIP
● Install the fuel hose securely onto the fuel
pump until a distinct “click” is heard. e. Connect the fuel pressure adapter “3”
● To install the fuel hose onto the fuel pump, between the fuel hose “1” and fuel pump
slide the fuel hose connector cover “1” on “2”.
the end of the hose in the direction of the f. Connect the pressure gauge “4” to the fuel
arrow shown. pressure adapter “3”.
Fuel pressure gauge
90890-03153
7-3
FUEL TANK FI
4
2
3
h. Start the engine.

i. Measure the fuel pressure.
Output pressure
250.0 kPa (36.3 psi, 2.50 kgf/cm²)
Below specification → Replace the fuel

pump.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-4
THROTTLE BODY FI
THROTTLE BODY
Removing the throttle body
5
9 12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.
R.
10
6
1
8
LT
2 Nm (0.2 m • kg, 1.4 ft • Ib) 2 New

T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

3 E
New
T.
R.
New
4
11
E
7 New
LS
LT

Passenger and rider seat / side covers Refer to “GENERAL CHASSIS” on page 1
Fuel tank Refer to “FUEL TANK” on page 1.
Air filter case Refer to “GENERAL CHASSIS” on page 1.
1 Fuel hose 1
2 Fuel injector coupler 1 Disconnect.
3 Fuel injector 1
4 Fuel injector gasket 1
5 FID (fast idle solenoid) coupler 1 Disconnect.
6 Throttle body sensor assembly coupler 1 Disconnect.
7 Throttle cable 2 Disconnect.
8 Throttle body joint clamp screw 2 Loosen.
NOTICE
9 Throttle body 1
The throttle body should not be disassembled.
10 Throttle body joint 1

11 Intake manifold 1
For installation, reverse the removal procedure.
7-5
THROTTLE BODY FI
REMOVING THE THROTTLE BODY CHECKING THE FUEL INJECTOR
1. Extract the fuel in the fuel tank through the 1. Check:
fuel tank filler hole with a pump. • Fuel injector
2. Disconnect: Damage → Replace.
• Fuel hose
CHECKING THE THROTTLE BODY
WARNING
1. Check:
Cover fuel hose connections with a cloth
• Throttle body
when disconnecting them. Residual pres-
Cracks/damage → Replace the throttle
body.
spurt out when removing the hoses.
2. Check:
TIP • Fuel passages
● To remove the fuel hose from the fuel injec- Obstruction → Clean.
tor, slide the fuel hose connector cover “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
on the end of the hose in the direction of the
a. Wash the throttle body in a petroleum-
arrow shown, and then remove the hose. based solvent.
● Remove the fuel hose manually without Do not use any caustic carburetor cleaning
using any tools. solution.
● Before removing the hose, place a few rags b. Blow out all of the passages with com-
in the area under where it will be removed. pressed air.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
INSTALLING THE THROTTLE BODY

1. Install:
• Throttle body joint clamps
TIP
1
Align the projections “a” on the throttle body
joint with the slot “b” in each throttle body joint
clamp.
3. Remove:
• Throttle body
NOTICE a
Do not remove the throttle body sensor
assembly “1” from the throttle body.
1 b
2. Install:
• Throttle body joint
TIP
Align the projection “a” on the throttle body
joint with the slot “b” in the intake manifold.
7-6
THROTTLE BODY FI
b
1
a
3. Install:
• Throttle body
TIP
Align the projection “a” on the throttle body
with the slot “b” in the throttle body joint.
b
a
4. Adjust:
GRIP FREE PLAY” on page 8.
5. Connect:
• Fuel hose
NOTICE
When installing the fuel hose, make sure
that it is securely connected, and that the
fuel hose connector cover on the fuel hose
is in the correct position, otherwise the fuel
hose will not be properly installed.
TIP
● Install the fuel hose securely onto the fuel
injector until a distinct “click” is heard.
● To install the fuel hose onto the fuel injector,
slide the fuel hose connector cover “1” on
the end of the hose in the direction of the
arrow shown.
7-7
THROTTLE BODY FI
7-8
– +
ELEC
CHAPTER 8
ELECTRICAL SYSTEM
IGNITION SYSTEM ......................................................................................... 8-1

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

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

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

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

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

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

CIRCUIT DIAGRAM ................................................................................ 8-29
ECU SELF-DIAGNOSTIC FUNCTION ....................................................8-31
SELF-DIAGNOSTIC FUNCTION TABLE ................................................8-33
TROUBLESHOOTING METHOD .................................................................. 8-34

YAMAHA DIAGNOSTIC TOOL ...............................................................8-35
DIAGNOSTIC CODE TABLE .................................................................. 8-36
SENSOR AND ACTUATOR OPERATION TABLE ................................. 8-38
Communication error with the FI diagnostic tool .....................................8-39
TROUBLESHOOTING DETAILS .................................................................. 8-39
FUEL PUMP SYSTEM...................................................................................8-53

CIRCUIT DIAGRAM ................................................................................ 8-53
– +
ELEC
ELECTRICAL COMPONENTS......................................................................8-57
CHECKING THE SWITCHES ................................................................. 8-59
CHECKING THE BULBS AND BULB SOCKETS ...................................8-62
CHECKING THE FUSE........................................................................... 8-63
CHECKING AND CHARGING THE BATTERY .......................................8-63
CHECKING THE RELAYS ......................................................................8-67
CHECKING THE TURN SIGNAL RELAY ............................................... 8-67
CHECKING THE DIODES....................................................................... 8-68
CHECKING THE SPARK PLUG CAP ..................................................... 8-68
CHECKING THE IGNITION COIL ...........................................................8-69
CHECKING THE IGNITION SPARK GAP............................................... 8-69
CHECKING THE CRANKSHAFT POSITION SENSOR..........................8-70
CHECKING THE LEAN ANGLE SENSOR..............................................8-70
CHECKING THE STARTER MOTOR OPERATION ............................... 8-71
CHECKING THE STATOR COIL ............................................................ 8-71
CHECKING THE RECTIFIER/REGULATOR .......................................... 8-71
CHECKING THE HORN .......................................................................... 8-72
CHECKING THE FUEL SENDER ...........................................................8-72
CHECKING THE SPEED SENSOR ........................................................ 8-73
CHECKING THE RADIATOR FAN MOTOR ........................................... 8-73
CHECKING THE COOLANT TEMPERATURE SENSOR....................... 8-73
CHECKING THE THROTTLE BODY SENSOR ASSEMBLY.................. 8-74
CHECKING THE FID (FAST IDLE SOLENOID) .....................................8-75
+
–
ELEC
2
R
BL6 R W BL6
R W
W1
B3 3
W1 W W2
B6
B W2 W
B4 B1 --- YR --- R Br3 BW L2 BL6YG BrW
J11
B1 OrB WY YW --- W2 RW3BL3 L4 BL1 PW GR
B2
Or GW Y Lg --- --- BL5 L1 BL2 YL GyR RW3
W2
W1
1
R1
BL6 SGND
(BLACK) Or Or 205
R IG
CRK
RW2
RW3
B3
IGNITION SYSTEM
R3
6
R
R1
R2
B4 W1 27
4 17 PW PW 26
W2 R1 R1R2 PB
R
R3
(BLACK) 7 LBBr4 RW1 RW

20 A
18 BrW BrW
(BLACK) J3 AT
B4
B4 BL5 BL5
9 1 SGND4 28
B1 LB YL YL YR YR Br
BL5 YL L4 PW BrW TP AC
B3 19 L4 L4
RW1
VCC2
LB
B Br4
2 Br YR
B2 MITSUBISHI CABLE INDUSTRIES
RW
J12 8
12 NO.PK605-05027
R2
1 (BLUE)
RW1 LB BL2 BL2
SGND3
RW
MAIN 10 RB LW
BL2 GR 29
ON R R2 20 OrB OrB RW1
RB
LW
GR GR IJ
Br1 RWBr4 WT
B4
BW
OFF Br (BLACK)
--- LW
B6 5 (RED) (RED) B SB
B
B2 B1 --- GyR GyR OrBRW1
RB
RB
O2 25
Br1 Br1
LW
B
(BLACK) GVR
B 21 (BLACK)
B
J13 B1 Br2 13 14 SUMITOMO 6189-6904
START STOP 2
11 Br RW 15 L2 L2
1 OFF OFF
LW --- 22 VCC
START RUN --- --- --- BL1 BL1
Sb Sb
Br2 Br2 Br3 --- RB SGND2 Y Y RW
L2 YG BL1 YG YG FP 30
J1 J4 1 LA
(BLACK)
Br
1 1 AI
B1
RW
1
Br4
Br
2 2
Br4
Br3
Br5
Br4 L1 L1 Y RW
Br4
Br4
VCC3
BL3 BL3
23 SGND5
16 L1W1BL3 W1 Lg EWL VB Br3 (BLACK)
VW RW3
L4 L3 Br3 GW W2
WWL SP
J9 J7 YW BW
Lg2 L2 WY TC CGND
B1
Br2
1 1 RFR PGND
24
L1
Br
L
8-1
SUMITOMO HOUSING : 6402-7601
CASE : 6409-0031
Br
B3 B2 --- --- --- --- Br 2

1 B1 B4 --- --- --- Br2 Br1
NEUTRAL 54
BR1
Br1 Sb
Br2
J8 2 2
Br
2 2
RW3
55
RW2
RW1
Br1
Br2
RW
W2
33
W3
W1
34
Br
RW1RW2 Br Br2 W1 W2 Gy1
Br2
56 TACHO
R2
RW3 RW BR3 --- W3 Gy2 Gy3
Br1
35 BrW (BLUE)
52 Br3 Br B1B2 B1 B2 SUMITOMO 31
Gy1 B2
51 32
B1
Br2 R2 P
GND W3 WY L HOUSING : 6403-7601
Gy2
CASE : 6409-0032
BrW BrW
SPEED
YW GY1BR1
Br5
Br2 Gy2
B4
TC
B1
B2
WY
Gy1
Gy2
B3
Gy3
Br3
Br
Br2
RB
57
P
L3
45 Y Y1
L
46 44
ILLUMI 43 G G
L4 PASS DIMMER HORN FLASHER
B B1
58 OFF H1 OFF L
L L 36
53 ON LO ON NL Dg Br5
B Br Dg
B N RB
B WB BrW BrW L3
NR
DIAG R B B P Ch Ch2 P
59 Lg2
(BLACK) (BLACK)
B
RB RB
HI BEAM B2
Y2 60 B
(BLUE) (BLUE)
WATER
Ch
B1
Y1
Dg
B2
61
G
GW
Y GY3
L2
TURN 62
Dg
L2 A L2
37
GA G
Ch2
Ch
Dg
IGNITION SYSTEM
L Y GY3 L2
Dg3
L1 A L1 B B2
GB B3 YAY Dg1
FUEL+ Ch3 J6 A
OrW J5
FUEL-
Y1
L1
GB
Dg2
49
Y
1
Y3
1
Ch
G
L1
Y L1 L1 Y
CIRCUIT DIAGRAM
Dg1
Ch1
63 1 Ch A Ch Ch1
B L2 L2 B
12V35/35W
L1 47
12V35/35W
---
12V5W
12V5W
Dg2
L B2
Ch
W3 L4 YW --- GW B3 Lg2 Br1 L1 L G Ch Ch G
L
Y B
J10 B B B
Sb --- --- Ch3 GB Dg3 Y2 OrW
12V10W
(BLACK) (BLACK)
12V10W
OrW
12V5W
G
12V10W
12V10W
39
B2
(BLACK) 48 40 MAIN HARNESS CORR HEAD LIGHT
Y3 B4 41 L L
B
50
Y2
B2
B4
OrWGB B B4
42 38
BA B
B4
B3
B3
B2
B3
B1
B3
B2
B4
1
J14
ELECTRICAL SYSTEM
– +
IGNITION SYSTEM ELEC
1. Junction
5. Main switch
6. Wire plus lead
7. Battery
8. Fuse
9. Wire minus lead
14. Engine stop switch
22.Lean angle sensor
25. E.C.U
26. Ignition coil
27. Spark plug
8-2
– +
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
• Before troubleshooting, remove the following part(s):
1. Passenger and rider seat
2. Fuel tank
3. Left side cover
4. Right front cowlings
1. Check the fuse. NG →

Refer to “CHECKING THE FUSE” on Replace the fuse.
page 8-63.
OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-63.
OK ↓
3. Check the spark plug. NG →
Refer to “CHECKING THE SPARK Re-gap or replace the spark plug.
PLUG” on page 3-9.
OK ↓
4. Check the ignition spark gap. OK →
Refer to “CHECKING THE Ignition system is OK.
IGNITION SPARK GAP” on page 8-
69.
NG ↓
5. Check the spark plug cap. NG →
Refer to “CHECKING THE SPARK Replace the spark plug cap.
PLUG CAP” on page 8-68.
OK ↓
6. Check the ignition coil. NG →
Refer to “CHECKING THE Replace the ignition coil.
IGNITION COIL” on page 8-69.
OK ↓
7. Check the crankshaft position NG →
sensor.
Replace the crankshaft position
Refer to “CHECKING THE
sensor/stator assembly.
CRANKSHAFT POSITION
SENSOR” on page 8-70.
OK ↓
8-3
– +
8. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-59.
OK ↓
9. Check the engine stop switch. NG → The engine stop switch is faulty. Replace
the right handlebar switch.
OK ↓
10.Check the lean angle sensor. NG →

Refer to ““CHECKING THE LEAN Replace the lean angle sensor.
ANGLE SENSOR” on page 8-70.
OK ↓
11.Check the entire ignition system NG →

wiring. Properly connect or repair the ignition
Refer to “CIRCUIT DIAGRAM” on system wiring.
page 8-1.
OK ↓
Replace the ECU.
8-4
+
2
R
BL6 R W BL6
R W
W1
–
B3 3
W1 W W2
B6
B W2 W
B4
ELEC
J11 B1 --- YR --- R Br3 BW L2 BL6 YG BrW

B1 OrB WY YW --- W2 RW3 BL3 L4 BL1 PW GR
B2
1
W2
W1
BL6
R1
(BLACK) SGND Or Or 205

R IG
CRK
B3
RW2
RW3
R3
6
R
27
R1
R2
B4 W1 PW PW
4 17 26
W2 R1 R1 R2 PB
R
R3
(BLACK) 7 LB Br4 RW1 RW

BrW BrW
20 A
(BLACK) J3 18 AT
B4 BL5
B4
BL5 SGND4 28
9 1
ELECTRIC STARTING SYSTEM
B3 19 L4 L4
VCC2
RW1
B Br4
LB
2 Br YR
J12 B2 8 MITSUBISHI CABLE INDUSTRIES
RW
12 NO.PK605-05027
R2
1 (BLUE)
RW1 LB BL2 BL2
SGND3
MAIN
RW 10 RB LW
BL2 GR 29
RB
LW
GR GR IJ
OFF Br1 RW Br4 WT
B4
Br (BLACK)
BW
--- LW
B
B2 B1 --- GyR GyR OrB RW1
RB O2 25
RB
Br1
B
(BLACK) GVR
LW
B 21 (BLACK)
B
Br1
J13 B1 Br2 13 14 SUMITOMO 6189-6904

START STOP 2
11 Br RW 15 L2 L2
1 OFF OFF
LW --- 22 VCC
START RUN --- --- --- BL1 BL1 Y
Br2 Br2 Br3 --- RB SGND2 Y RW
Sb Sb
J1 J4 LA
(BLACK) 1
1 1 AI
Br
B1
1
RW
Br4
Br 2 2
Br4
Br3
Br5
Br4
L1 L1 Y RW
VCC3
Br4
Br4
BL3 BL3
23 SGND5
16 L1 W1 BL3 W1 Lg EWL VB Br3 (BLACK)
VM RW3
L4 L3 Br3 GW SP W2
WL
J9 J7 YW BW
Lg2 L2 WY TC CGND
B1
1 1 RFR PGND
Br2
24
L1
Br
L
CASE : 6409-0031
8-5
Br
B3 B2 --- --- --- --- Br 2

