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2007 Yamaha XV1900 Roadliner & Stratoliner Service Manual

1. 2 17 CHASSIS TIGHTENING TORQUES eese 2 22 LUBRICATION POINTS AND LUBRICANT 5 2 27 zer p 2 27 CHASO 2 29 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 ENGINE OIL LUBRICATION 2 31 LUBRIGA TION DIAGRAM S aue eM DPI E EM 2 33 CABLE ROUTING KM E OF aes 2 45 EAS20280 GENERAL SPECIFICATIONS Model Model Dimensions Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius Weight With oil and fuel Maximum load GENERAL SPECIFICATIONS XV19SW 1D74 USA XV19SW 1076 CDN XV19SWC 1D75 California XV19W 4D45 USA XV19W 4D47 CDN XV19WC 4D46 California XV19MW 4D54 USA XV19MW 4056 CDN XV19MWC 4055 California XV19CTSW 2C54 USA XV19CTSW 2C56 CDN XV19CTSWC 2C55 California XV19CTW 4 04 USA XV19CTW 4P06 CDN XV19CTWC 4P05 California XV19CTMW 4P14 USA XV19CTMW 4 16 CDN XV19CTMWC 4P15 California 2580 mm 101 6 in 1100 mm 43 3 in 195 19 19 1100 mm 43 3 in XV19CTS C XV19CT C XV19CTM C 1515 mm 59 6 in 735 mm 28 9 in 1715 mm 67 5 in 155 mm 6 10 in 3480 mm 137 0 in XV19S C XV19 C XV19M C 340 0
2. a Turn the crankshaft b When the front and rear pistons are near TDC align the mark a on the generator drive gear of the crankshaft with the mark b on the generator shaft driven gear b DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 4 Install Generator rotor Refer to INSTALLING THE GENERATOR on page 5 75 5 Install Left balancer drive gear 1 Left balancer idle gear 2 Left balancer driven gear 3 NOTE Align the punch mark a on the left balancer drive gear with the punch mark b on the left balancer idle gear Align the punch marks c on the left balancer idle gear with the punch marks d on the left balancer driven gear 6 Tighten Left balancer drive gear bolt 1 Left balancer drive gear bolt 40 Nm 4 0 m kg 29 ft Ib NOTE While holding the generator rotor 2 with the sheave holder 3 tighten the left balancer drive gear bolt holder 4 90890 01701 Primary clutch holder YS 01880 A CLUTCH EAS25230 INSTALLING THE PRIMARY DRIVE GEAR 1 Install Washer e Straight key Primary drive gear Crankshaft position sensor rotor 1 e Spacer Primary drive gear bolt 72 Primary drive gear bolt 100 Nm 10 0 m kg 72 ft lb EC1D71007 CAUTION The timing marks on the crankshaft position sensor rotor must face outside NO
3. cu tn 3 20 ADJUSTING THE REAR DISC BRAISE 3 20 CHECKING THE BRAKE FLUID 3 20 CHECKING THE FRONT BRAKE 5 3 21 CHECKING THE REAR BRAKE PADS 3 21 CHECKING THE FRONT BRAKE 3 21 CHECKING THE REAR BRAKE HOSES 3 22 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 22 BLEEDING THE HYDRAULIC BRAKE 5 3 22 ADJUSTING THE SHIFT PEDAL mE es 3 23 ADJUSTING THE DRIVE BELT SEAQGIN 3 24 CHECKING AND ADJUSTING THE STEERING HEAD 3 25 CHECKING THE FRONT FORK i Peto peas ee 3 26 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3 27 CHECKING THE TIRES tae itt rois i dete es hos 3 27 CHECKING THE WHEELS 3 29 CHECKING AND LUBRICATING THE CABLES 3 29 LUBRICATING THE LEVER 5 nies 3 30 3 30 LUBRICATING THE SIDESTAIND siint 3 30 LUBRICATING THE REA
4. Disconnect the EXUP cables from the EXUP servo motor pulley b Disconnect the EXUP servo motor coupler from the wire harness c Connect the battery leads to the EXUP servo motor terminals as shown For counterclockwise rotation a Positive battery lead black green 1 Negative battery lead gt black red 2 For clockwise rotation b Positive battery lead black red 2 Negative battery lead gt black green 1 x B G B R d Check that the EXUP servo motor pulley ro tates several times in directions and b 7 90 ELECTRICAL COMPONENTS ECA14390 CAUTION To prevent damaging the EXUP servo motor perform this test within a few seconds of connecting the battery DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE INTAKE AIR PRESSURE SENSOR The following procedure applies to both of the in take air pressure sensors 1 Check e Intake air pressure sensor output voltage Out of specification Replace Intake air pressure sensor output voltage 3 75 4 25 V a Connect the pocket tester DC 20 V to the in take air pressure sensor coupler as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe pink white 1 or pink yellow Negative tester probe black blue 2 2 1 b
5. NN Oil pump housing cover 1 Oil scavenging pump outer rotor 1 Oil scavenging pump inner rotor 1 um 4 11 Pin 12 Oil pump housing cover 2 13 Relief valve spring 14 Relief valve Pin 5 96 OIL PUMP Disassembling the oil pump Nm 0 7 kg 5 1 ft Ib 7 Nm 0 7 kg 5 1 ft Ib Oil pump shaft 4 1 ur 157 For assembly reverse the disassembly pro cedure 5 97 EAS24960 CHECKING THE OIL PUMP 1 Check Oil pump housing Oil pump housing cover Cracks damage wear Replace the defec tive part s 2 Measure nner rotor to outer rotor tip clearance Outer rotor to oil pump housing clearance h Oil pump housing to inner rotor and outer rotor clearance c Out of specification Replace the oil pump Inner rotor to outer rotor tip clearance Less than 0 12 mm 0 0047 in Limit 0 20 mm 0 0079 in Oil pump housing to inner and outer rotor clearance 0 20 mm 0 0079 in Outer rotor to oil pump housing clearance 0 09 0 19 mm 0 0035 0 0075 in Limit 0 26 mm 0 0102 in 1 Inner rotor 2 Outer rotor 3 Oil pump housing OIL PUMP 3 Check Oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAS24970 CHECKING THE RELIEF VALVE 1 Check
6. 7 m S ANI 522 D af 727 27 2 47 OTF WN gt ODF TASOMONAARON Main switch lead Right handlebar switch lead Wire harness Left handlebar switch lead Air temperature sensor lead Front left turn signal position light lead Headlight lead Front right turn signal position light lead Headlight coupler high beam Headlight coupler low beam Air temperature sensor Main switch View with headlight lens unit removed Place the joint coupler behind the leads Place the sections of the handlebar switch leads that are not covered by their protective sleeves in the rear of the headlight housing Fasten the headlight leads front turn signal position light leads and accessory light lead with the holders along the side of the headlight housing Place the headlight leads front turn signal position light leads and accessory light lead near the base of the holder 30 mm 1 18 in View from rear of headlight lens unit Less than 20 mm 0 79 in Fasten the headlight lead low beam with the holder making sure to fasten the protective sleeve of the lead not the lead itself Route the headlight lead high beam between the headlight coupler beam and the stay Route the headlight lead high beam behind the headlight lead low beam Secure the plastic band by inserting the projection on the ban
7. 5 48 INSTALLING THE PISTONS AND CYLINDERS 5 48 CLUTCG e nee 5 50 REMOVING THE GLUTO H 5 60 REMOVING THE PRIMARY DRIVE 5 60 REMOVING THE LEFT BALANCER DRIVE 5 60 CHECKING TRE FRICTION PLATES oct 5 61 CHECKING THE CLUTCH PEAT ES ii tete eati bebes 5 61 CHECKING THE CLUTCH SPRING PLATE 5 61 CHECKING THE CLUTCH 5 62 CHECKING THE CLUTCH BOSS N nios 5 62 CHECKING THE PRESSURE PLATE 5 62 CHECKING THE CLUTCH PUSH RODS eene 5 62 CHECKING THE PRIMARY DRIVE 5 62 CHECKING THE PRIMARY DRIVEN 5 62 CHECKING THE LEFT BALANCER GEARS 5 62 INSTALLING THE LEFT BALANCER DRIVE 5 63 INSTALLING THE PRIMARY DRIVE 5 64 INSTALEING THE CLUTO eu i EU Ra ad 5 65 DISASSEMBLING THE CLUTCH MASTER CYLINDER 5 66 CHECKING THE CLUTCH MASTER CYLINDER 5 66 ASSEMBLING
8. 526640 REMOVING THE FUEL PUMP 1 Remove Fuel hose connector cover 2 Disconnect Fuel outlet hose EC1D71022 CAUTION Be sure to disconnect the fuel outlet hose by hand Do not forcefully disconnect the hose with tools Although the fuel has been removed from the fuel tank be careful when removing the fuel hoses since there may be fuel remain ing in them NOTE Remove the fuel hose manually without using any tools Before removing the hoses place few rags in the area under where they will be removed 3 Hemove Fuel pump ECA14720 CAUTION Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender EAS26670 CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Obstruction Clean Cracks damage Replace fuel pump as sembly 2 Check Diaphragms and gaskets Tears fatigue cracks Replace fuel pump assembly EAS26690 CHECKING THE FUEL PUMP OPERATION 1 Check Fuel pump operation Refer to CHECKING THE FUEL PUMP page 7 89 INSTALLING THE FUEL PUMP 1 Install Fuel pump Syr Fuel pump bolt 5 Nm 0 5 m kg 3 6 NOTE Do not damage the installation surfaces of the sub fuel tank when installing the fuel pump Always use a new fuel pump gasket FUEL TANK Install the fuel pump as shown in the illustra tion Align the projection on
9. a Remove the lock washer 1 the upper ring nut 2 and the rubber washer 3 3 N fe San Ld a 3 UN C 7 b Loosen lower ring nut 4 and then tight enitto the specified torque with a steering nut wrench 5 NOTE Set a torque wrench at a right angle to the steer ing nut wrench Steering nut wrench 90890 01403 Spanner wrench YU 33975 Lower ring nut initial tightening torque 52 Nm 5 2 m kg 37 ft lb C Loosen the lower ring nut completely and then tighten it to specification with a steering nut wrench EWA13140 Do not overtighten the lower ring nut CHASSIS Lower ring nut final tightening torque 18 Nm 1 8 m kg 13 ft lb d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD on page 4 69 e Install the rubber washer 3 f Install the upper ring nut g Finger tighten the upper ring nut 2 then align the slots of both ring nuts If necessary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 NOTE Make sure the lock washer tabs a sit correctly in the ring nut slots b q 7 2 2 Q
10. 8 2 PAU TY GEAR DING le 8 2 SHIFT PEDAL DOES nmn eua un qutm a 8 2 IS OUT OF GEAR A 8 2 0 at 8 2 OVE RRE ATIN I c KR REN 8 3 POOR BRAKING 8 3 FAULTY FRO n e 8 3 UNSTABLE HANDLING Pa 8 3 FAULTY LIGHTING OR SIGNALING SYSTEM EAS28450 TROUBLESHOOTING EAS28460 GENERAL INFORMATION NOTE The following guide for troubleshooting does not cover all the possible causes of trouble It should be helpful however as a guide to basic trouble shooting Refer to the relative procedure in this manual for checks adjustments and replace ment of parts EAS28470 STARTING FAILURES Engine 1 Cylinder s and cylinder head s Loose spark plug Loose cylinder head or cylinder e Damaged cylinder head gasket Damaged cylinder gasket Worn or damaged cylinder Incorrect valve clearance Improperly sealed valve Incorrect valve to valve seat contact Incorrect valve timing Faulty valve spring e Seized valve 2 Piston s and piston ring s Improperly installed piston ring Damaged worn or fatigued piston ring e Seized piston ring e Seized or damaged piston 3 Air filter Improperly installed air filter Clogged air filter element 4 Crankcase and crank
11. Cover the crankcase hole with a clean rag to prevent the straight key from falling into the crankcase Align the punch mark a on the camshaft driv en gear 1 with the punch mark b on the camshaft drive gear 2 Insert cross headed screwdriver into one of EAS24050 the holes in the outer camshaft driven gear and BLEEDING A VALVE LIFTER rotate the gear until the teeth of both driven A valve lifter must be bled in the following cases gears are aligned The teeth of both camshaft When installing a new valve lifter driven gears must be aligned for installation e When the valve lifter leaks oil mM 1 Bleed e Valve lifter a Fill a container with kerosene and place the valve lifter into the container as shown Pump the plunger side of the valve lifter with a press a number of times to let in kerosene ECA14630 CAUTION Do not pump the valve lifter excessively Kerosene is highly flammable 8 Tighten Camshaft driven gear bolt 1 ky KOrosene 2 Valve lifter Syr driven gear bolt b Install the valve lifter into the engine 60 Nm 6 0 m kg 43 ft Ib 5 29 ECA14650 CAUTION Be sure to install the valve lifter in its appro priate position c Start the engine and warm it up Stop the engine Remove the camshaft sprocket cover Rotate the camshaft until the punch
12. a Connect the pocket tester Q x 100 to the crankshaft position sensor coupler as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C 7 84 a Connect the lean angle sensor coupler to the wire harness b Connect the pocket tester DC 20 V to the lean angle sensor coupler as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe yellow green 1 Negative tester probe black blue 2 c Turn the lean angle sensor to 65 d Measure the lean angle sensor output volt age DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE STARTER MOTOR OPERATION 1 Check e Starter motor operation Does not operate Perform the electric starting system troubleshooting starting with step 5 Refer to TROUBLESHOOTING on page 7 11 Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 EWA13810 wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA ELECTRICAL COMPONENT
13. 1 1 dem N 21 1 93 09 u fo ufo ufo E E MM ER 08990 x 7 7 Main switch Main fuse Battery Starter relay 9 Starter motor 10 Diode 1 11 Relay unit 12 Starting circuit cut off relay 14 Neutral switch 15 Diode 2 16 Sidestand switch 27 ECU electronic control unit 54 Clutch switch 68 Engine stop switch 69 Start switch 77 gnition fuse 81 ECU fuse ELECTRIC STARTING SYSTEM 7 8 ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT OFF SYSTEM OPERATION If the engine stop switch is set to O and the main switch is turned ON both switch circuits are closed the starter motor can only operate if at least one of the following conditions is met The transmission is in neutral the neutral switch circuit is closed The clutch lever is pulled to the handlebar the clutch switch circuit is closed and the sidestand is up the sidestand switch circuit is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay stays open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be started by pushing the start switch 7 9 9 NA E WHEN THE TRANSM
14. gt gt gt gt gt 7 23 SIGNALING SYSTEM Replace the fuse s Clean the battery terminals Recharge or replace the battery Replace the main switch Properly connect or repair the signaling system wiring The horn switch is faulty Replace the left handlebar switch 2 Check the horns Refer to CHECKING THE HORNS on page 7 86 OK Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 21 OK This circuit is OK The tail brake light fails to come on 1 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 7 71 OK 2 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 7 71 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 21 OK This circuit is OK SIGNALING SYSTEM gt Replace the horn s gt connect or repair the signaling system wiring gt Replace front brake light switch gt Replace the rear brake light switch gt Properly connect or repair the signaling system wiring The turn signal light turn signal indicator light or both fail to blink 1 Check the condition of each bulb and bulb socket Refer to CHECKING THE BULBS AND BULB SOCKETS on page 7 74 OK Check the turn signal s
15. 4 71 INSTALLING THE STEERING ere EUR Der Me EPA 4 71 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM 4 73 HANDLING THE REAR SHOCK ABSORBER esses 4 76 DISPOSING OF A REAR SHOCK ABSORBER 4 76 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY AND SVINGA IN prt 4 76 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 77 CHECKING THE CONNECTING ARM AND RELAY ARM 4 77 CHECKING THE 5 4 77 INSTALLING THE RELAY ARM REAR SHOCK ABSORBER ASSEMBLY AND CONNECTING 4 77 INS TAELING SWINGARM 4 79 2 nh m e 4 80 REMOVING THE DRIVE BELT AND DRIVE PULLEY 4 82 CHECKING THE DRIVE BELT eu ERE Uta 4 82 INSTALLING THE DRIVE BELT AND DRIVE PULLEY 4 82 GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the windshield For XV19CTS C XV19CT C XV19CTM C 23 Nm 2 3 m kg 17 ft Ib 23 Nm 2 3 m kg 17 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib Job Parts to remove Q ty 2 4 5 Windshield screen E Windshield holder bracket assembly and 2 right For installation reverse the removal proce du
16. oly Ade Drain Engine oil Refer to CHANGING THE ENGINE OIL on page 3 11 Drain Transfer gear oil Refer to CHANGING THE TRANSFER GEAR OIL on page 3 14 Muffler Exhaust pipes Refer to REMOVAL on page 5 1 Clutch release cylinder ZEN Refer to on page 5 50 EN Drive pulley BEEN Refer to BELT DRIVE on page 4 80 wmewswews we ER mem 7 5 81 TRANSFER GEAR CASE Removing the middle driven shaft E 18 Nm 1 8 kg 13 ft Ib 5 y 8 Nm 0 8 kg 5 8 ft Ib 10 Nm 1 0 kg 7 2 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 40 Nm 4 0 kg 29 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib oer Www _ Oma 39 mE For installation reverse the removal proce dure 5 82 TRANSFER GEAR CASE Disassembling the transfer gear oil pump 4 Nm 0 4 kg 2 9 ft Ib Rm ansergearotpumpoueror p 9 Washer Transfer gear oil pump shaft Transfer gear oil pump housing For assembly reverse the disassembly pro cedure I 5 83 TRANSFER GEAR CASE Removing the transfer gear case 10 Nm 1 0 m kg 7 2 ft Ib 10 Nm 1 0 m kg 7 2 ft
17. Out of specification gt Replace the crank case assembly NOTE Measure the inside diameter of each crankshaft journal bearing at two places Crankshaft journal bearing inside diameter 50 010 50 030 mm 1 9689 1 9697 in 5 104 JP 1 V lt e 7 Calculate e Crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft and crankshaft journal bearings as a set NOTE Calculate the clearance by subtracting the crankshaft journal diameter from the crankshaft journal bearing inside diameter Crankshaft journal to crankshaft journal bearing clearance 0 030 0 060 mm 0 0012 0 0024 in EAS26150 INSTALLING THE CONNECTING RODS 1 Lubricate Bolt threads with the recommended lubricant Recommended lubricant Molybdenum disulfide grease 2 Lubricate Crankshaft pins Big end bearings Connecting rod inner surface with the recommended lubricant Recommended lubricant Engine oil 3 Install Big end bearings Connecting rods Connecting rod caps onto the crankshaft pins NOTE Align the projections a on the big end bear ings with the notches b in the connecting rods and connecting rod caps CRANKSHAFT Be sure to reinstall each big end bearing in its original place Make sure the projection c on the connecting rods face towards the left
18. 7 E 7 4 s reeeo N Reflector Reflector bracket Front brake caliper mE For installation reverse the removal proce dure 4 34 FRONT BRAKE Disassembling the front brake calipers 6 Nm 0 6 m kg 4 3 ft Ib The following procedure applies to both of the front brake calipers E T 3 5 For assembly reverse the disassembly pro cedure n 4 35 EAS22220 INTRODUCTION EWA14100 Disc brake components rarely require disas sembly Therefore always follow these pre ventive measures Never disassemble brake components un less absolutely necessary If any connection on the hydraulic brake system is disconnected the entire brake system must be disassembled drained cleaned properly filled and bled after reas sembly Never use solvents on internal brake com ponents Use only clean or new brake fluid for clean ing brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury FIRST AID FOR BRAKE FLUID ENTERING THE EYES Flush with water for 15 minutes and get im mediate medical attention EAS22240 CHECKING THE FRONT BRAKE DISCS The
