EAS00012TABLE OF CONTENTSGENERAL INFORMATIONGEN INFO1SPECIFICATIONSSPEC2PERIODIC CHECKS AND ADJUSTMENTSCHK ADJ3CHASSISCHAS4ENGINEENG5COOLING SYSTEMCOO
3 - 5CHKADJFUEL TANKREMOVING THE FUEL TANK1. Extract the fuel in the fuel tank through thefuel tank cap with a pump.2. Remove:• fuel return hose• fuel
3 - 6CHKADJFUEL TANKINSTALLING THE FUEL PUMP1. Install:• fuel pumpNOTE:• Do not damage the installation surfaces ofthe fuel tank when installing the f
3 - 7CHKADJCOWLINGSEAS00042COWLINGSOrder Job/Part Q’ty RemarksRemoving the cowlingsRemove the parts in the order listed.Rider and passenger seats Refe
3 - 8CHKADJAIR FILTER CASEEAS00043AIR FILTER CASET R..10 Nm (1.0 m • kg, 7.2 ft • Ib)3 Nm (0.3 m • kg, 2.2 ft • Ib)T R..Order Job/Part Q’ty RemarksRem
3 - 9CHKADJADJUSTING THE VALVE CLEARANCEEAS00045ENGINEADJUSTING THE VALVE CLEARANCEThe following procedure applies to all of thevalves.NOTE:_ • Valve
3 - 10CHKADJADJUSTING THE VALVE CLEARANCE4. Measure: • valve clearance Out of specification → Adjust.▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Turn
3 - 11CHKADJADJUSTING THE VALVE CLEARANCE5. Remove: • camshaftNOTE:_ • Refer to “DISASSEMBLING THEENGINE—CAMSHAFT AND CYLINDERHEAD” in chapter 5. • Wh
3 - 12CHKADJADJUSTING THE VALVE CLEARANCEc. Round off the original valve pad numberaccording to the following table.Last digit Rounded value0 or 2 055
3 - 13CHKADJADJUSTING THE VALVE CLEARANCEVALVE PAD SELECTION TABLEINTAKE EXHAUSTMeasured clearanceINSTALLED PAD NUMBER120 125 130 135 140 145150 155 1
3 - 14CHKADJADJUSTING THE VALVE CLEARANCE/SYNCHRONIZING THE THROTTLE BODIESNOTE:@ • Refer to “ASSEMBLING AND ADJUSTINGTHE ENGINE—CYLINDER HEAD ANDCAMS
CHAPTER 1GENERAL INFORMATIONMOTORCYCLE IDENTIFICATION ...1-1VEHICLE IDENTIFICATION NUMB
3 - 15CHKADJSYNCHRONIZING THE THROTTLE BODIES4. Install: • carburetor syncronizer 1(onto the synchronizing hose) • digital tachometer (near the spark
3 - 16CHKADJSYNCHRONIZING THE THROTTLE BODIES/ADJUSTING THE ENGINE IDLING SPEEDNOTE:@ The difference in vacuum pressure betweentwo throttle bodies sho
3 - 17CHKADJADJUSTING THE ENGINE IDLING SPEED/ADJUSTING THE THROTTLE CABLE FREE PLAY2. Install: • digital tachometer (onto the spark plug lead of cyli
3 - 18CHKADJADJUSTING THE THROTTLE CABLE FREE PLAY2. Remove: • rider seatRefer to “SEATS”.• fuel tankRefer to “FUEL TANK”.• air filter caseRefer to “A
3 - 19CHKADJADJUSTING THE THROTTLE CABLE FREE PLAY/CHECKING THE SPARK PLUGSd. Tighten the locknut.WARNING_ After adjusting the throttle cable free pla
3 - 20CHKADJCHECKING THE SPARK PLUGS/MEASURING THE COMPRESSION PRESSURE4. Check: • electrode 1 Damage/wear → Replace the spark plug. • insulator 2 Abn
3 - 21CHKADJMEASURING THE COMPRESSION PRESSURE1. Measure: • valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEAR-ANCE”.2
3 - 22CHKADJMEASURING THE COMPRESSION PRESSURE▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Set the main switch to “ON”. b. With the throttle wide open,
3 - 23CHKADJMEASURING THE COMPRESSION PRESSURE/CHECKING THE ENGINE OIL LEVEL7. Install: • spark plug • ignition coil8. Install: • rubber baffle• ignit
3 - 24CHKADJCHECKING THE ENGINE OIL LEVEL/CHANGING THE ENGINE OIL4. Start the engine, warm it up for several min-utes, and then turn it off.5. Check t
TIGHTENING TORQUES ...2-17GENERAL TIGHTENING TORQUE SPECIFICATIONS ...
3 - 25CHKADJCHANGING THE ENGINE OILc. Tighten the new oil filter cartridge to specifi-cation with an oil filter wrench.▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲
3 - 26CHKADJCHANGING THE ENGINE OIL/ADJUSTING THE CLUTCH CABLE FREE PLAY13.Check: • engine oil pressure▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Sli
3 - 27CHKADJADJUSTING THE CLUTCH CABLE FREE PLAY2. Adjust: • clutch cable free play▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼Handlebar sidea. Turn the
3 - 28CHKADJREPLACING THE AIR FILTER ELEMENTEAS00086REPLACING THE AIR FILTER ELEMENT1. Remove: • rider seatRefer to “SEATS”.• fuel tankRefer to “FUEL
3 - 29CHKADJCHECKING THE FUEL AND BREATHER HOSES/CHECKING THE CRANKCASE BREATHER HOSEEAS00096CHECKING THE FUEL AND BREATHER HOSESThe following procedu
3 - 30CHKADJCHECKING THE CRANKCASE BREATHER HOSE/CHECKING THE EXHAUST SYSTEM3. Install: • fuel tankRefer to “FUEL TANK”.• rider seatRefer to “SEATS”.E
3 - 31CHKADJADJUSTING THE EXUP CABLESEAS00101ADJUSTING THE EXUP CABLES1. Remove: • bottom cowlingRefer to “COWLINGS”.2. Remove: • EXUP valve pulley co
3 - 32CHKADJADJUSTING THE EXUP CABLES/CHECKING THE COOLANT LEVEL7. Install: • bottom cowlingRefer to “COWLINGS”.EAS00102CHECKING THE COOLANT LEVEL1. S
3 - 33CHKADJCHECKING THE COOLING SYSTEMEAS00104CHECKING THE COOLING SYSTEM1. Remove: • bottom cowling• side cowlingsRefer to “COWLINGS”.2. Check: • ra
3 - 34CHKADJCHANGING THE COOLANTEAS00105CHANGING THE COOLANT1. Remove:• side cowling• bottom cowlingRefer to “COWLINGS”.2. Disconnect: • coolant reser
ENGINE ...3-9ADJUSTING THE VALVE CLEARANCE ...
3 - 35CHKADJCHANGING THE COOLANT10.Fill: • cooling system (with the specified amount of the recom-mended coolant)Handling notes for coolantCoolant is
3 - 36CHKADJCHANGING THE COOLANT11.Install: • radiator cap12.Fill: • coolant reservoir (with the recommended coolant to the maxi-mum level mark a)13.I
3 - 37CHKADJADJUSTING THE FRONT BRAKEEAS00107CHASSISADJUSTING THE FRONT BRAKE1. Adjust: • brake lever position (distance a from the throttle grip to t
3 - 38CHKADJADJUSTING THE REAR BRAKEEAS00110ADJUSTING THE REAR BRAKE1. Check: • brake pedal position (distance a from the top of the brake pedalto the
3 - 39CHKADJADJUSTING THE REAR BRAKE/CHECKING THE BRAKE FLUID LEVEL3. Adjust: • rear brake light switch Refer to “ADJUSTING THE REAR BRAKELIGHT SWITCH
3 - 40CHKADJCHECKING THE FRONT AND REAR BRAKE PADS/ADJUSTING THE REAR BRAKE LIGHT SWITCHEAS00122CHECKING THE FRONT AND REAR BRAKE PADSThe following pr
3 - 41CHKADJCHECKING THE FRONT AND REAR BRAKE HOSES/BLEEDING THE HYDRAULIC BRAKE SYSTEMEAS00131CHECKING THE FRONT AND REAR BRAKE HOSESThe following pr
3 - 42CHKADJBLEEDING THE HYDRAULIC BRAKE SYSTEM1. Bleed: • hydraulic brake system▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Fill the brake fluid rese
3 - 43CHKADJADJUSTING THE SHIFT PEDAL/ADJUSTING THE DRIVE CHAIN SLACKEAS00136ADJUSTING THE SHIFT PEDAL1. Check: • shift pedal position (distance a fro
3 - 44CHKADJADJUSTING THE DRIVE CHAIN SLACK3. Check: • drive chain slack a Out of specification → Adjust.T R..Drive chain slack 40 ~ 50 mm (1.57 ~ 1.9
CHAPTER 4CHASSISFRONT WHEEL AND BRAKE DISCS ...4-1FRONT WHEEL ...
3 - 45CHKADJLUBRICATING THE DRIVE CHAIN/CHECKING AND ADJUSTING THE STEERING HEADEAS00142LUBRICATING THE DRIVE CHAINThe drive chain consists of many in
3 - 46CHKADJCHECKING AND ADJUSTING THE STEERING HEAD3. Remove: • upper bracketRefer to “HANDLEBARS” and “STTERLINGHEAD” in chapter 4.4. Adjust: • stee
3 - 47CHKADJCHECKING AND ADJUSTING THE STEERING HEADe. Install the rubber washer 3. f. Install the upper ring nut 2. g. Finger tighten the upper ring
3 - 48CHKADJCHECKING AND ADJUSTING THE STEERING HEAD/CHECKING THE FRONT FORKg. Reinstall the upper bracket and measure thesteering head tension again
3 - 49CHKADJADJUSTING THE FRONT FORK LEGSEAS00155ADJUSTING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.WARNING_ •
3 - 50CHKADJADJUSTING THE FRONT FORK LEGSRebound dampingCAUTION:_ Never go beyond the maximum or mini-mum adjustment positions. 1. Adjust: • rebound d
3 - 51CHKADJADJUSTING THE FRONT FORK LEGS/ADJUSTING THEREAR SHOCK ABSORBER ASSEMBLY▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲Direction aCompression dam
3 - 52CHKADJADJUSTING THE REAR SHOCK ABSORBERASSEMBLY▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲Rebound dampingCAUTION:_ Never go beyond the maximum or
3 - 53CHKADJADJUSTING THE REAR SHOCK ABSORBERASSEMBLY/CHECKING THE TIRES1. Adjust: • compression damping▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Tu
3 - 54CHKADJCHECKING THE TIRES* Total weight of rider, passenger, cargo and acces-soriesWARNING_ It is dangerous to ride with a worn-out tire.When the
HANDLEBARS ...4-56REMOVING THE HANDLEBARS ...