1 B1 B4 --- --- --- Br2 Br1
NEUTRAL 54
Br1 Sb
BR1
Br2
J8
2 2 2
Br
55 2
RW3
RW2
RW1
RW
Br1
Br2
33
W2
34
W3
W1
Br
RW1 RW2 Br Br2 W1 W2 Gy1
56 TACHO
Br2
R2
Br1
35 BrW (BLUE)
52 Br3 Br B1 B2 B1 B2 SUMITOMO 31
Br2 R2 51 32
B2
B1
P HOUSING : 6403-7601
GND W3 WY L
ELECTRIC STARTING SYSTEM
CASE : 6409-0032
Gy2
Gy1
BrW BrW
SPEED
YW Br2 Gy2 GY1 BR1
Br5
TC
B4
B1
B2
WY
B3
Br
Gy1
Gy2
Br3
Gy3
Br2
57
RB
P
L3
45 Y Y1
L
46 44
ILLUMI 43 G G
B B1
58 OFF H1 OFF L
L L 36
B Br Dg
B N RB
B WB BrW BrW L3
NR
59 Lg2
(BLACK)
B
(BLACK)
RB RB
HI BEAM B2
Y2 60 B
(BLUE) (BLUE)
WATER
Ch
Dg
B1
61
Y1
B2
G
GW
GY3
L2
TURN 62
Dg
Y
37
L2 A L2
G AG
Ch2
Ch
Dg
L Y GY3 L2
Dg3
L1 A L1 B B2
GB B3 Y AY Dg1
FUEL+ Ch3 J6 A
OrW J5
CIRCUIT DIAGRAM
FUEL-
Y1
L1
Dg2
49
GB
Y
1 1
Y3
G
Ch
L1
Y L1 L1 Y
Dg1
1 Ch A Ch Ch1
Ch1
63 L1 B L2 L2 B
47
12V35/35W
---
12V35/35W
12V5W
12V5W
Dg2
L1 L B2 Ch Ch G
W3 L4 YW --- GW B3 Lg2 Br1
Ch
L G
L
Y B
J10 B B B
Sb --- --- Ch3 GB Dg3 Y2 OrW (BLACK) (BLACK)
12V10W
12V10W
G
OrW
12V5W
39
12V10W
48 40
B2
12V10W
(BLACK) Y3 B4 MAIN HARNESS CORRHEAD LIGHT
41 L L
50
B
Y2
B2
B4
OrW GB B B4
42 38
B A B
B4
B3
B3
B2
B3
B1
B3
B2
B4
1
J14
– +
ELECTRIC STARTING SYSTEM ELEC
5. Main switch
6. Wire plus lead
7. Battery
8. Wire minus lead
9. Fuse
10. Starter relay
11. Starting motor
12. Relay assy 1
13. Start switch
15. Diode
16. Neutral switch
36. Clutch Switch
55. Neutral indicator light
8-6
– +
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION
If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the
starter motor can only operate if at least one of the following conditions is met:
• The transmission is in neutral (the neutral switch is closed).
• The clutch lever is pulled to the handlebar (the clutch 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 “ ”.
2
3
10
5
6
11
9
a b
8-7
– +
a. WHEN THE TRANSMISSION IS IN
NEUTRAL
b. WHEN CLUTCH LEVER IS PULLED TO THE
HANDLEBAR
1. Battery
2. Fuse
3. Main switch
5. Starting circuit cut-off relay
6. Clutch switch
7. Diode
8. Neutral switch
9. Start switch
10. Starter relay
11. Starter motor
8-8
– +
TROUBLESHOOTING
The starter motor fails to turn.
TIP
2. Fuel tank
4. Starter motor

page 8-63.
OK ↓
page 8-63.
OK ↓
3. Check the starter motor operation. OK →
Starter motor is OK. Perform the electric
starting system troubleshooting, starting
STARTER MOTOR OPERATION” on
with step 5.
page 8-71.
NG ↓
4. Check the starter motor. NG →
Refer to “CHECKING THE STARTER Repair or replace the starter motor.
MOTOR” on page 5-36.
OK ↓
5. Check the starting circuit cut-off NG →
relay.
Replace the starting circuit cut-off relay.
Refer to “CHECKING THE RELAYS”
on page 8-67.
OK ↓
6. Check the diodes. NG →
Refer to “CHECKING THE DIODES” Replace the diode(s).
on page 8-68.
OK ↓
7. Check the starter relay. NG →
Refer to “CHECKING THE RELAYS” Replace the starter relay.
on page 8-67.
OK ↓
8-9
– +
OK ↓
9. Check the engine stop switch. NG →
The engine stop switch is faulty. Replace
OK ↓
10.Check the neutral switch. NG →
Refer to “CHECKING THE Replace the neutral switch.
OK ↓
11.Check the clutch switch. NG →
Refer to “CHECKING THE Replace the clutch switch.
OK ↓
NG →
12.Check the start switch.
The start switch is faulty. Replace the right
handlebar switch.
OK ↓
13.Check the entire starting system NG →

wiring. Properly connect or repair the starting
page 8-5.
OK ↓
The starting system circuit is OK.
8-10
+
2
–
R
BL6 R W BL6
R W
W1
ELEC
B3 3
W1 W W2
B6
B W2 W
B4 B1 --- YR --- R Br3 BW L2 BL6 YG BrW
J11
B1 OrB WY --- W2 RW3 BL3 L4 BL1 PW GR
B2
1
W2
W1
BL6
R1

R IG
CRK
B3
RW2
RW3
R3
6
R
27
R1
R2
B4 W1 PW PW
4 17 26
W2 R1 R1 R2 PB
R
R3

BrW BrW
CHARGING SYSTEM
20 A
(BLACK) J3 18 AT
B4 BL5
B4
BL5 28
9 1 SGND4
B3 19 L4 L4
VCC2
RW1
B Br4
LB
2 Br YR
J12 B2 8
RW MITSUBISHI CABLE INDUSTRIES
12 NO.PK605-05027
R2
1 (BLUE)
RW1 LB BL2 BL2
SGND3
10 RB LW
RW
MAIN BL2 GR
R 20 29 RW1
ON R2 OrB OrB
RB
LW
GR GR IJ
OFF Br1 RW Br4 WT
B4
Br BW (BLACK)
--- LW
B
RB O2 25
RB
Br1
B
(BLACK) GVR
LW
B 21 (BLACK)
B
Br1
J13 B1 Br2 13 14 SUMITOMO 6189-6904

START STOP 2
11 Br RW 15 L2 L2
1 OFF OFF
LW --- 22 VCC
Sb Sb
J1 J4 LA
(BLACK) 1
1 1 AI
Br
B1
1
RW
Br4
2 2
Br
Br4
Br3
Br5
Br4
L1 L1 Y RW
VCC3
Br4
Br4
BL3 BL3
23 SGND5
VM RW3
L4 L3 Br3 GW W2
WWL SP
J9 J7 YW BW
Lg2 L2 WY TC CGND
B1
1 1 RFR PGND
Br2
24
L1
8-11
Br
L
Br CASE : 6409-0031
B3 B2 --- --- --- --- Br 2
1 B1 B4 --- --- --- Br2 Br1
NEUTRAL 54
Br1 Sb
BR1
Br2
J8
2 2 2
Br
55 2
RW3
RW2
RW1
RW
Br1
Br2
33
W2
34
W3
W1
Br
56 TACHO
Br2
R2
Br1
35 BrW (BLUE)
Br2 R2 51 32
B2
B1
P HOUSING : 6403-7601
GND W3 WY L
CASE : 6409-0032
Gy2
Gy1
BrW BrW
SPEED
YW Br2 Gy2 GY1 BR1
Br5
TC
B4
B1
B2
WY
B3
Br
Gy1
Gy2
Br3
Gy3
Br2
57
RB
P
L3
45 Y Y1
L
46 44
ILLUMI 43 G G
B B1
58 OFF H1 OFF L
L L 36
B Br Dg
B N RB
B WB BrW BrW L3
NR
59 Lg2
(BLACK)
B
(BLACK)
RB RB
HI BEAM B2
CHARGING SYSTEM
Y2 60 B
(BLUE) (BLUE)
WATER
Ch
Dg
B1
61
Y1
B2
G
GW
GY3
L2
TURN 62
Dg
Y
37
L2 A L2
G AG
Ch2
Ch
Dg
L Y GY3 L2
Dg3
L1 A L1
CIRCUIT DIAGRAM
B B2
GB B3 Y AY Dg1
FUEL+ Ch3 J6 A
OrW J5
FUEL-
Y1
L1
Dg2
49
GB
Y
1 1
Y3
G
Ch
L1
Y L1 L1 Y
Dg1
1 Ch A Ch Ch1
Ch1
63 L1 B L2 L2 B
47
12V35/35W
---
12V35/35W
12V5W
12V5W
Dg2
L1 L B2 Ch Ch G
Ch
L G
L
Y B
J10 B B B
12V10W
12V10W
G
OrW
12V5W
39
12V10W
48 40
B2
12V10W
41 L L
50
B
Y2
B2
B4
OrW GB B B4
42 38
B A B
B4
B3
B3
B2
B3
B1
B3
B2
B4
1
– +
CHARGING SYSTEM ELEC
1. Junction
3. AC Magneto
4. Rectifier / Regulator
6. Wire plus lead
7. Battery
8. Wire minus lead
9. Fuse
8-12
– +
TROUBLESHOOTING
The battery is not being charged.
TIP
2. Left side cover
3. Windshield

page 8-63.
OK ↓
page 8-63.
OK ↓
3. Check the stator coil. NG →
Replace the crankshaft position
Refer to “CHECKING THE STATOR
sensor/stator assembly.
COIL” on page 8-71.
OK ↓
4. Check the rectifier/regulator. NG →
Replace the rectifier/regulator.
RECTIFIER/REGULATOR” on
page 8-71.
OK ↓
5. Check the entire charging system NG →
wiring. Properly connect or repair the charging
page 8-11.
OK ↓
The charging system circuit is OK.
8-13
– +
8-14
+
2
R
BL6 R W BL6
R W
W1
–
B3 3
W1 W W2
B6
B W2 W
J11
ELEC

B2
1
W2
W1
BL6
R1

R IG
CRK
B3
RW2
RW3
R3
6
R
27
R1
R2
B4 W1 PW PW
4 17 26
W2 R1 R1 R2 PB
R
R3

BrW BrW
20 A
(BLACK) J3 18 AT
B4 BL5 BL5
B4
9 1 SGND4 28
Bl5 YL L4 PW BrW TP AC
B3 19 L4 L4
VCC2
RW1
LIGHTING SYSTEM
B Br4
LB
2 Br YR
RW
12 NO.PK605-05027
R2
1 (BLUE)
RW1 LB BL2 BL2
SGND3
10 RB LW
RW
MAIN BL2 GR
R 20 29 RW1
ON R2 OrB OrB
RB
LW
GR GR IJ
OFF Br1 RW Br4 WT
B4
Br (BLACK)
BW
--- LW
B6 5 (RED) (RED) B B SB
RB O2 25
RB
Br1
B
(BLACK) GVR
LW
B 21 (BLACK)
B
Br1
J13 B1 Br2 13 14 SUMITOMO 6189-6904

START STOP 2
11 Br RW 15 L2 L2
1 OFF OFF
LW --- 22 VCC
Sb Sb
J1 J4 LA
(BLACK) 1
1 1 AI
Br
B1
1
RW
Br4
2 2
Br
Br4
Br3
Br5
Br4
L1 L1 Y RW
VCC3
Br4
Br4
BL3 BL3
23 SGND5
VM RW3
L4 L3 Br3 GW W2
WWL SP
J9 J7 YW BW
Lg2 L2 WY TC CGND
B1
1 1 RFR PGND
Br2
24
L1
Br
L
CASE : 6409-0031
8-15
Br
B3 B2 --- --- --- --- Br 2

1 B1 B4 --- --- --- Br2 Br1
NEUTRAL 54
Br1 Sb
BR1
Br2
J8 2 2
Br
55 2 2
RW3
RW2
RW1
RW
Br1
Br2
33
W2
34
W3
W1
Br
56 TACHO
Br2
R2
Br1
35 BrW (BLUE)
Br2 R2 51 32
B2
B1
P HOUSING : 6403-7601
GND W3 WY L
CASE : 6409-0032
Gy2
Gy1
BrW BrW
SPEED
YW Br2 Gy2 GY1 BR1
Br5
TC
B4
B1
B2
W1
B3
Br
Gy1
Gy2
Br3
Gy3
Br2
57
RB
P
L3
45 Y Y1
L
46 44
ILLUMI 43 G G
B B1
58 OFF H1 OFF L
L L 36
B Br Dg
B N RB
B WB BrW BrW L3
NR
59 Lg2
(BLACK)
B
(BLACK)
RB RB
HI BEAM B2
Y2 60 B
(BLUE) (BLUE)
WATER
Ch
Dg
B1
61
Y1
B2
G
GW
GY3
L2
TURN 62
Dg
LIGHTING SYSTEM
Y
37
L2 A L2
G AG
Ch2
Ch
Dg
L Y GY3 L2
Dg3
L1 A L1 B B2
GB B3 Y AY Dg1
FUEL+ Ch3 J6 A
OrW J5
FUEL-
Y1
L1
Dg2
49
GB
Y
1 1
Y3
G
CIRCUIT DIAGRAM
Ch
L1
Y L1 L1 Y
Dg1
1 Ch A Ch Ch1
Ch1
63 L1 B L2 L2 B
47
12V35/35W
---
12V35/35W
12V5W
12V5W
Dg2
L1 L B2 Ch Ch G
Ch
L G
L
Y B
J10 B B B
12V10W
12V10W
G
OrW
12V5W
39
12V10W
48 40
B2
12V10W
41 L L
50
B
Y2
B2
B4
OrW GB B B4
42 38
B A B
B4
B3
B3
B2
B3
B1
B3
B2
B4
1
J14
– +
LIGHTING SYSTEM ELEC
1. Junction
5. Main switch
6. Wire plus lead
7. Battery
8. Wire minus lead
9. Fuse
10. Starter relay
37. Tail light
38. Licence light
45. Dimmer switch
46. Pass switch
47. Head light left
48. Auxiliary light left
49. Head light right
50. Auxiliary light right
58. Illumination light
60. High beam indicator light
8-16
– +
TROUBLESHOOTING
Any of the following fail to light: headlight, high beam indicator light, taillight, license plate light, auxiliary
light or meter light.
TIP
2. Fuel tank
3. Upper panels
1. Check the condition of each bulb and NG →

bulb socket.
Refer to “CHECKING THE BULBS Replace the bulb(s) and bulb socket(s).
AND BULB SOCKETS” on page 8-
62.
OK ↓
page 8-63.
OK ↓
page 8-63.
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 entire lighting system NG →
wiring. Properly connect or repair the lighting
page 8-15.
OK ↓
Replace the ECU or meter assembly.
8-17
– +
8-18
+
2
R
BL6 R W BL6
R W
W1
B3 3
–
W1 W W2
B6
B W2 W
J11
B1
ELEC
OrB WY YW --- W2 RW3 BL3 L4 BL1 PW GR

B2
1
W2
W1
BL6
R1

R IG
CRK
B3
RW2
RW3
R3
6
R
27
R1
R2
B4 W1 PW PW
4 17 26
W2 R1 R1 R2 PB
R
R3

BrW BrW
20 A
(BLACK) J3 18 AT
B4 BL5 BL5
B4
9 1 SGND4 28
B3 19 L4 L4
VCC2
RW1
B Br4
SIGNALING SYSTEM
LB
2 Br YR
RW
12 NO.PK605-05027
R2
1 (BLUE)
RW1 LB BL2 BL2
SGND3
10 RB LW
RW
MAIN BL2 GR
R 20 29 RW1
ON R2 OrB OrB
RB
LW
GR GR IJ
OFF Br1 RW Br4 WT
B4
Br (BLACK)
BW
--- LW
B2 B B1 --- GyR GyR OrB RW1
RB O2 25
RB
Br1
B
(BLACK) GVR
LW
B 21 (BLACK)
B
Br1
J13 B1 Br2 13 14 SUMITOMO 6189-6904

START STOP 2
11 Br RW 15 L2 L2
1 OFF OFF
LW --- 22 VCC
Sb Sb
J1 J4 LA
(BLACK) 1
1 1 AI
Br
B1
1
RW
Br4
2 2
Br
Br4
Br3
Br5
Br4
L1 L1 Y RW
VCC3
Br4
Br4
BL3 BL3
23 SGND5
VM RW3
L4 L3 Br3 GW W2
WWL SP
J9 J7 YW BW
Lg2 L2 WY TC CGND
1 1 PGND B1
Br2
RFR
24
L1
Br
L
CASE : 6409-0031
8-19
Br
B3 B2 --- --- --- --- Br 2