19. 45 a Top ring b Upper oil ring rail c Oil ring expander d Lower oil ring rail e 2nd ring A forward 5 Install Cylinder 1 NOTE While compressing the piston rings with one hand install the cylinder with the other hand 5 49 CLUTCH EAS25060 CLUTCH Removing the clutch cover 12 Nm 1 2 kg 8 7 ft Ib Job Parts to remove Drain Engine oil Refer to CHANGING THE ENGINE OIL on page 3 11 EE Tuum to GENERAL CHASSIS on page Refer to THROTTLE BODIES on page 6 6 Horn 1 Canister For California only Fuel tank Sub fuel tank Refer to FUEL TANK on page 6 1 DERE Left rider footrest assembly Shift rod Sidestand Refer to ENGINE REMOVAL on page 5 1 Refer to GENERATOR AND STARTER Refer to TRANSFER GEAR CASE on page 5 81 4 Clutch cover gasket 5 50 CLUTCH Removing the clutch cover 12 Nm 1 2 kg 8 7 ft Ib Job Parts to remove dure R2 For installation reverse the removal proce 5 51 CLUTCH Removing the crankshaft position sensor 10 Nm 1 0 m kg 7 2 ft Ib 9 4604 9 Job Parts to remove Q ty Clutch cover damper plate Clutch cover damper 1 5 Crankshaft position sensor lead holder 6 Crankshaft position sensor For installation reverse the removal proce dure 5 52 CLUTCH Remo
20. 6iov18 eg DADA x 115 16 uo Cp gro 145 a 1 GI9 4 OOP LET oig AL 4 G2 GC n me 19 1 a 28 09 EI 19 foro BE QIS wio 1 4 GD p yg 1 4 1 1 1 Gma 9 9 Y Bil END 7 27 Main switch Main fuse Battery 7 Fuel injection system fuse 11 Relay unit 12 Starting circuit cut off relay 13 Fuel pump relay 14 Neutral switch 15 Diode 2 16 Sidestand switch 17 Fuel pump 19 Crankshaft position sensor 20 Throttle position sensor 21 Cylinder 1 intake air pressure sensor 22 Cylinder 2 intake air pressure sensor 23 Lean angle sensor 24 Speed sensor 25 Air temperature sensor 26 Engine temperature sensor 27 ECU electronic control unit 28 Cylinder 1 left ignition coil 29 Cylinder 1 right ignition coil 30 Cylinder 2 left ignition coil 31 Cylinder 2 right ignition coil 32 Spark plug 33 15 idle speed control unit 34 EXUP servo motor 35 Injector 1 36 Injector 2 37 sensor 40 Multi function meter 41 Reset switch 42 Engine trouble warning light 52 Headlight relay 55 Dimmer switc
21. Fuel tank Refer to FUEL TANK on page 6 1 3 Remove Cylinder 1 intake air pressure sensor brack et 1 Cylinder 2 intake air pressure sensor brack et 2 d Hold the adjusting screw to prevent it from Me 2 moving and tighten the locknut to specifica N tion 1 SA Cs i Locknut rocker arm adjusting screw 20 Nm 2 0 m kg 14 ft Ib pom J Tappet adjusting tool 4 mm 90890 04133 4 Disconnect Valve adjustment wrench 3 mm amp Cylinder 1 intake air pressure sensor hose 4mm 1 08035 Cylinder 2 intake air pressure sensor hose 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 DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 13 Install 1 All removed parts Refer to CAMSHAFTS on page 5 14 NOTE For installation reverse the removal procedure 5 Install YS Hose 1 Parts No 5JW 2431 1 00 3 way joint 2 Parts No 90413 05014 SYNCHRONIZING THE THROTTLE BODIES e Vacuum gauge hose for 1 3 NOTE Vacuum gauge hose for 2 4 Prior to synchronizing the throttle bodies the 2 Cylinder 2 intake air pressure sensor hose should be properly adjusted and the ignition tim P ing should be
22. 7 1 1 0 0 lt lt 2 NO s N 4d Lower front fork cover bolt Drive pulley nut Drive pulley cover damper plate screw B lt TIGHTENING TORQUES Thread size Drive pulley cover bolt 10 Nm 1 0 m kg 7 2 ft Ib Rectifier regulator cover bolt 6 6 10 Nm 1 0 m kg 7 2 ft lb ead cover bolt M6 ____ 6 2 Q ty Tightening torque 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 2 2 Sm 05 mig 86 f cable guide bolt upper 7 Nm 0 7 m kg 5 1 ft lb a i cable guide bolt lower M6 10 Nm 1 0 7 2 ft lb Rear shock absorber locknut 1 30 Nm 3 0 m kg 22 ft lb Windshield holder bracket as sembly 30 Nm 3 0 m kg 22 ft lb Windshield brace mu 72 6 8 Nm 0 8 m kg 5 8 ft lb Backrest upper bracket and back rest lower bracket bolt 4 23 Nm 2 3 m kg 17 ft lb M M M M CO Backrest pad and backrest up per bracket 10 Nm 1 0 m kg 7 2 ft lb Backrest pad and backrest up per bracket stay bolt 10 Nm 1 0 m kg 7 2 ft lb Backrest lock nut M24 12 Nm 1 2 m kg 8 7 ft lb Passenger footrest and sidebag M10 47 Nm 4 7 m kg 34 ft lb 23 Nm 2 3 m kg 17 ft lb 23 Nm 2 3 m kg 17 ft lb bracket bolt left and right Sidebag bracket Sidebag bracket bra
23. Job Parts to remove Q ty 00000 83 Brake 4 Ode For assembly reverse the disassembly cedure 4 46 REAR BRAKE Removing the rear brake caliper 27 Nm 2 7 kg 19 ft Ib Omer Job Parts to remove NEN BRAKE SYSTEM on page 3 22 1 Reriehwewinbd ee NM _____________ mE For installation reverse the removal proce dure 4 47 REAR BRAKE Disassembling the rear brake caliper 6 Nm 0 6 m kg 4 3 ft Ib Job Parts to remove 1 Brake caliper piston e 2 _ 2 E Bleed screw For assembly reverse the disassembly pro cedure 4 48 EAS22560 INTRODUCTION EWA14100 Disc brake components rarely require disas sembly Therefore always follow these pre ventive measures Never disassemble brake components un less absolutely necessary If any connection on the hydraulic brake system is disconnected the entire brake system must be disassembled drained cleaned properly filled and bled after reas sembly Never use solvents on internal brake com ponents Use only clean or new brake fluid for clean ing brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid imm
24. The charging system circuit is OK system wiring 7 15 CHARGING SYSTEM LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM EAS27240 EAS27250 8 8 T ovas 1 69 E 09 160 149 TURNS d o Wigs 4 CL i esu o E 19 mon oN 8 Hafan 1 i 09 a ova va ans 1 8 giu au giu ad E EE a t 95 9 1 8 1 8 7 9 0 9 9 o E DER 9 1 4 JI Ya 9 4 9 5 NMA AN IN CWI 1 7 17 3 Main switch 4 Main fuse 6 Battery 27 ECU electronic control unit 44 Meter light 47 High beam indicator light 52 Headlight relay 55 Dimmer switch 59 Front right turn signal position light 60 Front left turn signal position light 64 Headlight high beam 65 Headlight low beam 70 Accessory light switch 71 Accessory light OPTION 72 Tail brake light 73 plate light 78 Headlight fuse 79 Signaling system fuse 80 Taillight fuse 81 ECU fuse 7 18 LIGHTING SYSTEM EAS27260 TROUBLESHOOTING LIGHTING SYSTEM Any of the following fail to light headlight high beam headlight low beam hi
25. 4 50 DISASSEMBLING THE REAR BRAKE 4 50 CHECKING THE REAR BRAKE 4 51 ASSEMBLING THE REAR BRAKE 4 51 INSTALLING THE REAR BRAKE 4 51 REMOVING THE REAR BRAKE MASTER CYLINDER 4 52 CHECKING THE REAR BRAKE MASTER CYLINDER 4 52 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 53 INSTALLING THE REAR BRAKE MASTER CYLINDER 4 53 HANDLEBAR iiiter dtu 4 55 REMOVING TEE HANDLEBAR iiti 4 57 CHECKING THE HANDLEBAR oe redo 4 57 INSTALLING THE HANDLEBAR tiet ica cops 4 57 FRONT FORK HR 4 60 REMOVING THE FRONT FORK 5 eene 4 64 DISASSEMBLING THE FRONT FORK 4 64 CHECKING THE FRONT FORK LEGS 4 65 ASSEMBLING THE FRONT FORK LEGS eee 4 65 INSTALLING THE FRONT FORK LEGS 4 68 STEERING HEAD sro pite E NOS qu RARE UPS 4 69 REMOVING THE LOWER atr SECURE 4 71 CHECKING THE STEERING EAD thru Sn
26. 7 90 IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM 60v 18 amp 8 c coc r 1 41 mo d OOF JOVIS 69 109 L 9 Bel wra 69 69 42 gt JA M 8 A oe 9 a maze Bo 6 GO Lm 9 X p 1 L en C icu 4 EEE 1 1 1 4 09 CED 8 I Bs 7 1 3 Main switch 4 Main fuse 6 Battery 11 Relay unit 14 Neutral switch 16 Sidestand switch 19 Crankshaft position sensor 23 Lean angle sensor 27 ECU electronic control unit 28 Cylinder 1 left ignition coil 29 Cylinder 1 right ignition coil 30 Cylinder 2 left ignition coil 31 Cylinder 2 right ignition coil 32 Spark plug 68 Engine stop switch 77 gnition fuse 81 ECU fuse 7 2 IGNITION SYSTEM IGNITION SYSTEM ET1D71043 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear the engine will stop if the sidestand is moved down This is because the electric current from the igni
27. Error is detected while reading or writing on EE PROM CO adjustment val ue Power supply to the fuel in jection system is not nor mal Faulty ECU memory When this malfunction is detected in the ECU the fault code number might not appear on the meter No signals are received from the ECU FUEL INJECTION SYSTEM Probable cause of malfunction Open or short circuit in wire sub lead Open or short circuit in wire harness Malfunction in cylinder 22 left or right igni tion coil Malfunction in ECU Malfunction in a component of ignition cut off circuit system Open circuit in wire harness Malfunction in throttle body Malfunction in throttle cables SC valve is stuck fully open due to discon nected ISC unit hose or coupler High en gine idle speed is detected with the ISC valve stuck fully open even though signals for the valve to close are continuously being transmitted by the ECU Malfunction in ECU ECU fuse is blown Open or short circuit in wire harness Defective lean angle sensor Malfunction in ECU Open circuit in wire harness Defective speed sensor Malfunction in vehicle speed sensor detect ed Defective neutral switch Malfunction in the engine side of the neutral switch Malfunction in ECU Open or short circuit in wire harness Malfunction in ECU Malfunction in ECU The CO adjustment
28. Hg a BH EL Bm lt 0 0 0 0 9 9 o 09 09 85 g C d O nd 0 0 09 4 4 5 m ml m ___ 0 m H zl T gt gt gt EE ei a tr tr a 045 5 1 Li a eel gt S 5 66 EAS28740 WIRING DIAGRAM XV19SW C XV19W C XV19MW C XV19CTSW C XV19CTW C XV19CTMW C 2007 1 AC magneto Rectifier regulator Main switch Main fuse Backup fuse odometer and clock Battery Fuel injection system fuse Starter relay Starter motor 10 Diode 1 11 Relay unit 12 Starting circuit cut off relay 13 Fuel pump relay 14 Neutral switch 15 Diode 2 16 Sidestand switch 17 Fuel pump 18 Fuel sender fuel pump 19 Crankshaft position sensor 20 Throttle position sensor 21 Cylinder 1 intake air pressure Sensor 22 Cylinder 2 intake air pressure Sensor 23 Lean angle sensor 24 Speed sensor 25 Air temperature sensor 26 Engine temperature sensor 27 ECU electronic control unit 28 Cylinder 1 left ignition coil 29 Cylinder 1 right ignition coil 30 Cylinder 2 left ignition coil 31 Cylinder 2 right ignition coil 32 Spark plug 33 ISC idle speed contro
29. Relief valve body Relief valve Relief valve spring Damage wear Replace the defective part s 1071035 CHECKING THE BALL SPRING AND RELIEF VALVE SPRING 1 Measure Ball spring free length Relief valve spring free length Out of specification Replace the defective part s Ball spring Free length 34 70 mm 1 37 in Limit 32 97 mm 1 30 in Relief valve spring Free length 28 95 mm 1 14 in Limit 27 50 mm 1 08 in a Free length 5 98 2 Measure Ball spring force Relief valve spring force Out of specification Replace the defective part s Ball spring Installed compression spring force 2 23 N 0 60 Ib 0 27 kgf or less Installed length 29 4 mm 1 12 in Relief valve spring Installed compression spring force 52 4 N 11 78 Ib 5 34 kgf or less Installed length 16 8 mm 0 66 in a Spring force b Installed length EAS24990 CHECKING THE OIL STRAINER 1 Check e Oil strainer 1 Damage Replace Contaminants Clean with solvent EAS25000 ASSEMBLING THE OIL PUMP 1 Lubricate e Inner rotor e Outer rotor 5 99 OIL PUMP Oil pump shaft with the recommended lubricant Recommended lubricant Engine oil 2 Install Oil pump housing 2 1 Ball guide 2 Ball 3 Oil seal 4 Circlip 5 Oil seal 6 Oil pump shaft 7 Pin 8 Oil feed pump inner rotor 9
30. Washer 3 Engine mounting bolt rear lower side 4 Engine mounting nut rear lower side 5 Engine mounting bolt front lower side 6 Engine mounting nut front lower side 7 Engine brackets rear upper side 8 Engine bracket bolts rear upper side 9 Engine bracket nuts rear upper side 10 Engine mounting bolt rear upper side 11 Engine mounting nut rear upper side 12 Engine bracket left upper side 13 Engine mounting bolts left upper side 14 Engine bracket bolts left upper side 15 Engine bracket right upper side 16 Engine mounting bolts right upper side 17 Engine bracket bolts right upper side 18 NOTE Lubricate the engine mounting bolt front lower side threads and nut with engine oil Apply locking agent LOCTITES to the threads of the engine mounting bolts left upper side Do not fully tighten the bolts and nuts 2 Remove Engine mounting nut front lower side 7 5 12 ENGINE REMOVAL 3 Tighten Spacer bolt 1 Spacer bolt 18 Nm 1 8 m kg 13 NOTE Tighten the spacer bolt 1 to specification with a pivot shaft wrench When tightened the spacer bolt should be flat against the engine surface Pivot shaft wrench 90890 01485 Frame mount insert wrench YM 01485 4 Tighten Engine mounting nut rear lowe
31. Brake caliper piston seals 2 EW1D71001 Do not loosen the bolts 3 Blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper 13560 Cover the brake caliper pistons with a rag Be careful not to get injured when the pis tons are expelled from the brake caliper Never try to pry out the brake caliper pis tons 4 38 b Remove brake caliper piston seals DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA ae EAS22390 CHECKING THE FRONT BRAKE CALIPERS Recommended brake component replace ment schedule Brake pads If necessary Every two years and Brake fluid whenever the brake is disassembled 1 Check Brake caliper pistons 1 Rust scratches wear Replace the brake caliper pistons Brake caliper cylinders 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air EWA13600 A WARNING Whenever a brake caliper is disassembled replace the piston seals 4 39 FRONT BRAKE EAS22410 ASSEMBLING THE FRONT BRAKE CALIPERS EWA13620 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fl
32. Refer to CHECKING THE SPARK PLUGS on page 3 9 OK 4 Re gap or replace the spark plug s Check the ignition spark gap OK gt Refer to CHECKING THE IGNI TION SPARK GAP on page 7 82 Ignition system is OK Check the spark plug caps gt Refer to CHECKING THE SPARK PLUG CAPS on page 7 83 OK Replace the spark plug cap s Check the ignition coils NG gt Refer to CHECKING THE IGNI TION COILS on page 7 83 OK 4 Replace the ignition coil s 7 Check the crankshaft position sen NG sor Refer to CHECKING THE CRANK Replace the crankshaft position sensor SHAFT POSITION SENSOR on page 7 84 OK 7 4 8 Check the main switch gt Refer to CHECKING THE SWITCHES on page 7 71 OK Check the engine stop switch gt Refer to CHECKING THE SWITCHES on page 7 71 10 Check the neutral switch gt Refer to CHECKING THE SWITCHES on page 7 71 11 Check the sidestand switch gt Refer to CHECKING THE SWITCHES on page 7 71 OK 12 Check the relay unit diode gt Refer to CHECKING THE DI ODES on page 7 81 13 Check the lean angle sensor gt Refer to CHECKING THE LEAN ANGLE SENSOR on page 7 84 14 Check the entire ignition system gt wiring Refer to CIRCUIT DIAGRAM on page 7 1 OK Replace the ECU 7
33. Replace 2 Check Cable operation Rough movement Lubricate Recommended lubricant Engine oil or a suitable cable lu bricant 3 29 Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubricating device EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal to metal moving parts of the levers Recommended lubricant Lithium soap based grease EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal to metal moving parts of the pedal Recommended lubricant Lithium soap based grease EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand Recommended lubricant Lithium soap based grease EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension Recommended lubricant Lithium soap based grease S NOTE Lubricate the pivoting points and contact surfac es between the connecting rod and frame and between the swingarm and frame 3 30 CHASSIS EAS21750 ELECTRICAL SYSTEM EAS21760 CHECKING AND CHARGING THE BATTERY Refer to ELECTRICAL COMPONENTS on page 7 67 EAS21770 CHECKING THE FUSES Refer to ELECTRICAL COMPONENTS page 7 67 EAS21790 REPLACING THE HEADLIGHT BULBS 1 Remove e Windshield For XV19CTS C XV19CT C XV19CTM C Ref
34. Rider seat Tool kit tray Rider seat bracket assembly Left side cover Headlight assembly Check the fuses Main fuel injection system ignition and ECU Refer to CHECKING THE FUS ES on page 7 75 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 76 Check the main switch Refer to CHECKING THE SWITCHES on page 7 71 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 7 71 Check the relay unit fuel pump lay Refer to CHECKING THE RE 5 on page 7 79 OK 4 Check the diode 2 Refer to CHECKING THE DI 5 on page 7 81 Check the fuel pump Refer to CHECKING THE FUEL PUMP on page 7 89 gt gt gt gt gt gt gt 7 65 FUEL PUMP SYSTEM Replace the fuse s Clean the battery terminals Recharge or replace the battery Replace the main switch The engine stop switch is faulty Replace the right handlebar switch the relay unit Replace the diode 2 Replace the fuel pump assembly FUEL PUMP SYSTEM 8 Check the entire fuel pump system NG wiring Properly connect or repair the fuel pump Refer to CIRCUIT DIAGRAM on system wiring page 7 63 OK Replace the 7 66 ELECTRICAL COMPONEN
35. Shift arm NOTE Clutch cover While holding the generator rotor 2 with the Clutch cover gasket sheave holder 3 loosen the primary drive gear bolt EAS20100 SYMBOLS 5 2 with engine mounted Filling fluid The following symbols are used in this manual 3 Lubricant for easier understanding 4 Special tool NOTE 5 Tightening torque The following symbols are not relevant to every 6 Wear limit clearance vehicle 7 Engine speed 8 Electrical data 9 Engine oil 10 Gear oil 9 c JN 15 1 n New 11 Molybdenum disulfide oil 12 Wheel bearing grease 13 Lithium soap based grease 14 Molybdenum disulfide grease 15 Apply locking agent LOCTITE 16 Replace the part GENERAL INFORMATION 1 SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS IK CHASSIS FUEL SYSTEM o ELECTRICAL SYSTEM TROUBLESHOOTING 8 GENERAL INFORMATION IDENTIFICATION ER OR 1 1 VEHICLE IDENTIFICATION 1 1 MODEL LABEL N td de UE 1 1 2 NRU LIH 1 2 OUTLINE tice edita ure EM eus 1 2 mea OTEN cT E 1 3 M aD E Lem ERES 1 4 IMPORTANT INFORMATION
36. amp x bearings looseness Check belt tension um soap based grease every 16000 mi 25000 km or 24 E lithium soap based Brake and shift all pedal pivot shafts all purpose grease Check operation Sidestand pivot Check bearing for looseness P EP Steering bearings Moderately repack with lithi months Check all chassis fitting and Chassis fasteners fasteners Correct if necessary Apply lithium soap based Brake and clutch s lever pivot all purpose grease Apply lithium soap based grease all purpose grease lightly Check Sn and replace Check and for oil leakage y y Replace if necessary Shock absorber Check operation and for oil assembl leakage y if necessary Rear suspension Apply lithium soap based link pivots grease Engine oil filter RENI RN Check for leakage Change initia 600 mi 1000 Transfer case oil km or 1 month and thereaf Change Change ter every 16000 mi 25000 km or 24 months Front and rear 23 brake switches Check Check operation 0000 Yamaha chain and ca Control cables ble lube or engine oil SAE y y y 10W 30 thoroughly Check operation and free Throttle grip housing and ca ble GIRO play Adjust the throttle cable free play if necessary Lubricate the thrott