3 - 55CHKADJCHECKING THE TIRESWARNING_ • Do not use a tubeless tire on a wheeldesigned only for tube tires to avoid tirefailure and personal injury fr
3 - 56CHKADJCHECKING THE TIRES/CHECKING THE WHEELSFront tireRear tireWARNING_ New tires have a relatively low grip on theroad surface until they have
3 - 57CHKADJCHECKING AND LUBRICATING THE CABLES/LUBRICATING THE LEVERS AND PEDALS/LUBRICATING THESIDESTAND/LUBRICATING THE REAR SUSPENSIONEAS00170CHEC
3 - 58CHKADJCHECKING AND CHARGING THE BATTERYEAS00178ELECTRICAL SYSTEMCHECKING AND CHARGING THE BATTERYWARNING_ Batteries generate explosive hydrogen
3 - 59CHKADJCHECKING AND CHARGING THE BATTERYNOTE:_ Since MF batteries are sealed, it is not possi-ble to check the charge state of the battery bymeas
3 - 60CHKADJCHECKING AND CHARGING THE BATTERY5. Charge: • battery (refer to the appropriate charging methodillustration)WARNING_ Do not quick charge a
3 - 61CHKADJCHECKING AND CHARGING THE BATTERYCharging method using a variable-current (voltage) chargerMeasure the open-circuitvoltage prior to chargi
3 - 62CHKADJCHECKING AND CHARGING THE BATTERYCharging method using a constant voltage chargerMeasure the open-circuitvoltage prior to charging.Connect
3 - 63CHKADJCHECKING AND CHARGING THE BATTERY/CHECKING THE FUSES6. Install: • battery 7. Connect: • battery leads (to the battery terminals)CAUTION:_
3 - 64CHKADJCHECKING THE FUSES3. Replace: • blown fuse▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Set the main switch to “OFF”. b. Install a new fuse
CYLINDER HEAD ...5-19REMOVING THE CYLINDER HEAD ...
3 - 65CHKADJREPLACING THE HEADLIGHT BULBSEAS00183REPLACING THE HEADLIGHT BULBSThe following procedure applies to both of theheadlight bulbs.1. Disconn
3 - 66CHKADJADJUSTING THE HEADLIGHT BEAMEAS00184ADJUSTING THE HEADLIGHT BEAM1. Adjust: • headlight beam (vertically)▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼
4 - 1CHASEAS00514CHASSISFRONT WHEEL AND BRAKE DISCSOrder Job/Part Q’ty RemarksRemoving the front wheel and brake discs Remove the parts in the order l
4 - 2CHASFRONT WHEEL AND BRAKE DISCSEAS00518FRONT WHEELOrder Job/Part Q’ty RemarksDisassembling the front wheel Remove the parts in the order listed.
4 - 3CHASFRONT WHEEL AND BRAKE DISCSEAS00521REMOVING THE FRONT WHEEL1. Stand the motorcycle on a level surface.WARNING_ Securely support the motorcycl
4 - 4CHASFRONT WHEEL AND BRAKE DISCS3. Measure: • radial wheel runout 1 • lateral wheel runout 2 Over the specified limits → Replace.Radial wheel runo
4 - 5CHASFRONT WHEEL AND BRAKE DISCSEAS00533CHECKING THE BRAKE DISCSThe following procedure applies to all of thebrake discs.1. Check: • brake disc Da
4 - 6CHASFRONT WHEEL AND BRAKE DISCSd. Measure the brake disc deflection. e. If out of specification, repeat the adjustmentsteps until the brake disc
4 - 7CHASFRONT WHEEL AND BRAKE DISCS8. Tighten wheel axle pinch bolt 1, and thenpinch bolt 2 to the specified torque.9. Tap the outer side of the righ
4 - 8CHASFRONT WHEEL AND BRAKE DISCS▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Spin the front wheel. b. When the front wheel stops, put an “X1”mark a
OIL PAN AND OIL PUMP ...5-51OIL PUMP ...
4 - 9CHASREAR WHEEL AND BRAKE DISCEAS00551REAR WHEEL AND BRAKE DISCT R..27 Nm (2.7 m • kg, 20 ft • Ib)T R..150 Nm (15.0 m • kg, 108 ft • lb)Order Job/
4 - 10CHASREAR WHEEL AND BRAKE DISCEAS00560REAR WHEELOrder Job/Part Q’ty RemarksDisassembling the rear wheel Remove the parts in the order listed. 1Sp
4 - 11CHASREAR WHEEL AND BRAKE DISCT R..18 Nm (1.8 m • kg, 13 ft • Ib)T R..100 Nm (10 m • kg, 72 ft • lb)Order Job/Part Q’ty RemarksRemove the brake d
4 - 12CHASREAR WHEEL AND BRAKE DISCEAS00561REMOVING THE REAR WHEEL1. Stand the motorcycle on a level surface.WARNING_ Securely support the motorcycle
4 - 13CHASREAR WHEEL AND BRAKE DISC5. Remove: • left collar 1 • rear wheel drive hub 2 • rear wheel drive hub damper • right collarEAS00565CHECKING TH
4 - 14CHASREAR WHEEL AND BRAKE DISCEAS00568CHECKING AND REPLACING THE REAR WHEEL SPROCKET1. Check: • rear wheel sprocket More than 1/4 tooth a wear →
4 - 15CHASREAR WHEEL AND BRAKE DISC2. Adjust: • drive chain slackRefer to “ADJUSTING THE DRIVE CHAINSLACK” in chapter 3.3. Tighten: • wheel axle nut•
4 - 16CHASFRONT AND REAR BRAKESEAS00577FRONT AND REAR BRAKESFRONT BRAKE PADST R..6 Nm (0.6 m • kg, 4.3 ft • Ib)T R..6 Nm (0.6 m • kg, 4.3 ft • Ib)T R.
4 - 17CHASFRONT AND REAR BRAKESREAR BRAKE PADST R..6 Nm (0.6 m • kg, 4.3 ft • Ib)T R..27 Nm (2.7 m • kg, 20 ft • Ib)Order Job/Part Q’ty RemarksRemovin
4 - 18CHASFRONT AND REAR BRAKESEAS00579CAUTION:_ Disc brake components rarely require dis-assembly. Therefore, always follow these preventivemeasures:
CHAPTER 6COOLING SYSTEMRADIATOR ...6-1CHECKING THE
4 - 19CHASFRONT AND REAR BRAKES2. Remove: • brake pad clips 1 • brake pad pins 2 • brake pad spring 3 3. Remove: • brake pads 1 (along with the brake
4 - 20CHASFRONT AND REAR BRAKES▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Connect a clear plastic hose 1 tightly to thebleed screw 2. Put the other e
4 - 21CHASFRONT AND REAR BRAKESEAS00583REPLACING THE REAR BRAKE PADSNOTE:_ When replacing the brake pads, it is not neces-sary to disconnect the brake
4 - 22CHASFRONT AND REAR BRAKES▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Connect a clear plastic hose 1 tightly to thebleed screw 2. Put the other e
4 - 23CHASFRONT AND REAR BRAKESEAS00584FRONT BRAKE MASTER CYLINDERT R..30 Nm (3.0 m • kg, 22 ft • Ib)T R..9 Nm (0.9 m • kg, 6.5 ft • Ib)Order Job/Part
4 - 24CHASFRONT AND REAR BRAKEST R..30 Nm (3.0 m • kg, 22 ft • Ib)T R..9 Nm (0.9 m • kg, 6.5 ft • Ib)Order Job/Part Q’ty Remarks13 Brake hose 114 Brak
4 - 25CHASFRONT AND REAR BRAKESEAS00585Order Job/Part Q’ty RemarksDisassembling the front brake master cylinder Remove the parts in the order listed.
4 - 26CHASFRONT AND REAR BRAKESEAS00586REAR BRAKE MASTER CYLINDERT R..18 Nm (1.8 m • kg, 13 ft • Ib)T R..30 Nm (3.0 m • kg, 22 ft • Ib)T R..3 Nm (0.3
4 - 27CHASFRONT AND REAR BRAKESEAS00587T R..16 Nm (1.6 m • kg, 12 ft • Ib)Order Job/Part Q’ty RemarksDisassembling the rear brake master cylinder Remo
4 - 28CHASFRONT AND REAR BRAKESEAS00588DISASSEMBLING THE FRONT BRAKE MASTER CYLINDERNOTE:_ Before disassembling the front brake mastercylinder, drain
AIR INDUCTION SYSTEM ...7-37AIR INDUCTION ...
4 - 29CHASFRONT AND REAR BRAKESEAS00593CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERSThe following procedure applies to both of thebrake master cy
4 - 30CHASFRONT AND REAR BRAKESEAS00607ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDERWARNING_ • Before installation, all internal brake com
4 - 31CHASFRONT AND REAR BRAKES3. Fill: • brake fluid reservoir (with the specified amount of the recom-mended brake fluid)WARNING_ • Use only the des
4 - 32CHASFRONT AND REAR BRAKESEAS00610ASSEMBLING THE REAR BRAKE MASTER CYLINDER1. Install: • copper washers • brake hose• union bolt CAUTION:_ When
4 - 33CHASFRONT AND REAR BRAKES3. Bleed: • brake system Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.4. Check: • brake fluid level Below
4 - 34CHASFRONT AND REAR BRAKESEAS00613FRONT BRAKE CALIPERST R..6 Nm (0.6 m • kg, 4.3 ft • Ib)T R..40 Nm (4.0 m • kg, 29 ft • Ib)T R..30 Nm (3.0 m • k
4 - 35CHASFRONT AND REAR BRAKESEAS00615T R..6 Nm (0.6 m • kg, 4.3 ft • Ib)Order Job/Part Q’ty RemarksDisassembling the front brake calipers Remove the
4 - 36CHASFRONT AND REAR BRAKESEAS00616REAR BRAKE CALIPERT R..30 Nm (3.0 m • kg, 22 ft • Ib)T R..27 Nm (2.7 m • kg, 20 ft • Ib)Order Job/Part Q’ty Rem
4 - 37CHASFRONT AND REAR BRAKESEAS00617T R..6 Nm (0.6 m • kg, 4.3 ft • Ib)Order Job/Part Q’ty RemarksDisassembling the rear brake caliper Remove the p
4 - 38CHASFRONT AND REAR BRAKESEAS00625DISASSEMBLING THE FRONT BRAKE CALIPERSThe following procedure applies to both of thebrake calipers.NOTE:_ Befor
COOLING SYSTEM ...8-41CIRCUIT DIAGRAM ...