1 B1 B4 --- --- --- Br2 Br1
NEUTRAL 54
Br1 Sb
BR1
Br2
J8
2 2 2
Br
55 2
RW3
RW2
RW1
RW
Br1
Br2
33
W2
34
W3
W1
Br
56 TACHO
Br2
R2
Br1
35 BrW (BLUE)
Br2 R2 51 32
B2
B1
P HOUSING : 6403-7601
GND W3 WY L
CASE : 6409-0032
Gy2
Gy1
BrW BrW
SPEED
YW Br2 Gy2 GY1 BR1
Br5
TC
B4
B1
B2
WY
B3
Br
Gy1
Gy2
Br3
Gy3
Br2
57
RB
P
L3
45 Y Y1
L
46 44
ILLUMI 43 G G
B B1
58 OFF H1 OFF L
L L 36
B Br Dg
B N RB
B WB BrW BrW L3
NR
59 Lg2
(BLACK)
B
(BLACK)
RB RB
HI BEAM B2
Y2 60 B
(BLUE)
(BLUE)
WATER
Ch
Dg
B1
61
Y1
B2
G
GW
SIGNALING SYSTEM
GY3
L2
TURN 62
Dg
Y
37
L2 A L2
G AG
Ch2
Ch
Dg
L Y GY3 L2
Dg3
L1 A L1 B B2
GB B3 Y AY Dg1
FUEL+ Ch3 J6 A
OrW J5
FUEL-
Y1
L1
Dg2
49
GB
Y
CIRCUIT DIAGRAM
1 1
Y3
G
Ch
L1
Y L1 L1 Y
Dg1
1 Ch A Ch Ch1
Ch1
63 L1 47 B L2 L2 B
12V35/35W
---
12V35/35W
12V5W
12V5W
Dg2
L1 L B2 Ch Ch G
Ch
L G
L
Y B
J10 B B B
12V10W
12V10W
G
OrW
12V5W
39
12V10W
48 40
B2
12V10W
41 L L
50
B
Y2
B2
B4
OrW GB B B4
42 38
B A B
B4
B3
B3
B2
B3
B1
B3
B2
B4
1
J14
– +
SIGNALING SYSTEM ELEC
1. Junction
5. Main switch
6. Wire plus lead
7. Battery
8. Wire minus lead
9. Fuse
16. Neutral switch
23. Speed sensor
25. E.C.U
33. Front stop switch
35. Flasher relay
37. Tail light
39. Rear
40. Rear
41. Front
42. Front
43. Flasher switch
44. Horn swich
51. Horn
57. Multifunction meter
62. Turn indicator light
63. Fuel sender
8-20
– +
TROUBLESHOOTING
• Any of the following fail to light: turn signal lights, brake light or indicator lights.
• The horn fails to sound.
• The fuel gauge fails to operate.
• The speedometer fails to operate.
TIP
2. Fuel tank
4. Right side cover

page 8-63.
OK ↓
page 8-63.
OK ↓
OK ↓
4. Check the entire signaling system NG →
wiring. Properly connect or repair the signaling
page 8-19.
OK ↓
Check the condition of each of the
signaling system circuits. Refer to
“Checking the signaling system”.
Check 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
– +
2. Check the horn. NG →
Refer to “CHECKING THE HORN” Replace the horn.
on page 8-72.
OK ↓
page 8-19.
OK ↓
This circuit is OK.
The tail/brake light fails to come on.
1. Check the front brake light switch. NG →

Refer to “CHECKING THE Replace the front brake light switch.
OK ↓
NG →
2. Check the rear brake light switch.
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.
AND BULB SOCKETS” on page 8-
62.
OK ↓
2. Check the turn signal switch. NG →

The turn signal switch is faulty. Replace
the left handlebar switch.
OK ↓
3. Check the turn signal relay. NG →
Refer to “CHECKING THE TURN Replace the turn signal relay.
SIGNAL RELAY” on page 8-67.
OK ↓
8-22
– +
page 8-19.
OK ↓
Replace the meter assembly.
The neutral indicator light fails to come on.

NG →
1. Check the neutral switch.
Refer to “CHECKING THE Replace the neutral switch.
OK ↓
page 8-19.
OK ↓
The fuel gauge fails to operate.

1. Check the fuel sender. NG →
Refer to “CHECKING THE FUEL Replace the fuel sender.
SENDER” on page 8-72.
OK ↓
page 8-19.
OK ↓
The speedometer fails to operate.

1. Check the speed sensor. NG →
Refer to “CHECKING THE SPEED Replace the speed sensor.
OK ↓
page 8-19.
OK ↓
8-23
– +
8-24
+
2
R
BL6 R W BL6
R W
–
W1
B3 3
W1 W W2
B6
B W2 W
ELEC

J11
B1 OrB WY --- W2 RW3 BL3 L4 BL1 PW GR
B2
1
W2
W1
BL6
R1

R IG
CRK
B3
RW2
RW3
R3
6
R
27
R1
R2
B4 W1 PW PW
4 17 26
W2 R1 R1 R2 PB
R
R3

BrW BrW
20 A
(BLACK) J3 18 AT
B4 BL5
B4
BL5 SGND4 28
9 1
COOLING SYSTEM
B3 19 L4 L4
VCC2
RW1
B Br4
LB
2 Br YR
RW
12 NO.PK605-05027
R2
1 (BLUE)
RW1 LB BL2 BL2
SGND3
10 RB LW
RW
MAIN BL2 GR
R 20 29 RW1
ON R2 OrB OrB
RB
LW
GR GR 1J
OFF Br1 RW Br4 WT
B4
Br (BLACK)
BW
--- LW
B B1 --- OrB RW1
B2 RB GyR GyR
O2 25
RB
Br1
B
(BLACK) GVR
LW
B 21 (BLACK)
B
Br1
J13 B1 Br2 13 14 SUMITOMO 6189-6904

START STOP 2
11 Br RW 15 L2 L2
1 OFF OFF
LW --- 22 VCC
Sb Sb
J1 J4 LA
(BLACK) 1
1 1 A1
Br
B1
1
RW
Br4
2 2
Br
Br4
Br3
Br5
Br4
L1 L1 Y RW
VCC3
Br4
Br4
BL3 BL3
23 SGND5
VM RW3
L4 L3 Br3 GW SP W2
WL
J9 J7 YW BW
Lg2 L2 WY TC CGND
B1
1 1 RFR PGND
Br2
24
L1
Br
L
CASE : 6409-0031
8-25
Br
B3 B2 --- --- --- --- Br 2

1 B1 B4 --- --- --- Br2 Br1
NEUTRAL 54
Br1 Sb
BR1
Br2
J8
2 2 2
Br
55 2
RW3
RW2
RW1
RW
Br1
Br2
33
W2
34
W3
W1
Br
56 TACHO
Br2
R2
Br1
35 BrW (BLUE)
Br2 R2 51 32
B2
B1
P HOUSING : 6403-7601
GND W3 WY L
CASE : 6409-0032
Gy2
Gy1
BrW BrW
SPEED
YW Br2 Gy2 GY1 BR1
Br5
TC
B4
B1
B2
WY
B3
Br
Gy1
Gy2
Br3
Gy3
Br2
57
RB
P
L3
45 Y Y1
L
46 44
ILLUMI 43 G G
B B1
58 OFF H1 OFF L
L L 36
B Br Dg
B N RB
B WB BrW BrW L3
NR
59 Lg2
(BLACK)
B
(BLACK)
RB RB
HI BEAM B2
Y2 60 B
(BLUE) (BLUE)
WATER
Ch
Dg
B1
61
Y1
B2
G
GW
GY3
L2
TURN 62
Dg
Y
37
L2 A L2
COOLING SYSTEM
G AG
Ch2
Ch
Dg
L Y GY3 L2
Dg3
L1 A L1 B B2
GB B3 Y AY Dg1
FUEL+ Ch3 J6 A
OrW J5
FUEL-
Y1
L1
Dg2
49
GB
Y
1 1
Y3
G
Ch
L1
CIRCUIT DIAGRAM
Y L1 L1 Y
Dg1
1 Ch A Ch Ch1
Ch1
63 L1 B L2 L2 B
12V36/35W
--- 47
12V35/35W
12V5W
12V5W
Dg2
L1 L B2 Ch Ch G
Ch
L G
L
Y B
J10 B B B
12V10W
12V10W
G
OrW
12V5W
39
12V10W
48 40
B2
12V10W
41 L L
50
B
Y2
B2
B4
OrW GB B B4
42 38
B A B
B4
B3
B3
B2
B3
B1
B3
B2
B4
1
J14
– +
COOLING SYSTEM ELEC
1. Junction
5. Main switch
6. Wire plus lead
7. Battery
8. Wire minus lead
9. Fuse
20. Coolant temperature sensor
25. E.C.U
52. Relay assy 2
53. fan motor
61. Coolant temperature indicator light
8-26
– +
COOLING SYSTEM ELEC
TROUBLESHOOTING
• The radiator fan motor fails to turn.
• The coolant temperature warning light fails to come on.
TIP
2. Fuel tank

page 8-63.
OK ↓
page 8-63.
OK ↓
OK ↓
4. Check the radiator fan motor. NG →
Replace the radiator fan motor.
RADIATOR FAN MOTOR” on
page 8-73.
OK ↓
5. Check the radiator fan motor relay. NG →

Refer to “CHECKING THE RELAYS” Replace the radiator fan motor relay.
on page 8-67.
OK ↓
6. Check the coolant temperature NG →

sensor.
Refer to “CHECKING THE Replace the coolant temperature sensor.
COOLANT TEMPERATURE
OK ↓
7. Check the entire cooling system NG →

wiring. Properly connect or repair the cooling
page 8-25.
OK ↓
8-27
– +
COOLING SYSTEM ELEC
8-28
+
2
R
BL6 R W BL6
R W
W1
–
B3 3
W1 W W2
B6
B W2 W
J11
ELEC

B2
1
W2
W1
BL6
R1

R IG
CRK
B3
RW2
RW3
R3
6
R
27
R1
R2
B4 W1 PW PW
4 17 26
W2 R1 R1 R2 PB
R
R3

BrW BrW
20 A
(BLACK) J3 18 AT
B4 BL5 BL5
B4
9 1 SGND4 28
B3 19 L4 L4
VCC2
FUEL INJECTION SYSTEM
RW1
B Br4
LB
2 Br YR
RW
12 NO.PK605-05027
R2
1 (BLUE)
RW1 LB BL2 BL2
SGND3
10 RB LW
RW
MAIN BL2 GR
R 20 29 RW1
ON R2 OrB OrB
RB
LW
GR GR 1J
OFF Br1 RW Br4 WT
B4
Br (BLACK)
BW
--- LW
B2 B B1 ---
RB GyR GyR OrB RW1
O2 25
RB
Br1
B
(BLACK) GVR
LW
B 21 (BLACK)
B
Br1
J13 B1 Br2 13 14 SUMITOMO 6189-6904

START STOP 2
11 Br RW 15 L2 L2
1 OFF OFF
LW --- 22 VCC
Sb Sb
J1 J4 LA
(BLACK) 1
1 1 A1
Br
B1
1
RW
Br4
2 2
Br
Br4
Br3
Br5
Br4
L1 L1 Y RW
VCC3
Br4
Br4
BL3 BL3
23 SGND5
VM RW3
L4 L3 Br3 GW W2
WWL SP
J9 J7 YW BW
Lg2 L2 WY TC CGND
B1
1 1 RFR PGND
Br2
24
L1
Br
L

CASE : 6409-0031
8-29
Br
B3 B2 --- --- --- --- Br 2

1 B1 B4 --- --- --- Br2 Br1
NEUTRAL 54
Br1 Sb
BR1
Br2
J8
2 2 2
Br
55 2
RW3
RW2
RW1
RW
Br1
Br2
33
W2
34
W3
W1
Br
56 TACHO
Br2
R2
Br1
35 BrW (BLUE)
Br2 R2 51 32
B2
B1
P HOUSING : 6403-7601
GND W3 WY L
CASE : 6409-0032
Gy2
Gy1
BrW BrW
SPEED
YW Br2 Gy2 GY1 BR1
Br5
TC
B4
B1
B2
WY
B3
Br
Gy1
Gy2
Br3
Gy3
Br2
57
RB
P
L3
45 Y Y1
L
46 44
ILLUMI 43 G G
B B1
58 OFF H1 OFF L
L L 36
FUEL INJECTION SYSTEM
B Br Dg
B N RB
B WB BrW BrW L3
NR
59 Lg2
(BLACK)
B
(BLACK)
RB RB
HI BEAM B2
Y2 60 B
(BLUE) (BLUE)
WATER
Ch
Dg
B1
61
Y1
B2
G
GW
GY3
L2
TURN 62
Dg
Y
37
L2 A L2
G AG
Ch2
Ch
Dg
L Y GY3 L2
Dg3
L1 A L1 B B2
GB B3 Y AY Dg1
FUEL+ Ch3 J6 A
OrW J5
FUEL-
CIRCUIT DIAGRAM
Y1
L1
Dg2
49
GB
Y
1 1
Y3
G
Ch
L1
Y L1 L1 Y
Dg1
1 Ch A Ch Ch1
Ch1
63 L1 B L2 L2 B
47
12V35/35W
---
12V35/35W
12V5W
12V5W
Dg2
L1 L B2 Ch Ch G
Ch
L G
L
Y B
J10 B B B
12V10W
12V10W
G
OrW
12V5W
39
12V10W
48 40
B2
12V10W
41 L L
50
B
Y2
B2
B4
OrW GB B B4
42 38
B A B
B4
B3
B3
B2
B3
B1
B3
B2
B4
1
J14
– +
FUEL INJECTION SYSTEM ELEC
1. Junction
5. Moon Switch
6. Wire plus lead
7. Battery
8. Wire minus lead
9. Fuse
17. Intake pressure sensor
18. Intake temperature sensor
19. Throttle position sensor
20. Coolant temperatur sensor
21. O2 sensor
22. Lean agle sensor
23. Speed sensor
24. Service tool
25. E.C.U
26. Ignition coil
27. Spark plug
28. F.I.D
29. Injector
30. Fuel pump
31. J / C2
32. J / C1
52. Relay assy 2
53. Fan motor
61. Water temperature indicator light
8-30
– +
EAS27350
ECU SELF-DIAGNOSTIC FUNCTION

The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is
operating normally. If this function detects a malfunction in the system, it immediately operates the en-
gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider
that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is
stored in the memory of the ECU.
• To inform the rider that the fuel injection system is not functioning, the engine trouble warning light
flashes when the start switch is being pushed to start the engine.
• If a malfunction is detected in the system by the self-diagnostic function, the ECU provides an appro-
priate substitute characteristic operation, and alerts the rider of the detected malfunction by illuminat-
ing the engine trouble warning light.
• After the engine has been stopped, the lowest fault code number is indicated by the engine trouble
warning light (or displayed on the FI diagnostic tool). It remains stored in the memory of the ECU until
it is deleted.
1
x 1000 r/min
Engine trouble warning light fault code indication

Digit of 10: Cycles of 1 sec. on and 1.5 sec. off.
Digit of 1: Cycles of 0.5 sec. on and 0.5 sec. off.
Example: 42
a. Light on
b. Light off
c. 1
d. 1.5
e. 0.5
f. 3
8-31
– +
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
substitute
Can or cannot be
characteristics in
Remains on Malfunction detected operated depending on
accordance with the
the fault code
description of the
malfunction
* The warning light flashes when any one of the conditions listed below is present and the start switch
is pushed:
Lean angle sensor
12: Crankshaft postion sensor 41:
(open or short circuit)
Lean angle sensor ECU internal malfunction
30: 50:
(latch up detected) (memory check error)
Fuel injector
39:
(open or short circuit)
Checking the engine trouble warning light

The engine trouble warning light comes on for 3 seconds after the main switch has been set to “ON”. If
the warning light does not come on under these conditions, the warning light (LED) may be defective.
a b
c d c
a. Main switch “OFF” d. Engine trouble warning light on for 3 seconds

b. Main switch “ON”
c. Engine trouble warning light off
8-32
– +
EAS00902
SELF-DIAGNOSTIC FUNCTION TABLE

If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi-
nates the engine trouble warning light and provides the engine with alternate operating instructions that
are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue to operate or stop operating, depending on the conditions.
Self-Diagnostic Function table

Fault Able/unable Able/unable
Item Symptom
code to start to drive
No normal signals are received from
12 Crankshaft position sensor Unable Unable
the crankshaft position sensor.
Intake pressure sensor No normal signals are received from
13 Able Able
(Open or Short) the intake pressure sensor.
Faulty throttle body
(Clogged sensor hole or detached
Intake pressure sensor sensor)
14 Able Able
(Clogged hole) Faulty intake air system
(Stable pressure is not supplied to the
sensor)
Able (depend- Able (depend-
Throttle position sensor No normal signals are received from
15 ing on circum- ing on circum-
(Open or short) the throttle position sensor.
stances) stances)
Throttle position sensor
16 Stuck throttle position sensor detected. Able Able
(Stuck)
Coolant temperature
21 sensor Able Able
the coolant temperature sensor.
(Open or short)
Intake temperature sensor No normal signals are received from
22 Able Able
(Open or short) the intake temperature sensor.
24 O2 sensor Able Able
the O2 sensor.
Lean angle sensor No normal signals are received from
30 Unable Unable
Latch up detected the lean angle sensor.
39
Injector No normal signals are received from
Unable Unable
(Open) the fuel injector.
Lean angle sensor No normal signals are received from
41 Unable Unable
(Open or short) the lean angle sensor.
42 Speed sensor Able Able
the speed sensor.
Able (depend- Able (depend-
44 EEPROM writing error Error is detected on EEPROM. ing on circum- ing on circum-
stances) stances)
The regulator is not functioning
46
Power supply to fuel properly.
Able Able
injector The battery cannot be charged
properly.
The program and data are not properly
50 Faulty ECU memory written on or read from the internal Unable Unable
memory.
Waiting for ECU internal malfunction No signals are transmitted to the
Able Able
connection (output signal error) service tool.
ECU internal malfunction No signals are received from the
Er-4 Able Able
(Input signal error) service tool.
8-33
– +
EAS00904
TROUBLESHOOTING METHOD
There is no engine operation signal or the engine trouble warning light is lit.
*If there is no engine operation signal, the engine trouble warning light may not be able to light up.
The engine trouble warning light lights up. The engine trouble warning light is not lit.
Check the error code displayed on the FI diagnostic tool.