37. mM For installation reverse the removal proce dure 5 2 ENGINE REMOVAL Removing the cylinder 1 ignition coils and sidestand 7 Nm 0 7 m kg 5 1 ft Ib 12 Nm 1 2 kg 8 7 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 16 Nm 1 6 kg 11 ft Ib 13 Nm 1 3 m kg 9 4 ft Ib C t 48 Nm 4 8 kg 35 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 18 Nm 1 8 m kg 13 ft Ib MEN Rider seat Left side cover Battery box Air filter Refer to GENERAL CHASSIS on page case 4 1 7 Fuel tank Sub fuel tank Refer to FUEL TANK on page 6 1 Throttle body Intake manifold Pressure regula a tor bracket Rollover valve Canister Refer to THROTTLE BODIES on page 6 6 Rear brake master cylinder bracket Refer to REAR BRAKE on page 4 43 Drive pulley Refer to BELT DRIVE on page 4 80 Drain Engine oil Refer to CHANGING THE ENGINE OIL on page 3 11 Drain Transfer gear oil Refer to CHANGING THE TRANSFER GEAR OIL on page 3 14 EE EE Heer to ELECTRIC STARTER on page 2 Swap 7 3 4 s I N 5 3 ENGINE REMOVAL Removing the cylinder 1 ignition coils and sidestand 7 Nm 0 7 m kg 5 1 ft Ib 12 Nm 1 2 kg 8 7 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 16 Nm 1 6 kg 11 ft Ib 13 Nm 1 3
38. 51 Turn signal relay 56 Turn signal switch 57 Horn switch 59 Front right turn signal position light 60 Front left turn signal position light 61 Rear right turn signal light 62 Rear left turn signal light 67 Front brake light switch 72 Tail brake light 74 brake light switch 77 gnition fuse 79 Signaling system fuse 81 ECU fuse p 7 22 SIGNALING SYSTEM EAS27290 TROUBLESHOOTING Any of the following fail to light turn signal light brake light or an indicator light he horn fails to sound The fuel level gauge fails to operate The speedometer fails to operate NOTE Before troubleshooting remove the following part s Rider seat Tool kit tray Rider seat bracket assembly Headlight assembly Fuel tank Check the fuses Main backup ignition signaling system and ECU Refer to CHECKING THE FUS ES on page 7 75 OK 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 76 OK Check the main switch Refer to CHECKING THE SWITCHES on page 7 71 OK 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 21 Check the condition of each of the sig naling system s circuits Refer to Checking the signaling system Checking the signaling system The horn fails to sound 1 Check the horn switch Refer to CHECKING THE SWITCHES on page 7 71
39. 54 ISC valve This operation takes approxi mately 12 seconds until it is completed The ISC unit vibrates when the ISC valve operates Illuminates the engine trou ble warning light EAS27460 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter Check and service the items or components that are the probable cause of the malfunction following the order given After the check and service of the malfunctioning part has been completed reset the meter display ac cording to the reinstatement method Fault code No Code number displayed on the meter when the engine failed to work normally Refer to Self Diagnostic Function table Diagnostic code No Diagnostic code number to be used when the diagnostic mode is operated Refer to DIAGNOSTIC MODE on page 7 33 7 40 FUEL INJECTION SYSTEM Fault code No Symptom normal signals are received from the crankshaft posi tion sensor Item components and probable Check or maintenance job Reinstatement method Installed condition of crankshaft posi Check for looseness or pinching Cranking the Connections Check the coupler for any pins Crankshaft position sensor coupler that may be pulled out Main wire harness ECU coupler Check the locking condition of the coupler f there is malfunction repair it and connect the coupler se curely Open or short circuit in wire harness Repair or repla
40. CABLE ROUTING on page 2 45 Refer to ENGINE REMOVAL on page 5 1 7 Install e Transfer gear case Drive pulley case Refer to TRANSFER GEAR CASE on page 5 81 8 Install Drive pulley e Transfer gear case bracket Refer to BELT DRIVE on page 4 80 ENGINE REMOVAL 9 Tighten Engine bracket nut front upper side 3 e Engine cross member bracket bolts 5 Engine mounting nut front upper side 7 Engine bracket nut front upper side 53 Nm 5 3 m kg 38 ft lb Engine cross member bracket bolt 30 Nm 3 0 m kg 22 ft lb LOCTITE Engine mounting nut front upper side 98 Nm 9 8 m kg 71 ft lb CAMSHAFTS EAS23750 CAMSHAFTS Removing the camshaft sprocket cover 18 Nm 1 8 m kg 13 ft Ib 7 e 2 A 10 Nm 1 0 m kg 7 2 ft Ib Omer Job Parts to remove 7 Fuel tank 7 Refer to FUEL TANK on page 6 1 NEM mom ME Refer to GENERAL CHASSIS on Muffler Exhaust pipes Refer to ENGINE REMOVAL on page 5 1 e fenm OOOO Shitpedalassembiy 6 Timing mark accessing screw Gamshatt sprocket cover 9 12 mE For installation reverse the removal proce dure 5 14 CAMSHAFTS Removing the cylinder head covers 7 Nm 0 7 kg 5 1 ft Ib Cylinder head breather hose Oil tank breather hose Disconnect Wire harness guide Fuel
41. Headlight lens unit Wwietunsspe 7 T _ 9 Wire harness stopper bracket 4 WsWemwrwi ue Wes dure N 4 10 GENERAL CHASSIS Removing the battery Tool kit tray Seat bracket to GENERAL CHASSIS on page 3 EU p _ 2 Gwen p _ 4 39 Wee 7 p _ s 70 3 p mer _ 4 11 GENERAL CHASSIS Removing the battery Job Parts to remove Q ty Plastic locking tie For installation reverse the removal proce dure 4 12 GENERAL CHASSIS Removing the air filter case Job Parts to remove Fuel tank E 2 mu C e Wesen 1 Grinder ai pressure sensor couier T 4 Grinders intake air pressure sensorhose T air pressure sensor T 7 6 3 3 3 9 3 3 3 3 14 Refer to GENERAL CHASSIS on page 4 1 Refer to FUEL TANK on page 6 1 Refer to THROTTLE BODIES on page 6 6 Disconnect Disconnect Dis
42. Hose guide and lower handlebar Front brake master cylinder hold 10 Nm 1 0 m kg 7 2 ft lb mE er bolt Front brake hose union bolt front brake master cylinder side 2 mE Clutch master cylinder holder bolt 10 Nm 1 0 m kg 7 2 ft Ib 23 17 Lower handlebar holder nut 50 Nm 5 0 m kg 36 ft lb Upper bracket cover bolt 2 19 Nm 1 9 m kg 13 ft Ib Upper bracket cover bolt 16 Nm 1 6 m kg 11 ft Ib d Front brake hose guide and front brake hose guide bracket bolt KG ee REND Front brake hose guide and lower Front brake hose joint bolt 1 10 Nm 1 0 m kg 7 2 ft lb Bolt lower bracket hole 16 Nm 1 6 m kg 11 ft Ib Front fender stay bolt 7 Nm 0 7 m kg 5 1 ft lb ONE IR Fo Front fender bolt 16 Nm 1 6 m kg 11 ft lb Fuel sender bolt 4 Nm 0 4 m kg 2 9 ft Ib 2 23 TIGHTENING TORQUES Thread a size ly Fuel tank bracket bolt front side 16 Nm Fuel tank bracket nut rear side 10 Nm Sub fuel tank bolt 3 6 3 Hider seat bracket bolt 23 Nm 2 Tightening torque 1 6 m kg 11 ft lb 4 1 0 m kg 7 2 ft lb i 10 Nm 1 0 m kg 7 2 ft lb BEN 2 3 m kg 17 ft lb Fuel tank and fuel tank bracket bolt front side 7 Nm 0 7 m kg 5 1 ft lb Fuel tank and fuel tank bracket gt Fuel pump bolt 5 Nm 0 5 m kg 3 6 ft lb 1 1122 Fuel return pipe ho
43. Ib 70 Nm 7 0 kg 50 ft Ib e 25 Omer Job Parts to remove qe 3 4 Disconnect Refer to ENGINE REMOVAL on page 5 1 Refer to GENERAL CHASSIS on page Emme S ote aan S omi E omg S a ew ER we ee ewe E or installation reverse the removal proce 5 84 TRANSFER GEAR CASE Disassembling the oil tank 28 Nm 2 8 m kg 20 ft Ib iy Ramee Sekunde 7 64 Opes p _ For assembly reverse the disassembly pro cedure lt a a N 5 85 EAS25470 REMOVING THE MIDDLE DRIVEN SHAFT NOTE Loosen the middle drive gear nut before remove the drive pulley 1 Install Right rider footrest assembly Refer to ENGINE REMOVAL on page 5 1 2 Loosen Middle drive gear nut 1 NOTE When loosening the middle drive gear nut press down on the brake pedal so the middle drive gear does not move 3 Remove Primary chain 1 e Middle drive gear 2 Middle driven shaft 3 NOTE Remove the primary chain middle drive gear and middle driven shaft at the same time EAS25480 CHECKING THE MIDDLE DRIVE 1 Check Middle drive gear Middle driven gear Damage wear Replace the middle
44. The following procedure applies to all of the fus es EC1D71019 CAUTION To avoid a short circuit always turn the main switch to OFF when checking or replacing a fuse 1 Remove e Rider seat Refer to GENERAL CHASSIS on page 4 1 2 Check e Fuse a Connect the pocket tester to the fuse and check the continuity 7 75 0 03112 b If the pocket tester indicates oo replace the fuse DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Replace Blown fuse Turn the main switch to OFF Install a new fuse of the correct amperage rating Set on the switches to verify if the electrical circuit is operational If the fuse immediately blows again check the electrical circuit ELLEN rating Ignition 25 Fudiecionsysem 18A 1 Backup odometer and clock EWA13310 Never use a fuse with an amperage rating other than that specified Improvising or us ing a fuse with the wrong amperage rating may cause extensive damage to the electri cal system cause the lighting and ignition systems to malfunction and could possibly cause fire 4 Install e Hider seat Refer to GENERAL CHASSIS on page 4 1 EAS28030 CHECKING AND CHARGING THE BATTERY E
45. bracket bolt 6 7 Nm 0 7 m kg 5 1 ft lb Pivot shaft nut 125 Nm 12 5 m kg 90 ft lb 5 Relay arm nut relay arm and 59 Nm 5 9 m kg 43 ft lb swingarm 2 22 2 2 1 1 4 2 Engine bracket nut left rear low er side 3 58 Nm 5 8 m kg 42 ft lb 2 2 2 4 4 4 53 Nm 5 3 m kg 38 ft lb 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 2 Nm 0 2 m kg 1 4 ft lb B Engine bracket bolt right rear lower side 53 Nm 5 3 m kg 38 ft lb lt TIGHTENING TORQUES Thread a i EM Tightening torque Remarks M12 1 59 Nm 5 9 m kg 43 ft lb connecting arm Rear shock absorber assembly nut rear side M10 1 40 Nm 4 0 m kg 29 ft lb Rearshockabsorberassemby T Upper drive belt cover bolt 7 Nm 0 7 m kg 5 1 ft lb MEE Lower drive belt cover bolt 7 Nm 0 7 m kg 5 1 ft lb Rear brake hose guide bolt 7 Nm 0 7 m kg 5 1 ft lb Upper bracket pinch bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Headlight cover bolt 7 Nm 0 7 m kg 5 1 ft lb MEN and throttle 10 Nm 1 0 m kg 7 2 ft lb Headlight body bolt 7 Nm 0 7 m kg 5 1 ft lb Steering stem nut 115 Nm 11 5 m kg 85 ft lb Upper handlebar holder bolt 28 Nm 2 8 m kg 20 ft lb Lower ring nut initial tightening torque M30 1 52 Nm 5 2 m kg 37 ft lb NOTE Lower ring nut final tightening oee torque M30 1 18 Nm 1 8 m kg 13 ft lb NOTE
46. c Insert the key into the windshield lock turn it counterclockwise until it stops to lock the fas tener and then remove the key 1 Lock 2 Fastener 4 3 GENERAL CHASSIS GENERAL CHASSIS Removing the sidebags and backrest For XV19CTS C XV19CT C XV19CTM C 23 Nm 2 3 m kg 17 ft Ib Water can be harmful to untreated leather Use Yamaha Saddle Soap or another quality brand according to the manufacturer s direc tions to clean the leather on the sidebags Polish the dry leather with a soft cloth and then treat with Yamaha Mink Oil or another high quality leather protectant for increased water resistance 5 LN 7 Backrest lower bracket left and right For installation reverse the removal proce dure 4 4 REMOVING THE BACKREST 1 Remove e Backrest Open the sidebag lids b Insert the key 1 into the backrest lock turn it counterclockwise and then remove the 2 Unlock c Pull the lever 1 on each side of the backrest upward 07 D 7 d While holding the levers in the upward posi tion lift the backrest upward and remove it by pulling it to the rear Ji AY ASSEMBLING THE BACKREST 1 Install e Backr
47. ders Able depending on the number of faulty cylin ders Able un able to drive Able depending on the number of faulty cylin ders Able depending on the number of faulty cylin ders Able depending on the number of faulty cylin ders Able depending on the number of faulty cylin ders 37 ISC valve stuck fully Engine speed is high when the en Able Able open gine is idling Lean angle sensor Lean angle sensor open or short open or short circuit circuit detected aR x No normal signals received from the speed sensor 5 pen or short circuit is detected in the neutral switch The ECU is unable to monitor the battery voltage an open or short circuit in the line NO Fuel system voltage monitoring voltage iN CO gt O A to the ECU Error is detected while reading or writing on EEPROM adjust ment value Error in writing the amount of CO adjust ment on EEPROM Vehicle system power supply Monitoring voltage Power supply to the fuel injection system is not normal Faulty ECU memory When this malfunction is detected in the ECU the fault code number might not appear on the meter ECU internal malfunc tion memory check error 7 31 Fault code No Engine idling stop FUEL INJECTION SYSTEM Symptom Engine has been lef
48. 0 0047 in 2nd ring Ring side clearance 0 030 0 070 mm 0 0012 0 0028 1 Limit 0 120 mm 0 0047 in 2 Install Piston ring into the cylinder NOTE Level the piston ring into the cylinder with the piston crown a 10 mm 0 39 in 3 Measure Piston ring end gap Out of specification Replace the piston ring NOTE The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings Piston ring Top ring End gap installed 0 20 0 35 mm 0 0079 0 0138 in Limit 0 55 mm 0 0217 in 2nd ring End gap installed 0 45 0 60 mm 0 0177 0 0236 in Limit 0 95 mm 0 0374 in ring End gap installed 0 20 0 70 mm 0 0079 0 0276 in EAS24440 CHECKING THE PISTON PINS The following procedure applies to all of the pis ton pins 1 Check Piston pin Blue discoloration grooves Replace the piston pin and then check the lubrication sys tem 2 Measure Piston pin outside diameter a Out of specification Replace the piston pin Piston pin outside diameter 22 991 23 000 mm 0 9052 0 9055 in Limit 22 971 mm 0 9044 in CYLINDERS AND PISTONS 3 Measure Piston pin bore diameter b Out of specification Replace the piston Piston pin bore inside diameter 23 004 23 015 mm 0 9057 0 9061 in Limit 23 045 mm 0 9073 in 4 Calculate Piston pin to piston pin bore cleara
49. 1 Stand the vehicle on a level surface NOTE e Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Remove e Rider seat Refer to GENERAL CHASSIS on page 4 1 3 Check e Brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level Front brake Recommended fluid DOT 4 Rear brake Recommended fluid DOT 4 A Front brake B Rear brake EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful 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 ECA13540 CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately NOTE In order to ensure a correct reading of the brake fluid level make sure the top of the brake fluid reservoir is horizontal 4 nstall e Rider seat Refer to GENERAL CHASSIS on page 4 1 CHASSIS EAS21250 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake
50. 1 8 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 8 REPLACEMENT PARTS cias etit qp a Dura 1 8 GASKETS OIL SEALS AND 1 8 LOCK WASHERS PLATES AND COTTER 1 8 BEARINGS AND OIL SEALES sterio amu 1 9 1 9 CHECKING THE 5 1 10 SPECIAE TOOLS uito damp me tutu reta 1 11 EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe ZR MODEL LABEL The model label 1 is affixed to the frame under the rider seat This information will be needed to order spare parts VO A 5 1 i ANS 1 1 IDENTIFICATION FEATURES EAS20170 FEATURES ET1D71017 OUTLINE OF THE SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air fuel ratio in accordance with the engine operating conditions and the atmospheric temperature In the conventional carburetor system the air fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor Despite the same volume of intake air
51. 2 Refer to CHECKING THE TRANSFER GEAR OIL LEVEL on page 3 13 10 Install Exhaust pipes Muffler Refer to ENGINE REMOVAL on page 5 1 S T ln i EAS20890 Pa CHECKING THE CLUTCH FLUID LEVEL 2 p C 1 Stand the vehicle on a level surface 1 MAN I NOTE Place the vehicle on a suitable stand Transfer gear oil completely from the transfer gear case 2 Check 5 Check Clutch fluid level Transfer gear oil drain bolt gasket Below the minimum level mark a Add the Damage Replace recommended clutch fluid to the proper level Recommended clutch fluid Transfer gear oil drain bolt Brake fluid DOT 4 along with the gasket Syr Transfer gear oil drain bolt 18 Nm 1 8 m kg 13 ft Ib 7 Fill Transfer gear case with the specified amount of the recom mended transfer gear oil Quantity 0 55 L 0 58 US qt 0 48 Imp qt Quantity disassembled EWA13370 0 60 L 0 63 US qt 0 53 Imp qt MEE Use only the designated clutch fluid Other clutch fluids may cause the rubber seals to deteriorate causing leakage and poor clutch performance 3 14 Refill with the same type of clutch fluid that is already in the system Mixing clutch flu ids may result in a harmful chemical reac tion leading to poor clutch performance When refilling be careful that water does not enter the clutch fluid reservoir Water Will significantl
52. 2 Check Front brake pad Wear indicator grooves 1 almost disap peared Replace the brake pads as a set Refer to FRONT BRAKE on page 4 31 JAN Nae 5 5902 521260 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Rear brake pad Wear indicators 1 almost touch the brake disc Replace the brake pads as a set Refer to REAR BRAKE on page 4 43 EAS21280 CHECKING THE FRONT BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps 1 Check Brake hoses 1 Cracks damage wear Replace SRNY RES 227 2 Brake hose clamps Loose Tighten the clamp bolt 3 Hold the vehicle upright and apply the brake several times 4 Check Brake hoses Brake fluid leakage Replace the damaged hose Refer to FRONT BRAKE on page 4 31 EAS21290 CHECKING THE REAR BRAKE HOSES 1 Remove e Rider seat Refer to GENERAL CHASSIS on page 4 1 2 Check Brake hoses 1 Cracks damage wear Replace 3 Check Brake hose clamp Loose connection Tighten the clamp bolt 4 Check Brake hose guide Loose Tighten the guide bolt 5 Hold the vehicle upright and apply the brake several times 6 Check Brake hoses Brake fluid leakage Replace the damaged hose Refer to REAR BRAKE on page 4
53. 2 258 Left foot operation 38 16 2 375 33 21 1 571 29 25 1 160 26 28 0 929 24 30 0 800 0 08 mm 0 0032 in 0 08 mm 0 0032 in Guide bar 0 025 mm 0 0010 in 6 26 6 39 mm 0 2465 0 2516 in Oil coated paper element Electrical 1D7 MITSUBISHI 5 5 441 0 637 0 kPa 63 9 92 4 psi 4 41 6 37 kgf cm INP 101 2 NIPPON INJECTOR 43 2 MIKUNI XV19M XV19S XV19 XV19CTM XV19CTS XV19CT 1D71 00 XV19MC XV19SC XV19C XV19CTMC XV19CTSC XV19CTC 1D72 10 100 4 0 6 0 kQ blue black 0 63 0 73 V 248 372 9 3 75 4 25 V 0 90 1 10 at 100 C 212 F ENGINE SPECIFICATIONS Idling condition Engine idling speed 850 950 r min Intake vacuum 31 3 35 3 kPa 9 3 10 4 inHg 235 265 mmHg Oil temperature 80 0 90 0 C 176 00 194 00 F Throttle cable free play 4 0 6 0 mm 0 16 0 24 in 2 9 EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Caster angle Trail Front wheel Wheel type Him size Him material Wheel travel Radial wheel runout limit Lateral wheel runout limit Rear wheel Wheel type Him size Him material Wheel travel Radial wheel runout limit Lateral wheel runout limit Front tire Type Size Manufacturer model Manufacturer model Wear limit front Rear tire Type Size Manufacturer model Manufacturer model Wear limit rear Tire air pressure measured on cold tires Loading condition Front Hear Loading condition Front Hear High speed
54. 2410 Collar 5th wheel gear 5 109 TRANSMISSION gt o gt x 5 O o a For assembly reverse the disassembly pro cedure y t Q Omer Job Parts to remove 5 110 EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 1 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace EWA12840 Do not attempt to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as a set las N TRANSMISSION EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum groove Damage scratches wear Replace the shift drum assembly Shift drum segment 1 Damage wear Replace the shift drum as sembly Shift drum bearing 2 Damage pitting Replace the shift drum as sembly EAS26300 CHECKING THE TRANSMISSION 1 Measure Main axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle Main axle runout limit 0 08 mm 0 0032 in 2 Measure Drive axle runout with a centering device and d