4 - 39CHASFRONT AND REAR BRAKESEAS00627DISASSEMBLING THE REAR BRAKE CALIPERNOTE:_ Before disassembling the brake caliper, drainthe brake fluid from th
4 - 40CHASFRONT AND REAR BRAKESEAS00633CHECKING THE FRONT AND REAR BRAKE CALIPERSRecommended brake component replacement scheduleBrake pads If necessa
4 - 41CHASFRONT AND REAR BRAKESEAS00640ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERSThe following procedure applies to both of thebrake calipers.
4 - 42CHASFRONT AND REAR BRAKES4. Fill: • brake fluid reservoir (with the specified amount of the recom-mended brake fluid)WARNING_ • Use only the des
4 - 43CHASFRONT AND REAR BRAKESASSEMBLING AND INSTALLING THE REAR BRAKE CALIPERWARNING@ • Before installation, all internal brake com-ponents should b
4 - 44CHASFRONT AND REAR BRAKES4. Fill: • brake fluid reservoir (with the specified amount of the recom-mended brake fluid)WARNING_ • Use only the des
4 - 45CHASFRONT FORKEAS00647FRONT FORKT R..23 Nm (2.3 m • kg, 17 ft • Ib)T R..6 Nm (0.6 m • kg, 4.3 ft • Ib)T R..23 Nm (2.3 m • kg, 17 ft • Ib)T R..13
4 - 46CHASFRONT FORKEAS00648T R..40 Nm (4.0 m • kg, 29 ft • Ib)Order Job/Part Q’ty RemarksDisassembling the front fork legs Remove the parts in the or
4 - 47CHASFRONT FORKT R..40 Nm (4.0 m • kg, 29 ft • Ib)Order Job/Part Q’ty RemarksC Damper rod assembly bolt 1D Copper washer 1E Damper rod assembly 1
4 - 48CHASFRONT FORKEAS00649REMOVING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Stand the motorcycle on a lev
FAULTY FRONT FORK LEGS ...9-5LEAKING OIL ...
4 - 49CHASFRONT FORKNOTE:@ Use the side of the rod holder that is marked“B”.c. Loosen the nut.d. Remove the cap bolt.e. Remove the rod holder and fork
4 - 50CHASFRONT FORKEAS00656CHECKING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Check: • inner tube 1 • outer
4 - 51CHASFRONT FORKEAS00659ASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.WARNING_ • Make sure the oil l
4 - 52CHASFRONT FORK4. Install: • dust seal 1 • oil seal clip 2 • oil seal 3 • washer 4 CAUTION:@ Make sure the numbered side of the oil sealfaces out
4 - 53CHASFRONT FORK8. Install: • rod puller 1(onto the damper rod 2)Rod pullerYM-014379. Fill: • front fork leg (with the specified amount of the rec
4 - 54CHASFRONT FORKd. Press down on the spacer with the forkspring compressor 1.e. Pull up the rod puller and install the rodholder 2 between the nu
4 - 55CHASFRONT FORKEAS00662INSTALLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Install: • front fork leg T
4 - 56CHASHANDLEBARSEAS00665HANDLEBARST R..9 Nm (0.9 m • kg, 6.5 ft • Ib)T R..13 Nm (1.3 m • kg, 9.4 ft • Ib)T R..26 Nm (2.6 m • kg, 19 ft • Ib)T R..1
4 - 57CHASHANDLEBARST R..9 Nm (0.9 m • kg, 6.5 ft • Ib)T R..13 Nm (1.3 m • kg, 9.4 ft • Ib)T R..26 Nm (2.6 m • kg, 19 ft • Ib)T R..115 Nm (11.5 m • kg
4 - 58CHASHANDLEBARSEAS00667REMOVING THE HANDLEBARS1. Stand the motorcycle on a level surface.WARNING_ Securely support the motorcycle so thatthere is
1 - 1GENINFOEAS00014GENERAL INFORMATION MOTORCYCLE IDENTIFICATIONEAS00017VEHICLE IDENTIFICATION NUMBERThe vehicle identification number 1 isstamped in
4 - 59CHASHANDLEBARS2. Install: • right handlebar switch 1 NOTE:_ Align the projection a on the right handlebarswitch with the hole b in the right han
4 - 60CHASHANDLEBARS6. Install: • left handlebar switch 1NOTE:_ Align the projection a on the left handlebarswitch with the hole b in the left handleb
4 - 61CHASSTEERING HEADEAS00676STEERING HEADT R..1st 50 Nm (5.0 m • kg, 36 ft • lb)2nd 9 Nm (0.9 m • kg, 6.5 ft • lb)T R..115 Nm (11.5 m • kg, 83
4 - 62CHASSTEERING HEADT R..1st 50 Nm (5.0 m • kg, 36 ft • lb)2nd 9 Nm (0.9 m • kg, 6.5 ft • lb)T R..115 Nm (11.5 m • kg, 83 ft • lb)T R..26 Nm (2
4 - 63CHASSTEERING HEADEAS00677REMOVING THE LOWER BRACKET1. Stand the motorcycle on a level surface.WARNING_ Securely support the motorcycle so thatth
4 - 64CHASSTEERING HEADb. Remove the bearing race 3 from the lowerbracket with a floor chisel 4 and hammer. c. Install a new rubber seal and new beari
4 - 65CHASREAR SHOCK ABSORBER ASSEMBLYEAS00685REAR SHOCK ABSORBER ASSEMBLYT R..45 Nm (4.5 m • kg, 33 ft • Ib)T R..45 Nm (4.5 m • kg, 33 ft • Ib)T R..4
4 - 66CHASREAR SHOCK ABSORBER ASSEMBLYEAS00687HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDERWARNING_ This rear shock absorber and gas cylinderconta
4 - 67CHASREAR SHOCK ABSORBER ASSEMBLYEAS00690REMOVING THE REAR SHOCK ABSORBER ASSEMBLY1. Stand the motorcycle on a level surface.WARNING_ Becurely su
4 - 68CHASREAR SHOCK ABSORBER ASSEMBLYEAS00695CHECKING THE REAR SHOCK ABSORBER ASSEMBLY1. Check: • rear shock absorber rod Bends/damage → Replace the
1 - 2GENINFOFEATURESFEATURESOUTLINE OF FI SYSTEMThe main function of a fuel supply system is to provide fuel to the combustion chamber at the opti-mum
4 - 69CHASSWINGARM AND DRIVE CHAINEAS00700SWINGARM AND DRIVE CHAINT R..7 Nm (0.7 m • kg, 5.1 ft • Ib)T R..5 Nm (0.5 m • kg, 3.6 ft • Ib)T R..105 Nm (1
4 - 70CHASSWINGARM AND DRIVE CHAINT R..7 Nm (0.7 m • kg, 5.1 ft • Ib)T R..5 Nm (0.5 m • kg, 3.6 ft • Ib)T R..105 Nm (10.5 m • kg, 76 ft • lb)T R..7 Nm
4 - 71CHASSWINGARM AND DRIVE CHAINEAS00703REMOVING THE SWINGARM1. Stand the motorcycle on a level surface.WARNING_ Securely support the motorcycle so
4 - 72CHASSWINGARM AND DRIVE CHAINEAS00704REMOVING THE DRIVE CHAIN1. Stand the motorcycle on a level surface.WARNING_ Securely support the motorcycle
4 - 73CHASSWINGARM AND DRIVE CHAIN3. Wash: • pivot shaft • dust covers • spacer • washers • bearingsRecommended cleaning solvent Kerosene4. Check: • d
4 - 74CHASSWINGARM AND DRIVE CHAIN2. Check: • drive chain Stiffness → Clean and lubricate or replace.3. Clean: • drive chain▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼
4 - 75CHASSWINGARM AND DRIVE CHAIN6. Check: • drive sprocket • rear wheel sprocket More than 1/4 tooth a wear → Replace thedrive chain sprockets as a
5 - 1ENGEAS00188OVERHAULING THE ENGINEENGINEDRIVE SPROCKETT R..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R..85 Nm (8.5 m • kg, 61 ft • Ib)Order Job/Part Q’ty R
5 - 2ENGENGINEEAS00189EXHAUST PIPET R..20 Nm (2.0 m • kg, 14 ft • Ib)T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R..20 Nm (2.0 m • kg, 14 ft • Ib)T R..38 Nm
5 - 3ENGENGINET R..20 Nm (2.0 m • kg, 14 ft • Ib)T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R..20 Nm (2.0 m • kg, 14 ft • Ib)T R..38 Nm (3.8 m • kg, 27 ft
1 - 3GENINFOFEATURESFI SYSTEMThe fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains thefuel pressure that i
5 - 4ENGENGINELEADS AND HOSEST R..20 Nm (2.0 m • kg, 14 ft • Ib)T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)Order Job/Part Q’ty RemarksDisconnecting the leads
5 - 5ENGENGINET R..20 Nm (2.0 m • kg, 14 ft • Ib)T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)Order Job/Part Q’ty Remarks3 Clutch cable 14 Crankcase breather h
5 - 6ENGENGINEEAS00191ENGINET R..50 Nm (5.0 m • kg, 36 ft • Ib)45 Nm (4.5 m • kg, 33 ft • Ib)T R..T R..45 Nm (4.5 m • kg, 33 ft • Ib)T R..50 Nm (5.0 m
5 - 7ENGENGINEEAS00192INSTALLING THE ENGINE1. Install: • engine mounting adjust bolts 1 • rear mounting bolts 2 • self-locking nuts 3 • left front mou
5 - 8ENGCAMSHAFTEAS00194CAMSHAFTCYLINDER HEAD COVERS T R..13 Nm (1.3 m • kg, 9.4 ft • Ib)T R..12 Nm (1.2 m • kg, 8.7 ft • Ib)T R..10 Nm (1.0 m • kg, 7
5 - 9ENGCAMSHAFTEAS00196CAMSHAFTST 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..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R..7 Nm
5 - 10ENGCAMSHAFTT 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..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R..7 Nm (0.7 m • kg, 5.