In the diagnostic mode, inspect and operate the
following sensors and actuators. Refer to
“SENSOR AND ACTUATOR OPERATION
TABLE”.
Find the system malfunction. Refer to 39: Fuel injector
“SELF-DIAGNOSTIC FUNCTION TABLE”.
Normal Abnormal
Find the possible reason for the system malfunction.
Refer to “DIAGNOSTIC CODE TABLE”.
Faulty sensor or
Engine malfunction.
Inspecting and repairing the possible cause of error actuator.
Fault code No. No fault code No.
Inspect and repair.
Refer to “TROUBLE-
Inspecting and repairing Sensors and
SHOOTING DETAILS”. Inspect and repair.
In the diagnostic mode, internal parts. actuators conform to
Refer to Refer to “ENGINE” in inspection and
view and operate the “SELF-DIAGNOSTIC chapter 4. repair.
sensors and actuators. FUNCTION GUIDE”.
Refer to “SENSOR AND
Normal Normal
ACTUATOR OPERA-
TION TABLE”.
Abnormal
Inspect engine situation.

For ECU reinstallation, refer to recovering initial
status in “TROUBLESHOOTING DETAILS”.
Normal
Error code displays.
Turn the main switch to “OFF” and then back to
“ON”. Check if an error code is displayed.
There is no error code displayed.
Repair complete.
Erase the malfunction history: *

Turning the main switch to “OFF” will not erase the malfuntion history.
Erase the malfunction history in the diagnostic mode. Refer to “SENSOR AND ACTUATOR OPERATION
TABLE (Diagnostic code No. 62)”.
*For when engine trouble warning light is lit.
8-34
– +
EAS59C1803
YAMAHA DIAGNOSTIC TOOL

This model uses the Yamaha diagnostic tool to identify malfunctions.
For information about using the Yamaha diagnostic tool, refer to the operation manual that is included
with the tool.
FI diagnostic tool
90890-03215
Features of the Yamaha diagnostic tool

1. You can use the Yamaha diagnostic tool to identify malfunctions quicker than with conventional
methods.
2. By connecting the adapter interface, which is connected to the USB port of a computer, to a vehicle's
ECU using the communication cable, you can display information that is necessary for identifying
malfunctions and for maintenance to display on the computer. The displayed information includes
the sensor output data and information recorded in the ECU.
Functions of the Yamaha diagnostic tool

Fault diagnosis mode: Error codes recorded on the CEU are read, and the contents are dis-
played.
Function diagnostic mode: Check the operation of the output value of each sensor and actuator.
Inspection mode: Determine whether each sensor or actuator is functioning properly.
CO adjustment mode: Adjust the concentration of CO emissions during idling.
Monitoring mode: Displays a graph of sensor output value in actual driving conditions.
Logging mode: Records and saves the sensor output values for actual operating condi-
tions.
View log: Displays the logging data.
ECU rewrite: If necessary, the ECU is rewritten using ECU rewrite data provided by
Yamaha.
Ignition timing adjustment, etc. cannot be changed from the vehicle's
original state.
However, the diagnostic tool cannot be used to freely change the basic vehicle function, such as ad-
justing the ignition timing.
Connecting the Yamaha diagnostic tool

Disconnect the coupler (Light Green / Blue) 1, and then connect the Yamaha diagnostic tool to the
coupler.
TIP
When the Yamaha diagnostic tool is connected to the vehicle, the operation of the multifunction meter
and indicators will be different from the normal operation.
8-35
– +
DIAGNOSTIC CODE TABLE
Fault code
Diagnostic
(Meter Symptom Probable cause of malfunction
code No.
display)
12 No normal signals are received • Faulty coupler. —
from the crankshaft position • Open or short circuit in wire harness.
sensor. • Defective crankshaft position sensor.
• Malfunction in generator rotor.
• Malfunction in ECU (engine control unit).
• Improperly installed sensor.
13 Open or short circuit detected. • Faulty coupler D03
• Open or short circuit in wire harness.
• Defective intake air pressure sensor.
14 Faulty throttle body • Sensor module is detached. D03
(Clogged sensor hole or • Improperly installed throttle body.
detached sensor) • Intake air pressure sensor hole is clogged.
Faulty intake air system
(Stable pressure is not
supplied to the sensor)
15 No normal signals are received • Faulty coupler. D01
from the throttle position • Open or short circuit in wire harness.
sensor. • Defective throttle position sensor.
• Improperly installed sensor module.
16 Stuck throttle position sensor • Improperly installed sensor module. D01
detected. • Defective throttle position sensor.
• Mechanical connection is not correct between
from throttle position sensor to throttle body.
22 No normal signals are received • Faulty coupler D05
from the intake temperature • Open or short circuit in wire harness.
sensor. • Defective intake temperature sensor.
24 No normal signals are received • Faulty coupler. —
from the O2 sensor. • Open or short circuit in wire harness.
• Defective O2 sensor.
• Improperly fuel pressure.
• Improperly installed O2 sensor.
30 No normal signals are received • The vehicle has overturned. D08
from the lean angle sensor. • Improperly installed lean angle sensor.
• Defective lean angle sensor.
• Malfunction in ECU.
39 No normal signals are received • Faulty coupler D36
from the fuel injector. • Open or short circuit in wire harness.
• Defective fuel injector.
8-36
– +
Fault code
Diagnostic
(Meter Symptom Probable cause of malfunction
code No.
display)
41 No normal signals are received • Open or short circuit in wire harness. D08
from the lean angle sensor. • Defective lean angle sensor.
42 No normal signals are received • Open or short circuit in wire harness. D07
from the speed sensor. • Defective speed sensor.
• Malfunction in meter.
44 Error is detected while reading • Malfunction in ECU (engine control unit). (The D60
or writing on EEPROM (CO CO adjustment value is not properly written on or
adjustment value) read from the internal memory).
46 The regulator is not functioning • Battery overcharging (faulty rectifier/regulator) —
properly. • Battery overcharging (broke or disconnected
The battery cannot be charged lead in rectifier/regulator wire harness)
properly. • Battery over-discharging (broken or
disconnected lead in charging system)
• Battery over-discharging (faulty
rectifier/regulator)
50 The program and data are not • Malfunction in ECU (engine control unit). —
properly written on or read
from the internal memory.
Preset The battery voltage drops • Battery over-discharging D09
lighting immediately after the main • Faulty battery
pattern switch is set to “ON”. • Battery deterioration
• Faulty charging system
Waiting for No signals are transmitted to • Improperly connected. —
connection the service tool. • Faulty coupler.
• Malfunction in Service tool.
• Malfunction in ECU
Er-4 No signals are received from • Faulty coupler. —
the service tool. • Open or short circuit in wire harness.
• Malfunction in service tool.
8-37
– +
EAS00907
SENSOR AND ACTUATOR OPERATION TABLE

TIP
• Inspect air temperature at each closed air intake and the engine temperature, which may be the same
as that of the intake air temperature sensor and the engine temperature sensor.
• If the intake air temperature cannot be confirmed, use the nearby air temperature as a reference.
Diagnostic
Item Checking method Meter display or Actuation
code
Throttle angle Throttle angle. 0–125
D01
Fully closed position Fully closed position: 14–20
Intake pressure Displays intake air pressure. 0–126[kPa]
Check intake manifold pressure Stop engine: Display atmospheric
Push starter switch, and check pressure 0 m (0 ft) above sea level:
pressure difference Approx. 101 kPa (757.6 mmHg,
D03
29.8 inHg)
3000 m (9800 ft) above sea level: Approx.
70 kPa (525.0 mmHg, 20.7 inHg)
Cranking engine: Display data is changing
Intake temperature Display intake temperature. -30–120 degree
Check temperature inside of intake Cold engine: Display close open air
D05 manifold or air cleaner. temperature
Warm up engine: Open air temperature +
about 20 degree
Coolant temperature Display coolant temperature. -30–150 [°C]
Check coolant temperature. Cold engine: Display open air
temperature
D06
(Minimum display: -30 degree)
Warm up engine: Display coolant
temperature (Example: 60-100 degree)
Vehicle speed pulse Display vehicle speed pulse 0–999[pulse]
Stop front wheel rotation: Display is not
D07 change
Front wheel is rotated several turns by
hand:Number increases
Lean angle sensor Display lean angle sensor value 0–5 [V]
D08
Upright: 0-1.4 [V] Overturn: 3.7-4.4 [V]
Battery voltage Display fuel system voltage 0–18.7[V]
D09
Standard data: about 12[V]
Ignition coil Check continuity ignition coil Actuates the ignition coil five times at one
Check Spark second intervals
D30
Illuminates the engine trouble warning
light.
Injector Check continuity injector (NOTICE) Before operating this step,
Check the operating sound or visually remove fuel pump coupler.
of fuel injector Actuates the fuel injector five times at one
D36
second intervals.
light.
Radiator fan motor relay Check operating sound of radiator fan Actuates the radiator fan motor relay, five
D51 relay times at one-second intervals. Illuminates
the engine trouble warning light.
FID Check operating sound of FID Actuates the FID solenoid, five times at
one-second intervals.
D54
light.
EEPROM fault code No. Display EEPROM fault code 00: No history
If more than one code number is 01: CO adjustment value is detected.
D60 detected, the display alternates every
two seconds to show all the detected
code numbers.
Malfunction history code Display malfunction history code 00: No history
display If more than one code number is Fault code No.: History exists
D61 detected, the display alternates every
two seconds to show all the detected
code numbers.
Malfunction history code Erase malfunction history code 00: No history
D62
erasure Displays total number of malfunctions
D70 Control number Check control number 0–254 [-]
8-38
– +
Communication error with the FI diagnostic tool
LCD displays Symptom Possible reason for error
Waiting for connection. No signals are transmitted to the • Improperly connected.
service tool. • Faulty coupler.
• Malfunction in Service tool.
• Malfunction in ECU
Er-4 No signals are received from the • Faulty coupler.
service tool. • Open or short circuit in wire harness.
• Malfunction in service tool.
EAS00908
TROUBLESHOOTING DETAILS
This section explains how to handle problems when the FI diagnostic tool shows error codes. Follow
the sequence to check and repair the reasons and factors that cause faults.
After checking and repairing the faulty items, follow the adjustment method to make the message
displayed on the FI diagnostic tool “Recover initial status”.
Error code No.:

Error code No. will be displayed on the FI diagnostic tool when the engine is operating
abnormally.
Refer to “DIAGNOSTIC CODE TABLE”.
Diagnostic code No.:

The diagnostic code No. is the diagnostic code displayed in the diagnostic mode. Refer to
“SENSOR AND ACTUATOR OPERATION TABLE”.
Crankshaft position sensor: no normal signals

Fault code 12 Symptom
are received from the crankshaft position sensor.
Diagnostic code No.:---
Probable cause of malfunction Confirmation of service

Item Maintenance job
and check completion
1 • Connection of crankshaft Improperly connected → Connect the coupler • Crank the engine.
position sensor coupler. securely or repair / replace the wire harness. • Fault code number is not
• Check the locking condition of displayed → Service is
the coupler. finished.
• Disconnect the coupler and • Fault code number is
check the pins (bent or broken displayed → Go to item 2.
terminals and locking condition
of the pins).
2 • Connection of wire harness Improperly connected → Connect the coupler • Crank the engine.
ECU coupler. securely or repair / replace the wire harness. • Fault code number is not
of the pins).
3 Continuity of wire harness • Open or short circuit → Replace the wire • Crank the engine.
harness. • Fault code number is not
• Between the crankshaft position sensor displayed → Service is
coupler and ECU coupler. finished.
(Red-Red) • Fault code number is
(White - White) displayed → Go to item 4.
8-39
– +
Crankshaft position sensor: no normal signals
are received from the crankshaft position sensor.
Diagnostic code No.:---

4 • Installed condition of crankshaft Improperly installed sensor → Reinstall or • Crank the engine.
position sensor. replace the sensor. • Fault code number is not
• Check for looseness or displayed → Service is
pinching. finished.
• Fault code number is
displayed → Go to item 5.
5 Defective crankshaft position • Check the crankshaft position sensor. • Crank the engine.
sensor. • Fault code number is not
displayed → Service is
finished.
6 Malfunction in ECU. • Replace the ECU.
Fault code 13 Symptom Intake air pressure sensor: open or short circuit detected.
Diagnostic code No.: D03 (Intake air pressure)
TIP
Do not remove the sensor module.
If fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first.
1 • Connection of sensor and ISC Improperly connected → Connect the coupler • Set the main switch to “ON”.
module coupler. securely or repair / replace the wire harness. • Fault code number is not
check the pins (bent or broken displayed → Go to item 2
of the pins).
2 • Connection of wire harness Improperly connected → Connect the coupler • Set the main switch to “ON”.
ECU coupler. securely or repair / replace the wire harness. • Fault code number is not
of the pins).
3 Wire harness continuity. • Open or short circuit → Replace the wire • Set the main switch to “ON”.
• Between intake air pressure sensor coupler displayed → Service is
and ECU coupler. finished.
(Black / blue-Black / blue) • Fault code number is
(Pink / white-Pink / white) displayed → Go to item 4.
(Blue-Blue)
4 Installed condition of sensor. Improperly installed sensor → Reinstall or • Set the main switch to “ON”.
replace the sensor. • Fault code number is not
finished.
8-40
– +
Fault code 13 Symptom Intake air pressure sensor: open or short circuit detected.
Diagnostic code No.: D03 (Intake air pressure)