55. 35 90 36 10 mm 1 4134 1 4213 in 30 90 31 10 mm 1 2165 1 2244 in 1 10 1 30 mm 0 0433 0 0512 in 2 0 mm 0 08 in 1 10 1 30 mm 0 0433 0 0512 in 2 0 mm 0 08 in 1 15 1 45 mm 0 0453 0 0571 in 0 4 mm 0 02 in 1 15 1 45 mm 0 0453 0 0571 in 0 4 mm 0 02 in 5 975 5 990 mm 0 2352 0 2358 in 5 945 mm 0 2341 in 5 960 5 975 mm 0 2346 0 2352 in 5 920 mm 0 2331 in 6 000 6 012 mm 0 2362 0 2367 in 6 050 mm 0 2382 in Valve guide inside diameter exhaust Limit Valve stem to valve guide clearance intake Limit Valve stem to valve guide clearance exhaust Limit Valve stem runout Valve spring Free length intake Limit Free length exhaust Limit Installed length intake Installed length exhaust Spring rate intake Spring rate K2 intake Spring rate K1 exhaust Spring rate K2 exhaust Installed compression spring force intake Installed compression spring force exhaust Spring tilt intake Spring tilt exhaust mE 7 Winding direction intake Winding direction exhaust Valve lifter Valve lifter outside diameter intake Valve lifter outside diameter exhaust Valve lifter hole inside diameter intake Valve lifter hole inside diameter exhaust Valve lifter to valve lifter hole clearance Valve push rod Valve push rod 1 length Valve push rod 2 length 2 5 ENGINE SPECIFICATIONS 6 000 6 012 mm 0 2362 0 2367 in 6 050 mm 0 2382 in 0 010 0 037 mm 0 00
56. 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 FRONT BRAKE REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 6 Nm 0 6 kg 4 3 ft Ib 27 Nm 2 7 kg 19 ft Ib Omer Job Parts to remove Rear brake caliper bolt 1 2 Rear brake caliper 3 llli M NNNM NE cw Rear brake pad 2 For installation reverse the removal proce ure 4 A3 REAR BRAKE Removing the rear brake master cylinder 7 Nm 0 7 kg 5 1 ft Ib 30 Nm 3 0 kg 22 ft Ib Omer Job Parts to remove Reier to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 2 BmeWWiresmerdapwgmher 4 Brake 5 Brake tuidresenornese 3 6 Rerwiemmtroidecwr 7 Rerwiehwewinbd 1 8 9 Rear brake pose 9 waerm ______ 1 3i gt Brake rod ka t4 Bekemaseronderbade I gt I 4 44 REAR BRAKE Removing the rear brake master cylinder 7 Nm 0 7 kg 5 1 ft Ib S 129 No lt gt EAE 5 SS 30 Nm 3 0 kg 22 ft Ib For installation reverse the removal proce dure 4 45 REAR BRAKE Disassembling the rear brake master cylinder
57. 7 A7 FUEL INJECTION SYSTEM Fault code No Symptom Cylinder 2 intake air pressure sensor open or short cir cuit detected Diagnostic code No Cylinder 2 intake air pressure sensor Item components and probable Check or maintenance job cause Connections Cylinder 2 intake air pressure sen sor coupler Main wire harness ECU coupler e Sub wire harness 3 coupler Open or short circuit in wire harness and or sub lead Defective cylinder 2 intake air pres sure sensor Reinstatement method Check the coupler for any pins that may be pulled out Check the locking condition of the coupler f there is a malfunction repair it and connect the coupler se curely Turning the main switch to ON Repair or replace if there is open or short circuit Between cylinder 2 intake air pressure sensor coupler and ECU coupler black blue black blue pink yellow pink yellow blue blue Execute the diagnostic mode Code No 04 Replace if defective Refer to CHECKING THE IN TAKE AIR PRESSURE SEN on page 7 90 7 48 FUEL INJECTION SYSTEM Fault code No Symptom Cylinder 2 intake air pressure sensor hose system mal function clogged or detached hose Diagnostic code No Cylinder 2 intake air pressure sensor Item components and probable Check or maintenance job Reinstatement cause method Cylinder 2 intake air pressure sensor
58. 9 5 m kg 68 ft Ib Rm A 2 2 3 4 Oil seal 5 Circlip Gp 0 7 6 s Rerwedamembdmpr dure 4 26 REAR WHEEL Disassembling the rear wheel 3 ew E p _ 0a 8 Emm For assembly reverse the disassembly pro cedure 4 27 EAS28760 REMOVING THE REAR WHEEL DISC 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Remove Rear brake caliper 1 NOTE Do not depress the brake pedal when removing the brake caliper 3 Loosen Drive belt adjusting locknuts 1 Drive belt adjusting bolts 2 4 Hemove Hear wheel axle nut 1 Hear wheel axle 2 e Hear wheel NOTE Push the rear wheel forward and remove the drive belt from the rear wheel pulley REAR WHEEL EAS22080 DISASSEMBLING THE REAR WHEEL 1 Remove Oil seals Wheel bearings Refer to DISASSEMBLING THE FRONT WHEEL on page 4 18 EAS22090 CHECKING THE REAR WHEEL 1 Check Rear wheel axle Rear wheel Wheel bearings Oil seals Hefer to CHECKING THE FRONT WHEEL on page 4 18 2 Che
59. Air vent hose 2 Breather hose 3 Cracks damage Replace Loose connection Connect properly ECA14940 CAUTION Make sure the fuel tank breather hose is rout ed correctly PLES JAS eee 2 3 LO Wr SSS ARA AIVAN NE rS c N SSS N 3 Install Fuel tank Refer to FUEL TANK on page 6 1 Rider seat bracket assembly Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS21050 CHECKING THE CYLINDER HEAD BREATHER HOSE 1 Remove Rider seat Rider seat bracket assembly Refer to GENERAL CHASSIS on page 4 1 e Fuel tank Refer to FUEL TANK on page 6 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 2 Check Cylinder head breather hose 1 Cracks damage Loose connection Connect properly ECA14920 CAUTION Make sure the cylinder head breather hose is routed correctly 3 Install Air filter case Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 1 Rider seat bracket assembly Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS21060 CHECKING THE OIL TANK BREATHER HOSE 1 Remove Right side cover Refer to GENERAL CHASSIS on page 4 1 2 Check Oil tank breather hose 1 Cracks damage Replace Loose connection Connect properly ECA14930 CAUTION Make sure the oil tank breather hose is ro
60. Bushing e Washer Bearings e Collars Recommended cleaning solvent Kerosene 4 Check Washer Oil seals Bushing Damage wear Replace Bearings Damage pitting Replace Collar Damage scratches Replace ET1D71003 INSTALLING THE RELAY ARM REAR SHOCK ABSORBER ASSEMBLY AND CONNECTING ARMS 1 Lubricate Oil seals Recommended lubricant Lithium soap based grease 4 77 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM 2 Install Spacer 2 Bearings 1 2 3 _ to the relay arm CAUTION Oil seals 4 5 When inserting spacer into the connect to the relay arm ing arms and the rear shock absorber be careful not to damage the bushings and O Installed depth a rings 4 5 mm 0 18 in Installed depth _ 1 0 mm 0 04 in Install the bushings so that the slits b in the Installed depth bushings are within the areas shown in the illus 6 0 mm 0 24 in tration Installed depth d 2 5 0 101 m Installed depth a 4 5 mm 0 18 in A Right side 3 Connecting arm 4 Rear shock absorber 3 Lubricate A Right side Bushings B Left side Oil seals C 90 O rings Clar 5 Install Connecting arms Recommended lubricant Rear shock absorber assembly Lithium soap based grease to relay arm Relay arm NOTE to the swingarm Apply grease only to the collar between the
61. Check breather hose for T cracks or damage y y y if necessary S Fuelinection Agustsmenonzaion S Check for leakage Tighten if necessary Exhaust system Replace gasket s if neces sary Evaporative emis sion control sys tem For California only Since these items require special tools data and technical skills have a Yamaha dealer perform the service Check control system for damage Replace if necessary EAU32183 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS ITEM ROUTINE i e Check condition and ramage e Check operation and fluid Clutch leakage y Correct if necessary Check operation fluid level and for fluid leakage Front brake brake pads if neces y Check operation fluid level and for fluid leakage Pear brake Replace brake pads if neces sary E ENTRE TUNER e Check for cracks or damage PERIODIC MAINTENANCE INITIAL ODOMETER READINGS ITEM ROUTINE Check runout and for dam 3 age y y y e Replace if necessary e Check tread depth and for damage Tires Replace if necessary Check air pressure Correct if necessary Check bearings for smooth Wheel bearings operation y Replace if necessary da pivot Check bearing assemblies for
62. ES S 10 Nm 1 0 m kg 7 2 ft Ib Order Job Parts to remove ELAN Clutch fluid Refer to BLEEDING THE HYDRAULIC SYSTEM on 3 15 1 Left rearview mirror rearview mirror eee master Clutch master cylinder reservoir cap reservoir cap master cylinder reservoir diaphragm 3 holder Ca po a S 6 Clutch master cylinder push rod pin BEBE 2 owes 3 dure 5 56 CLUTCH Disassembling the clutch master cylinder _ _ z 5 Owemawroiderody For assembly reverse the disassembly cedure 5 57 CLUTCH Removing the clutch release cylinder 19 Nm 1 9 kg 13 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 0 Bus CLUTCH SYSTEM on page 3 15 Muffler Exhaust pipes Refer to ENGINE REMOVAL on page 5 1 1 Owhppewintdtap S 8 Owhppewint _____ 8 _____ 4 8 Outen release yinder ____ 2 dure 5 5 CLUTCH Disassembling the clutch release cylinder 6 Nm 0 6 kg 4 3 ft Ib Rema 2 3 _ 4 tf 5 2 __ ______
63. Exhaust A 42 530 42 630 mm 1 6744 1 6783 in cylinder 1 42 531 42 631 mm 1 6744 1 6784 in cylinder 2 Limit 42 430 mm 1 6705 in cylinder 1 42 431 mm 1 6705 in cylinder 2 Exhaust B 4 Measure 35 950 36 050 mm 1 4154 Camshaft journal diameter camshaft cover 1 4193 in side a Limit 35 850 1 4114 Out of specification Replace the camshaft Camshaft journal diameter cam shaft cover side 27 957 27 980 mm 1 1007 1 1016 in 5 23 5 Measure Crankcase hole inside diameter Out of specification Replace the crank case Crankcase hole inside diameter 25 000 25 021 mm 0 9843 0 9851 in 6 Measure Camshaft cover hole inside diameter a Out of specification Replace the camshaft COVer Camshaft cover hole inside diam eter 28 000 28 021 mm 1 1024 1 1032 in 7 Calculate e Camshaft to crankcase clearance Out of specification Replace the defective part s CAMSHAFTS NOTE Calculate the clearance by subtracting the cam shaft journal diameter crankcase side from the crankcase hole inside diameter Camshaft to crankcase clearance 0 020 0 064 mm 0 0008 0 0025 in 8 Calculate Camshaft to camshaft cover clearance Out of specification Replace the defective part s NOTE Calculate the clearance by subtracting the cam shaft journal diameter camshaft cover side from t
64. Fault codes 12 70 If more than one code number is detected the dis play alternates every two seconds to show all the de tected code numbers When all code numbers are shown the display repeats the same process 0 Up to 25 fault codes 7 38 Checking method Set the engine stop switch to Q and then compare with the actually measured battery voltage If the bat tery voltage is lower per form recharging Compare the actually mea sured engine temperature with the meter display val ue Set on off the sidestand switch with the transmis sion in gear Shift the transmission To erase the history set the engine stop switch O FUEL INJECTION SYSTEM o Meter display Checking method Actuator operation table Cylinder 1 left or right ig nition coil Cylinder 2 left or right ig nition coil Cylinder 1 left or right ig nition coil Cylinder 2 left or right ig nition coil Injector 1 Injector 2 Fuel pump relay Actuates the cylinder 1 left or right ignition coil five times at one second intervals Illuminates the engine trou ble warning light Actuates cylinder 2 left or right ignition coil five times at one second intervals Illuminates the engine trou ble warning light Actuates the cylinder 1 left or right ignition coil five times at one second intervals Illuminates the engine trou ble warning light Actuates cylinder 2 left
65. Out of specification Replace Left balancer driven gear inside diameter 59 010 59 028 mm 2 323 2 324 in Limit 59 100 mm 2 327 in 3 Measure balancer driven gear housing outside di ameter Out of specification Replace Left balancer driven gear hous ing outside diameter 58 925 58 960 mm 2 320 2 321 in Limit 58 900 mm 2 318 in 4 Calculate eft balancer driven gear to left balancer driven gear housing clearance Out of specification Replace the defective part s 5 63 CLUTCH NOTE Calculate the clearance by subtracting the left balancer driven gear housing outside diameter from the left balancer driven gear inside diame ter Left balancer driven gear to left balancer driven gear housing clearance 0 050 0 103 mm 0 0020 0 0041 in ET1D71022 INSTALLING THE LEFT BALANCER DRIVE GEAR 1 Install Left balancer weight 1 1 balancer weight 2 2 Left balancer driven gear 3 NOTE Make sure that the punch marks a on the left balancer driven gear are facing toward left bal ancer weight 2 Left balancer weight bolt 10 Nm 1 0 m kg 7 2 ft lb LOCTITE 2 Remove Generator rotor Refer to REMOVING THE GENERATOR on page 5 74 3 Align Mark a on the generator drive gear of the crankshaft with the mark b on the generator shaft driv en gear
66. Turn the main switch to ON c Measure the intake air pressure sensor out put voltage CHECKING THE AIR TEMPERATURE SENSOR 1 Remove Air temperature sensor EW1D71004 Handle the air temperature sensor with special care Never subject the air temperature sensor to strong shocks If the air temperature sen sor is dropped replace it 2 Check Air temperature sensor resistance Out of specification Replace Air temperature sensor resis tance 290 390 at 80 C 176 F a Connect the pocket tester 0 100 to the air temperature sensor terminals as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C b Immerse the air temperature sensor 1 in a container filled with water 2 NOTE Make sure that the air temperature sensor termi nals do not get wet c Place a thermometer 3 in the water d Slowly heat the water then let it cool down to the specified temperature e Measure the air temperature sensor resis tance DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 7 91 ELECTRICAL COMPONENTS TROUBLESHOOTING IROUBLESHOOTING rnb 8 1 GENERAL INFORMATION 8 1 STARTING PAIL UIA 8 1 INCORRECT ENGINE IDLING SPEED 8 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE
67. because this will damage the bearing surfac es CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives 1 9 IMPORTANT INFORMATION EAS20250 CHECKING THE CONNECTIONS Check the leads couplers and connectors for stains rust moisture etc 1 Disconnect e ead Coupler Connector 2 Check e ead Coupler Connector Moisture Dry with an air blower Rust stains Connect and disconnect sev eral times 3 Check All connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect ead Coupler Connector Make sure all connections are tight 5 Check Continuity with the pocket tester CHECKING THE CONNECTIONS Pocket tester 90890 03112 Analog pocket tester YU 03112 C NOTE f there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at most part stores SPECIAL TOOLS SPECIAL TOOLS The following special tools are necessary for complete and accurate tune up and assembly Use only the appropr
68. equipment 9 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 8 10 Install Fuel tank Refer to FUEL TANK on page 6 1 Cylinder 1 ignition coil cover Refer to ENGINE REMOVAL on page 5 1 e Rider seat bracket assembly Rider seat Refer to GENERAL CHASSIS on page 4 1 Throttle cable free play 4 0 6 0 mm 0 16 0 24 in EAS20630 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE Prior to adjusting the throttle cable free play the engine idling speed and throttle body synchroni zation should be adjusted properly 1 Check Throttle cable free play a Out of specification Adjust Throttle cable free play 4 0 6 0 mm 0 16 0 24 in 2 Adjust Throttle cable free play Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained Direction a Throttle cable free play is increased Direction b Throttle cable free play is decreased Tighten the locknut 1 EWA12910 After adjusting the throttle cable free play start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE SPARK PLUGS The following procedure applies to all of
69. placed GENERATOR AND STARTER CLUTCH DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE TORQUE LIMITER 1 Check Torque limiter Damage wear Replace NOTE Do not disassemble the torque limiter EAS24600 INSTALLING THE STARTER CLUTCH 1 Install e Starter clutch Starter clutch bolt 24 Nm 2 4 m kg 17 ft lb LOCTITE NOTE 42 While holding the generator rotor 1 with the sheave holder 2 tighten the starter clutch bolts Sheave holder 90890 01701 Primary clutch holder YS 01880 A EAS24510 INSTALLING THE GENERATOR 1 Install Woodruff key Generator rotor 1 Washer Generator rotor bolt 2 NOTE Clean the tapered portion of the generator shaft and the generator rotor hub When installing the rotor make sure the woo druff key is properly seated in the key way of the generator shaft ubricate the generator rotor bolt threads and washer mating surfaces with engine oil 2 Tighten e Generator rotor bolt 1 Generator rotor bolt 80 Nm 8 0 m kg 58 16 NOTE While holding the generator rotor 2 with a sheave holder 3 tighten the generator rotor bolt VE Sheave holder gt 90890 01701 Primary clutch holder YS 01880 A 3 Apply e Sealant onto the stator coil lead grommet GENERATOR AND STARTER CLUTCH 5 Yamaha bond No 1215 90890 85505 Three Bond No 12159 5 76
70. the fuel volume requirement varies by the engine operating con ditions such as acceleration deceleration or operating under a heavy load Carburetors that meter the fuel through the use of jets have been provided with various auxiliary devices so that an optimum air fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the en gine As the requirements for the engine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injection Fl 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 Fl system has resulted in a highly precise fuel supply improved engine response better fuel economy and reduced exhaust emissions 1 2 3 45678 910 11 12 il 21 2016 19 18 17 16 15 14 13 1 Air temperature sensor 15 Lean angle sensor 2 SC idle speed control unit 16 Spark plug 3 Cylinder 2 intake air pressure sensor 17 1 4 Engine temperature sensor 18 Crankshaft position sensor 5 Cylinder 1 right ignition coil 19 Injector 2 6 Throttle position sen
71. 1 Blue 2 Black 3 Brown 4 Green 5 Yellow 105 80 106 20 mm 4 165 4 181 in 0 040 mm 0 0016 in 0 320 0 474 mm 0 0126 0 0187 in 0 037 0 074 mm 0 0015 0 0029 0 09 mm 0 0035 in 0 030 0 060 mm 0 0012 0 0024 in 0 10 mm 0 0039 in Wet multiple disc Hydraulic inner push Left hand operation 2 90 3 10 mm 0 114 0 122 in 2 80 mm 0 110 in 10 pcs 2 92 3 08 mm 0 115 0 121 in 2 82 mm 0 111 in 1 pcs 1 90 2 10 mm 0 075 0 083 10 pcs 0 20 mm 0 0079 in 6 78 mm 0 27 in 6 28 mm 0 25 in 1 pcs 0 100 0 110 mm 0 0039 0 0043 in 0 020 0 066 mm 0 0008 0 0026 in Constant mesh 5 speed Primary reduction system Primary reduction ratio oecondary reduction system Secondary reduction ratio Operation Gear ratio 1st 2nd 3rd 4th oth Main axle runout limit Drive axle runout limit Shifting mechanism Shift mechanism type Shift fork guide bar bending limit Shift fork thickness Air filter Air filter element Fuel pump Pump type Model manufacturer Maximum consumption amperage Output pressure Fuel injection Model quantity Manufacturer Throttle body Type quantity Manufacturer ID mark Throttle valve size Throttle position sensor Resistance Output voltage at idle Fuel injection sensor Crankshaft position sensor resistance Intake air pressure sensor output voltage Engine temperature sensor resistance ENGINE SPECIFICATIONS Spur gear 72 51 1 412 Belt drive 70 31