5 - 11ENGCAMSHAFTEAS00198REMOVING THE CAMSHAFTS1. Align: • TDC mark on the pickup coil rotor (with thecrankcase mating surface)▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼
5 - 12ENGCAMSHAFT6. Remove: • timing chain guide (exhaust side) 1 • camshaft caps • dowel pinsCAUTION:_ To prevent damage to the cylinder head,camshaf
5 - 13ENGCAMSHAFT3. Measure: • camshaft runout Out of specification → Replace.4. Measure: • camshaft-journal-to-camshaft-cap clear-ance Out of specifi
1 - 4GENINFOFEATURESFuel control blockThe fuel control block consists of the following main components:An engine trouble warning light is provided on
5 - 14ENGCAMSHAFT5. Measure: • camshaft journal diameter a Out of specification → Replace the cam-shaft. Within specification → Replace the cylinderhe
5 - 15ENGCAMSHAFTEAS00210CHECKING THE TIMING CHAIN TENSIONER1. Check: • timing chain tensioner Cracks/damage → Replace. 2. Check: • one-way cam operat
5 - 16ENGCAMSHAFTCAUTION:_ The camshaft cap bolts must be tightenedevenly or damage to the cylinder head,camshaft caps, and camshafts will result. 4.
5 - 17ENGCAMSHAFT6. Install: • timing chain tensioner▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. While lightly pressing the timing chain ten-sioner ro
5 - 18ENGCAMSHAFT9. Tighten: • camshaft sprocket bolts CAUTION:_ Be sure to tighten the camshaft sprocketbolts to the specified torque to avoid thepos
5 - 19ENGCYLINDER HEADEAS00221CYLINDER HEAD 2nd 140˚ or 65 Nm (6.5 m • kg, 47 ft • lb) T R..1st 20 Nm (2.0 m • kg, 14 ft • lb)2nd 105˚ or 50 Nm
5 - 20ENGCYLINDER HEADEAS00222REMOVING THE CYLINDER HEAD1. Remove: • cylinder head nuts• cylinder head boltsNOTE:_ • Loosen the nuts in the proper seq
5 - 21ENGCYLINDER HEADEAS00233INSTALLING THE CYLINDER HEAD1. Install: • gasket 1• dowel pins 2 2. Install: • cylinder headNOTE:_ Pass the timing chai
5 - 22ENGVALVES AND VALVE SPRINGSEAS00236VALVES AND VALVE SPRINGS Order Job/Part Q’ty RemarksRemoving the valves and valve springsRemove the parts in
5 - 23ENGVALVES AND VALVE SPRINGSOrder Job/Part Q’ty Remarks10 Exhaust valve lifter 811 Exhaust valve pad 812 Exhaust valve cotter 1613 Exhaust valve
1 - 5GENINFOFEATURESCOMPONENTSECU (Electronic Control Unit)The ECU is mounted underneath the seat. The main functions of the ECU are ignition control,
5 - 24ENGVALVES AND VALVE SPRINGSEAS00237REMOVING THE VALVESThe following procedure applies to all of thevalves and related components.NOTE:_ Before r
5 - 25ENGVALVES AND VALVE SPRINGS4. Remove: • upper spring seat 1 • valve spring 2 • valve stem seal 3 • lower spring seat 4 • valve 5NOTE:_ Identify
5 - 26ENGVALVES AND VALVE SPRINGS▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲3. Eliminate: • carbon deposits (from the valve face and valve seat)4. Check
5 - 27ENGVALVES AND VALVE SPRINGSEAS00240CHECKING THE VALVE SEATSThe following procedure applies to all of thevalves and valve seats. 1. Eliminate: •
5 - 28ENGVALVES AND VALVE SPRINGS▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Apply a coarse lapping compound a to thevalve face.CAUTION:_ Do not let t
5 - 29ENGVALVES AND VALVE SPRINGS2. Measure: • compressed valve spring force a Out of specification → Replace the valvespring.bInstalled lengthCompres
5 - 30ENGVALVES AND VALVE SPRINGS2. Lubricate: • valve stem 1 • valve stem seal 2 (with the recommended lubricant)Recommended lubricant Molybdenum dis
5 - 31ENGVALVES AND VALVE SPRINGS5. To secure the valve cotters onto the valvestem, lightly tap the valve tip with a soft-facehammer.CAUTION:_ Hitting
5 - 32ENGGENERATOR T R..14 Nm (1.4 m • kg, 10 ft • Ib)T R..12 Nm (1.2 m • kg, 8.7 ft • Ib)T R..65 Nm (6.5 m • kg, 47 ft • Ib) + 60˚ Order Job/Part Q’t
5 - 33ENGGENERATORREMOVING THE GENERATOR1. Remove: • generator rotor cover 1NOTE:@ Loosen each bolt 1/4 of a turn at a time, instages and in a crisscr
1 - 6GENINFOFEATURES• Ignition controlThe ignition control function of the ECU controls the ignition timing and the duration of ignitionenergizing. Th
5 - 34ENGGENERATORCAUTION:• Clean the tapered portion of the crank-shaft and the generator rotor hub withlacquer thinner. • Lubricate the generator ro
5 - 35ENGGENERATORWARNINGWhen the bolt are tightened more than thespecified angle, do not loosen the bolt andthen retighten it.Replace the bolt with a
5 - 36ENGPICKUP COILPICKUP COIL T R..12 Nm (1.2 m • kg, 8.7 ft • Ib)T R..15 Nm (1.5 m • kg, 11 ft • Ib)T R..60 Nm (6.0 m • kg, 43 ft • Ib)T R..10 Nm (
5 - 37ENGPICKUP COILT R..12 Nm (1.2 m • kg, 8.7 ft • Ib)T R..15 Nm (1.5 m • kg, 11 ft • Ib)T R..60 Nm (6.0 m • kg, 43 ft • Ib)T R..10 Nm (1.0 m • kg,
5 - 38ENGPICKUP COILREMOVING THE PICKUP COIL ROTOR1. Remove: • clutch cable holder 1 • pickup coil lead holder 2• pickup coil rotor cover 3NOTE:@ Loos
5 - 39ENGPICKUP COIL2. Tighten: • pickup coil rotor bolt 1 NOTE:@ While holding the generator rotor 2 with therotor holding tool 3, tighten the pickup
5 - 40ENGCLUTCHCLUTCHCLUTCH COVER T R..12 Nm (1.2 m • kg, 8.7 ft • Ib)T R..12 Nm (1.2 m • kg, 8.7 ft • Ib)Order Job/Part Q’ty RemarksRemoving the clut
5 - 41ENGCLUTCHPULL LEVER SHAFTOrder Job/Part Q’ty RemarksRemoving the pull lever shaftRemove the parts in the order listed.1Circlip 22 Pull lever 13
5 - 42ENGCLUTCHEAS00274CLUTCHT R..12 Nm (1.2 m • kg, 8.7 ft • Ib)T R..105 Nm (10.5 m • kg, 76 ft • lb)T R..8 Nm (0.8 m • kg, 5.8 ft • Ib)Order Job/Par
5 - 43ENGCLUTCHT R..12 Nm (1.2 m • kg, 8.7 ft • Ib)T R..105 Nm (10.5 m • kg, 76 ft • lb)T R..8 Nm (0.8 m • kg, 5.8 ft • Ib)Order Job/Part Q’ty Remarks
1 - 7GENINFOFEATURESFuel pumpThe fuel pump, which is mounted in the fuel tank, draws the fuel directly from the tank and pumps itto the injector.A fil
5 - 44ENGCLUTCHEAS00277REMOVING THE CLUTCH1. Straighten the lock washer tab. 2. Loosen: • clutch boss nut 1NOTE:_ While holding the clutch boss 2 with
5 - 45ENGCLUTCHEAS00281CHECKING THE CLUTCH PLATESThe following procedure applies to all of theclutch plates.1. Check: • clutch plate Damage → Replace
5 - 46ENGCLUTCHEAS00286CHECKING THE PRESSURE PLATE1. Check: • pressure plate 1 Cracks/damage → Replace. • bearing 2 Damage/wear → Replace.EAS00287CHEC
5 - 47ENGCLUTCH2. Check: • starter clutch operation▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Install the starter clutch drive gear onto thestarter c
5 - 48ENGCLUTCH5. Install: • friction plates • clutch platesNOTE:_ First, install a friction plate and then alternatebetween a clutch plate and a fric
5 - 49ENGSHIFT SHAFTEAS00327SHIFT SHAFTSHIFT SHAFT AND STOPPER LEVER T R..12 Nm (1.2 m • kg, 8.7 ft • Ib)T R..22 Nm (2.2 m • kg, 16 ft • Ib)Order Job/
5 - 50ENGSHIFT SHAFTCHECKING THE SHIFT SHAFT1. Check: • shift shaft 1 Bends/damage/wear → Replace. • shift shaft spring 2 Damage/wear → Replace.CHECKI
5 - 51ENGOIL PAN AND OIL PUMPEAS00356OIL PAN AND OIL PUMP T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R..43 Nm (4.3 m • kg, 31 ft • Ib)T R..10 Nm (1.0 m • k
5 - 52ENGOIL PAN AND OIL PUMPT R..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R..43 Nm (4.3 m • kg, 31 ft • Ib)T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R..10 Nm (1.