5 Defective intake air pressure • Execute the diagnostic mode. (Code No. D03) • Set the main switch to “ON”.
sensor. • When engine is stopped: Atmospheric • Fault code number is not
pressure at the current altitude and weather displayed → Service is
conditions is indicated. finished.
• At sea level: Approx. 101 kPa • Fault code number is
1000 m above sea level: Approx. 90 kPa displayed → Go to item 6.
2000 m above sea level: Approx. 80 kPa
3000 m above sea level: Approx. 70 kPa
• When engine is cranking: Make sure that the
indication value changes.
• The value does not change when engine is
cranking. → Replace the throttle body.
Fault code 14 Symptom Intake air pressure sensor malfunction (clogged hole or loose).
Diagnostic code No.: d03 (Intake air pressure)
TIP
If fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first.
1 The intake air pressure sensor is Check the mounting section for loose or pinched • Start the engine and let it idle
loosen. mounting. for approximately 5 seconds.
• Fault code number is not
finished.
displayed → Proceed to the
next item.
2 Defective intake air pressure • Execute the diagnostic mode.
sensor. (Code No. d03)
• When engine is stopped: Atmospheric
pressure at the current altitude and weather
conditions is indicated.
At sea level:
Approx. 101 kPa
1000 m above sea level:
Approx. 90 kPa
Approx. 80 kPa
Approx. 70 kPa
• When engine is cranking: Make sure that the
indication value changes.
• The value does not change when engine is
cranking. → Replace the throttle body.
8-41
– +
Fault code 15 Symptom Throttle position sensor: open or short circuit detected.
Diagnostic code No.: d01 (Throttle position sensor)
TIP
1 • Connection of throttle position Improperly connected → Connect the coupler • Set the main switch to “ON”.
sensor coupler. securely or repair / replace the wire harness. • Fault code number is not
of the pins).
2 • Connection of ECU wire Improperly connected → Connect the coupler • Set the main switch to “ON”.
harness coupler. securely or repair / replace the wire harness. • Fault code number is not
of the pins).
• Between throttle position sensor coupler and displayed → Service is
ECU coupler. finished.
Black / blue-Black / blue • Fault code number is
Yellow-Yellow displayed → Go to item 4.
Blue-Blue
4 Installed condition of sensor. • Improperly installed sensor → Reinstall or • Set the main switch to “ON”.
replace the throttle body. • Fault code number is not
finished.
5 Defective throttle position sensor. • Execute the diagnostic mode. • Set the main switch to “ON”.
(Code No. d01). • Fault code number is not
• When throttle is fully closed: displayed → Service is
A value of 14-20 is indicated. finished.
• When throttle is fully open: • Fault code number is
A value of 97-107 is indicated. displayed → Go to item 6.
• If the indication is outside of range → Replace
the throttle body.
6 Malfunction in ECU. Replace the ECU.
8-42
– +
Throttle position sensor: stuck throttle position sensor detected.
(signal from throttle position sensor will not change.)
Diagnostic code No.: d01 (Throttle position sensor)
TIP
1 Installed condition of sensor. • Check for loose mounting, pinched mounting, • Set the main switch to “ON”.
or hard mounting. • Fault code number is not
• Make sure that the mounting position is displayed → Service is
correct. finished.
2 Defective throttle position sensor. • Execute the diagnostic mode. • Set the main switch to “ON”.
(Code No. d01). • Fault code number is not
• When throttle is fully closed: displayed → Service is
A value of 14-20 is indicated. finished.
• When throttle is fully open: • Fault code number is
A value of 97-107 is indicated. displayed → Go to item 3.
• If the indication is outside of range → Replace
the throttle body.
Fault code 21 Symptom Coolant temperature sensor: open or short circuit detected.
Diagnostic code No.: d06 (Coolant temperature sensor)
TIP
Make sure that the engine is completely cool before checking the following items.
1 • Connection of coolant Improperly connected → Connect the coupler Set the main switch to “ON”.
temperature sensor coupler securely or repair/replace the wire harness. Fault code number is not
• Check the locking condition of displayed. Service is finished.
the coupler. Fault code number is displayed
• Disconnect the coupler and → Go to item 2.
check the pins (bent or broken
terminals and locking conditions
of the pins
2 • Connection of wire harness Improperly connected → Connect the coupler Set the main switch to “ON”.
ECU coupler securely or repair/replace the wire harness. Fault code number is not
• Check the locking condition of displayed → Service is finished.
the coupler. Fault code number is displayed
• Disconnect the coupler and → Go to item 3.
check the pins (bent or broken
terminals and locking conditions
of the pins
3 Wire harness continuity. Open or short circuit → Replace the wire Set the main switch to “ON”.
harness. Between engine temperature sensor Fault code number is not
coupler and ECU coupler. displayed → Service is finished.
Black/blue–Black/blue Fault code number is displayed
Green/red–Green/red → Go to item 4.
8-43
– +
Fault code 21 Symptom Coolant temperature sensor: open or short circuit detected.
Diagnostic code No.: d06 (Coolant temperature sensor)
TIP
4 Installed condition of coolant Improperly installed sensor → Reinstall or Set the main switch to “ON”.
temperature sensor. replace the sensor. Fault code number is not
Check for looseness or pinching. displayed → Service is finished.
Fault code number is displayed
→ Go to item 5.
5 Defective coolant temperature Execute the diagnostic mode. Set the main switch to “ON”.
sensor (Code No. d06). During cold starting: Fault code number is not
A temperature close to the ambient temperature displayed → Service is finished.
is indicated. Indication is incorrect → Replace Fault code number is displayed
the coolant temperature sensor. → Go to item 6.
8-44
– +
Intake air temperature sensor: open or short circuit detected.
(no normal signals are received from the intake air temperature sensor.)
Diagnostic code No.: d05 (Intake air temperature)
TIP
1 • Connection of intake air Improperly connected → Connect the coupler • Set the main switch to “ON”.
temperature sensor coupler securely or repair / replace the wire harness. • Fault code number is not
of the pins).
2 • Connection of wire harness Improperly connected → Connect the coupler • Set the main switch to “ON”.
ECU coupler securely or repair / replace the wire harness. • Fault code number is not
of the pins).
• Between intake air temperature sensor coupler displayed → Service is
and ECU coupler. finished.
(Black / blue-Black / blue) • Fault code number is
(Brown / white-Brown / white) displayed → Go to item 4.
4 • Installed condition of sensor Improperly installed sensor → Reinstall or • Set the main switch to “ON”.
module. replace the sensor. • Fault code number is not
• Check for looseness or displayed → Service is
pinching. finished.
5 Defective intake air temperature • Execute the diagnostic mode. • Set the main switch to “ON”.
sensor. (Code No. d05) • Fault code number is not
• During cold starting: A temperature close to displayed → Service is
the ambient temperature is indicated. finished.
• Indication is incorrect. → Replace the throttle • Fault code number is
body. displayed → Go to item 6.
8-45
– +
Fault code 24 Symptom O2 sensor: Not activated.
Diagnostic code No. ---

1 Installed condition of O2 sensor. Improperly installed sensor → Reinstall or • Start the engine, warm it up,
replace the sensor. and then race it.
finished.
2 • Connection of O2 sensor Improperly connected → Connect the coupler • Start the engine, warm it up,
coupler. securely or repair / replace the wire harness. and then race it.
• Check the locking condition of • Fault code number is not
the coupler. displayed → Service is
• Disconnect the coupler and finished.
check the pins (bent or broken • Fault code number is
terminals and locking condition displayed → Go to item 3.
of the pins).
3 • Connection of wire harness Improperly connected → Connect the coupler • Start the engine, warm it up,
ECU coupler securely or repair / replace the wire harness. and then race it.
of the pins).
4 Wire harness continuity. • Open or short circuit → Replace the wire • Start the engine, warm it up,
harness. and then race it.
• Between O2 sensor coupler and ECU coupler. • Fault code number is not
• Gray / red-Gray / red displayed → Service is
finished.
5 Check fuel pressure. Refer to “CHECKING THE FUEL PRESSURE”. • Start the engine, warm it up,
and then race it.
finished.
6 O2 sensor malfunction • Check the O2 sensor for an abnormality. • Start the engine, warm it up,
• O2 sensor malfunction → Replace the O2 and then race it.
sensor.” • Fault code number is not
Refer to “REMOVING THE ENGINE” displayed → Service is
finished.
8-46
– +
Fault code 30 Symptom No normal signal is received from the lean angle sensor.
Diagnostic code No. d08 (Lean angle sensor)
Probable cause of malfunction

Item Maintenance job Confirmation of service completion
and check
1 Turnover of vehicle Upright of vehicle. Set the main switch to “ON - OFF - ON”.
Then, check the fault code indication.
No fault code indicated. → Recovered.
Fault code indicated. → Go to item 2.
2 Installed condition of lean angle Check for looseness or pinching. Set the main switch to “ON - OFF - ON”.
sensor. Check installing position of sensor Then, check the fault code indication.
(Upside and downside) → Reinstall No fault code indicated. → Recovered.
the sensor propery. Fault code indicated. → Go to item 3.
3 Defective lean angle sensor. Execute the diagnostic mode. Set the main switch to “ON - OFF - ON”.
(Code No. d:08) Then, check the fault code indication.
Turnover: 0.4 - 1.4 [V] No fault code indicated. → Recovered.
Upright: 3.7 - 4.4 [V] Fault code indicated. → Go to item 4.
If the indication is outside of range
→ Replace the lean angle sensor.
8-47
– +
Fault code 39 Symptom Fuel injector-open or short circuit detected.
Diagnostic code No.: d36 (Fuel injector)

1 • Connection of fuel injector Improperly connected → Connect the coupler • Execute the diagnostic mode.
coupler. securely or repair / replace the wire harness. (Code No. d36)
• Check the locking condition of • Fuel injector operation sound
the coupler. is heard. → Go to item 6.
• Disconnect the coupler and • Fuel injector operation sound
check the pins (bent or broken is not heard. → Go to item 2.
of the pins).
2 Defective injector • Measure the injector resistance. • Execute the diagnostic mode.
If the resistance is not 12 Ω, replace the (Code No. d36)
injector. • Fuel injector operation sound
is heard. → Go to item 6.
• Fuel injector operation sound
is not heard. → Go to item 3.
3 • Connection of wire harness Improperly connected → Connect the coupler • Execute the diagnostic mode.
ECU coupler. securely or repair / replace the wire harness. (Code No. d36)
• Check the locking condition of • Fuel injector operation sound
the coupler. is heard. → Go to item 6.
• Disconnect the coupler and • Fuel injector operation sound
check the pins (bent or broken is not heard. → Go to item 4.
of the pins).
4 Continuity of wire harness • Open or short circuit → Replace the wire • Execute the diagnostic mode.
harness. (Code No. d36)
• Between fuel injection coupler and ECU • Fuel sound is heard. → Go to
coupler item 6.
(Orange / black-Orange / black) • Fuel injector operation sound
• Between fuel injection coupler and main switch is not heard. → Go to item 5.
coupler
(Red/White - Red/White)
5 Malfunction in ECU. • Replace the ECU. ---
6 • Delete the fault codes. --- ---
• Start the engine and let it idle for
approximately 5 seconds.
• After completing the above
operation, check the fault code
display.
8-48
– +
Fault code 41 Symptom Lean angle sensor: open or short circuit detected
Diagnostic code No.: d08 (Lean angle sensor)

1 Connection of lean angle sensor Improperly connected → Connect the coupler Set the main switch to
coupler. Check the locking securely or repair/replace the wire harness. “ON - OFF - ON”.
condition of the coupler. Then, check the fault code
Disconnect the coupler and check indication. No fault code
the pins (bent or broken terminals indicated. → Recovered.
and locking condition of the pins). Fault code indicated. → Go to
item 2.
2 Connection of ECU coupler Improperly connected → Connect the coupler Set the main switch to
Check the locking condition of the securely or repair/replace the wire harness. “ON - OFF - ON”.
coupler. Disconnect the coupler Then, check the fault code
and check the pins (bent or indication. No fault code
broken terminals and locking indicated. → Recovered.
condition of the pins). Fault code indicated. → Go to
item 3.
3 Continuity of wire harness Open or short circuit → Replace the wire Set the main switch to
harness. Between lean angle sensor coupler “ON - OFF - ON”.
and ECU coupler Then, check the fault code
Blue–Blue indication. No fault code
Yellow/green–Yellow/green indicated. → Recovered.
Fault code indicated. → Go to
item 4.
4 Defective lean angle sensor Refer to “CHECKING THE LEAN ANGLE
SENSOR”.
8-49
– +
Fault code 42 Symptom No normal signals are received from the speed sensor.
Diagnostic code No. D07 (Vehicle speed pulse)

1 • Connection of speed sensor • Improperly connected → Connect the coupler • Set the main switch to “ON”.
(meter) coupler. securely or repair/replace the wire harness. • Rotate the front wheel a few
• Check the locking condition of turns manually to enter the
the coupler. speed pulse.
• Disconnect the coupler and • Then, check the fault code
check the pins (bent or broken indication.
terminals and locking condition • No fault code indicated. →
of the pins). Service is finished.
• Fault code indicated. → Go to
item 2.
2 • Connection of wire harness • Improperly connected → Connect the coupler • Set the main switch to “ON”.
ECU coupler. securely or repair/replace the wire harness. • Rotate the front wheel a few
• Check the locking condition of turns manually to enter the
the coupler. speed pulse.
• Disconnect the coupler and • Then, check the fault code
check the pins (bent or broken indication.
terminals and locking condition • No fault code indicated. →
of the pins). Service is finished.
item 3.
harness. • Rotate the front wheel a few
between speed sensor coupler and ECU turns manually to enter the
coupler. speed pulse.
(Blue–Blue) • Then, check the fault code
(Black/blue–Black/blue) indication.
• Between speed sensor coupler and • No fault code indicated. →
(White–White) Service is finished.
item 4.
4 Defective speed sensor. • Check the speed sensor cable. • Set the main switch to “ON”.
• Check the speed sensor cable installation • Rotate the front wheel a few
condition. turns manually to enter the
• Execute the diagnostic mode (Code No. D07). speed pulse.
• Front wheel stop: The pulse integrated value • Then, check the fault code
should be constant. indication.
• Rotate the front wheel a few turns manually • No fault code indicated. →
and enter the speed pulse: The pulse Service is finished.
integrated value will be added. • Fault code indicated. → Go to
• Indication is incorrect. → Replace the speed item 5.
meter.
8-50
– +
Fault code 44 Symptom Error is detected while reading or writing on EEPROM.
Diagnostic code No.: d60 (EEPROM fault code display)

1 Locate the malfunction. • Check in the diagnostic mode (Code No. D60) ----
00: Perform the procedure in item 4.
2 • “01” is indicated in Diagnostic • Change the CO concentration, and rewrite in Set the main switch to “ON”.
mode (Code No. D60) EEPROM. Fault code number is not
• EEPROM data error for Refer to “ADJUSTING THE EXHAUST GAS displayed → Service is finished.
adjustment of CO concentration VOLUME” on page 3-5. Fault code number is
• After this adjustment is made, the main switch displayed → Repeat the
is turned OFF procedure in item 1.
If the same number is
indicated, perform the
procedure in item 4.
3 “04” is indicated in Diagnostic Set the main switch to “ON”. Set the main switch to “ON”.
mode (Code No. d:60) Operate the throttle grip full open and full close. Fault code number is not
EEPROM data error for learning Set the main switch to “OFF”. displayed → Service is finished.
value of throttle full closed Fault code number is
position displayed → Repeat the
If the same number is
indicated, perform the
Fault code 46 Symptom Incorrect voltage is supplied to the ECU.
Diagnostic code No.: -----

1 Malfunction in charging system. • Check the charging system. • Start the engine and let it idle
Refer to “CHARGING SYSTEM” on page 8-11. for approximately 10 seconds.
• Check the rectifier / regulator, AC magneto • Fault code number is not
and wire harness. → Replace if defective. displayed → Service is
finished.
displayed → Repeat the
Fault code 50 Symptom Faculty ECU memory.
Diagnostic code No.: -----

1 Malfunction in ECU • Replace the ECU. • Set the main switch to “ON”.
• Check that the fault code
number is not displayed.
8-51
– +
Fault code Er-4 Symptom No signals are received from the FI diagnostic tool.
Diagnostic code No.: ------

1 • Connection of FI diagnostic tool Improperly connected → Connect the coupler • Set the sub-lead switch of FI
connector. securely or repair / replace the wire harness. diagnostic tool to “ON”.
the connector. displayed → Service is
• Disconnect the connector and finished.
check the connector (bent or • Fault code number is
broken terminals and locking displayed → Go to item 2.
condition of the connector).
2 • Connection of wire harness Improperly connected → Connect the coupler • Set the sub-lead switch of FI
ECU coupler. securely or repair / replace the wire harness. diagnostic tool to “ON”.
of the pins).
3 Wire harness continuity. • Open or short circuit → Replace the wire • Set the sub-lead switch of FI
harness. diagnostic tool to “ON”.
Between FI diagnostic tool coupler and ECU • Fault code number is not
coupler. displayed → Service is
(Light green-Light green) finished.
4 Defective FI diagnostic tool. • Replace FI diagnostic tool. • Set the sub-lead switch of FI
diagnostic tool to “ON”.
finished.
8-52
+
2
R
–
BL6 R W BL6
R W
W1
B3 3
W1 W W2
B6
ELEC
B W2 W
J11
B1 OrB WY YW W2 RW3 BL3 L4 BL1 PW GR
B2
Or GW Y Lg --- --- BL5 L1 BL2 YL GyR BW3
1
W2
W1
BL6
R1