72. 2 Remove Fuel tank EC1D71021 CAUTION Although the fuel has been removed from the fuel tank be careful when removing the fuel hoses since there may be fuel remain ing in them a Remove the fuel hose joint caps 1 NOTE After removing the fuel hose joint caps clean the projection on each cap so that no foreign mate rial will enter the fuel lines b Lubricate the O ring 1 with the recommend ed silicone lubricant 2 Recommended lubricant Silicone protectant and lubri cant ACC SLCNS PR AY NOTE opray the silicone lubricant in the areas shown in the illustration c Turn the screws 1 clockwise NOTE Turn the screws until they stop FUEL TANK ES 2 AC W S E lt SM Y A d Disconnect the fuel hose fuel hose joint to fuel pump 1 and air vent hose fuel pump to fuel hose joint 2 NOTE Before removing the hoses place a few rags in the area under where they will be removed e Install the fuel hose joint cap 1 and rubber plug 2 NOTE Insert the projection on the fuel hose joint cap completely into the pipe of the fuel hose joint and insert the rubber plug into the end of the fuel hose fuel hose joint to fuel pump 1 2 3p f Remove the fuel tank
73. 2 20 TIGHTENING TORQUES Cylinder head tightening sequence A Front cylinder B Rear cylinder 2 21 TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Thread a i Tightening torque Engine mounting bolt left upper M12 2 66 Nm 6 6 m kg 48 16 side Engine mounting bolt right upper M12 side Engine mounting nut rear upper M12 side Engine mounting spacer bolt 18 Nm 1 8 m kg 13 ft lb Engine bracket bolt left upper 53 Nm 5 3 m kg 38 ft lb c 59 Nm 5 9 m kg 43 ft lb 98 Nm 9 8 m kg 71 ft lb 1 1 side Engine bracket bolt right upper 53 Nm 5 3 m kg 38 ft lb Engine bracket nut rear upper side 53 Nm 5 3 m kg 38 ft lb Engine mounting nut front upper side 98 Nm 9 8 m kg 71 ft lb 98 Nm 9 8 m kg 71 ft lb 105 Nm 10 5 m kg 75 ft lb 4 t M12 Engine mounting nut rear lower M12 side M12 1 1 Engine mounting nut front lower 1 side 1 1 Engine bracket nut front upper M10 53 Nm 5 3 m kg 38 ft Ib side is cross member bracket M10 30 Nm 3 0 m kg 22 ft lb Transfer gear case bracket and transfer gear case bolt Transfer gear case bracket and M10 frame bolt Cylinder 1 ignition coil bolt Cylinder 2 ignition coil bolt M6 4 Lean angle sensor bolt Horn bolt 6 10 Nm 1 0 m kg 7 2 ft lb ISC idle speed control unit bolt 7 Nm 0 7 m kg 5 1 ft lb ISC idle speed control unit
74. 280 kPa 41 psi 2 80 kgf cm Maximum load XV19S C XV19 C XV19M C 210 kg 463 Ib XV19CTS C XV19CT C XV19CTM C 186 kg 410 Ib Total weight of rider passenger cargo and accessories CHASSIS A WARNING It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit re place the tire immediately 2 Check e Tire surfaces Damage wear Replace the tire Wear limit front 1 0 mm 0 04 in Wear limit rear 1 0 mm 0 04 in Pb Tire tread depth _ Side wall 3 Wear indicator EWA14080 Do not use a tubeless tire on a wheel de signed only for tube tires to avoid tire fail ure and personal injury from sudden deflation When usinga tube tire be sure to install the correct tube Always replace a new tube tire and a new tube as a set To avoid pinching the tube make sure the wheel rim band and tube are centered in the wheel groove Patching a punctured tube is not recom mended If it is absolutely necessary to do SO use great care and replace the tube as soon as possible with a good quality re placement 3 28 RENS 2 EN m 59912 FOR TUBELESS gura A Tire B Wheel Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire EWA14090 After extensive tests the tires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by the same manufact
75. 4000 spark checker YM 34487 2 Spark plug cap c Turn the main switch to ON and engine stop switch to d Measure the ignition spark gap a e Crank the engine by pushing the start switch and gradually increase the spark gap un til a misfire occurs DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE SPARK PLUG CAPS The following procedure applies to all of the spark plug caps 1 Check Spark plug cap resistance Out of specification Replace Resistance 10 0 a Remove the spark plug cap from the spark plug lead b Connect the pocket tester x 1k to the spark plug cap as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C 7 83 ELECTRICAL COMPONENTS c Measure the spark plug cap resistance DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE IGNITION COILS The following procedure applies to all of the igni tion coils 1 Check Primary coil resistance Out of specification Replace VVVVV VV VV VV VV VV VV VV VV VV VV VV VV VV a Disconnect the ignition coil connectors from the ignition coil terminals b Connect the pocket tester Q x 1 to the igni tion coil as shown Primary coil resistance 2 16 2 64 Q Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe black red 1 Negative tester probe orange or gra
76. 5 SYSTEM Replace the main switch The engine stop switch is faulty Replace the right handlebar switch Replace the neutral switch Replace the sidestand switch the relay unit Replace the lean angle sensor Properly connect or repair the ignition sys tem wiring IGNITION SYSTEM ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM amp YSSANYVH 85 SS3NHVH3u M 610v 18 6148155 SS3NHVH dH M 8 M 5 pag 79 SSANHVH 3H M ES EEEN CE e g g L 60v 18 Foi m DOA 09 169 7140 8 9 1 1 1 1 1 1 1 Cal pu oe oova 1 69 19 19 Lema K 97 Wy 1 EYES aE oma M M M a0 uva ET Ma Qvu9 Git LT 1 8 NER 1 eX M 7 8 L 1 Sy
77. 7 79 CHECKING THE TURN SIGNAL RELAY 7 80 CHECKING THE DIODES dias mah 7 81 CHECKING THE IGNITION SPARK 7 82 CHECKING THE SPARK 7 83 CHECKING THE IGNITION 7 83 CHECKING THE CRANKSHAFT POSITION SENSOR 7 84 CHECKING THE LEAN ANGLE SENSOR 7 84 CHECKING THE STARTER MOTOR 7 85 CHEOKING THE STATOR COIL iis rrr tr 85 CHECKING THE RECTIFIER REGULATOR eese 7 85 CHECKING THE HORN dote 7 86 CHECKING THE ENGINE TEMPERATURE 7 87 CHECKING THE FUEL SENDER FUEL 7 87 CHECKING THE FUEL SENDER FUEL 88 CHECKING THE FUEL LEVEL WARNING LIGHT 88 CHECKING SPEED SENSO 002 88 CHECKING THE THROTTLE POSITION SENSOR 7 89 CHECKING THE FUEL PUMP 7 89 CHECKING THE EXUP SERVO MOTOR 7 90 CHECKING THE INTAKE AIR PRESSURE SENSOR 7 90 CHECKING THE AIR TEMPERATURE
78. C 68 F Insulation resistance 2 Above 1 MQ at 20 C 68 F b If any resistance is out of specification re place the starter motor DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 5 Measure Brush length a Out of specification Replace the brushes as a Set Limit 5 00 mm 0 20 in 6 Measure e Brush spring force Out of specification Replace the brush springs as a set Brush spring force 7 36 11 04 N 26 49 39 74 oz 750 1126 gf 5 79 7 Check Gear teeth Damage wear gt the gear 8 Check Bearings Oil seal Damage wear Replace the defective part s EAS24800 ASSEMBLING THE STARTER MOTOR 1 Install e Starter motor yoke 1 NOTE Align the projection a on the brush holder with the slot b in the starter motor yoke I ES 2 Install e Starter motor front cover 1 NOTE Align the match mark a on the starter motor yoke with the match mark b on the starter mo tor front cover 11 4 5 80 ELECTRIC STARTER TRANSFER GEAR CASE EAS25460 TRANSFER GEAR CASE Removing the middle driven shaft 18 Nm 1 8 kg 13 ft Ib 5 8 Nm 0 8 kg 5 8 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 40 Nm 4 0 kg 29 ft Ib 10 Nm 1 0 kg 7 2 ft Ib 10 Nm 1 0 kg 7 2 ft Ib Rider seat Right side cover mE id
79. C XV19M C 171 0 mm 6 73 in XV19CTS C XV19CT C XV19CTM C 165 0 mm 6 50 in Maximum 171 0 mm 6 73 in c Installed spring length c Tighten the locknut to specification Locknut rear shock absorber spring preload adjusting nut 30 Nm 3 0 m kg 22 1 3 27 ECA13600 CAUTION Always tighten the locknut against the ad justing nut and torque it to specification DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE TIRES The following procedure applies to both of the tires 1 Check e Tire pressure Out of specification Regulate EWA13180 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature The tire pressure and the suspension must be adjusted according to the total weight including cargo rider passenger and ac cessories and the anticipated riding speed Operation of an overloaded vehicle could cause tire damage an accident or an injury NEVER OVERLOAD THE VEHICLE Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 Ib Front 250 kPa 36 psi 2 50 kgf cm Rear 280 kPa 41 psi 2 80 kgf cm Loading condition 195 19 19 90 210 kg 198 463 Ib XV19CTS C XV19CT C XV19CTM C 90 186 kg 198 410 Ib Front 250 kPa 36 psi 2 50 kgf cm Rear 280 kPa 41 psi 2 80 kgf cm High speed riding Front 250 kPa 36 psi 2 50 kgf cm Rear
80. CONNECTING 5 102 CHECKING THE CRANKSHAFT AND CONNECTING RODS 5 102 INSTALLING THE CONNECTING RODS sees 5 105 INSTALLING THE CRANKSHAFT ASSEMBLY 5 106 TRANSMISSION 2 H 5 107 CHECKING THE SENE T FORKS 5 111 CHECKING THE SHIFT DRUM 55 5 111 CHECKING THE 55 5 111 ASSEMBLING THE AXLE AND DRIVE 5 112 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 5 112 ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the muffler and exhaust pipes 10 Nm 1 0 m kg 7 2 ft Ib 29 Nm 2 9 kg 21 ft Ib 53 Nm 5 3 kg 38 ft Ib 44 Nm 4 4 kg 32 ft Ib 7 Nm 0 7 kg 5 1 ft Ib 20 Nm 2 0 kg 14 ft Ib UNI dem TNT Wee 3 2 BEEN EXUP valve pulley cover ee M 11 e m es ooo UNE NNNM NEMINEM 5 1 ENGINE REMOVAL Removing the muffler and exhaust pipes 10 Nm 1 0 m kg 7 2 ft Ib 29 Nm 2 9 kg 21 ft Ib 53 Nm 5 3 kg 38 ft Ib Nm 4 4 kg 32 ft Ib 7 Nm 0 7 kg 5 1 ft Ib 20 Nm 2 0 m kg 14 ft Ib
81. Clutch boss splines Damage pitting wear Replace the clutch boss NOTE Pitting on the clutch boss splines will cause er ratic clutch operation EAS25170 CHECKING THE PRESSURE PLATE 1 Check Pressure plate Cracks damage CLUTCH Bearing Damage wear Replace EAS25190 CHECKING THE CLUTCH PUSH RODS 1 Check O ring Short clutch push rod ong clutch push rod Ball Cracks damage wear Replace the defec tive part s 2 Measure Long clutch push rod bending limit Out of specification Replace the defective part s Long clutch push rod bending limit 0 30 mm 0 0118 in EAS25200 CHECKING THE PRIMARY DRIVE GEAR 1 Check Primary drive gear Damage wear Replace the primary drive and primary driven gears as a set Excessive noise during operation Replace the primary drive and primary driven gears as a set EAS25210 CHECKING THE PRIMARY DRIVEN GEAR 1 Check Primary driven gear 1 Damage wear Replace the primary drive and primary driven gears as a set Excessive noise during operation Replace the primary drive and primary driven gears as a set ET1D71033 CHECKING THE LEFT BALANCER GEARS 1 Check Left balancer drive gear eft balancer driven gear eft balancer idle gear Burrs chips roughness wear Replace the defective part s 2 Measure Left balancer driven gear inside diameter a
82. ELECTRIC STARTER ELECTRIC STARTER Removing the starter motor dure 5 77 ELECTRIC STARTER Disassembling the starter motor 2 o New Oy Rom 2 Beam a 3 5 7 Brush holder along with the brushes _ Gem For assembly reverse the disassembly pro cedure 5 78 EAS24790 CHECKING THE STARTER MOTOR 1 Check Commutator Dirt Clean with 600 grit sandpaper 2 Measure Commutator diameter Out of specification Replace the starter motor Limit 27 5 mm 1 08 in 3 Measure Mica undercut a Out of specification Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator NOTE Mica undercut depth 1 50 mm 0 06 in The mica of the commutator must be undercut to ensure proper operation of the commutator 4 Armature assembly resistances commutator and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester ELECTRIC STARTER Pocket tester 90890 03112 Analog pocket tester YU 03112 C Armature coil Commutator resistance 1 0 0081 0 0099 at 20
83. If the valve seat width is out of specification reface and lap the valve seat SX 524310 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure Valve spring free length a Out of specification Replace the valve spring 5 42 VALVES AND VALVE SPRINGS Free length intake Spring tilt intake 46 71 mm 1 84 in 2 5 2 0 mm Limit Spring tilt exhaust 44 71 mm 1 76 in 2 5 2 0 mm Free length exhaust 46 71 mm 1 84 in Limit 44 71 mm 1 76 in gt ______ INSTALLING THE VALVES The following procedure applies to all of the 2 Measure valves and related components Compressed valve spring force 1 Deburr Out of specification Replace the valve Valve stem end spring with an oil stone Installed compression spring force intake 217 00 249 00 N 48 78 55 98 Ib 22 13 25 39 kgf Installed compression spring force exhaust 217 00 249 00 N 48 78 55 98 Ib 22 13 25 39 kgf Installed length intake 32 66 mm 1 29 in Installed length exhaust 2 Lubricate 32 66 mm 1 29 in Valve stem 1 Valve stem seal 2 with the recommended lubricant Recommended lubricant Molybdenum disulfide oil b Installed length 3 Measure Valve spring tilt a Out of specification Rep
84. NOTE Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss 4 Mesh the stopper lever with the shift drum seg ment assembly 2 Install Washers Circlips Shift shaft spring 1 Shift shaft 2 NOTE Hook the end of the shift shaft spring onto the shift shaft spring stopper 3 5 71 GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the stator coil 10 Nm 1 0 m kg 7 2 ft Ib S 10 Nm 1 0 m kg 7 2 ft Ib 10 Nm 1 0 kg 7 2 ft Ib Job Parts to remove 002 20 Drain Engine oil Refer to CHANGING THE ENGINE OIL on page 3 11 Rer DRIVE on page 80 7 2 emer 7 4 TP spew T MN NUN NE For installation reverse the removal proce dure 5 72 GENERATOR AND STARTER CLUTCH Removing the generator rotor 10 Nm 1 0 m kg 7 2 ft Ib 80 Nm 8 0 m kg 58 ft Ib Rm 2 emer p _ 7 6 Wem 9 For installation reverse the removal proce dure 5 3 GENERATOR AND STARTER CLUTCH EAS24490 REMOVING THE GENERATOR 1 Remove e Generator rotor bolt 1 e Washer NOTE While holding the generato
85. Oil feed pump outer rotor 10 Relief valve 711 Relief valve spring 12 Oil pump housing cover 2 13 Oil pump housing cover 2 screw 7 Nm 0 7 5 1 ft Ib e Pin 14 Oil scavenging pump inner rotor 2 15 Oil scavenging pump outer rotor 2 16 Ball spring 17 Pins 18 Oil strainer 19 Oil pump housing 1 20 e Pin 21 Oil scavenging pump inner rotor 1 22 Oil scavenging pump outer rotor 1 23 Oil pump housing cover 1 24 Oil pump housing cover 1 screw 7 Nm 0 7 m kg 5 1 ft Ib NOTE When installing the inner rotor align the pin in the oil pump shaft with the groove in the inner ro tor 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 98 INSTALLING THE OIL PUMP 1 Install Oil pump assembly 1 Syr pump assembly bolt 24 Nm 2 4 m kg 17 ft lb ECA13890 CAUTION After tightening the bolts make sure the oil pump turns smoothly 5 100 OIL PUMP CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft 15 Nm 1 5 m kg 11 ft Ib Specified angle 125 1352 Separate EE 2 7 3 a For installation reverse the removal proce dure NO 5 101 EAS26010 REMOVING THE CONNECTING RODS 1 Remove Connecting rod caps 1 Connec
86. Open or short circuit in wire harness Defective EXUP servo motor potentiome ter circuit Open or short circuit in wire harness e Stuck EXUP servo motor mechanism e Stuck EXUP servo motor motor 7 34 FUEL INJECTION SYSTEM Diagnostic Symptom Probable cause of malfunction cade No A break or disconnection of the blue black lead of the ECU is detected Open circuit in wire harness coupler Malfunction in ECU Open or short circuit in wire harness Defective air temperature sensor Malfunction in ECU Improperly installed air temperature sensor Air temperature sensor open or short circuit detect ed Open or short circuit in wire harness No normal signal is re Defective sensor ceived from the sensor Malfunction in ECU Improperly installed sensor Open or short circuit in wire sub lead Cylinder 2 intake air pres Open or short circuit in wire harness sure sensor open or short Defective cylinder 2 intake air pressure circuit detected Sensor Malfunction in ECU Cylinder 22 intake air pres sure sensor hose system malfunction clogged or de tached hose Cylinder 2 intake air pressure sensor hose is detached clogged kinked or pinched Malfunction in ECU Open or short circuit in wire sub lead Engine temperature sen Open or short circuit in wire harness sor open or short circuit Defective
87. Place a folded copper washer 3 between the teeth of the right balancer drive gear and right balancer driven gear in order to lock them Place a folded copper washer 4 between the teeth of the right balancer drive gear and right balancer driven gear in order to lock them Do not damage the teeth of the right balancer drive and right balancer driven gears 6 Remove Right balancer driven gear Camshaft drive gear Right balancer drive gear e Straight keys NOTE Cover the crankcase hole with a clean rag to prevent the straight keys from falling into the crankcase 7 Remove Oil delivery pipe 1 1 Camshaft cover 2 NOTE Loosen each bolt 1 4 of a turn at a time in stag es and in a crisscross pattern After all of the bolts are fully loosened remove them 5 22 CAMSHAFTS EAS23860 CHECKING THE CAMSHAFTS 1 Check Blue discoloration pitting scratches Re place the camshaft 2 Measure Cam dimensions and B Out of specification Replace the camshaft Camshaft lobe dimensions 3 Measure Intake A Camshaft journal diameter crankcase side 42 532 42 632 mm 1 6745 Out of specification gt Replace the camshaft 42 432 mm 1 6705 in Intake B 35 950 36 050 mm 1 4154 1 4193 in Limit Camshaft journal diameter crankcase side 24 957 24 980 mm 0 9826 0 9835 in 35 850 mm 1 4114 in
88. Rectifier regulator Regulator type Model manufacturer No load regulated voltage Hectifier capacity Withstand voltage Battery Model Voltage capacity Manufacturer Ten hour rate amperage Headlight Bulb type Bulb voltage wattage quantity Low beam headlight High beam headlight Tail brake light Front turn signal position light Rear turn signal light License plate light Meter lighting ELECTRICAL SPECIFICATIONS 12V Transistorized coil ignition digital Electrical 10 0 900 r min F008T83271 MITSUBISHI 2JN MORIC 6 0 mm 0 24 in 2 16 2 64 Q 8 64 12 96 Resin 10 0 kQ F4T38971 MITSUBISHI 14 0 V 32 0 A 5000 r min 0 112 0 168 Semi conductor short circuit FHO12AA SHINDENGEN 14 2 14 8 V 50 0A 40 0 V GT14B 4 12 V 12 0 Ah GS YUASA 1 20A Halogen bulb 12 V 51 0W x 1 12 V 55 0W x 1 LED 12 V 23 W 8 0 W x2 12 V 24 0W x2 12 V 5 0 W LED Indicator light Neutral indicator light Turn signal indicator light High beam indicator light Fuel level warning light Engine trouble warning light Electric starting system System type Starter motor Model manufacturer Power output Armature coil resistance Brush overall length Limit Brush spring force Commutator diameter Limit Mica undercut depth Starter relay Model manufacturer Amperage Coil resistance Horn Horn type Quantity Model manufacturer Maximum amperage Coil resistance Performance Turn signal relay Relay ty
89. Repair or replace NOTE otraighten any flattened fins with a thin flathead screwdriver 14110401 e Oil cooler inlet hose e Oil cooler outlet hose Cracks damage Replace 5 7 ENGINE REMOVAL ENGINE REMOVAL Disconnecting the leads 10 Nm 1 0 m kg 7 2 ft Ib 1 M T n ss xn 1 4 ly gt gt C 10 Nm 1 0 kg 7 2 ft Ib Nm 0 7 m kg 5 1 ft Ib MEM Drive pulley case to TRANSFER GEAR CASE on mmt qWemmesgi TP S NO Horn 2 lead 10 Rear brake light switch lead 11 Sidestand switch lead Crankshaft position sensor coupler Crankshaft position sensor lead 14 Rectifier regulator lead Disconnect ENGINE REMOVAL Disconnecting the leads 10 Nm 1 0 m kg 7 2 ft Ib C 10 Nm 1 0 kg 7 2 ft Ib Nm 0 7 m kg 5 1 ft Ib Speed sensor lead a __ ___ _ For installation reverse the removal dure 5 9 ENGINE REMOVAL Removing the engine 105 Nm 10 5 kg 75 ft Ib 59 Nm 5 9 kg 43 ft Ib 53 Nm 5 3 kg 38 ft Ib 18 Nm 1 8 m kg 13 ft Ib 66 Nm 6 6 m kg 48 ft Ib 198 Nm 9 8 m kg 71 ft Ib 53 Nm 5 3 kg 38 ft Ib 30 Nm 3 0 kg 22 ft Ib 53 Nm 5 3 kg 38 ft Ib Place a suitable s