5 - 53ENGOIL PAN AND OIL PUMPEAS00360OIL PUMPT R..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R..15 Nm (1.5 m • kg, 11 ft • Ib)Order Job/Part Q’ty RemarksDisasse
1 - 8GENINFOFEATURESPressure regulatorIt regulates the fuel pressure that is applied to the injectors that are provided in the cylinders in orderto ma
5 - 54ENGOIL PAN AND OIL PUMPEAS00362REMOVING THE OIL PAN1. Remove: • oil level switch 1 • oil pan 2 • gasket • dowel pinsNOTE:_ Loosen each bolt 1/4
5 - 55ENGOIL PAN AND OIL PUMP3. Check: • oil pump operation Rough movement → Repeat steps (1) and(2) or replace the defective part(s).EAS00365CHECKING
5 - 56ENGOIL PAN AND OIL PUMPEAS00374ASSEMBLING THE OIL PUMP1. Lubricate: • inner rotor • outer rotor • oil pump shaft (with the recommended lubricant
5 - 57ENGOIL PAN AND OIL PUMPEAS00378INSTALLING THE OIL STRAINER1. Install: • oil strainer housing 1NOTE:_ The arrow mark a on the oil strainer housin
5 - 58ENGCRANKCASEEAS00381CRANKCASET R..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)Order Job/Part Q’ty RemarksRemoving the cra
5 - 59ENGCRANKCASET R..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)Order Job/Part Q’ty Remarks6Washer 17 Oil/water pump assembl
5 - 60ENGCRANKCASEEAS00384DISASSEMBLING THE CRANKCASE1. Place the engine upside down. 2. Remove:• crankcase boltsNOTE:_ • Loosen each bolt 1/4 of a tu
5 - 61ENGCRANKCASEEAS00399CHECKING THE CRANKCASE1. Thoroughly wash the crankcase halves in amild solvent. 2. Thoroughly clean all the gasket surfacesa
5 - 62ENGCRANKCASEEAS00414ASSEMBLING THE CRANKCASE1. Lubricate: • crankshaft journal bearings (with the recommended lubricant)Recommended lubricant En
5 - 63ENGCRANKCASE6. Install: • lower crankcase 1 (onto the upper crankcase 2)CAUTION:_ Before tightening the crankcase bolts,make sure the transmissi
YZF-R1PYZF-R1PCSERVICE MANUALLIT-11616-15-47 5PW-28197-10
1 - 9GENINFOFEATURESFuel injectorUpon receiving injection signals from the ECU, the fuel injector injects fuel. In the normal state, thecore is presse
5 - 64ENGCONNECTING RODS AND PISTONSEAS00382CONNECTING RODS AND PISTONST R..20 Nm (2.0 m • kg, 14 ft • Ib) + 120˚Order Job/Part Q’ty RemarksRemoving t
5 - 65ENGCONNECTING RODS AND PISTONSEAS00393REMOVING THE CONNECTING RODS AND PISTONSThe following procedure applies to all of theconnecting rods and p
5 - 66ENGCONNECTING RODS AND PISTONS3. Remove: • top ring • 2nd ring • oil ringNOTE:_ When removing a piston ring, open the endgap with your fingers a
5 - 67ENGCONNECTING RODS AND PISTONSb. If out of specification, replace the cylinder,and the pistons and piston rings as a set. Cylinder bore “C”74.00
5 - 68ENGCONNECTING RODS AND PISTONSEAS00263CHECKING THE PISTON RINGS1. Measure: • piston ring side clearance Out of specification → Replace the pisto
5 - 69ENGCONNECTING RODS AND PISTONSCHECKING THE PISTON PINSThe following procedure applies to all of thepiston pins.1. Check: • piston pin Blue disco
5 - 70ENGCONNECTING RODS AND PISTONS▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼The following procedure applies to all of theconnecting rods.CAUTION:@ Do
5 - 71ENGCONNECTING RODS AND PISTONSe. Tighten the connecting rod nuts. f. Replace the connecting rod bolts and nutswith new ones. CAUTION:Tighten the
5 - 72ENGCONNECTING RODS AND PISTONS2. Select: • big end bearings (P1 ~ P4)NOTE:@ • The numbers È stamped into the crankshaftweb and the numbers 1 on
5 - 73ENGCONNECTING RODS AND PISTONS2. Install: • piston 1 (onto the respective connecting rod 2)• piston pin 3 • piston pin clip 4NOTE:@ • Apply eng
1 - 10GENINFOFEATURESCrankshaft position sensorThe crankshaft position sensor uses the signals of the pickup coil that is mounted on the right sideof
5 - 74ENGCONNECTING RODS AND PISTONS6. Install: • big end bearings • connecting rod assembly (into the cylinder and onto the crankshaftpin).• connecti
5 - 75ENGCONNECTING RODS AND PISTONSe. Tighten the nut further to reach the speci-fied angle (120°).WARNINGWhen the nut is tightened more than thespec
5 - 76ENGCRANKSHAFTCRANKSHAFTOrder Job/Part Q’ty RemarksRemoving the crankshaft assembly Remove the parts in the order listed.Crankcase Separate.Refer
5 - 77ENGCRANKSHAFTEAS00395CHECKING THE CRANKSHAFT1. Measure: • crankshaft runout Out of specification → Replace the crank-shaft.2. Check: • crankshaf
5 - 78ENGCRANKSHAFTc. Install the crankshaft journal upper bearings1 and the crankshaft into the upper crank-case.NOTE:_ Align the projections a on th
5 - 79ENGCRANKSHAFTg. Remove the lower crankcase and the crank-shaft journal lower bearings. h. Measure the compressed Plastigauge®width c on each cra
5 - 80ENGCRANKSHAFTEAS00407INSTALLING THE CRANKSHAFT1. Install: • crankshaft journal upper bearings 1(into the upper crankcase)NOTE:_ • Align the proj
5 - 81ENGTRANSMISSIONEAS00419TRANSMISSIONT R..12 Nm (1.2 m • kg, 8.7 ft • Ib)T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)Order Job/Part Q’ty RemarksRemoving t
5 - 82ENGTRANSMISSIONT R..12 Nm (1.2 m • kg, 8.7 ft • Ib)T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)Order Job/Part Q’ty Remarks10 Shift drum assembly 111 Shi
5 - 83ENGTRANSMISSIONOrder Job/Part Q’ty RemarksDisassembling the main axle assemblyDisassembly the parts in the order listed.1 2nd pinion gear 12 Too
1 - 11GENINFOFEATURESCylinder identification sensorThe cylinder identification sensor is mounted on the middle of exhaust side head cover. When theexh
5 - 84ENGTRANSMISSIONOrder Job/Part Q’ty RemarksA Main axle/1st pinion gear 1B Bearing 1C Main axle bearing housing 1For assembly, reverse the disasse
5 - 85ENGTRANSMISSIONOrder Job/Part Q’ty RemarksDisassembling the drive axle assemblyDisassembly the parts in the order listed.1 Washer 12 1st wheel g
5 - 86ENGTRANSMISSIONOrder Job/Part Q’ty RemarksA 4th wheel gear 1B 6th wheel gear 1C 2nd wheel gear 1D Spacer 1E Drive axle 1F Bearing 1G Spacer 1For
5 - 87ENGTRANSMISSIONEAS00420REMOVING THE TRANSMISSION1. Remove: • main axle assembly 1 (with the Torx® wrench T30)▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼
5 - 88ENGTRANSMISSIONEAS00422CHECKING THE SHIFT DRUM ASSEMBLY1. Check: • shift drum grooves Damage/scratches/wear → Replace theshift drum assembly. •
5 - 89ENGTRANSMISSION4. Check: • transmission gear engagement (each pinion gear to its respective wheelgear) Incorrect → Reassemble the transmissiona
6 - 1COOLEAS00454COOLING SYSTEMRADIATOROrder Job/Part Q’ty RemarksRemoving the radiator Remove the parts in the order listed. Rider seat and fuel tank
6 - 2COOLRADIATOROrder Job/Part Q’ty Remarks3 Radiator inlet hose 14 Radiator outlet hose 15 Water pump breather hose 16Radiator 17 Radiator fan 18 Wa
6 - 3COOLRADIATOREAS00455CHECKING THE RADIATOR1. Check: • radiator fins Obstruction → Clean. Apply compressed air to the rear of the radi-ator. Damage
6 - 4COOLRADIATOREAS00456INSTALLING THE RADIATOR1. Fill: • cooling system (with the specified amount of the recom-mended coolant) Refer to “CHANGING T
1 - 12GENINFOFEATURESThrottle position sensorThe throttle position sensor measures the intake air volume by detecting the position of the throttlevalv
6 - 5COOLOIL COOLEREAS00457OIL COOLERT R..35 Nm (3.5 m • kg, 25 ft • Ib)T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R..10
6 - 6COOLOIL COOLEREAS00458CHECKING THE OIL COOLER1. Check: • oil cooler Cracks/damage → Replace.2. Check: • oil cooler inlet hose • oil cooler outlet
6 - 7COOLTHERMOSTATEAS00460THERMOSTATT R..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)Order Job/Part Q’ty RemarksRemoving the t
6 - 8COOLTHERMOSTATT R..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)Order Job/Part Q’ty Remarks5 Thermostat assembly 16 Thermos
6 - 9COOLTHERMOSTATEAS00461‘T R..18 Nm (1.8 m • kg, 13 ft • Ib)T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)Order Job/Part Q’ty RemarksDisassembling the thermo
6 - 10COOLTHERMOSTATEAS00462CHECKING THE THERMOSTAT1. Check: • thermostatDoes not open at 71 ~ 85 °C (160 ~ 185 °F)→ Replace.▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼
6 - 11COOLTHERMOSTATEAS00464ASSEMBLING THE THERMOSTAT ASSEMBLY1. Install: • thermostat housing 1 • thermostat 2 • O-ring 3 • thermostat housing cover
6 - 12COOLWATER PUMPEAS00468WATER PUMPT R..10 Nm (1.0 m • kg, 7.2 ft • Ib)Order Job/Part Q’ty RemarksRemoving the impeller shaftRemove the parts in th
6 - 13COOLWATER PUMPT R..10 Nm (1.0 m • kg, 7.2 ft • Ib)Order Job/Part Q’ty Remarks5 Water pump seal 16Oil seal 17Bearing 1For installation, reverse t