R IG
CRK
B3
RW2
RW3
R3
6
R
27
R1
R2
B4 W1 PW PW
4 17 26
W2 R1 R1 R2 PB
R
R3

BrW BrW
20 A
(BLACK) J3 18 AT
B4 BL5
B4
BL5 SGND4 28
9 1
FUEL PUMP SYSTEM
B3 19 L4 L4
VCC2
RW1
B Br4
LB
2 Br YR
RW
12 NO.PK605-05027
R2
1 (BLUE)
RW1 LB BL2 BL2
SGND3
10 RB LW
RW
MAIN BL2 GR
R 20 29 RW1
ON R2 OrB OrB
RB
LW
GR GR 1J
OFF Br1 RW Br4 WT
B4
Br (BLACK)
BW
--- LW
B B1 --- OrB RW1
B2 RB GyR GyR
O2 25
RB
Br1
B
(BLACK) GVR
LW
B 21 (BLACK)
B
Br1
J13 B1 Br2 13 14 SUMITOMO 6189-6904

START STOP 2
11 Br RW 15 L2 L2
1 OFF OFF
LW --- 22 VCC
Sb Sb
J1 J4 LA
(BLACK) 1
1 1 A1
Br
B1
1
RW
Br4
2 2
Br
Br4
Br3
Br5
Br4
L1 L1 Y RW
VCC3
Br4
Br4
BL3 BL3
23 SGND5
VM RW3
L4 L3 Br3 GW W2
WWL SP
J9 J7 YW BW
Lg2 L2 WY TC CGND
B1
1 1 RFR PGND
Br2
24
L1
Br
L
8-53
CASE : 6409-0031
Br
B3 B2 --- --- --- --- Br 2

1 B1 B4 --- --- --- Br2 Br1
NEUTRAL 54
Br1 Sb
BR1
Br2
J8
2 2 2
Br
55 2
RW3
RW2
RW1
RW
Br1
Br2
33
W2
34
W3
W1
Br
56 TACHO
Br2
R2
Br1
35 BrW (BLUE)
Br2 R2 51 32
B2
B1
P HOUSING : 6403-7601
GND W3 WY L
CASE : 6409-0032
Gy2
Gy1
BrW BrW
SPEED
YW Br2 Gy2 GY1 BR1
Br5
TC
B4
B1
B2
WY
B3
Br
Gy1
Gy2
Br3
Gy3
Br2
57
RB
P
L3
45 Y Y1
L
46 44
ILLUMI 43 G G
B B1
58 OFF H1 OFF L
L L 36
B Br Dg
B N RB
B WB BrW BrW L3
NR
59 Lg2
(BLACK)
B
(BLACK)
RB RB
HI BEAM B2
60
Y2 B
(BLUE)
FUEL PUMP SYSTEM
(BLUE)
WATER
Ch
Dg
B1
61
Y1
B2
G
GW
GY3
L2
TURN 62
Dg
Y
37
L2 A L2
G AG
Ch2
Ch
Dg
L Y GY3 L2
Dg3
L1 A L1 B B2
GB B3 Y AY Dg1
FUEL+ Ch3 J6 A
OrW J5
CIRCUIT DIAGRAM
FUEL-
Y1
L1
Dg2
49
GB
Y
1 1
Y3
G
Ch
L1
Y L1 L1 Y
Dg1
1 Ch A Ch Ch1
Ch1
63 L1 B L2 L2 B
47
12V35/35W
---
12V35/35W
12V5W
12V5W
Dg2
L1 L B2 Ch Ch G
Ch
L G
L
Y B
J10 B B B
12V10W
12V10W
G
OrW
12V5W
39
12V10W
48 40
B2
12V10W
41 L L
50
B
Y2
B2
B4
OrW GB B B4
42 38
B A B
B4
B3
B3
B2
B3
B1
B3
B2
B4
1
J14
– +
FUEL PUMP SYSTEM ELEC
1. Junction
5. Main switch
6. Wire plus lead
7. Battery
8. Wire minus lead
9. Fuse
25. E.C.U
30. Fuel pump
31. J / C2
32. J / C1
8-54
– +
TROUBLESHOOTING
The fuel pump fails to operate.
TIP
2. Fuel tank

page 8-63.
OK ↓
page 8-63.
OK ↓
OK ↓
4. Check the engine stop switch. NG →
The engine stop switch is faulty. Replace
OK ↓
5. Check the fuel pump operation. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump.
PRESSURE” on page 7-3.
OK ↓
6. Check the entire fuel pump system NG →
wiring. Properly connect or repair the fuel pump
page 8-53.
OK ↓
Replace the ECU.
8-55
– +
8-56
– +
ELECTRICAL COMPONENTS ELEC
ELECTRICAL COMPONENTS
4 6
3
5
2
1 7
22
21 9
10
20
11
19
18
12
17
16
15 13
14
8-57
– +
1. Main switch
2. Clutch switch
3. Front brake light switch
4. Ignition coil
5. Throttle body sensor assembly (intake air
pressure sensor, ntake air temperature
sensor, throttle position sensor)
6. FID (fast idle solenoid)
9. Starting circuit cut-off relay
10. Turn signal relay
11. Radiator fan motor relay
12. Starter relay
13. Battery
14. Rear brake light switch
15. Neutral switch
17. Coolant temperature sensor
18. Speed sensor
19. O2 sensor
20. Radiator fan
21. Rectifier / Regulator
22. Horn
8-58
– +
CHECKING THE SWITCHES
1
R Br
8
ON
OFF
B
B
R
Br (BLACK)
(RED)
2
9
R/B Br R/W
OFF
B RUN
10 Br R/W
3 OFF
L/W B
L/W
Br Y START RB
OFF Y
ON (BLACK)
G
4 B
Y L G
11
HI
LO Br Dg
B
W/B Br/W
5 B
P Ch
Ch Br/W Dg (BLACK)
L
NL
R/B
N
NR B
R
(BLUE)
6
B P
OFF
ON
7
Sb
8-59
– +
1. Main switch
2. Clutch switch
3. Pass switch
4. Dimmer switch
5. Turn signal switch
6. Horn switch
7. Neutral switch
8. Front brake light switch
10. Start switch
11. Rear brake light switch
8-60
– +
Check each switch for continuity with the multimeter. If the continuity reading is incorrect, check the
wiring connections and, if necessary, replace the switch.
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.

90890-03174
TIP
• Before checking for continuity, set the Digital circuit tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back and forth between the switch positions a few times.
The switches and their terminal connections are illustrated as in the following example of the main
switch.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in the
top row.
The continuity (i. e., a closed circuit) between switch terminals at a given switch position is indicated by
“ ”. There is continuity between red and brown when the switch is set to “ON”.
b
R Br
a ON
OFF
R
Br
8-61
– +
CHECKING THE BULBS AND BULB SOCK- 1. Remove:
ETS • Bulb
TIP
WARNING
Do not check any of the lights that use LEDs.
Since the headlight bulbs get extremely hot,
Check each bulb and bulb socket for damage or keep flammable products and your hands
wear, proper connections, and also for continuity away from them until they have cooled
between the terminals. down.
Damage/wear → Repair or replace the bulb,
NOTICE
bulb socket or both.
Improperly connected → Properly connect. • Be sure to hold the socket firmly when re-
No continuity → Repair or replace the bulb, bulb moving the bulb. Never pull the lead, other-
socket or both. wise it may be pulled out of the terminal in
the coupler.
Types of bulbs • Avoid touching the glass part of a headlight
The bulbs used on this vehicle are shown in the bulb to keep it free from oil, otherwise the
illustration. transparency of the glass, the life of the
• Bulbs “a” are used for the headlights and usu- bulb, and the luminous flux will be adverse-
ally use a bulb holder that must be detached ly affected. If the headlight bulb gets soiled,
before removing the bulb. thoroughly clean it with a cloth moistened
• Bulbs are used for turn signal lights and can be with alcohol or lacquer thinner.
removed from the socket by pushing and turn- 2. Check:
ing the bulb counterclockwise. • Bulb (for continuity)
• Bulbs “b” and “c” are used for meter and indi- (with the Digital circuit tester)
cator lights and can be removed from their re- No continuity → Replace.
spective socket by carefully pulling them out.
90890-03174
a
TIP
Before checking for continuity, set the Digital cir-
cuit tester to “0” and to the “Ω × 1” range.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to termi-
nal “1” and the negative tester probe to ter-
minal “2”, and check the continuity.
b. Connect the positive tester probe to termi-
nal “1” and the negative tester probe to ter-
minal “3”, and check the continuity.
b c c. If either of the readings indicate no continu-
ity, replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the condition of the bulbs

bulbs.
8-62
– +
Checking the condition of the bulb sockets c. Set on the switches to verify if the electrical
The following procedure applies to all of the bulb circuit is operational.
sockets. d. If the fuse immediately blows again, check
1. Check: the electrical circuit.
• Bulb socket (for continuity) Amperage
(with the Digital circuit tester) Item Q'ty
rating
No continuity → Replace. Fuse 20 A 1
Digital circuit tester Spare 20 A 1
90890-030
WARNING
TIP Never use a fuse with an amperage rating
Check each bulb socket for continuity in the other than that specified. Improvising or us-
same manner as described in the bulb section, ing a fuse with the wrong amperage rating
however, note the following. may cause extensive damage to the electri-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
cal system, cause the lighting and ignition
a. Install a good bulb into the bulb socket. systems to malfunction and could possibly
cause a fire.
b. Connect the Digital circuit tester probes to
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
the respective leads of the bulb socket.
4. Install:
c. Check the bulb socket for continuity. If any
of the readings indicate no continuity,
Refer to “GENERAL CHASSIS” on page 4-1.
replace the bulb socket.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING AND CHARGING THE BATTERY
CHECKING THE FUSE WARNING
NOTICE Batteries generate explosive hydrogen gas
and contain electrolyte which is made of poi-
To avoid a short circuit, always turn the main
sonous and highly caustic sulfuric acid.
switch to “OFF” when checking or replacing
Therefore, always follow these preventive
a fuse.
measures:
1. Remove: • Wear protective eye gear when handling or
• Passenger and rider seat working near batteries.
Refer to “GENERAL CHASSIS” on page 4-1. • Charge batteries in a well-ventilated area.
2. Check: • Keep batteries away from fire, sparks or
• Fuse open flames (e.g., welding equipment,
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ lighted cigarettes).
a. Connect the Digital circuit tester to the fuse • DO NOT SMOKE when charging or han-
and check the continuity. dling batteries.
TIP • KEEP BATTERIES AND ELECTROLYTE
Set the Digital circuit tester selector to “Ω × 1”. OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
90890-03174
FIRST AID IN CASE OF BODILY CONTACT:
b. If the Digital circuit tester indicates “∞”, EXTERNAL
replace the fuse. • Skin — Wash with water.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Eyes — Flush with water for 15 minutes and
get immediate medical attention.
3. Replace:
• Blown fuse INTERNAL
• Drink large quantities of water or milk fol-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
lowed with milk of magnesia, beaten egg or
a. Set the main switch to “OFF”.
vegetable oil. Get immediate medical atten-
b. Install a new fuse of the correct amperage tion.
rating.
8-63
– +
NOTICE
• This is a VRLA (Valve Regulated Lead Acid)
2
battery. Never remove the sealing caps be-
cause the balance between cells will not be
maintained and battery performance will
deteriorate.
• Charging time, charging amperage and
charging voltage for a VRLA (Valve Regu-
lated Lead Acid) battery are different from 1
those of conventional batteries. The VRLA
4. Remove:
(Valve Regulated Lead Acid) battery should
• Battery
be charged according to the appropriate
charging method. If the battery is over- 5. Check:
charged, the electrolyte level will drop con- • Battery charge
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
siderably. Therefore, take special care
when charging the battery. a. Connect a multimeter to the battery termi-
nals.
TIP
Since VRLA (Valve Regulated Lead Acid) bat- • Positive tester probe →
teries are sealed, it is not possible to check the positive battery terminal
charge state of the battery by measuring the • Negative tester probe →
specific gravity of the electrolyte. Therefore, the negative battery terminal
charge of the battery has to be checked by mea- TIP
suring the voltage at the battery terminals. • The charge state of a VRLA (Valve Regulated
1. Remove: Lead Acid) battery can be checked by measur-
• Passenger and rider seat ing its open-circuit voltage (i.e., the voltage
Refer to “GENERAL CHASSIS” on page 4-1. when the positive battery terminal is discon-
2. Remove: nected).
• Battery band “1” • No charging is necessary when the open-cir-
• Battery rubber cover “2” cuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown
in the charts and the following example.
2
Example
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20-30%
1
3. Disconnect:
• Battery leads
(from the battery terminals)
NOTICE
First, disconnect the negative battery lead
“1”, and then positive battery lead “2”.
A. Open-circuit voltage (V)

B. Charging time (hours)
C. Relationship between the open-circuit volt-
age and the charging time at 20 °C (68 °F)
D. These values vary with the temperature, the
8-64
– +
condition of the battery plates, and the elec- • If the battery becomes hot to the touch at
trolyte level. 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
charging is completed before measuring
the open-circuit voltage.
B. Charging condition of the battery (%)
C. Ambient temperature 20 °C (68 °F)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Charge:
• Battery
(refer to the appropriate charging method)
WARNING
Do not quick charge a battery.
NOTICE B. Time (minutes)
C. Charging
• Never remove the MF battery sealing. D. Ambient temperature 20 °C (68 °F)
• Do not use a high-rate battery charger E. Check the open-circuit voltage.
since it forces a high-amperage current ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
into the battery quickly and can cause bat- Charging method using a variable-current
tery overheating and battery plate damage. (voltage) charger
• If it is impossible to regulate the charging a. Measure the open-circuit voltage prior to
current on the battery charger, be careful charging.
not to overcharge the battery.
• When charging a battery, be sure to remove TIP
it from the vehicle. (If charging has to be Voltage should be measured 30 minutes after
done with the battery mounted on the vehi- the engine is stopped.
cle, disconnect the negative battery lead b. Connect a charger and ammeter to the bat-
from the battery terminal.) tery and start charging.
• To reduce the chance of sparks, do not TIP
plug in the battery charger until the battery Set the charging voltage to 16-17 V. If the setting
charger leads are connected to the battery. is lower, charging will be insufficient. If too high,
• Before removing the battery charger lead the battery will be over-charged.
clips from the battery terminals, be sure to c. Make sure that the current is higher than
turn off the battery charger. the standard charging current written on the
• Make sure the battery charger lead clips are battery.
in full contact with the battery terminal and TIP
that they are not shorted. A corroded bat- If the current is lower than the standard charging
tery charger lead clip may generate heat in current written on the battery, set the charging
the contact area and a weak clip spring may voltage adjust dial at 20-24 V and monitor the
cause sparks. amperage for 3-5 minutes to check the battery.
8-65
– +
• Standard charging current is reached 12.8 V or more --- Charging is complete.
Battery is good. 12.7 V or less --- Recharging is required.
• Standard charging current is not reached Under 12.0 V --- Replace the battery.
Replace the battery.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
d. Adjust the voltage so that the current is at 7. Install:
the standard charging level. • Battery
e. Set the time according to the charging time
8. Connect:
suitable for the open-circuit voltage.
• Battery leads
f. If charging requires more than 5 hours, it is
(to the battery terminals)
advisable to check the charging current
after a lapse of 5 hours. If there is any NOTICE
change in the amperage, read just the volt-
First, connect the positive battery lead “1”,
age to obtain the standard charging current.
and then the negative battery lead “2”.
g. Measure the battery open-circuit voltage
after leaving the battery unused for more
than 30 minutes.
1
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Charging method using a constant volt- 2
age charger
a. Measure the open-circuit voltage prior to 9. Check:
charging. • Battery terminals
Dirt → Clean with a wire brush.
TIP Loose connection → Connect properly.
Voltage should be measured 30 minutes after
10.Lubricate:
the engine is stopped.
• Battery terminals
b. Connect a charger and ammeter to the bat- Recommended lubricant
tery and start charging. Dielectric grease
c. Make sure that the current is higher than
the standard charging current written on the 11.Install:
battery. • Battery rubber cover
TIP • Battery band
If the current is lower than the standard charging
NOTICE
current written on the battery, this type of battery
charger cannot charge the VRLA (Valve Regu- Before installing the battery band ensure
lated Lead Acid) battery. A variable voltage battery rubber cover is fitted properly.
charger is recommended.
12.Install:
d. Charge the battery until the battery’s charg- • Passenger and rider seat
ing voltage is 15 V. Refer to “GENERAL CHASSIS” on page 4-1.
TIP
Set the charging time at 20 hours (maximum).
e. Measure the battery open-circuit voltage
after leaving the battery unused for more
than 30 minutes.
8-66
– +
CHECKING THE RELAYS Radiator fan motor relay
Check each switch for continuity with the multi-
meter. If the continuity reading is incorrect, re- 1 3
place the relay.
90890-03174 2 4
1. Disconnect the relay from the wire harness. Br2 R2
2. Connect the multimeter (Ω × 1) and battery WY L
(12 V) to the relay terminal as shown.
Check the relay operation.
Out of specification → Replace. 1. Positive battery terminal
2. Negative battery terminal
Starter relay 3. Positive tester probe
4. Negative tester probe
3
Result
R
1 2 Continuity
(between “3” and “4”)
R1 R2
LB Br4 CHECKING THE TURN SIGNAL RELAY