90. THE OIL STRAINER SA ERES 5 86 CHECKING THE TRANSFER GEAR OIL PUMP 5 86 CHECKING THE OIL PIPE a 5 87 ASSEMBLING THE TRANSFER GEAR OIL 5 87 INSTALLING THE TRANSFER GEAR 0 87 CRANKCASE uate eee eee 5 89 DISASSEMBLING THE CRANKCASE 5 92 CHECKING THE CRANKCASE 5 92 CHECKING THE BEARINGS AND OIL SEAL 5 92 CHECKING THE OIL DELIVERY PIPE AND OIL PIPE 5 92 CHECKING THE OIE STRAINERS 5 92 CHECKING THE ENGINE OIL PUMP DRIVEN GEAR 5 93 INSTALLING THE BEARING RETAINERS 5 93 ASSEMBLING THE CRANKCASE 5 93 ee nae vere tea 5 95 CHECKING THE 5 98 CHECKING THE RELIEF VALVE EU RURSUM Ex 5 98 CHECKING THE BALL SPRING AND RELIEF VALVE SPRING 5 98 CHECKING THE OIL S TRAINER ap epee 5 99 ASSEMBLING THE Eden extus 5 99 INSTALLING THE OIL PUMP rur hs 5 100 5 101 REMOVING THE
91. Test the primary and secondary coils for continuity Replace if defective Refer to CHECKING THE IG NITION COILS on page 7 83 7 54 Fault code No Diagnostic code No Throttle valve does not fully close ISC valve is stuck fully open due to disconnected ISC unit hose or cou pler High engine idle speed is de tected with the ISC valve stuck fully open even though signals for the valve to close are continuously being trans mitted by the ECU ISC valve is not moving correctly FUEL INJECTION SYSTEM Check the ECU fuse Refer to CHECKING THE FUSES on page 7 75 Check the throttle bodies Refer to THROTTLE BODIES on page 6 6 e Check the throttle cables Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3 8 Check that the ISC unit hose 15 not disconnected Check that the ISC unit coupler is not disconnected The ISC valve is stuck fully open if it does not operate when the main switch is turned OFF Touch the ISC unit with your hand and check if it is vibrating to confirm if the ISC valve is op erating Execute the diagnostic mode Code No 54 After the ISC valve is fully closed it opens to the standby opening position when the en gine is started This operation takes approximately 12 sec onds Start the engine If the er ror recurs replace the throttle body assembly 7 55 Symptom Engine speed is high when the engine is idlin
92. Therefore take special care when charging the battery NOTE Since MF batteries are sealed it is not possible to check the charge state of the battery by mea suring the specific gravity of the electrolyte Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals 1 Remove e Hider seat Refer to GENERAL CHASSIS on page 4 1 2 Hemove ECU band 1 3 Remove 4 Disconnect Battery leads from the battery terminals ECA13640 CAUTION First disconnect the negative battery lead 1 and then positive battery lead 2 5 Remove Battery 6 Check Battery charge a Connect a pocket tester to the battery termi nals Positive tester probe positive battery terminal Negative tester probe negative battery terminal NOTE he charge state of an MF battery can be checked by measuring its open circuit voltage i e the voltage when the positive battery ter minal is disconnected No charging is necessary when the open cir cuit voltage equals or exceeds 12 8 V b Check the charge of the battery as shown in the charts and the following example Example Open circuit voltage 12 0 V Charging time 6 5 hours Charge of the battery 20 30 Open circuit voltage V Charging time hours Relationship between the open circui
93. Turn the key to ON and then release the SELECT switch after five seconds Item number 1 is displayed 1 Multi function meter unit panel 2 number 3 Brightness level Adjust the multi function meter unit panel brightness level by pushing the RESET switch Push the SELECT switch to select the LCD Item number 2 is displayed Adjust the LCD brightness level by pushing the RESET switch 1 LCD 2 Item number 3 Brightness level 6 Push the SELECT switch to select the speedometer tachometer and the fuel gauge needles Item number 3 is displayed Adjust the brightness level of the speedome ter tachometer and the fuel gauge needles by pushing the RESET switch FEATURES 3 ri Speedometer needle Tachometer needle Fuel gauge needle Item number Brightness level 7 Push the SELECT switch The odometer tripmeter clock display will re turn to the prior mode 1 7 EAS20180 IMPORTANT INFORMATION EAS20190 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 Before removal and disassembly remove all dirt mud dust and foreign material 2 Use only the proper tools and cleaning equip ment Refer to SPECIAL TOOLS on page 1 11 3 When disassembling always keep mated parts together This includes gears cylinders pistons and other parts that have been mat ed through normal wear Mated parts must always be reused or replace
94. again EC1D71001 CAUTION Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angle i Remove the connecting rod and big end bearings j Measure the compressed Plastigauge width on the crankshaft pin the crankshaft pin to big end bearing clearance is out of specification select re placement big end bearings 5 103 ec ANE 5 V DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 4 Select Big end bearings P P gt NOTE The numbers a stamped into the crankshaft web and the numbers b on the connecting rods are used to determine the replacement big end bearing sizes P P refer to the bearings shown in the crankshaft illustration CRANKSHAFT For example if the connecting rod P and the crankshaft web P numbers are 5 and 2 respectively then the bearing size for P4 connecting rod crankshaft 5 2 3 brown Bearing color code 1 Blue 2 Black 3 Brown 4 Green 5 Yellow 5 Measure Crankshaft journal diameter Out of specification Replace the crank shaft NOTE Measure the diameter of each crankshaft journal at two places Crankshaft journal diameter 49 968 49 980 mm 1 9672 1 9677 in 6 Measure Crankshaft journal bearing inside diameter
95. ating it at idle the coupler f there is a malfunction repair it and connect the coupler se curely Replace or charge the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 76 Replace if defective Refer to CHARGING SYS on page 7 13 Repair or replace if there is open or short circuit Between battery and main fuse red red Between main fuse and main switch red red Between main switch and igni tion fuse brown blue brown blue Between ignition fuse and ECU red white red white Fault code No Symptom Faulty ECU memory When this malfunction is detected in the ECU the fault code number might not appear on the meter Item components and probable Check or maintenance job Reinstatement cause method Malfunction in ECU Replace the ECU NOTE Do not perform this procedure with the main switch turned to ON Turning the main switch to ON 7 60 FUEL INJECTION SYSTEM Fault code No Ert Symptom signals are received from ECU Reinstatement method Connections Check the coupler for any pins Turning Main wire harness ECU coupler that may be pulled out main switch to Main wire harness meter assembly Check the locking condition of ON coupler the coupler f there is a malfunction repair it and connect the coupler se curely Open or short circuit in wire harness Repair o
96. battery termi nal red red Between relay unit coupler fuel pump relay and diode 2 cou pler red white red white Between diode 2 coupler and engine stop switch coupler black red black red 3 Malfunction or open circuit in relay Execute the diagnostic mode unit fuel pump relay Code No 09 Replace if defective f there is no malfunction with the relay unit fuel pump relay replace the ECU Fault code No Symptom Error is detected while reading or writing on EEPROM CO adjustment value Diagnostic code No 60 EEPROM improper cylinder indication Item components and probable Check or maintenance job Reinstatement cause method 1 Malfunction in ECU Execute the diagnostic mode Turning the Code No 60 main switch to 1 Check the faulty cylinder If ON multiple cylinders are defec tive the number of the faulty cylinders appears alternate ly at 2 second intervals Replace ECU if defective 7 59 Fault code No Diagnostic code No Connections Main wire harness ECU coupler Faulty battery Malfunction in rectifier regulator Open or short circuit in wire harness FUEL INJECTION SYSTEM 46 Symptom supply to the fuel injection system is not normal Check or maintenance job Reinstatement method Check the coupler for any pins Starting the en that may be pulled out gine and oper Check the locking condition of
97. bolt 10 Nm 1 0 m kg 7 2 ft lb Oil pump P screw transfer M5 4 Nm 0 4 m kg 2 9 ft lb gear case 9 Transfer gear oil check bolt M6 1 8 Nm 0 8 m kg 5 8 ft lb Transfer gear case bolt 4 50 Nm 5 0 m kg 36 ft lb 2 19 TIGHTENING TORQUES Thread a Dipstick joint bolt 10 Nm 1 0 m kg 7 2 ft Ib Drive pulley case bolt M10 8 70 Nm 7 0 m kg 50 ft lb Oil strainer bolt oil tank 10 Nm 1 0 m kg 7 2 ft lb Oil pipe 5 bolt 10 Nm 1 0 m kg 7 2 ft lb Transfer gear case cover plate 5 Nm 0 5 m kg 3 6 ft lb bolt M8 1 6 1 10 Nm 1 0 m kg 7 2 ft lb N gt 2 8 m kg 20 ft lb 2 2 m kg 16 ft lb 1 0 m kg 7 2 ft lb 1 0 m kg 7 2 ft lb 4 Nm 0 4 m kg 2 9 ft lb 2 2 10 Nm 1 0 m kg 7 2 ft lb 1 1 2 22 Nm 10 Nm Sina sprna we Seeker 10 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 7 Nm 0 7 m kg 5 1 ft lb Neutral switch lead clamp screw Speed sensor bolt M6 Oicoierhoebdi 8 NOTE Tighten the connecting rod bolts to 15 Nm 1 5 m kg 11 ft lb and then tighten them further to reach the specified angle 125 135 Install the crankcase stud bolts M12 so that their installed length is 141 5 mm 5 57 in Install the crankcase stud bolts M10 so that their installed length is 70 5 mm 2 78 in
98. checked _ Vacuum gauge 1 Stand the vehicle on a level surface e Tachometer 72 Vacuum gauge Place the vehicle on a suitable stand 2 90890 03094 2 Remove Carburetor synchronizer e Rider seat YU 44456 Rider seat bracket assembly Refer to GENERAL CHASSIS on page 4 1 3 7 a NONE 3 52 2 lt 0 6 Install e Fuel tank Refer to FUEL TANK on page 6 1 7 Adjust hrottle body synchronization a Start the engine and let it warm up for several minutes and then let it run at specified en gine idling speed b With throttle body 1 as standard adjust throttle body 2 using air screw 1 for throttle body 2 Engine idling speed 850 950 r min NOTE After each step the engine two or three times each time for less than a second and check the synchronization again f the air screw was removed turn the screw 3 4 turn in and be sure to synchronize the throt tle body ECA14900 CAUTION Do not use the throttle valve adjusting screws to adjust the throttle body synchroni zation Intake vacuum 31 3 35 3 kPa 9 3 10 4 inHg 235 265 mmHg 3 8 ENGINE NOTE The difference in vacuum pressure between two throttle bodies should not exceed 1 33 kPa 10 mmHg DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 8 Stop the engine and remove the measuring
99. couplers Fuel sender coupler NOTE Make sure that the couplers are positioned as shown in the illustration in the following order from left to right fuel sender coupler 1 6 pin black meter assembly coupler 2 6 pin white meter assembly coupler 3 and 3 pin black meter assembly coupler 4 6 5 FUEL TANK THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the rollover valves 10 Nm 1 0 m kg 7 2 ft Ib Omer Job Parts to remove For California only p _ p _ 77 4 Fecttankbreateroverfownose TT 1 Canister For California only Canister breather hose For California only For installation reverse the removal proce dure NO 6 6 THROTTLE BODIES Removing the pressure regulator 24 FNS QT LL BUNC Omer Job Parts to remove Q ty Pressure regulator cover 1 Fuel hose intake manifold assembly to pres sure regulator Air filter case breather hose 1 Air filter case breather hose 2 6 Pressure regulator EE EM Fuel return pipe _ 9 Pressure regulator bracket For installation reverse the removal proce dure 6 7 THROTTLE BODIES Removing the throttle bodies 3 Nm 0 3 m kg 2 2 ft Ib MEM Rider seat Rider seat bracket ed Fuel tank EN Refer to FUEL TANK on page 6 1 TA Arial to GENERAL CHASSIS on page HERE Cylinder 1 i
100. drive gear middle driven shaft and primary chain as a set TRANSFER GEAR CASE 2 Check e Primary chain Damage stiffness Replace the primary chain middle drive gear and middle driven shaft as a set EAS25490 CHECKING THE OIL STRAINER 1 Check Oil strainer Damage Replace Contaminants Clean with engine oil EAS25500 CHECKING THE TRANSFER GEAR OIL PUMP 1 Check Transfer gear oil pump housing Transfer gear oil pump cover Cracks damage wear Replace the defec tive part s 2 Measure nner rotor to outer rotor tip clearance a Outer rotor to oil pump housing clearance h Oil pump housing to inner rotor and outer rotor clearance c Out of specification Replace the transfer gear oil pump ALY 277 Tr 1 Transfer gear oil pump inner rotor 2 Transfer gear oil pump outer rotor 3 Transfer gear oil pump housing N 2 Inner rotor to outer rotor tip clearance Less than 0 12 mm 0 0047 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump housing clearance 0 10 0 15 mm 0 0039 0 0059 in Limit 0 22 mm 0 0087 in Oil pump housing to inner and outer rotor clearance 0 04 0 09 mm 0 0016 0 0035 in Limit 0 160 mm 0 0063 in 3 Check Transfer gear oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAS25510 CHECKING THE OIL
101. drive belt in a mixture of mild deter gent and water Then remove any dirt from the drive belt c Remove the drive belt from the mixture and rinse it off with clean water Then let drive belt thoroughly dry 2 Check e Drive belt ECA14690 CAUTION To protect the drive belt from damage han dle it with care BELT DRIVE e The drive belt can not be bent smaller than 127 mm 5 in e The removed drive belt can not be twisted inside out 3 Check Drive pulley Rear wheel pulley Bent teeth Replace the drive belt and pul leys as a set EAS23540 INSTALLING THE DRIVE BELT AND DRIVE PULLEY 1 Install Drive pulley 1 Conical spring washer 2 Drive pulley nut 3 NOTE Install the conical spring washer 2 with the OUT mark a facing out E By 2 Install e Drive belt ECA14710 CAUTION Install the drive belt facing the same way it was removed Do not twist the drive belt when installing it 4 82 3 Install e Swingarm Hear shock absorber Refer to REAR SHOCK ABSORBER 5 SEMBLY AND SWINGARM on page 4 73 Rear wheel Refer to REAR WHEEL on page 4 23 4 Tighten Drive pulley nut Syr Drive pulley nut 140 Nm 14 0 m kg 100 NOTE When tightening the drive pulley nut press down o
102. fluid reservoir to the proper level with the recommended brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 20 After bleeding the hydraulic brake system check the brake operation 3 Install e Hider seat Refer to GENERAL CHASSIS on page 4 1 EAS21380 ADJUSTING THE SHIFT PEDAL NOTE The shift pedal position is determined by the in stalled shift rod length a 1 Measure Installed shift rod length Incorrect Adjust Installed shift rod length 312 0 316 0 12 28 12 44 2 Adjust Installed shift rod length Loosen both locknuts 1 b Turnthe shift rod 2 in direction a or b until the specified installed shift rod length is ob tained Direction a Installed shift rod length increases Direction b Installed shift rod length decreases NOTE Make sure that the exposed thread length c be tween the locknut and joint on both ends of the shift rod is 10 mm or less c Tighten both locknuts Syr Locknut shift rod 12 Nm 1 2 m kg 8 7 ft lb d Make sure the installed shift rod length is within specification DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS21430 ADJUSTING THE DRIVE BELT SLACK NOTE The drive belt slack must be checked at the tight est point on the belt CAUTION A dr
103. following procedure applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 15 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Brake disc deflection limit 0 10 mm 0 0039 in a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflec tion turn the handlebar to the left or right to ensure that the front wheel is stationary c Remove the brake caliper d Hold the dial gauge at a right angle against the brake disc surface FRONT BRAKE e Measure the deflection 1 5 mm 0 06 in be low the edge of the brake disc 4 Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Brake disc thickness limit 4 5 mm 0 18 in 5 Adjust e Brake disc deflection a Remove the brake disc b Rotate the brake disc by one bolt hole c Install the brake disc Front brake disc bolt 23 Nm 2 3 m kg 17ft Ib LOCTITE NOTE Apply locking agent LOCTITE to the threads of the brake disc bolts Tighte
104. fuel tank Fuel tank Fuel hose fuel tank to fuel hose joint Fuel return hose fuel return pipe to sub fuel tank Air vent hose fuel hose joint to fuel tank Fuel hose joint Fuel outlet hose Fuel pump Sub fuel tank Fuel hose fuel hose joint to fuel pump Fuel return pipe Fuel return hose pressure regulator to fuel return pipe Pressure regulator Rollover valve 1 Rollover valve 2 Cylinder 2 left spark plug lead Rollover valve hose 1 Rollover valve hose 2 Starter motor lead Fuel tank breather overflow hose Rollover valve hose 4 Rollover valve hose 3 Air vent hose fuel pump to fuel hose joint Fuel pump coupler Canister purge hose for California only Canister for California only Canister breather hose for California only Align the blue paint mark on the fuel hose fuel hose joint to fuel tank with the round indentation on the bend in the fuel hose joint Face the fastener of the clamp downward making sure that the projections on the clamp are positioned as shown in the illustration Align the white paint mark on the end of the fuel return hose fuel return pipe to sub fuel tank with the white paint mark on the fuel return pipe White paint mark Align the ends of the hose clamp with the white paint mark on the fuel return hose Align the paint marks on the hoses with the hose joint as shown in the illustration Fasten the fuel tank breather overflow hose to the throttle cable gu
105. horn 1 lead and rear brake light switch lead along the frame in the area shown in the illustration making sure not to cross the leads Align the positioning tape on the starter motor lead with the engine mounting bolt front lower side H Pass the fuel tank breather overflow hose through lt 2 the horn 1 bracket making sure to position the end of the hose as shown in the illustration Fasten the starter motor lead horn 1 lead and rear brake light switch lead with the plastic locking tie and then face the end of the tie inward Fasten the horn 1 lead rear brake light switch lead and starter motor lead with the plastic locking tie Face the end of the plastic locking tie inward and then cut off the excess end of the tie Route the horn 1 lead to the rear of the starter motor lead Pass the throttle cables through the cable guides as shown in the illustration Install the lead cover making sure not to pinch the stator coil lead and rectifier regulator lead Pass the plastic locking tie through the hole in the battery box projection and then fasten the wire harness with the tie Fasten the stator coil lead at the white tape with the plastic locking tie Fasten the stator coil lead with the plastic locking ties AA Pass the plastic locking tie through the hole in the battery box projection and then fasten the wire harness with the tie AB Route the wire harness along the side