6 - 14COOLWATER PUMPEAS00471DISASSEMBLING THE WATER PUMP1. Remove: • water pump seal 1 NOTE:_ Tap out the water pump seal from the inside ofthe water
1 - 13GENINFOFEATURESIntake air pressure sensor and atmospheric pressure sensor• Intake air pressure sensorThe intake air pressure sensor is used for
6 - 15COOLWATER PUMPEAS00475ASSEMBLING THE WATER PUMP1. Install: • oil seal 1 (into the water pump housing 2)NOTE:_ • Before installing the oil seal
6 - 16COOLWATER PUMP4. Measure: • impeller shaft tilt Out of specification → Repeat steps (3) and(4).CAUTION:_ Make sure the rubber damper and rubberd
7 - 1FIFUEL INJECTION SYSTEMFUEL INJECTION SYSTEM1 Ignition coil 2 Air filter case3 Intake temperature sensor4 Fuel delivery hose5 Fuel tank6 Fuel pum
7 - 2FIFUEL INJECTION SYSTEMWIRING DIAGRAMOFFRUNL/RR/YBr/WP/WYB/L(BLACK)(BLACK)YB/LBr/WP/W(BLACK)G/WBR/LBCORD HEAD LIGHTMAIN HARNESSAWIRE SUB LEAD 4MA
7 - 3FIFUEL INJECTION SYSTEMECU’S SELF-DIAGNOSTIC FUNCTIONThe ECU is equipped with a self-diagnostic function in order to ensure that the engine contr
7 - 4FIFUEL INJECTION SYSTEMSUBSTITUTE CHARACTERISTICS OPERATION CONTROL (FAIL-SAFE ACTION)If the ECU detects an abnormal signal from a sensor while t
7 - 5FIFUEL INJECTION SYSTEMTROUBLESHOORING CHART“Engine runs irregularly.” or “Engine trouble warning light is illuminated.”* Engine trouble warning
7 - 6FIFUEL INJECTION SYSTEMDIAGNOSTIC MODE• In this mode, diagnostic codes are input into the ECU in accordance with the number of times thestart swi
7 - 7FIFUEL INJECTION SYSTEMDiagnostic fault code tableFaultCode No.Symptom Probable cause of malfunctionCode of diagnostic mode11No normal signals ar
7 - 8FIFUEL INJECTION SYSTEM33Open circuit is detected in the primary lead of the ignition coil (#1).• Open or short circuit in wiring harness.• Malfu
1 - 14GENINFOFEATURESCoolant temperature sensorThe signals from the coolant temperature sensor are used primarily for making fuel volume compen-sation
7 - 9FIFUEL INJECTION SYSTEMDiagnostic mode tableSet the meter display from the regular mode to the diagnosis mode. For the setting method, refer to“D
7 - 10FIFUEL INJECTION SYSTEM32Ignition coil #3 After 1 second has elapsed from the time the engine stop switch has been turned from OFF to ON, it act
7 - 11FIFUEL INJECTION SYSTEM52Headlight relay 1 After 1 second has elapsed from the time the engine stop switch has been turned from OFF to ON, it ac
7 - 12FIFUEL INJECTION SYSTEMTROUBLESHOOTING DETAILSThis section describes the measures per fault code number displayed on the meter.Carry out checkan
7 - 13FIFUEL INJECTION SYSTEMFault code No. 12 Symptom No normal signals are received from the crankshaft position sensor.Used diagnostic code No.--In
7 - 14FIFUEL INJECTION SYSTEMFault code No. 13 Symptom Intake air pressure sensor - open or short circuit detected.Used diagnostic code No. 03 (intake
7 - 15FIFUEL INJECTION SYSTEMFault code No. 14 Symptom Intake air pressure sensor - hose system malfunction (clogged or detached hose).Used diagnostic
7 - 16FIFUEL INJECTION SYSTEMFault code No. 17 Symptom EXUP servo motor potention circuit - open or short circuit detected.Used diagnostic code 53Insp
7 - 17FIFUEL INJECTION SYSTEMFault code No. 18 Symptom EXUP servo motor is stuck.Used diagnostic code 53Inspection operation item and probable cause O
7 - 18FIFUEL INJECTION SYSTEMFault code No. 19 Symptom Open circuit is detected in the input line from the sidestand switch to the ECU.Used diagnostic
1 - 15GENINFOFEATURESLean angle cut-off switchThe lean angle cut-off switch stops the supply of fuel to the engine in case the motorcycle overturns.Wh
7 - 19FIFUEL INJECTION SYSTEMFault code No. 22 Symptom Open or short circuit detected from the intake temperature sensor.Used diagnostic code No. 05 (
7 - 20FIFUEL INJECTION SYSTEMFault code No. 23 Symptom Open or short circuit detected from the atmospheric pressure sensor.Used diagnostic code No. 02
7 - 21FIFUEL INJECTION SYSTEMFault code No. 30 Symptom The motorcycle has overturned.Used diagnostic code No. 08 (lean angle cut-off switch)Inspection
7 - 22FIFUEL INJECTION SYSTEMFault code No. 33 Symptom Malfunction detected in the primary lead of the ignition coil (#1).Used diagnostic code No. 30
7 - 23FIFUEL INJECTION SYSTEMFault code No. 36 Symptom Malfunction detected in the primary lead of the ignition coil (#4).Used diagnostic code No. 33
7 - 24FIFUEL INJECTION SYSTEMFault code No. 42 Symptom 1 No normal signals are received from the speed sensor.2 Open or short circuit is detected in t
7 - 25FIFUEL INJECTION SYSTEMFault code No. 43 Symptom The ECU is unable to monitor the battery voltage.Used diagnostic code No. 09 (fuel system volta
7 - 26FIFUEL INJECTION SYSTEMFault code No. 44 Symptom Error is detected while reading or writing on EEP-ROM.Used diagnostic No. 60 (EEP-ROM improper
7 - 27FIFUEL INJECTION SYSTEMFault code No. Er-1 Symptom No signal are received from the ECU.Used diagnostic code No. --Inspection operation item and
7 - 28FIFUEL INJECTION SYSTEMFault code No. Er-4 Symptom Non-registered data has been received from the meter.Used diagnostic code No. --Inspection op
1 - 16GENINFOFEATURESFUEL INJECTION SYSTEMOperation and controlThe fuel injection timing, injection duration, ignition timing, and the coil energizing
7 - 29FITHROTTLE BODIESTHROTTLE BODIESOrder Job/Part Q’ty RemarksRemoving the throttle bodiesRemove the parts in the order listed.Seats/fuel tank/rubb
7 - 30FITHROTTLE BODIESOrder Job/Part Q’ty Remarks5 Throttle cable 2 Disconnect.6 Plunger control unit hose 2 Disconnect.7 Throttle body joint 4For in
7 - 31FITHROTTLE BODIESOrder Job/Part Q’ty RemarksRemoving the injectorRemove the parts in the order listed.1 Throttle position sensor coupler 1 Disco
7 - 32FITHROTTLE BODIESOrder Job/Part Q’ty Remarks11 Intake air pressure sensor 112 Fuel distributor 113 Injector 414 Throttle position sensor 1For in
7 - 33FITHROTTLE BODIESCAUTION:The throttle bodies should not be disas-sembled unnecessarily.CHECKING THE INJECTOR1. Check:• injectorDamage → Replace.
7 - 34FITHROTTLE BODIESCHECKING THE PRESSURE REGULATOR1. Check:• pressure regulatorDamage → Replace.CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPER
7 - 35FITHROTTLE BODIESFaulty → Replace the pressure regulator.▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲Increase the vacuum pressure →Fuel pressure is
7 - 36FITHROTTLE BODIESf. While slowly opening the throttle, check thatthe throttle position sensor resistance iswithin the specified range.The resist
7 - 37FIAIR INDUCTION SYSTEMEAS00507AIR INDUCTION SYSTEMAIR INDUCTIONThe air induction system burns unburnedexhaust gases by injecting fresh air (seco
7 - 38FIAIR INDUCTION SYSTEMEAS00509AIR INDUCTION SYSTEM DIAGRAMS1Air cut-off valve 2Reed valve 3Air cleaner ÈTo cylinder #1 ÉTo cylinder #2 ÊTo cylin
1 - 17GENINFOFEATURESDetermining the final injection durationThe intake air volume determines the basic injection duration. However, at a given intake
7 - 39FIAIR INDUCTION SYSTEMEAS00510CHECKING THE AIR INDUCTION SYSTEM1. Check: • hoses Loose connection → Connect properly. Cracks/damage → Replace. •
7 - 40FIAIR INDUCTION SYSTEM5. Check• Al system solenoid▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Remove the AI system solenoid couplerfrom the wire
8 - 1– +ELECEAS00729ELECTRICALELECTRICAL COMPONENTS1Fuse box2Front brake switch3Clutch switch4Battery 5Starter relay6Fuel injection system fuse7Main f
8 - 2– +ELECELECTRICAL COMPONENTS1 Coolant temperature sensor2 Intake air temperature sensor3 Intake air pressure sensor4 Lean angle cut-off switch5 A
8 - 3– +ELECCHECKING SWITCH CONTINUITYEAS00730CHECKING SWITCH CONTINUITYCheck each switch for continuity with thepocket tester. If the continuity read
8 - 4– +ELECCHECKING THE SWITCHESEAS00731CHECKING THE SWITCHESCheck each switch for damage or wear, proper connections, and also for continuity betwee
8 - 5– +ELECCHECKING THE BULBS AND BULB SOCKETSEAS00732CHECKING THE BULBS AND BULB SOCKETSCheck each bulb and bulb socket for damageor wear, proper co
8 - 6– +ELECCHECKING THE BULBS AND BULB SOCKETSCHECKING THE CONDITION OF THE BULBSThe following procedure applies to all of thebulbs. 1. Remove: • bul
8 - 7– +ELECCHECKING THE BULBS AND BULB SOCKETSCHECKING THE CONDITION OF THE BULB SOCKETSThe following procedure applies to all of thebulb sockets. 1.