RW 1. Check:
• Turn signal relay input voltage
4 Out of specification → The wiring circuit
from the main switch to the turn signal
1. Positive battery terminal relay coupler is faulty and must be
2. Negative battery terminal repaired.
3. Positive tester probe
4. Negative tester probe Turn signal relay input voltage
DC 12 V
Result
Continuity ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
(between “3” and “4”) a. Connect the multimeter (DC 20 V) to the
turn signal relay terminal as shown.
Starting circuit cut-off relay Digital circuit tester
90890-03174
1 3
• Positive tester probe →
brown “1”
• Negative tester probe →
2 4
ground
R1 R2
LB Br4
1. Positive battery terminal

2. Negative battery terminal Br/W
3. Positive tester probe Br
4. Negative tester probe
1
Result
Continuity
(between “3” and “4”) b. Set the main switch to “ON”.
8-67
– +
c. Measure the turn signal relay input voltage. Continuity
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Positive tester probe → sky
2. Check: blue “1”
• Turn signal relay output voltage Negative tester probe →
Out of specification → Replace. red/black “2”
No continuity
Turn signal relay output voltage Positive tester probe →
DC 12 V red/black “2”
Negative tester probe → sky
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ blue “1”
a. Connect the multimeter (DC 20 V) to the
turn signal relay terminal as shown.
90890-03174 1
• Positive tester probe → Sb
brown/white “1” R/B

ground 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the diode from the wire harness.
1 b. Connect the multimeter (Ω × 1) to the diode
Br/W terminals as shown.
Br
c. Check the diode for continuity.
d. Check the diode for no continuity.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE SPARK PLUG CAP

b. Set the main switch to “ON”. 1. Check:
c. Measure the turn signal relay output volt- • Spark plug cap resistance
age. Out of specification → Replace.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Resistance
CHECKING THE DIODES 3.75-6.25 kΩ
1. Check:
• Diode a. Remove the spark plug cap from the spark
Out of specification → Replace. plug lead.
b. Connect the multimeter (Ω × 1k) to the
Digital circuit tester spark plug cap as shown.
90890-03174
Digital Circuit tester
TIP 90890-03174
The multimeter or the analog multimeter read-
ings are shown in the following table.
8-68
– +
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the igni-
tion coil.
b. Connect the multimeter (Ω × 1k) to the igni-
tion coil as shown.
90890-03174

ignition coil terminal “1”
c. Measure the spark plug cap resistance. • Negative tester probe →
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ spark plug lead “2”
CHECKING THE IGNITION COIL
1. Check:
• Primary coil resistance
Primary coil resistance
2.16-2.64 Ω at 20 °C (68 °F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the ignition coil connectors from
the ignition coil terminals.
b. Connect the Digital circuit tester (Ω × 1) to c. Measure the secondary coil resistance.
the ignition coil as shown. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Digital circuit tester CHECKING THE IGNITION SPARK GAP

90890-03174
1. Check:
• Ignition spark gap
• Positive tester probe → Out of specification → Perform the igni-
ignition coil terminal “1” tion system troubleshooting, starting with
• Negative tester probe → step 5.
ignition coil terminal “2” Refer to “TROUBLESHOOTING” on
page 8-3.
Minimum ignition spark gap
6.0 mm (0.24 in)
TIP
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.
a. Disconnect the spark plug cap from the

spark plug.
b. Connect the ignition checker “1” as shown.
c. Measure the primary coil resistance. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Ignition checker
2. Check: 90890-06754
• Secondary coil resistance
Secondary coil resistance
8.64-12.96 kΩ at 20 °C (68 °F)
8-69
– +
R W
1 2
2. Spark plug cap b. Measure the crankshaft position sensor
c. Set the main switch to “ON” and the engine resistance.
stop switch to “ ”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
d. Measure the ignition spark gap “a”.
e. Crank the engine by pushing the start CHECKING THE LEAN ANGLE SENSOR
switch “ ” and gradually increase the 1. Remove:
spark gap until a misfire occurs. • Lean angle sensor
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Lean angle sensor output voltage
CHECKING THE CRANKSHAFT POSITION
SENSOR
1. Disconnect: Lean angle sensor output volt-
• Crankshaft position sensor coupler age
Less than 65°: 0.4-1.4 V
(from the wire harness)
More than 65°: 3.7-4.4 V
2. Check:
• Crankshaft position sensor resistance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Out of specification → Replace the crank- a. Connect the lean angle sensor to the wire
shaft position sensor/stator assembly. harness.
Crankshaft position sensor b. Connect the Digital circuit tester (DC 20 V)
resistance to the lean angle sensor coupler as shown.
228-342 Ω at 20 °C (68 °F) Digital circuit tester
90890-03174
a. Connect the multimeter (Ω × 100) to the
crankshaft position sensor coupler as
shown. • Positive tester probe →
yellow/green “1”
Digital circuit tester • Negative tester probe →
90890-03174 black/blue “2”

red “1”
white “2”
L2
c. Set the main switch to “ON”.

d. Tilt the lean angle sensor to 65°.
e. Measure the lean angle sensor output volt-
age.
8-70
– +
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE STARTER MOTOR OPERA- 90890-03174
TION
1. Check: • Positive tester probe →
• Starter motor operation white “1”
Does not operate → Perform the electric • Negative tester probe →
starting system troubleshooting, starting white “2”
with step 4.
Refer to “TROUBLESHOOTING” on
page 8-3.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive battery terminal “1”
and starter motor lead “2” with a jumper
lead “3”.
1 W
WARNING W
• A wire that is used as a jumper lead must 2
have at least the same capacity of the bat-
tery lead, otherwise the jumper lead may b. Measure the stator coil resistance.
burn. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• This check is likely to produce sparks,
therefore, make sure no flammable gas or CHECKING THE RECTIFIER/REGULATOR
fluid is in the vicinity. 1. Check:
• Rectifier/regulator output voltage
Out of specification → Replace the recti-
fier/regulator.
Rectifier/regulator output volt-
age
14.0-15.0 V at 5000 r/min
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the engine tachometer to the spark plug
lead.
b. Connect the Digital circuit tester (DC 20 V)
to the rectifier/regulator coupler as shown.
b. Check the starter motor operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Digital circuit tester
90890-03174
CHECKING THE STATOR COIL
1. Disconnect: • Positive tester probe →
• Stator coil coupler red “1”
(from the wire harness) • Negative tester probe →
2. Check: black “2”
• Stator coil resistance
Out of specification → Replace the crank-
shaft position sensor/stator assembly.
Stator coil resistance
0.36-0.54 Ω at 20 °C (68 °F) W R
B W
a. Connect the Digital circuit tester (Ω × 1) to

the stator coil coupler as shown. 1 2
8-71
– +
c. Start the engine and let it run at approxi- • Fuel sender resistance
mately 5000 r/min. Out of specification → Replace the fuel
d. Measure the charging voltage. sender.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Sender unit resistance (full)
10.0-14.0 Ω
CHECKING THE HORN
Sender unit resistance (empty)
1. Check: 267.0-273.0 Ω
• Horn resistance
Out of specification → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the Digital circuit tester (Ω × 10) to
Coil resistance the fuel sender coupler as shown.
3.44-3.64 Ω
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 90890-03174
a. Disconnect the horn connectors from the
horn terminals. • Positive tester probe →
b. Connect the Digital circuit tester (Ω × 1) to green “1”
the horn terminals. • Negative tester probe →
black “2”
90890-03174
2 1
horn terminal “1” Or/W G/B Or/W G/B
horn terminal “2”
b. Move the fuel sender float to the minimum

1 “3” and maximum “4” level positions.
2 4
c. Measure the horn resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check: 3
• Horn sound
Faulty sound → Replace.
CHECKING THE FUEL SENDER c. Measure the fuel sender resistance.

1. Disconnect: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Fuel pump coupler
(from the wire harness)
2. Remove:
• Right side panel and cowlings
• Fuel tank
3. Remove:
• Fuel pump
(from the fuel tank)
4. Check:
8-72
– +
CHECKING THE SPEED SENSOR
1. Check:
• Speed sensor output voltage
Out of specification → Replace. 1
Output voltage reading cycle L

0 V to 5.0 V to 0 V to 5.0 V B
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 2
a. Connect the Digital circuit tester (DC 20 V)
to the speed sensor coupler (wire harness
end) as shown. c. Check the radiator fan motor movement.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
90890-03174 CHECKING THE COOLANT TEMPERATURE
SENSOR
• Positive tester probe → 1. Remove:
white “1” • Coolant temperature sensor
WARNING
black/blue “2”
• Handle the coolant temperature sensor
with special care.
1 • Never subject the coolant temperature sen-
L L sor to strong shocks. If the coolant temper-
W W ature sensor is dropped, replace it.
BL BL
2 2. Check:
• Coolant temperature sensor resistance
b. Set the main switch to “ON”. Out of specification → Replace.
c. Elevate the front wheel and slowly rotate it. Coolant temperature sensor
d. Measure the voltage of white and resistance
black/blue. With each full rotation of the 2.51-2.78 kΩ at 20 °C (68 °F)
front wheel, the voltage reading should 210-221 Ω at 80 °C (176 °F)
cycle from 0 V to 5.0 V to 0 V to 5.0 V. a. Connect the multimeter (Ω × 100) to the
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
coolant temperature sensor terminals as
CHECKING THE RADIATOR FAN MOTOR shown.
1. Check:
• Radiator fan motor Digital circuit tester
90890-03174
Faulty/rough movement → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b. Immerse the coolant temperature sensor
a. Disconnect the radiator fan motor coupler “1” in a container filled with coolant “2”.
from the wire harness.
b. Connect the battery (DC 12 V) as shown. TIP
Make sure the coolant temperature sensor ter-
• Positive tester probe → minals do not get wet.
blue “1”
• Negative tester probe → c. Place a thermometer “3” in the coolant.
black “2”
8-73
– +
Throttle position sensor input
voltage
3 5V
1 c. Connect the Digital circuit tester to the ter-
minals of the throttle body sensor assembly
coupler as shown.
2 yellow/blue terminal “3”
black/blue terminal “2”
d. Heat the coolant or let it cool down to the
specified temperatures. d. While slowly opening the throttle, check that
e. Measure the coolant temperature sensor the throttle position sensor output voltage is
resistance. increased.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Voltage does not change or it changes
3. Install: abruptly → Replace the throttle body.
• Coolant temperature sensor Out of specification (closed position) →
Replace the throttle body.
Coolant temperature sensor
18 Nm (1.8 m·kg, 13 ft·lb) Throttle position sensor output
T.
voltage (closed position)

R.
0.63-0.73 V
CHECKING THE THROTTLE BODY SENSOR
ASSEMBLY
WARNING
• Do not remove the throttle body sensor as-
sembly.
• Handle the throttle body sensor assembly
with special care. BL YL L PW BrW
• Never subject the throttle body sensor as-
sembly to strong shocks. If the throttle
body sensor assembly is dropped, replace 2 3 1
it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Throttle position sensor Intake air pressure sensor
1. Check: 1. Check:
• Throttle position sensor • Intake air pressure sensor output voltage
a. Connect the Digital circuit tester to the ter- Out of specification → Replace the throt-
minals of the throttle body sensor assembly tle body.
coupler as shown. Intake air pressure sensor out-
Digital circuit tester put voltage
90890-03174 0.789-4.000 V at 20.00-101.32
kPa
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
blue terminal “1” a. Connect the multimeter (DC 20 V) to the
• Negative tester probe → throttle body sensor assembly coupler as
black/blue terminal “2” shown.
b. Measure the throttle position sensor input Digital circuit tester
voltage. 90890-03174
Out of specification → Replace or repair the
wire harness.
8-74
– +
pink/white “1”
black/blue “2”
BL YL L PW BrW
BL YL L PW BrW 2 1
b. Measure the intake air temperature sensor
resistance.
2 1 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE FID (FAST IDLE SOLENOID)

b. Set the main switch to “ON”. 1. Disconnect:
c. Measure the intake air pressure sensor out- • FID (fast idle solenoid) coupler
put voltage. 2. Check:
• FID (fast idle solenoid) resistance
Intake air temperature sensor Out of specification → Replace the throt-
1. Disconnect: tle body assembly.
• Throttle body sensor assembly coupler
(from the wire harness) FID (fast idle solenoid) resis-
2. Check: tance
• Intake air temperature sensor resistance 31.5-38.5 Ω at 25 °C (77 °F)
Out of specification → Replace the throt- a. Connect the Digital circuit tester (Ω × 10) to
tle body. the terminals of the FID (fast idle solenoid).
Intake air temperature sensor
resistance
90890-03174
5.7-6.3 kΩ at 0 °C
a. Connect the Digital circuit tester (Ω × 1k) to • Positive tester probe →

the throttle body sensor assembly coupler Brown “1”
as shown. • Negative tester probe →
Digital circuit tester Yellow/Red “2”
90890-03174

brown/white “1”
black/blue “2”
1 2
b. Measure the FID (fast idle solenoid) resis-

tance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-75
– +
8-76
TRBL
SHTG
CHAPTER 9
TROUBLESHOOTING
TROUBLESHOOTING..................................................................................... 9-1
GENERAL INFORMATION ....................................................................... 9-1
STARTING FAILURES.............................................................................. 9-1
INCORRECT ENGINE IDLING SPEED .................................................... 9-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ........................... 9-2
FAULTY GEAR SHIFTING ........................................................................ 9-2
SHIFT PEDAL DOES NOT MOVE ............................................................ 9-2
JUMPS OUT OF GEAR............................................................................. 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 ........................................ 9-4
TRBL
SHTG
TRBL
TROUBLESHOOTING SHTG
EAS28450
Electrical system
TROUBLESHOOTING
TROUBLESHOOTING 1. Battery
EAS28460 • Discharged battery
GENERAL INFORMATION • Faulty battery
TIP 2. Fuse(s)
The following guide for troubleshooting does • Blown, damaged or incorrect fuse
not cover all the possible causes of trouble. It • Improperly installed fuse
should be helpful, however, as a guide to basic 3. Spark plug
troubleshooting. Refer to the relative proce- • Incorrect spark plug gap
dure in this manual for checks, adjustments, • Incorrect spark plug heat range
and replacement of parts. • Fouled spark plug
EAS28470
• Worn or damaged electrode
STARTING FAILURES • Worn or damaged insulator
• Faulty spark plug cap
Engine 4. Ignition coil
1. Cylinder and cylinder head • Cracked or broken ignition coil body
• Loose spark plug • Broken or shorted primary or secondary coils
• Loose cylinder head or cylinder • Faulty spark plug lead
• Damaged cylinder head gasket 5. Ignition system
• Damaged cylinder gasket • Faulty ECU
• Worn or damaged cylinder • Faulty crankshaft position sensor
• Incorrect valve clearance • Broken generator rotor woodruff key
• Improperly sealed valve
6. Switches and wiring
• Incorrect valve-to-valve-seat contact
• Faulty main switch
• Incorrect valve timing
• Faulty engine stop switch
• Faulty valve spring
• Broken or shorted wiring
• Seized valve
• Faulty neutral switch
2. Piston and piston ring(s) • Faulty start switch
• Improperly installed piston ring • Faulty clutch switch
• Damaged, worn or fatigued piston ring • Improperly grounded circuit
• Seized piston ring • Loose connections
• Seized or damaged piston
7. Starting system
3. Air filter • Faulty starter motor
• Improperly installed air filter • Faulty starter relay
• Clogged air filter element • Faulty starting circuit cut-off relay
4. Crankcase and crankshaft • Faulty starter clutch
• Improperly assembled crankcase
EAS28490
• Seized crankshaft
INCORRECT ENGINE IDLING SPEED
Fuel system
Engine
1. Fuel tank
1. Cylinder and cylinder head
• Empty fuel tank
• Incorrect valve clearance
• Clogged fuel filter
• Damaged valve train components
• Deteriorated or contaminated fuel
2. Air filter
2. Fuel pump
• Clogged air filter element
• Faulty fuel pump
3. Throttle body Fuel system
• Deteriorated or contaminated fuel 1. Throttle body
• Sucked-in air • Damaged or loose throttle body joint
• Improperly adjusted engine idling speed (pilot
screw)
• Improper throttle cable free play
9-1
TRBL
• Flooded throttle body • Improperly assembled transmission
• Faulty air induction system
EAS28550
JUMPS OUT OF GEAR