106. idle gear shaft bolt 10 Nm 1 0 m kg 7 2 ft lb Camshaft driven gear bolt 60 Nm 6 0 m kg 43 ft lb Camshaft drive gear bolt 60 Nm 6 0 m kg 43 ft lb Front cylinder camshaft gear bolt 40 Nm 4 0 m kg 29 ft lb m O rocker arm adjusting M7 4 20 Nm 2 0 m kg 14 ft lb screw Vave mercat _____ NM UTISTZRS 4 OiWercawdg 1 Rb Oipipe Turion bok 2 iNmQimig Oipipe Turion bok M amp _ M6 4 4 Oideeyppezbot 3 TAR Engine oil pump driven gear Oil pipe 3 bolt 10 Nm 1 0 m kg 7 2 ft lb 5 Oil pump bolt crankcase 24 Nm 2 4 m kg 17 ft lb iN 2 17 TIGHTENING TORQUES Q ty Tightening torque o N Oil pipe 2 bolt M6 Cil pipe 4 bolt Oil pump housing cover 1 screw crankcase 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 3 7 Nm 0 7 m kg 5 1 ft lb M 2 7 Nm 0 7 m kg 5 1 ft lb M 3 Nm 0 3 m kg 2 2 ft lb 7 Nm 0 7 m kg 5 1 ft lb M 10 Nm 1 0 m kg 7 2 ft lb 30 Nm 3 0 m kg 22 ft lb ES 20 Nm 2 0 m kg 14 ft lb M8 24 Nm 2 4 m kg 17 ft lb 20 Nm 2 0 m kg 14 ft lb 20 Nm 2 0 m kg 14 ft lb 20 Nm 2 0 m kg 14 ft lb 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb M 10 Nm 1 0 m kg 7 2 ft Ib 29 Nm 2 9 m kg 21 ft lb M1 53 Nm 5 3 m kg 38 ft lb 44 Nm 4 4
107. in Brake pad lining thickness out er 5 8 mm 0 23 in Limit 0 8 mm 0 03 in rnrn 2 Install Brake pads Brake pad springs NOTE Always install new brake pads and brake pad springs as a set Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container Loosen the bleed screw and push the brake caliper piston into the brake caliper with your finger c Tighten the bleed screw 3 Install Brake caliper Rear brake caliper bolt 27 Nm 2 7 m kg 19 ft Ib 4 Check Brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 20 Bleed screw rear brake caliper 6 Nm 0 6 m kg 4 3 ft lb 5 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem REAR BRAKE Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 EAS22590 REMOVING THE REAR BRAKE CALIPER NOTE Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Rear brake hose union bolt 1 Copper washers 2 Rear brake hose 3 NOTE Put the end of the brake hose into a co
108. in Out of round limit 0 050 mm 0 0020 in C maximum of D4 Dg T maximum of D4 or 02 maximum of Ds Dg maximum of D4 or Ds minimum of D 4 Dg b If out of specification rebore or replace the cylinder and replace the piston and piston rings as a set c Measure piston skirt diameter D a with the micrometer Piston Diameter D 99 960 99 975 mm 3 9354 3 9360 in b 10 mm 0 39 in from the bottom edge of the piston d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula Piston to cylinder clearance Cylinder bore Piston skirt diameter D Piston to cylinder clearance 0 025 0 050 mm 0 0010 0 0020 in Limit 0 15 mm 0 0059 in f If out of specification rebore or replace the cylinder and replace the piston and piston rings as a set CYLINDERS AND PISTONS EAS24430 CHECKING THE PISTON RINGS 1 Measure Piston ring side clearance Out of specification Replace the piston and piston rings as a set NOTE Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings Piston ring Top ring Ring side clearance 0 030 0 080 mm 0 0012 0 0032 1 Limit 0 120 mm
109. in the illustration Bulbs a and b are used for the headlights and usually use a bulb holder that must be de tached before removing the bulb The majority of these types of bulbs can be removed from their respective socket by turning them coun terclockwise Bulbs c are used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise Bulbs d and e are used for meter and indi cator lights and can be removed from their re spective socket by carefully pulling them out Checking the condition of the bulbs The following procedure applies to all of the bulbs 42 ELECTRICAL COMPONENTS 1 Remove e Bulb EW1D71009 Since headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down EC1D71006 CAUTION Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of a headlight bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adverse ly affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check Bulb for continuity with the pocket tester No continuity Replace Pocket tester 90890 03112 Analog pock
110. it run at approximate ly 5000 r min d Measure the charging voltage DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE HORNS 1 Check Horn resistance Out of specification Replace vVYYVYYYYYYYYYYYYYYYYYYYYYYYYYYYYY a Disconnect the horn 1 connectors and horn 2 coupler from the horn terminals b Connect the pocket tester 1 to the horn terminals Coil resistance 0 94 0 98 Pocket tester 90890 03112 Analog pocket tester YU 03112 C ELECTRICAL COMPONENTS Positive tester probe gt horn terminal 1 Negative tester probe horn terminal 2 A Horn 1 B Horn 2 c Measure the horn resistance 2 Check e Horn sound Faulty sound Adjust or replace a Connect a battery 12 V to the horn b adjusting screw in direction a or b until the horn sound is obtained A Horn 1 B Horn2 DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE ENGINE TEMPERATURE SENSOR 1 Remove Engine temperature sensor from the front cylinder head EWA14140 Handle the engine temperature sensor with special care Never subject the engine temperature sen sor to strong shocks If the engine temper ature sensor is dropped replace it 2 Check Engine temperature sensor resistance Out of specification Replace En
111. journals and lobes 2 Install Camshaft cover 1 1 Oil delivery pipe 1 2 Tighten the camshaft cover bolts in stages and in a crisscross pattern 3 Install e Straight keys Right balancer drive gear 1 Right balancer driven gear 2 e Camshaft driven gear NOTE Cover the crankcase hole with a clean rag to prevent the straight keys from falling into the crankcase Align the punch mark a on the right balancer drive gear 1 with the punch mark b on the right balancer driven gear 2 4 Tighten Camshaft drive gear bolt 1 Right balancer driven gear bolt 2 Camshaft drive gear bolt 60 Nm 6 0 m kg 43 16 Right balancer driven gear bolt 40 Nm 4 0 m kg 29 ft Ib NOTE Lubricate the camshaft drive gear bolt and right balancer driven gear bolt threads with engine oil Place a folded copper washer 3 between the teeth of the right balancer drive gear and right balancer driven gear in order to lock them Place a folded copper washer 4 between the teeth of the right balancer drive gear and right balancer driven gear in order to lock them Do not damage the teeth of the right balancer drive and right balancer driven gears After tightening the camshaft driven gear bolt remove the copper washer to clean the teeth of the right balancer drive gear and right balancer driven gear 5 Inst
112. kg 750 Ib XV19CTS C XV19CT C XV19CTM O 364 0 kg 802 Ib XV19S C XV19 C XV19M O 210 kg 463 Ib XV19CTS C XV19CT C XV19CTM O 186 kg 410 Ib EAS20290 ENGINE SPECIFICATIONS Engine Engine type Displacement Cylinder arrangement Bore x stroke Compression ratio Starting system Fuel Hecommended fuel Fuel tank capacity Fuel reserve amount Engine oil Lubrication system Type Recommended engine oil grade Engine oil quantity Total amount Engine Oil tank Without oil filter cartridge replacement With oil filter cartridge replacement Oil pressure hot Transfer gear oil Type Quantity disassembled Quantity filter Oil filter type Oil pump Oil pump type Inner rotor to outer rotor tip clearance Limit Outer rotor to oil pump housing clearance Limit Oil pump housing to inner and outer rotor clearance Limit Bypass valve opening pressure Relief valve operating pressure Transfer gear oil pump Oil pump type ENGINE SPECIFICATIONS Air cooled 4 stroke OHV 1854 0 cm V type 2 cylinder 100 0 x 118 0 mm 3 94 x 4 65 in 9 48 1 Electric starter Premium unleaded gasoline only 17 0 L 4 49 US gal 3 74 Imp gal 3 0 L 0 79 US gal 0 66 Imp gal Dry sump YAMALUBE 4 20W40 or 2 40 service SG type or higher JASO standard MA 5 20 L 5 50 US qt 4 58 Imp qt 3 2 L 3 38 US qt 2 82 Imp qt 2 0 L 2 11 US qt 1 76 Imp qt 4 10 L 4 33 US qt 3 61 Imp qt 4 90
113. level mark Add the recommended clutch fluid to the proper level Refer to CHECKING THE CLUTCH FLUID LEVEL on page 3 14 6 Check Clutch lever operation ooft or spongy feeling Bleed the clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 15 ET1D71004 REMOVING THE CLUTCH RELEASE CYLINDER 1 Remove Clutch pipe union bolt 1 Copper washers 2 Clutch pipe 3 NOTE Put the end of the clutch pipe into a container and pump out the clutch fluid carefully SHA Lt 2 2 a Se CLUTCH EAS25330 CHECKING THE CLUTCH RELEASE CYLINDER Recommended clutch component replace ment schedule Every two years and whenever the clutch is disassembled Clutch hose Every four years Clutch fluid 1 Install Clutch release cylinder body Cracks damage Replace the clutch re lease cylinder 2 Check Clutch release cylinder 1 Clutch release cylinder piston 2 Rust scratches wear Replace the clutch release cylinder and clutch release cylinder piston as a set EAS25340 ASSEMBLING THE CLUTCH RELEASE CYLINDER EW1D71006 PN Before installation all internal clutch com ponents must be cleaned and lubricated with clean or new clutch fluid e Never use solvents on internal clutch com ponents as they will cause the piston seal to swell and distort Whenever a clutch release
114. may be pulled out Main wire harness ECU coupler Check the locking condition of the coupler f there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between air temperature sen sor coupler and ECU coupler brown white brown white black blue black blue 4 Defective air temperature sensor Execute the diagnostic mode Code No 05 Replace if defective Refer to CHECKING THE AIR TEMPERATURE SENSOR on page 7 90 7 46 FUEL INJECTION SYSTEM Fault code No 24 Symptom No normal signal is received from the sensor Check or maintenance job Reinstatement method heck for looseness or pinching Starting the en ine an Connections Check the coupler for any pins 2 ating it at idle O sensor coupler that may be pulled out Main wire harness ECU coupler Check the locking condition of the coupler f there is a malfunction repair it and connect the coupler se curely Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between sensor coupler and ECU coupler gray white gray white red blue red blue gray green gray green black blue black blue 4 Check fuel pressure Refer to THROTTLE BODIES on page 6 6 Defective sensor Replace if defective
115. on page 7 79 the relay unit 6 Check the relay unit diode NG Refer to CHECKING THE DI the relay unit 5 on page 7 81 OK Check the diode 1 gt Refer to CHECKING THE DI ODES page 7 81 OK Check the diode 2 gt Refer to CHECKING THE DI Replace the diode 1 Replace the diode 2 5 on page 7 81 OK 7 11 9 Check the starter relay Refer to CHECKING THE RE LAYS on page 7 79 10 Check the main switch Refer to CHECKING THE SWITCHES on page 7 71 11 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 7 71 12 Check the neutral switch Refer to CHECKING THE SWITCHES on page 7 71 OK 13 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 7 71 OK 14 Check the clutch switch Refer to CHECKING THE SWITCHES on page 7 71 OK 15 Check the start switch Refer to CHECKING THE SWITCHES on page 7 71 OK 16 Check the entire starting system wiring Refer to CIRCUIT DIAGRAM on page 7 7 OK The starting system circuit is OK gt gt gt gt gt gt gt gt ELECTRIC STARTING SYSTEM Replace the starter relay Replace the main switch The engine stop switch is faulty Replace the r
116. only Install the cylinder 2 intake air pressure sensor hose onto the throttle body pipe up to the bend in the pipe making sure to face the white paint mark on the hose upward Face the ends of the hose clamp rearward Install the canister purge hose onto the throttle body pipe up to the bend in the pipe making sure to face the white paint mark on the hose upward for California only Face the ends of the hose clamp rearward angled to the left Align the white paint marks Align the yellow paint marks Route the canister purge hose over the air filter case joint clamp screw 2 58 CABLE ROUTING CABLE ROUTING O00 Ol d eo 10 11 12 13 14 15 16 17 18 19 I 0 Cylinder 1 intake air pressure sensor Cylinder 2 intake air pressure sensor hose Cylinder 2 intake air pressure sensor ISC idle speed control unit coupler ISC idle speed control unit Rollover valve 1 Rollover valve 2 ISC idle speed control unit inlet hose Cylinder 1 ISC idle speed control unit outlet hose Cylinder 2 ISC idle speed control unit outlet hose Hose joint Air filter case breather hose 2 Throttle position sensor Throttle body assembly Cylinder 1 intake air pressure sensor hose Cylinder head breather hose Cylinder 2 left ignition coil Cylinder 2 right ignition coil Sub wire harness 4 Face the ends of the hose clamp inward Face the ends of the hose clamps o
117. or right ignition coil five times at one second intervals Illuminates the engine trou ble warning light Actuates the injector 1 five times at one second inter vals Illuminates the engine trou ble warning light Actuates the injector 2 five times at one second inter vals Illuminates the engine trou ble warning light Actuates the fuel pump relay five times at one second in tervals Illuminates the engine trou ble warning light The engine trouble warning light is OFF when the relay is ON and the engine trouble warning light is ON when the relay is OFF 7 39 Checking method Check the spark five times Connect an ignition checker Check the spark five times Connect an ignition checker Check the spark five times Connect an ignition checker Check the spark five times Connect an ignition checker Check the operating sound of the injector 1 five times Check the operating sound of the injector 42 five times Check the operating sound of the fuel pump relay five times FUEL INJECTION SYSTEM Checking method Actuates the headlight relay for five cycles of five sec onds ON 2 seconds OFF 3 Check the operating sound Headlight relay seconds of the headlight relay five Illuminates the engine trou times ble warning light and head light Actuates and fully closes the ISC valve then opens it to the standby opening position when the engine is started
118. or short circuit in soeed sensor lead Gear for detecting vehicle speed has broken Defective speed sensor Reinstatement method Check the coupler for any pins that may be pulled out Check the locking condition of the coupler f there is a malfunction repair it and connect the coupler se curely Starting the en gine and acti vating the vehicle speed sensor by oper ating the vehi cle at 20 to 30 Repair or replace if there is an km h open or short circuit Between speed sensor coupler and ECU coupler blue blue white yellow white yellow black blue black blue Replace if defective Refer to TRANSMISSION on page 5 107 Execute the diagnostic mode Code No 07 Replace if defective Refer to CHECKING THE SPEED SENSOR on page 7 88 7 57 FUEL INJECTION SYSTEM Fault code No Symptom No normal signals are received from the speed sensor B Open circuit is detected in the neutral switch Diagnostic code No A Speed sensor Reinstatement method Connections e Check the coupler for any pins Starting the en Neutral switch coupler that may be pulled out gine and acti Main wire harness ECU coupler Check the locking condition of vating the the coupler vehicle speed f there is a malfunction repair it sensor by oper and connect the coupler se ating the vehi curely cle at 20 to 30 Open circuit in neutral switch lea
119. riding Front Hear CHASSIS SPECIFICATIONS Double cradle 31 20 152 0 mm 5 98 in Cast wheel 18M C x 4 00 Aluminum 130 0 mm 5 12 in 1 0 mm 0 04 in 0 5 mm 0 02 in Cast wheel 17M C x MT5 50 Aluminum 110 0 mm 4 33 in 1 0 mm 0 04 in 0 5 mm 0 02 in Tubeless 130 70R18M C 63H DUNLOP D251F BRIDGESTONE G851 RADIAL G 1 0 mm 0 04 in Tubeless 190 60R17M C 78H DUNLOP D251 BRIDGESTONE G850 RADIAL G 1 0 mm 0 04 in 0 90 kg 0 198 Ib 250 kPa 36 psi 2 50 kgf cm 280 kPa 41 psi 2 80 kgf cm XV19S C XV19 C XV19M C 90 210 kg 198 463 Ib XV19CTS O XV19CT C XV19CTM C 90 186 kg 198 410 Ib 250 kPa 36 psi 2 50 kgf cm 280 kPa 41 psi 2 80 kgf cm 250 kPa 36 psi 2 50 kgf cm 280 kPa 41 psi 2 80 kgf cm Front brake Type Operation Front disc brake Disc outside diameter x thickness Brake disc thickness limit Brake disc deflection limit Brake pad lining thickness inner Limit Brake pad lining thickness outer Limit Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Recommended fluid Rear brake Type Operation Brake pedal position Hear disc brake Disc outside diameter x thickness Brake disc thickness limit Brake disc deflection limit Brake pad lining thickness inner Limit Brake pad lining thickness outer Limit Master cylinder inside diameter Caliper cylinder inside diameter Recommende
120. rod cover Cranks damage Seal O ring Damage wear Replace the seal and O ring as a set EAS23980 CHECKING THE DECOMPRESSION SYSTEM 1 Check Decompression system NOTE Check that the decompression pin 1 projects from the camshaft Check that the decompression cam 2 and de compression pin 1 moves smoothly 2 Check Decompression cam Decompression pin Damage wear Replace ET1D71031 CHECKING THE DECOMPRESSION CAM SPRING The following procedure applies to all of the de compression cam springs 1 Measure Decompression cam spring free length a Out of specification Replace the decom pression cam spring Decompression cam spring Free length 20 0 mm 0 79 in Limit 19 0 mm 0 75 in 2 Measure Compressed decompression cam spring force a Out of specification Replace the decom pression cam spring Decompression cam spring Installed compression spring force 0 1335 0 1631 0 0300 0 0367 Ib 0 0136 0 0166 kgf Installed length 8 0 mm 0 31 in b Installed length EAS23990 CHECKING THE OIL DELIVERY PIPE 1 Check Oil delivery pipe 1 Damage Replace Obstruction Wash and blow out with com pressed air O rings Damage wear Replace CAMSHAFTS EAS24030 INSTALLING THE CAMSHAFTS 1 Install Camshafts NOTE Lubricate molybdenum disulfide oil onto the camshaft
121. tester 90890 03174 Model 88 Multimeter with ta chometer YU A1927 c Measure the throttle position sensor voltage d Adjust the throttle position sensor angle so that the voltage is within the specified range e After adjusting the throttle position sensor an gle tighten the throttle position sensor screws 3 Output voltage at idle 0 63 0 73 V 3 ve E 3 V LY LG 3 gt OZ OE LCS SANA AA4AAAAAAAAAAAAAAAAAAAAAAAAAAAAAA INSTALLING THE FUEL PIPE 1 Install e Fuel pipe 1 Fuel pipe bolt 30 Nm 3 0 m kg 22 ft lb NOTE Install the fuel pipe 1 so that it contacts the pro jections a on the injector joints RENS 1 be 22 1 TYS EC SSX SAC S ET1D71027 INSTALLING THE FUEL HOSE 1 Connect Fuel hose intake manifold assembly to pres sure regulator EC1D71015 CAUTION 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 NOTE Install the fuel hose securely onto the fuel pipe or pressure regulator until a distinct click is heard To install the fuel hose onto the fuel pipe or pressure regulator slide the fuel hose connec tor cover 1 on the end of the hose in the direc tion of the arr