8 - 8– +ELECIGNITION SYSTEMEAS00735IGNITION SYSTEMCIRCUIT DIAGRAMY/BL/RB/RCh DgB/YY/LSb/WL/RR/YBr/WP/WYB/L(BLACK)(BLACK)YB/LBr/WP/W(BLACK)G/WBR/LBCORD
1 - 18GENINFOFEATURESReactive injection duration:A lag is created between the time the ECU outputs a fuel injection signal to the injector and the tim
8 - 9– +ELECIGNITION SYSTEMEAS00737TROUBLESHOOTINGCheck: 1. main and ignition fuses 2. battery 3. spark plugs 4. ignition spark gap 5. ignition coil r
8 - 10– +ELECIGNITION SYSTEMEAS00743 EAS007474. Ignition spark gap The following procedure applies to all of thespark plugs. • Disconnect the spark pl
8 - 11– +ELECIGNITION SYSTEMEAS00748EAS00749EAS00750EAS00751EAS007526. Crankshaft position sensor resistance • Disconnect the crankshaft position sens
8 - 12– +ELECIGNITION SYSTEMEAS00753 EAS0075411.Starting circuit cut-off relay • Disconnect the starting circuit cut-off relaycoupler from the wire ha
8 - 13– +ELECELECTRIC STARTING SYSTEMEAS00755ELECTRIC STARTING SYSTEMCIRCUIT DIAGRAML/RR/YBr/WP/WYB/L(BLACK)(BLACK)YB/LBr/WP/W(BLACK)G/WBR/LBCORD HEAD
8 - 14– +ELECELECTRIC STARTING SYSTEMEAS00756STARTING CIRCUIT CUT-OFF SYSTEM OPERATIONIf the engine stop switch is set to “” and themain switch is set
8 - 15– +ELECELECTRIC STARTING SYSTEMEAS00757TROUBLESHOOTINGCheck: 1. main and ignition fuses 2. battery 3. starter motor 4. starting circuit cut-off
8 - 16– +ELECEAS00759EAS00761EAS00749EAS00750EAS007514. Starting circuit cut-off relay • Disconnect the starting circuit cut-off relaycoupler from the
8 - 17– +ELECELECTRIC STARTING SYSTEMEAS00752EAS00763EAS00764EAS007669. Sidestand switch • Check the sidestand switch for continuity. Refer to “CHECKI
8 - 18– +ELECELECTRIC STARTING SYSTEMEAS00767STARTER MOTORT R..5 Nm (0.5 m • kg, 3.6 ft • Ib)T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)Order Job/Part Q’ty Re
1 - 19GENINFOFEATURESTHREE-WAY CATALYTIC CONVERTER SYSTEMSystem outlineThis is a highly efficient exhaust gas cleaning system that effects air-fuel co
8 - 19– +ELECELECTRIC STARTING SYSTEMEAS00768T R..5 Nm (0.5 m • kg, 3.6 ft • Ib)Order Job/Part Q’ty RemarksDisassembling the starter motor Disassembly
8 - 20– +ELECELECTRIC STARTING SYSTEMEAS00769CHECKING THE STARTER MOTOR1. Check: • commutator Dirt → Clean with 600-grit sandpaper.2. Measure: • commu
8 - 21– +ELECELECTRIC STARTING SYSTEM5. Measure: • brush length a Out of specification → Replace the brushesas a set.Brush length wear limit 3.65 mm (
8 - 22– +ELECCHARGING SYSTEMEAS00773CHARGING SYSTEMCIRCUIT DIAGRAM(BLACK)RBr/LRBr/LL/YL/BL/BL/YRB(GRAY)WWWONOFFRWR/WL/WR/WL/WRRR RBBBBBRWRBRBRWWWWW RW
8 - 23– +ELECCHARGING SYSTEMEAS00774TROUBLESHOOTINGCheck: 1. main fuse 2. battery 3. charging voltage 4. stator coil resistance 5. wiring connections
8 - 24– +ELECCHARGING SYSTEMEAS00776EAS007794. Stator coil resistance • Remove the generator cover. • Connect the pocket tester (Ω × 1) to thestator c
8 - 25– +ELECLIGHTING SYSTEMEAS00780LIGHTING SYSTEMCIRCUIT DIAGRAML/RR/YBr/WP/WYB/L(BLACK)(BLACK)YB/LBr/WP/W(BLACK)G/WBR/LBCORD HEAD LIGHTMAIN HARNESS
8 - 26– +ELECLIGHTING SYSTEM1 Main switch 5 Battery 6 Fuse (main)C ECU X Hi beam indicator light [ Meter light c Dimmer switch l Auxiliary lightm Head
8 - 27– +ELECLIGHTING SYSTEMEAS00781TROUBLESHOOTINGCheck: 1. main, signal and headlight fuses 2. battery 3. main switch 4. dimmer switch 5. headlight
8 - 28– +ELECLIGHTING SYSTEMYESNOYESNOEAS007875. Headlight relay (on/off)• Disconnect the headlight relay (on/off)from the coupler.• Connect the pocke
1 - 20GENINFOFEATURESINSTRUMENT FUNCTIONMulti-function displayThe multi-function display is equipped with thefollowing:• a speedometer (which shows th
8 - 29– +ELECLIGHTING SYSTEMEAS00788 CHECKING THE LIGHTING SYSTEM1. The headlight and the high beam indicatorlight fail to come on.YESNOYESNO1. Headli
8 - 30– +ELECLIGHTING SYSTEMEAS007892. The meter light fails to come on.EAS007903. The tail/brake light fails to come on.1. Meter light bulb and socke
8 - 31– +ELECLIGHTING SYSTEMEAS007914. The auxiliary light fails to come on.EAS007925. The license plate light fails to come on.1. Auxiliary light bul
8 - 32– +ELECSIGNALING SYSTEMEAS00793SIGNALING SYSTEMCIRCUIT DIAGRAM L/RR/YBr/WP/WYB/L(BLACK)(BLACK)YB/LBr/WP/W(BLACK)G/WBR/LBCORD HEAD LIGHTMAIN HARN
8 - 33– +ELECSIGNALING SYSTEM1 Main switch 4 Fuse (back up)5 Battery 6 Fuse (main)0 Starting circuit cut-off relay B Fuel pump C ECU I Speed sensorR N
8 - 34– +ELECSIGNALING SYSTEMEAS00794TROUBLESHOOTINGCheck: 1. main, ignition, signaling and back up fuses 2. battery 3. main switch 4. wiring connecti
8 - 35– +ELECSIGNALING SYSTEMEAS007972. The tail/brake light fails to come on.2. Voltage • Connect the pocket tester (DC 20 V) to thehorn connector at
8 - 36– +ELECSIGNALING SYSTEMEAS007993. The turn signal light, turn signal indicatorlight or both fail to blink.YESNOThis circuit is OK. The wiring ci
8 - 37– +ELECSIGNALING SYSTEMEAS008014. The neutral indicator light fails to come on.Left turn signal light Positive tester probe → chocolate 1 Negati
8 - 38– +ELECSIGNALING SYSTEMEAS008025. The oil level warning light fails to come on.EAS008036. The fuel level indicator light fails to comeon.1. Oil
1 - 21GENINFOFEATURESDisplay brightness and engine speed indi-cator light control modeThis mode cycles through five control func-tions, allowing you t
8 - 39– +ELECSIGNALING SYSTEMEAS008067. The speedometer fails to come on.2. Fuel sender • Drain the fuel from the fuel tank andremove the fuel pump fr
8 - 40– +ELECSIGNALING SYSTEM2. Voltage • Connect the pocket tester (DC 20 V) to themeter assembly coupler (wire harnessside) as shown.Positive tester
8 - 41– +ELECCOOLING SYSTEMEAS00807COOLING SYSTEMCIRCUIT DIAGRAML/RR/YBr/WP/WYB/L(BLACK)(BLACK)YB/LBr/WP/W(BLACK)G/WBR/LBCORD HEAD LIGHTMAIN HARNESSAW
8 - 42– +ELECCOOLING SYSTEMEAS00808TROUBLESHOOTINGCheck: 1. main, ignition and radiator fan motor fuses 2. battery 3. main switch 4. radiator fan moto
8 - 43– +ELECCOOLING SYSTEMEAS00809YESNO4. Radiator fan motor • Disconnect the radiator fan motor couplerfrom the wire harness. • Connect the battery
8 - 44– +ELECCOOLING SYSTEMEAS00812EAS008136. Coolant temperature sensor • Remove the coolant temperature sensorfrom the thermostat housing. • Connect
8 - 45– +ELECFUEL PUMP SYSTEMFUEL PUMP SYSTEMCIRCUIT DIAGRAML/RR/YBr/WP/WYB/L(BLACK)(BLACK)YB/LBr/WP/W(BLACK)G/WBR/LBCORD HEAD LIGHTMAIN HARNESSAWIRE
8 - 46– +ELECFUEL PUMP SYSTEMEAS00815FUEL PUMP SYSTEMThe ECU includes the control unit for the fuelpump.1Battery 2Main fuse 3Main switch 4Ignition fus
8 - 47– +ELECFUEL PUMP SYSTEMEAS00816TROUBLESHOOTINGCheck: 1. Main and fuel injection system fuses 2. Battery 3. Main switch 4. Engine stop switch 5.
8 - 48– +ELECFUEL PUMP SYSTEMEAS00759 EAS00817EAS008185. Starting circuit cut-off relay • Disconnect the starting circuit cut-off relaycoupler from th
1 - 22GENINFOFEATURESTo set the engine speed indicator light activation functionNOTE:_ The indicator light activation function can be set between 7,00
8 - 49– +ELECFUEL PUMP SYSTEMEAS00819CHECKING THE FUEL PUMPWARNING_ Gasoline is extremely flammable and undercertain circumstances there can be a dan-
9 - 1TRBLSHTGEAS00844TROUBLESHOOTINGNOTE:_ The following guide for troubleshooting does not cover all the possible causes of trouble. It shouldbe help
9 - 2TRBLSHTGSTARTING FAILURES/INCORRECT ENGINE IDLING SPEEDELECTRICAL SYSTEMSBattery• Discharged battery • Faulty batteryFuse(s)• Blown, damaged or i
9 - 3TRBLSHTGPOOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/FAULTY GEAR SHIFTING/FAULTY CLUTCHEAS00848POOR MEDIUM-AND-HIGH-SPEED PERFORMANCERefer to “STARTING
9 - 4TRBLSHTGOVERHEATING/OVERCOOLING/POOR BRAKING PERFORMANCEEAS00855OVERHEATINGENGINEClogged coolant passages• Cylinder head(s) and piston(s) • Heavy
9 - 5TRBLSHTGFAULTY FRONT FORK LEGS/UNSTABLE HANDLINGEAS00861FAULTY FRONT FORK LEGSLEAKING OIL• Bent, damaged or rusty inner tube • Cracked or damaged
9 - 6TRBLSHTGFAULTY LIGHTING OR SIGNALING SYSTEMEAS00866FAULTY LIGHTING OR SIGNALING SYSTEMHEADLIGHT DOES NOT COME ON• Wrong headlight bulb • Too many
YZF-R1P/YZF-R1PC WIRING DIAGRAM 1 Main switch 2 AC magneto3 Rectifier/regulator4 Fuse (back up)5 Battery6 Fuse (main)7 Fuse (fuel injection system)8 S
YZF-R1P/YZF-R1PCWIRING DIAGRAMDark greenGreenGrayBlackBlueBrownChocolateCOLOR CODEOrangePinkRedSky blueBlack/WhiteBlack/YellowBlue/BlackBlue/RedBlue/W
YAMAHA MOTOR CO., LTD.2500 SHINGAI IWATA SHIZUOKA JAPANPRINTED IN U.S.A.