Electrical system
1. Battery Shift shaft
• Discharged battery • Incorrect shift pedal position
• Faulty battery • Improperly returned stopper lever
2. Spark plug
• Incorrect spark plug gap Shift forks
• Incorrect spark plug heat range • Worn shift fork
• Fouled spark plug
Shift drum
• Worn or damaged electrode
• Incorrect axial play
• Worn or damaged insulator
• Worn shift drum groove
• Faulty spark plug cap
3. Ignition coil Transmission
• Broken or shorted primary or secondary coils • Worn gear dog
• Faulty spark plug lead
EAS28560
• Cracked or broken ignition coil FAULTY CLUTCH
4. Ignition system
• Faulty ECU Clutch slips
• Faulty crankshaft position sensor 1. Clutch
• Broken generator rotor woodruff key • Improperly assembled clutch
EAS28510
• Improperly adjusted clutch cable
POOR MEDIUM-AND-HIGH-SPEED • Loose or fatigued clutch spring
PERFORMANCE • Worn friction plate
Refer to “STARTING FAILURES” on page 9-1. • Worn clutch plate
2. Engine oil
Engine • Incorrect oil level
1. Air filter • Incorrect oil viscosity (low)
• Clogged air filter element • Deteriorated oil
Fuel system Clutch drags

1. Fuel pump 1. Clutch
• Faulty fuel pump • Unevenly tensioned clutch springs
• Warped pressure plate
EAS28530
FAULTY GEAR SHIFTING • Bent clutch plate

• Swollen friction plate
Shifting is difficult • Bent clutch push rod
Refer to “Clutch drags”. • Broken clutch boss
• Burnt primary driven gear bushing
EAS28540
SHIFT PEDAL DOES NOT MOVE 2. Engine oil

• Incorrect oil level
Shift shaft • Incorrect oil viscosity (high)
• Bent shift shaft • Deteriorated oil
EAS28600
Shift drum and shift forks
OVERHEATING
• Foreign object in a shift drum groove
• Seized shift fork Engine
• Bent shift fork guide bar
1. Clogged coolant passages
Transmission • Cylinder head and piston
• Seized transmission gear • Heavy carbon buildup
• Foreign object between transmission gears
9-2
TRBL
2. Engine oil • Damaged brake hose
• Incorrect oil level • Oil or grease on the brake disc
• Incorrect oil viscosity • Oil or grease on the brake pad
• Inferior oil quality • Incorrect brake fluid level
Cooling system EAS28650
FAULTY FRONT FORK LEGS

1. Coolant
• Low coolant level Leaking oil
2. Radiator • Bent, damaged or rusty inner tube
• Damaged or leaking radiator • Cracked or damaged outer tube
• Faulty radiator cap • Improperly installed oil seal
• Bent or damaged radiator fin • Damaged oil seal lip
3. Water pump • Incorrect oil level (high)
• Damaged or faulty water pump • Loose damper rod assembly bolt
4. Thermostat • Damaged damper rod assembly bolt copper
• Thermostat stays closed washer
• Cracked or damaged front fork cap O-ring
5. Hose(s) and pipe(s)
• Damaged hose Malfunction
• Improperly connected hose • Bent or damaged inner tube
• Damaged pipe • Bent or damaged outer tube
• Improperly connected pipe • Damaged fork spring
• Worn or damaged outer tube bushing
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
Chassis Handlebar
1. Brake(s) • Bent or improperly installed right handlebar
• Dragging brake • Bent or improperly installed left handlebar
Electrical system 1. Steering head components
1. Spark plug • Improperly installed upper bracket
• Incorrect spark plug gap • Improperly installed lower bracket
• Incorrect spark plug heat range (improperly tightened ring nut)
• Bent steering stem
2. Ignition system
• Damaged ball bearing or bearing race
• Faulty ECU
2. Front fork leg(s)
EAS28610
• Unevenly oil levels (both front fork legs)
OVERCOOLING
• Unevenly tensioned fork spring (both front
Cooling system fork legs)
1. Thermostat • Broken fork spring
• Thermostat stays open • Bent or damaged inner tube
• Bent or damaged outer tube
EAS28640
POOR BRAKING PERFORMANCE 3. Swingarm

• Worn bearing
• Worn brake pad
• Bent or damaged swingarm
• Worn brake disc
• Air in hydraulic brake system Rear shock absorber assembly
• Leaking brake fluid • Faulty rear shock absorber spring
• Faulty brake caliper kit • Leaking oil
• Faulty brake caliper seal
• Loose union bolt
9-3
TRBL
Tire(s) • Faulty main switch
• Unevenly tire pressures (front and rear) • Faulty turn signal switch
• Incorrect tire pressure • Incorrect turn signal bulb
• Unevenly tire wear
Turn signal remains lit
Wheel(s) • Faulty turn signal relay
• Incorrect wheel balance • Burnt-out turn signal bulb
• Deformed cast wheel
• Damaged wheel bearing Turn signal blinks quickly
• Bent or loose wheel axle • Incorrect turn signal bulb
• Excessive wheel runout • Faulty turn signal relay
• Burnt-out turn signal bulb
Frame
• Bent frame Horn does not sound
• Damaged steering head pipe • Damaged or faulty horn
• Improperly installed bearing race • Faulty main switch
• Faulty horn switch
EAS28710
• Faulty battery
FAULTY LIGHTING OR SIGNALING
• Blown, damaged or incorrect fuse
SYSTEM • Faulty wire harness
Headlight does not come on
• Wrong headlight bulb
• Too many electrical accessories
• Hard charging
• Incorrect connection
• Improperly grounded circuit
• Poor contacts (main switch)
• Burnt-out headlight bulb
Headlight bulb burnt out

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

• Too many electrical accessories
• Burnt-out tail/brake light (LED) bulb
Turn signal does not come on

• Faulty turn signal switch
• Faulty turn signal relay
• Burnt-out turn signal bulb
• Damaged or faulty wire harness
• Faulty battery
• Blown, damaged or incorrect fuse
Turn signal blinks slowly

• Faulty turn signal relay
9-4
WIRING DIAGRAM 59. Engine trouble warning light EAS28750
COLOR CODE
60. Hi beam indicator light
YZF-R15 B Black
61. Water temperature indicator light
1. Junction Br Brown
62. Turn indicator light
2. Crankshaft position sensor Ch Chocolate
63. Fuel sender
3. AC Magneto Dg Darkgreen
4. Rectifier / Regulator G Green
5. Main Switch Gy Gray
6. Wire plus lead L Blue
7. Battery Lg Lightgreen
8. Wire minus lead O Orange
9. Fuse P Pink
R Red
10. Starter relay
Sb Skyblue
11. Starting motor W White
12. Relay assy 1 Y Yellow
13. Start switch B/L Black/Blue
14. Engine stop switch Br/L Brown/Blue
15. Diode Br/W Brown/White
16. Neutral switch G/R Green/Red
17. Intake pressure sensor G/W Green/White
18. Intake temperature sensor G/Y Green/Yellow
19. Throttle position sensor L/B Blue/Black
L/W Blue/White
20. Water temperatur sensor
O/B Orange/Black
21. O2 sensor P/W Pink/White
22. Lean angle sensor R/B Red/Black
23. Speed sensor R/L Red/Blue
24. Service tool R/W Red/White
25. E.C.U W/Y White/Yellow
26. Ignition coil Y/G Yellow/Green
27. Spark plug Y/L Yellow/Blue
28. F.I.D Y/R Yellow/Red
29. Injector
30. Fuel pump
31. J / C2
32. J / C1
33. Front stop switch
35. Flasher relay
36. Clutch switch
37. Tail light
38. Licence light
39. Rear
40. Rear
41. Front
42. Front
43. Flasher switch
44. Horn switch
45. Dimmer switch
46. Pass switch
47. Head light left
48. Auxiliary light left
49. Head light right
50. Auxiliary light right
51. Horn
52. Relay assy 2
53. Fan motor
54. Meter unit
56. Tachometer
57. Multifunction meter
58. Illumination light
9-5
WIRING DIAGRAM YZF-R15
2
R
BL6 R W BL6
R W
W1
B3 3
W1 W W2
B6
B W2 W
J11
B1 OrB WY YW --- W2 RW3BL3 L4 BL1 PW GR
B2
W2
W1
1
R1
BL6 SGND
(BLACK) Or Or 205
R IG
CRK
RW2
RW3
B3
R3
6
R1
R2
B4 W1 27
4 17 PW PW 26
W2 R1 R1 R2 PB
R3
20 A
18 BrW BrW
(BLACK) J3 AT
B4
B4 BL5 BL5
9 1 SGND4 28
B3 19 L4 L4
RW1
VCC2
LB
B Br4
2 Br YR
J12 B2 MITSUBISHI CABLE INDUSTRIES
RW
8
12 NO.PK605-05027
R2
1 (BLUE)
RW1 LB BL2 BL2
SGND3
RW
MAIN 10 RB LW
BL2 GR 29
RB
LW
GR GR IJ
Br1 RW Br4 WT
B4
BW
OFF Br (BLACK)
--- LW
B
RB
RB
O2 25
Br1 Br1
LW
B
(BLACK) GVR
B 21 (BLACK)
B
J13 B1 Br2 13 14 SUMITOMO 6189-6904
START STOP 2
11 Br RW 15 L2 L2
1 OFF OFF
LW --- 22 VCC
START RUN --- --- --- BL1 BL1
Sb Sb
Br2 Br2 Br3 --- RB SGND2 Y Y RW
J1 J4 LA
(BLACK) 1
Br
1 1 AI
B1
RW
1
Br4
Br
2 2
Br4
Br3
Br5
Br4
L1 L1 Y RW
Br4
Br4
VCC3
BL3 BL3
23 SGND5
16 L1W1BL3 W1 Lg EWL VB Br3 (BLACK)
VM RW3
L4 L3 Br3 GW W2
WWL SP
J9 J7 YW BW
Lg2 L2 WY TC CGND
B1
Br2
1 1 RFRPGND
24
L1
Br
L

CASE : 6409-0031
Br
B3 B2 --- --- --- --- Br 2

1 B1 B4 --- --- --- Br2 Br1
NEUTRAL 54
BR1
Br1 Sb
Br2
J8 2 2
Br
2 2
RW3
55
RW2
RW1
Br1
Br2
RW
W2
33
W3
W1
34
Br
RW1RW2 Br Br2 W1 W2 Gy1
Br2
56 TACHO
R2

Br1
35 BrW (BLUE)
52 Br3 Br B1B2 B1 B2 SUMITOMO 31
Gy1 B2
51 32
B1
Br2 R2 P
GND W3 WY L HOUSING : 6403-7601
Gy2
CASE : 6409-0032
BrW BrW
SPEED
YW GY1BR1
Br5
Br2 Gy2
B4
TC
B1
B2
WY
Gy1
Gy2
B3
Gy3
Br3
Br
Br2
RB
57
L
P
L3
45 Y Y1
L
46 44
ILLUMI 43 G G
B B1
58 OFF H1 OFF L
L L 36
B Br Dg
B N RB
B WB BrW BrW L3
NR
59 Lg2
(BLACK) (BLACK)
B
RB RB
HI BEAM B2
Y2 60 B
(BLUE) (BLUE)
WATER
Ch
B1
Y1
Dg
B2
61
G
GW
Y GY3
L2
TURN 62
Dg
L2 A L2
37
GAG
Ch2
Ch
Dg
L Y GY3 L2
Dg3
L1 A L1 B B2
GB B3 YAY Dg1
FUEL+ Ch3 J6 A
OrW J5
FUEL-
Y1
L1
GB
Dg2
49
Y
1
Y
Y3
Ch
G
L1
Y L1 L1 Y
Dg1
Ch1
63 1 Ch A Ch Ch1
47 B L2 L2 B
12V35/35W
L1
12V35/35W
---
12V5W
12V5W
Dg2
L B2
Ch
W3 L4 YW --- GW B3 Lg2 Br1 L1 L G Ch Ch G
L
Y B
J10 B B B
Sb --- --- Ch3 GB Dg3 Y2 OrW
12V10W
(BLACK) (BLACK)
12V10W
OrW
12V5W
G
12V10W
12V10W
39
B2
(BLACK) 48 40 MAIN HARNESS CORR HEAD LIGHT
Y3 B4 41 L L
B
B
50
Y2
B4
B2
OrW GB B B4
42 38
BA B
B4
B3
B3
B2
B3
B1
B3
B2
B4
J14
YAMAHA INDONESIA MOTOR MANUFACTURING

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2PLF8197E0.

book Page 1 Tuesday, April 22, 2014 1:46 PM

YZF-R15 (2PK1) 2014

Designs and specifications are subject to change without notice.

IMPORTANT MANUAL INFORMATION

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

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

3 New REMOVING THE CLUTCH PUSH LEVER

d. Move the coolant reservoir“2” forward as

Engine oil Refer to “CHANGING THE ENGINE OIL” on

Right bottom cowling Refer to “GENERAL CHASSIS” on page

SYMBOLS 1. Serviceable with engine mounted

18.Replace the part with a new one.

ELECTRICAL SYSTEM ELEC

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

IMPORTANT INFORMATION ......................................................................... 1-5

CHECKING THE CONNECTIONS .................................................................. 1-7

SPECIAL TOOLS ............................................................................................ 1-8

VEHICLE IDENTIFICATION NUMBER

ENGINE SERIAL NUMBER

1. Fuel pump 11.Throttle body sensor assembly

The multi-function display is equipped with the

• a speedometer (which shows the riding

Odometer and trip meter modes

GASKETS, OIL SEALS AND O-RINGS

Tool no. Tool name/Usage Illustration

90890-01235 This tool is used to hold the AC

90890-01348 This tool is used to loosen and tighten

This tool is used to install oil seals.

90890-01701 This tool is used for holding the

This tool is used for lapping the valve.

90890-06754 This instrument is necessary for

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

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

CHASSIS SPECIFICATIONS .......................................................................... 2-9

ELECTRICAL SPECIFICATIONS ................................................................. 2-12

TIGHTENING TORQUES .............................................................................. 2-14

LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-21

LUBRICATION SYSTEM DIAGRAMS .......................................................... 2-25

COOLING SYSTEM DIAGRAMS .................................................................. 2-29

CABLE ROUTING ......................................................................................... 2-31

GENERAL SPECIFICATIONS SPEC

ENGINE SPECIFICATIONS SPEC

ENGINE SPECIFICATIONS SPEC

ENGINE SPECIFICATIONS SPEC

Rocker arm/rocker arm shaft

Valve, valve seat, valve guide

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

Valve margin thickness D (intake) 0.50–0.90 mm (0.0197–0.0354 in)

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

ENGINE SPECIFICATIONS SPEC

Cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in)

Winding direction (intake) Clockwise

ENGINE SPECIFICATIONS SPEC

Offset 0.25 mm (0.0098 in)

End gap (installed) 0.10–0.25 mm (0.0039–0.0098 in)

End gap (installed) 0.10–0.25 mm (0.0039–0.0098 in)

End gap (installed) 0.20–0.70 mm (0.0079–0.0276 in)

ENGINE SPECIFICATIONS SPEC

ENGINE SPECIFICATIONS SPEC

Fuel injection sensor