1 - 23GENINFOIMPORTANT INFORMATIONEAS00020IMPORTANT INFORMATIONPREPARATION FOR REMOVAL AND DISASSEMBLY1. Before removal and disassembly, remove alldir
1 - 24GENINFOIMPORTANT INFORMATIONEAS00023LOCK WASHERS/PLATES AND COTTER PINSAfter removal, replace all lock washers/plates1 and cotter pins. After th
1 - 25GENINFOCHECKING THE CONNECTIONSEAS00026CHECKING THE CONNECTIONSCheck the leads, couplers, and connectors forstains, rust, moisture, etc.1. Disco
1 - 26GENINFOSPECIAL TOOLSEAS00027SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Useonly the a
1 - 27GENINFOSPECIAL TOOLSYU-38411Oil filter wrenchThis tool is needed to loosen or tighten the oil filter cartridge.YM-01434Rod holderThis tool is us
1 - 28GENINFOSPECIAL TOOLSMiddle driven shaft bearing driverYM-4058-1Mechanical seal installerYM-33221Middle driven shaft bearing driverMechanical sea
EAS00000 YZF-R1P/YZF-R1PCSERVICE MANUAL©2001 by Yamaha Motor Corporation, U.S.A.First edition, December 2001All rights reserved.Any reproduction or un
1 - 29GENINFOSPECIAL TOOLSYM-03112Pocket testerThis instrument is needed for checking the engine oil temperature.YB-35956Mity vacThis tool used to mea
2 - 1SPECSPECIFICATIONSGENERAL SPECIFICATIONSItem Standard LimitModel code5PW4 USA5PW5 California5PW6 Canada------------DimensionsOverall length 2,040
2 - 2SPECENGINE SPECIFICATIONSENGINE SPECIFICATIONS Item Standard LimitEngineEngine type Liquid-cooled, 4-stroke, DOHC ----Displacement 998 cm3 (60.9
2 - 3SPECENGINE SPECIFICATIONSOil filterOil filter type Cartridge (paper) ----Bypass valve opening pressure 80 ~ 120 kPa(0.8 ~ 1.2 kg/cm2, 11.6 ~ 17.4
2 - 4SPECENGINE SPECIFICATIONSCamshaftsDrive system Chain drive (right) ----Camshaft cap inside diameter 24.500 ~ 24.521 mm (0.9646 ~ 0.9654 in) ----C
2 - 5SPECENGINE SPECIFICATIONSTiming chainModel/number of links RH2015/130 ----Tensioning system Automatic ----Valves, valve seats, valve guidesValve
2 - 6SPECENGINE SPECIFICATIONSValve stem runout ---- 0.01 mm (0.0004 in)Valve seat widthIntake 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) ----Exhaust 0.9 ~ 1.1
2 - 7SPECENGINE SPECIFICATIONSCylindersCylinder arrangement Forward-inclined, parallel 4-cylinder ----Bore × stroke 74 × 58 mm (2.91 × 2.28 in) ----Co
2 - 8SPECENGINE SPECIFICATIONS2nd ringRing type Taper ----Dimensions (B × T) 0.8 × 2.8 mm (0.03 × 0.11 in) ----End gap (installed) 0.43 ~ 0.58 mm (0.0
2 - 9SPECENGINE SPECIFICATIONSClutchClutch type Wet, multiple disc ----Clutch release method Outer pull, rack and pinion pull ----Clutch release metho
EAS00003NOTICEThis manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-ers and their qualified mechanics. It is not
2 - 10SPECENGINE SPECIFICATIONSAir filter typeWet element ----Fuel pumpPump type Electrical ----Model (manufacturer) 5PW (DENSO) ----Output pressure 9
2 - 11SPECCHASSIS SPECIFICATIONSCHASSIS SPECIFICATIONSItem Standard LimitFrameFrame type Diamond ----Caster angle 24° ----Trail 103 mm (4.06 in) ----F
2 - 12SPECCHASSIS SPECIFICATIONSFront brakesBrake type Dual disc brake ----Operation Right hand operation ----Recommended fluid DOT 4 ----Brake lever
2 - 13SPECCHASSIS SPECIFICATIONSFront suspensionSuspension type Telescopic fork ----Front fork type Coil spring/oil damper ----Front fork travel 120 m
2 - 14SPECCHASSIS SPECIFICATIONSRear suspensionSuspension type Swingarm (link suspension) ----Rear shock absorber assembly type Coil spring/gas-oil da
2 - 15SPECELECTRICAL SPECIFICATIONSELECTRICAL SPECIFICATIONSItem Standard LimitSystem voltage12 V ----Ignition systemIgnition system type Transistoriz
2 - 16SPECELECTRICAL SPECIFICATIONSElectric starting systemSystem type Constant mesh ----Starter motorModel (manufacturer) 5JJ (YAMAHA) ----Power outp
2 - 17SPECCONVERSION TABLE/TIGHTENING TORQUESEAS00028CONVERSION TABLEAll specification data in this manual are listedin SI and METRIC UNITS. Use this
2 - 18SPECTIGHTENING TORQUESENGINE TIGHTENING TORQUESItem FastenerThread sizeQ’tyTightening torqueRemarksNm m·kg ft·lbSpark plugs — M10 4 13 1.3 9.4Cy
2 - 19SPECTIGHTENING TORQUESExhaust pipe and exhaust valve Bolt M6 4 10 1.0 7.2Exhaust valve and housing Bolt M6 3 10 1.0 7.2EXUP pulley and arm shaft
EAS00007 HOW TO USE THIS MANUALThis manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensiveexplanations of all inst
2 - 20SPECTIGHTENING TORQUESNOTE:1. First, tighten the bolt to approximately 20 Nm (2.0 m • kg, 14 ft • lb) with a torque wrench.2. Retighten the bolt
2 - 21SPECTIGHTENING TORQUESCHASSIS TIGHTENING TORQUESItemThread sizeTighteningRemarksNm m·kg ft·lbUpper bracket and front fork M8 26 2.6 19Steering s
2 - 22SPECTIGHTENING TORQUESNOTE:1.First, tighten the ring nut to approximately 50 Nm (5.0 m • kg, 36 ft • lb) with a torque wrench, thenloosen the ri
2 - 23SPECLUBRICATION POINTS AND LUBRICANT TYPESEAS00031LUBRICATION POINTS AND LUBRICANT TYPESENGINELubrication point LubricantOil seal lipsLSO-ringsL
2 - 24SPECLUBRICATION POINTS AND LUBRICANT TYPESEAS00032CHASSISLubrication point LubricantSteering bearings and bearing races (upper and lower)LSFront
2 - 25SPECCOOLING SYSTEM DIAGRAMSEAS00033COOLING SYSTEM DIAGRAMS1Radiator fan2Radiator3Water pump
2 - 26SPECCOOLING SYSTEM DIAGRAMS1 Thermostat2 Radiator cap3 Coolant reservoir4 Radiator5 Oil cooler6 Water jacket joint
2 - 27SPECCOOLING SYSTEM DIAGRAMS1 Water pump2 Radiator cap3 Thermostat4 Thermostat housing
2 - 28SPECCOOLING SYSTEM DIAGRAMS1 Radiator
2 - 29SPECENGINE OIL LUBRICATION CHARTENGINE OIL LUBRICATION CHARTExhaust camshaftIntake camshaftPiston coolerMain galleryOil filterOilcoolerReliefval
EAS00008 SYMBOLSThe following symbols are not relevant toevery vehicle. Symbols 1 to 9 indicate the subject of eachchapter.1General information 2Speci
2 - 30SPECLUBRICATION DIAGRAMSEAS00034LUBRICATION DIAGRAMS1Intake camshaft2Exhaust camshaft3Oil filter cartridge4Oil level switch
2 - 31SPECLUBRICATION DIAGRAMS1 Intake camshaft2 Exhaust camshaft3 Crankshaft4 Oil cooler5 Oil pipe6 Oil strainer7 Oil pump
2 - 32SPECLUBRICATION DIAGRAMS1 Oil cooler2 Oil filter cartridge3 Oil level switch4 Oil strainer5 Oil pump6 Oil pipe
2 - 33SPECLUBRICATION DIAGRAMS1 Main axle2 Oil delivery pipe3 Drive axle
2 - 34SPECLUBRICATION DIAGRAMS1 Cylinder head2 Crankshaft
2 - 35SPECCABLE ROUTINGEAS00035CABLE ROUTING1Headlight drain plugÈMake sure to securely insertthe coupler and boot. ÉThe headlight lead can berouted b
2 - 36SPECCABLE ROUTING1 Handlebar switch (left)2 Main switch3 Throttle position sensor lead4 Guide-air5 Handlebar switch (right)6 Wiring section ! 7
2 - 37SPECCABLE ROUTINGÈ Route the horn lead under therib of bracket horn positioningthe stepped part of protectoroutside the rib.É Make the horn lead
2 - 38SPECCABLE ROUTINGÚ Route under the wire harnessto the assembling point !.Û Insert the holding clamp of thewire harness to the frame.Ü Fasten the
2 - 39SPECCABLE ROUTINGPass the filter of throttle bodythrough the hole of rubberbaffle and release it underthe ignition coil plate.Route the sub lead
2 - 40SPECCABLE ROUTING1 Turn signal light lead 2 Radiator hose3 Reservoir tank breather hose(L = 440)4 Clutch cable5 Crankshaft position sensorlead6
2 - 41SPECCABLE ROUTINGÔ To turn signal lightÕ In this area, pass the handlebar switch (right) lead behind of the throttle cable.Ö Route the coolant t
2 - 42SPECCABLE ROUTING1 Ignition coil plate2 Rubber baffle3 Assembling point ± 4 Assembling point ! 5 To wiring section ± 6 To wiring sections ±, # 7
2 - 43SPECCABLE ROUTINGÊ Clamp the air cleaner drainhose, fuel tank breather hose,drain hose, AI system hose, AIsystem lead and AC magneto.Route the a
2 - 44SPECCABLE ROUTINGÕ Point the tip of the band to theinner side.Ö Routing position of each hoseexcept the AI system hose isnot regulated in the cl
2 - 45SPECfor California1 Canister2 Roll over valve assembly3 Hose (fuel tank breather – canister)4 Hose (canister – roll over valve)5 Hose (roll over
3 - 1CHKADJEAS00036PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended checks and adjust
3 - 2CHKADJ* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE:From 24,000 mi (37,000
3 - 3CHKADJSEATSEAS00039SEATST R..7 Nm (0.7 m • kg, 5.1 ft • Ib)Order Job/Part Q’ty RemarksRemoving the seatsRemove the parts in the order listed.1 Pa
3 - 4CHKADJFUEL TANKEAS00040FUEL TANKT R..7 Nm (0.7 m • kg, 5.1 ft • Ib)T R..4 Nm (0.4 m • kg, 2.9 ft • Ib)T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)Order J
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