122. 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 code No Crankshaft position Sensor NO pressure sensor hose system Sor EXUP servo motor Circuit N EXUP servo motor lock Blue black ECU lead broken or discon nected Air temperature sor NO NO Cylinder 1 intake air pressure sensor open or short circuit Cylinder 1 intake air Throttle position sen open or short circuit open or short circuit open or short circuit Able un able to drive ae Symptom Able un able to start No normal signals are received from the crankshaft position sen sor Cylinder 1 intake air pressure sensor open or short circuit de tected Cylinder 1 intake air pressure sensor hose system malfunction clogged or detached hose Throttle position sensor open or short circuit detected EXUP servo motor is stuck A break or disconnection of the blue black lead of the ECU is de tected Air temperature sensor open or short circuit detected No normal signal is received from N
123. the end of the throttle cable 4 57 HANDLEBAR 3 Pass the left and right handlebar switch leads through the handlebar 4 Install Handlebar 1 Upper handlebar holder 2 Upper handlebar holder bolt 28 Nm 2 8 m kg 20 ft lb ECA14250 CAUTION First tighten the bolts on front side of the handlebar holder and then on the rear side Turn the handlebar all the way to the left and right If there is any contact with the fuel tank adjust the handlebar position NOTE Align the match marks a on the handlebar with the upper surface of the lower handlebar hold ers 5 Install Handlebar grip a Apply a thin coat of rubber adhesive onto the left end of the handlebar Slide the handlebar grip over the left end of the handlebar Wipe off any excess rubber adhesive with a clean rag b EWA13700 Do not touch the handlebar grip until the rub ber adhesive has fully dried AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 6 Install e eft handlebar switch 1 NOTE Align the projection a on the left handlebar switch with the hole b in the handlebar 7 Install Clutch master cylinder 1 Clutch master cylinder holder 2 Clutch master cylinder holder bolt 10 Nm 1 0 m kg 7 2 ft lb NOTE Align the end of the clutch master cylinder holder with the punch mark a on t
124. the fuel pump with the slot in the fuel pump bracket Tighten the fuel pump bolts in the proper tight ening sequence as shown 2 Connect Fuel outlet hose 3 Install Fuel hose connector cover 1 EC1D71023 CAUTION When installing the fuel outlet hose make sure that it is securely connected and that the fuel hose connector cover is installed correctly otherwise the fuel outlet hose will not be properly installed NOTE Install the fuel outlet hose connector securely onto the sub fuel tank until a distinct click is heard and then make sure that it does not come loose Install the holder a of the fuel hose connector cover and then install the holder b After in stalling the fuel hose connector cover make sure that it is installed securely x xx c NUM PREZ ET1D71025 INSTALLING THE FUEL TANK 1 Install e Fuel tank a Install the fuel tank b Remove the fuel hose joint caps c Connect the fuel hose fuel hose joint to fuel pump and air vent hose fuel pump to fuel hose joint d Turn the screws 1 counterclockwise NOTE Turn the screws until they contact the clips a e Install the fuel hose joint caps NOTE Install the fuel hose joint caps completely onto the fuel hose joints DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 2 Install Meter assembly
125. the steering head pipe with a long rod 1 and hammer Remove the bearing race from the lower bracket with a floor chisel 2 and hammer Install a new dust seal and new bearing rac es CAUTION If the bearing race is not installed properly the steering head pipe could be damaged b C Always replace the bearings and bearing races as a set Whenever the steering head is disassembled replace the dust seal S DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 4 Check Upper bracket ower bracket along with the steering stem Bends cracks damage Replace EAS23140 INSTALLING THE STEERING HEAD 1 Lubricate Upper bearing ower bearing Bearing races Recommended lubricant Lithium soap based grease 2 Install Lower ring nut 1 Rubber washer 2 Upper ring nut 3 Lock washer 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 25 3 Install Front brake hose joint 1 Front brake hose guide 2 NOTE Make sure that the projection a on the lower bracket contacts the side b of the front brake hose joint 1 Align the projection c on the front brake hose guide with the hole d in the lower bracket on ae UM S Nore 2 b a 4 Install Front fork legs Upper bracket Refer to FRONT FORK on page 4 60 N X D N 2 CN
126. tighten the left front fender stay bolt rear side and right front fend er stay bolts to specification 9 Tighten e Front fender bolts Front fender bolt 16 Nm 1 6 m kg 11 ft Ib LOCTITE FRONT WHEEL a 4 22 REAR WHEEL EAS22020 REAR WHEEL Removing the rear fender 23 Nm 2 3 kg 17 ft Ib 40 Nm 4 0 kg 29 ft Ib MEM Rider seat Passenger seat Tool kit tray mE 1 Dowel pin Rear fender assembly dure 4 23 REAR WHEEL Removing the rear wheel 16 Nm 1 6 kg 11 ft Ib gt 150 Nm 15 0 kg 110 ft Ib 7 Nm 0 7 kg 5 1 ft Ib NOTE _ Place the vehicle on a suitable stand so that the rear wheel is elevated Muffler Refer to ENGINE REMOVAL on page 5 1 121 L 17 0 _ 3 4 5 mewwepd E 7 6 e femme 8 mewedmg 11 Left drive belt puller merwwecsperbadet 4 24 REAR WHEEL Removing the rear wheel 16 Nm 1 6 kg 11 ft Ib wT 1150 Nm 15 0 kg 110 ft Ib 7 Nm 0 7 kg 5 1 ft Ib AN ON SERO Omer Job Parts to remove 5 Rerwhel 0 p 4d o 0 dure 4 25 REAR WHEEL Removing the rear brake disc and rear wheel drive hub 18 Nm 1 8 kg 13 ft Ib 95 Nm
127. to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful 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 ECA13540 CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Hefer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 6 Check Brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 20 REAR BRAKE 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 EAS22700 REMOVING THE REAR BRAKE MASTER CYLINDER NOTE Before removing the rear brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Rear brake hose union bolt 1 Copper washers 2 Rear brake hose 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS22720 CHECKING THE REAR BRAKE MASTE
128. value is not properly written on or read from the internal memory Malfunction in the charging system Refer to CHARGING SYSTEM on page 7 13 Malfunction in ECU The program and data are not properly written on or read from the internal memory Open or short circuit in wire harness e Malfunction in meter e Malfunction in ECU Defective wire connection of the ECU cou pler 7 36 Diagnostic code No Symptom No signals are received from the ECU within the specified duration Data from the ECU cannot be received correctly Non registered data has been received from the meter Throttle angle Fully closed position Fully opened position Pressure difference atmospheric pressure and cylinder 1 intake air pres Pressure difference atmospheric pressure and cylinder 2 intake air pres sure Air temperature Vehicle speed pulse Lean angle sensor Upright Overturned FUEL INJECTION SYSTEM Probable cause of malfunction Diagnostic code No connection in wire harness e Malfunction in meter e Malfunction in ECU connection in wire harness e Malfunction in meter e Malfunction in ECU Improper connection in wire harness e Malfunction in meter e Malfunction in ECU Meter display Displays the cylinder 1 in take air pressure Displays the cylinder 2 in take air pressure Displays the
129. with the projection on the clutch release cylinder CABLE ROUTING lA mg eri 7 CY lt jl TRR D D lt H e i 2 51 QM Oo Ur Im o 15 16 17 18 19 20 21 22 23 24 25 26 2f 28 29 30 31 32 33 34 35 36 UJ OOo m Clutch hose Throttle cable decelerator cable Throttle cable accelerator cable Cylinder 2 left spark plug cap Cylinder 1 left spark plug cap Sub wire harness 1 Rectifier regulator Crankshaft position sensor lead Stator coil lead Rectifier regulator lead Lean angle sensor Horn 2 lead Horn 2 Sidestand switch Horn 1 lead Rear brake light switch lead Horn 1 Starter motor lead Clutch pipe Fuel tank breather overflow hose Rollover valve Front brake hose Headlight assembly Front fork Frame Main fuse Diode 1 Relay unit Turn signal relay Headlight relay Starter relay EXUP servo motor EXUP cable Speed sensor lead Wire harness Canister Route the throttle cables to the inside of the clutch hose Pass the cylinder 2 left spark plug lead through the guide 30 40 mm 1 18 1 57 in Position the buckle of the plastic locking tie to the inside of the frame Fasten the crankshaft position sensor lead neutral switch lead and sidestand switch lead with the holders Fasten the starter motor lead speed senso
130. 0 CAUTION To avoid scratching the crankshaft and to ease the installation procedure lubricate the oil seal lips with lithium soap based grease and each bearing with engine oil NOTE Make sure that the generator shaft drive gear teeth and generator shaft driven gear teeth mesh correctly Align the punch mark on the generator shaft driven gear with the punch mark b on the gen erator shaft drive gear Align the right connecting rod with the front cyl inder sleeve hole 5 106 TRANSMISSION EAS26240 TRANSMISSION Removing the transmission shift drum assembly and shift forks Separate E Shift drum assembly EO T 4 5 Memes dure J j 5 107 TRANSMISSION gt 2 o o gt E jud O 5 o Toothed lock washer EE lS 1 Lens For assembly reverse the disassembly pro cedure 5 108 TRANSMISSION gt o gt x 5 O o a Omer Job Parts to remove 3 Www T T 3 p ew RN 0000 3 p 3 p T T T T T T T T T T 16 8 Y _____ 1
131. 0 0020 in 0 025 0 050 mm 0 0010 0 0020 in 0 15 mm 0 0059 in 99 960 99 975 mm 3 9354 3 9360 in 10 0 mm 0 39 in 0 50 mm 0 0197 in 23 004 23 015 mm 0 9057 0 9061 in 23 045 mm 0 9073 in 22 991 23 000 mm 0 9052 0 9055 in 22 971 mm 0 9044 in 0 004 0 024 mm 0 00016 0 00094 in 0 074 mm 0 00291 in Barrel 1 20 x 3 80 mm 0 05 x 0 15 in 0 20 0 35 mm 0 0079 0 0138 0 55 mm 0 0217 in 0 030 0 080 mm 0 0012 0 0032 in 0 120 mm 0 0047 in Taper 1 20 x 4 00 mm 0 05 x 0 16 in 0 45 0 60 mm 0 0177 0 0236 0 95 mm 0 0374 in 0 030 0 070 mm 0 0012 0 0028 in 0 120 mm 0 0047 in Oil ring Dimensions B x T 31 1 End gap installed Connecting rod Oil clearance using plastigauge Bearing color code Crankshaft Width A Runout limit C Big end side clearance D Big end radial clearance E Limit Journal oil clearance using plastigauge Limit Clutch Clutch type Clutch release method Operation Friction plate 1 3 thickness Wear limit Plate quantity Friction plate 2 thickness Wear limit Plate quantity Clutch plate thickness Plate quantity Warpage limit Clutch spring free length Minimum length Spring quantity Clutch housing thrust clearance Clutch housing radial clearance Transmission Transmission type ENGINE SPECIFICATIONS 2 50 x 3 40 mm 0 10 x 0 13 in 0 20 0 70 mm 0 0079 0 0276 in 0 050 0 074 mm 0 0020 0 0029 in
132. 04 0 0015 in 0 080 mm 0 0032 in 0 025 0 052 mm 0 0010 0 0020 in 0 100 mm 0 0039 in 0 010 mm 0 0004 in 46 71 mm 1 84 in 44 71 mm 1 76 in 46 71 mm 1 84 in 44 71 mm 1 76 in 32 66 mm 1 29 in 32 66 mm 1 29 in 16 58 N mm 94 67 Ib in 1 69 kgf mm 21 98 N mm 125 51 Ib in 2 24 kgf mm 16 58 N mm 94 67 Ib in 1 69 kgf mm 21 98 N mm 125 51 Ib in 2 24 kgf mm 217 00 249 00 N 48 78 55 98 Ib 22 13 25 39 kgf 217 00 249 00 N 48 78 55 98 Ib 22 13 25 39 kgf 2 5 2 0 mm 2 5 2 0 mm Clockwise Clockwise 22 962 22 974 mm 0 9040 0 9045 in 22 962 22 974 mm 0 9040 0 9045 in 23 000 23 021 mm 0 9055 0 9063 in 23 000 23 021 mm 0 9055 0 9063 in 0 026 0 059 mm 0 0010 0 0023 in gt 286 5 mm 11 280 in 288 5 mm 11 358 in Valve push rod runout Cylinder Bore Taper limit Out of round limit Piston Piston to cylinder clearance Limit Diameter D Height H Jn AC D Offset Piston pin bore inside diameter Limit Piston pin outside diameter Limit Piston pin to piston pin bore clearance Limit Piston ring Top ring Ring type Dimensions B x T LL LT End gap installed Limit Ring side clearance Limit 2nd ring Ring type Dimensions B x T T End gap installed Limit Ring side clearance Limit ENGINE SPECIFICATIONS 0 3 mm 0 012 in 100 000 100 010 mm 3 9370 3 9374 in 0 050 mm 0 0020 in 0 050 mm
133. 1 72 4 72 STEERING HEAD REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM ET1D71001 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM Removing the rear shock absorber assembly and swingarm 48 Nm 4 8 m kg 35 ft Ib Nm 0 7 m kg 5 1 ft Ib 48 Nm 4 8 kg 35 ft Ib 59 Nm 5 9 kg 43 ft Ib NN aw Reto ENGINE REMOVAL on pages Loosen Engine mounting nut rear lower side Refer to ENGINE REMOVAL on page 5 1 Horn 1 coupler Disconnect Passenger footrest left and right For XV19S C XV19 C XV19M C only 1 2 3 NOTE O sensor lead guide 5 Rear brake hose guide Self locking nut Bolt Spacer Washer 1 1 1 1 7 Pivot shaft nut Washer 1 Pass the sensor lead through the guide Pivot shaft Rear shock absorber and swingarm assembly 4 73 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM Removing the rear shock absorber assembly and swingarm 48 Nm 4 8 kg 35 ft Ib N 2 2 2 2 f pF 7 E PA 3 2 AEN B TR UM gt 7 T Z lt ihe RA 21 Nm 0 7 kg 5 1 ft Ib 48 Nm 4 8 kg 35 ft Ib 59 Nm 5 9 kg 43 ft Ib mE For installation reverse the removal proce dure 4 74 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM Removing the rear shock absorber and swingarm 59 Nm 5 9 kg 43 ft Ib 59 Nm
134. 21100 ADJUSTING THE EXUP CABLES 1 Remove EXUP valve pulley cover 1 OG rg S d 2 EXUP system operation a Turn the main switch to ON b Check that the EXUP valve operates proper ly NOTE Check that the projection a on the EXUP valve pulley contact the stopper b fully open posi tion and the stopper c fully closed position D Ecos 6 DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Check e EXUP cable free play at the EXUP valve pul ley a and b 59 EXUP cable free play at the EXUP valve pulley a 3 mm 0 12 in or less b 3 mm 0 12 in or less 4 Adjust EXUP cable free play Loosen both locknuts 1 b Turn both adjusting bolts 2 in or out until the specification Turn in a gt Free play is increased Turn out b gt Free play is decreased ENGINE c Tighten both locknuts d Turn the main switch to ON and check that the projection c on the EXUP valve pulley contacts the stoppers fully open and fully closed positions then stops between the lines d on the cable holder 5 Install EXUP valve pulley cover
135. 40 LUBRICATION SYSTEM CHART AND DIAGRAMS gt LUBRICATION SYSTEM CHART AND DIAGRAMS Oil pipe 5 Transfer gear oil pump Oil strainer transfer gear case Middle drive shaft Oil strainer oil tank From the oil pump 2 42 LUBRICATION SYSTEM CHART AND DIAGRAMS ug Gi SE H HL Bi 2 43 LUBRICATION SYSTEM CHART AND DIAGRAMS 1 Transfer gear oil pump 2 Middle driven shaft 2 44 CABLE ROUTING EAS20430 CABLE ROUTING 2 45 gt moO Clutch hose Right handlebar switch lead Main switch Left handlebar switch lead Front brake hose Throttle cable decelerator cable Throttle cable accelerator cable Horn 1 lead Horn 1 Rear brake light switch Rear brake light switch lead Cross the left and right handlebar switch leads Either lead can be routed on top 70 mm 2 76 in 5 25 10 307 Fasten the rear brake light switch lead with the plastic locking tie Face the end of the plastic locking tie inward and then cut off the excess end of the tie Make sure that there is no slack in the rear brake light switch lead the area shown in the illustration Fasten the rear brake light switch lead with the plastic locking tie Face the end of the plastic locking tie downward and then cut off the excess end of the tie 2 46 CABLE ROUTING CABLE ROUTING
136. 43 CHASSIS EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear brake light switch is operated by move ment of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts 1 Check Rear brake light operation timing Incorrect Adjust 2 Adjust Rear brake light operation timing a Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time Direction a Brake light comes on sooner Direction b Brake light comes on later 9 f Tp L arene LY ANS 92 7 DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA BLEEDING THE HYDRAULIC BRAKE SYSTEM 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 1 Remove e Rider seat Refer to GENERAL CHASSIS on page 4 1 3 22 NOTE Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow When bleeding the hydraulic brake system make sure there is always enough brake fluid before applying the brake Ignoring this caution could allow
137. 5 Measure Valve margin thickness D a Out of specification Replace the valve Valve margin thickness D intake 1 15 1 45 mm 0 0453 0 0571 in Limit 0 4 mm 0 02 in Valve margin thickness D ex haust 1 15 1 45 mm 0 0453 0 0571 in Limit 0 4 mm 0 02 in 6 Measure Valve stem runout Out of specification Replace the valve NOTE When installing a new valve always replace the valve guide f the valve is removed or replaced always place the valve stem seal Valve stem runout 0 010 mm 0 0004 in EAS24300 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats VALVES AND VALVE SPRINGS 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width C Out of specification Replace the cylinder head Valve seat width C intake 1 10 1 30 mm 0 0433 0 0512 in Limit 2 0 mm 0 08 in Valve seat width C exhaust 1 10 1 30 mm 0 0433 0 0512 in Limit 2 0 mm 0 08 in Apply Mechanic s blueing dye Dykem b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width NOTE Where the va
138. 5 9 kg 43 ft Ib 1 2 1 Self locking nut Washer Bolt Oil seal Collar Bushing Bearing Swingarm Self locking nut Washer Bolt 1 1 1 Connecting arm O ring Spacer ELS NE NN Bushing EN NE 2 4 4 Self locking nut Washer Bolt 1 2 1 1 1 Hear shock absorber 1 Relay arm 1 2 1 1 2 1 2 2 2 1 2 Oil seal Spacer Bearing Oil seal Spacer Bearing Collar Oil seal Spacer Bearing For installation reverse the removal proce dure 4 75 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM EAS23180 HANDLING THE REAR SHOCK ABSORBER EWA13740 This rear shock absorber contains highly compressed nitrogen gas Before handling the rear shock absorber read and make sure you understand the following information The manufacturer cannot be held responsi ble for property damage or personal injury that may result from improper handling of the rear shock absorber Do not tamper or attempt to open the rear shock absorber Do not subject the rear shock absorber to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pressure Do not deform or damage the rear shock absorber in any way Rear shock absorber damage will result in poor damping perfor mance EAS23190 DISPOSING OF A REAR SHOCK ABSORBER 1 Gas pressure must be released before dis posing of a rear shock absorber To release the gas pressure drill a 2 3 mm 0 08 0 12 in hole through the
139. 9 ln c d Place the other end of the hose into a con tainer e Slowly squeeze the clutch lever several times f Fully squeeze the clutch lever without releas ing it g Loosen the bleed screw This will release the tension and cause the clutch lever to contact the handlebar grip h Tighten the bleed screw and then release the clutch lever i Repeat steps e to h until all of the air bub bles have disappeared from the clutch fluid in the plastic hose j Tighten the bleed screw to specification Bleed screw clutch release cylin der 6 Nm 0 6 m kg 4 3 ft lb k Add the recommended clutch fluid to the proper level Refer to CHECKING THE CLUTCH FLUID LEVEL on page 3 14 EWA13010 After bleeding the hydraulic clutch system check the clutch operation REPLACING THE AIR FILTER ELEMENT 1 Remove e Hider seat Refer to GENERAL CHASSIS on page 4 1 2 Hemove Fuel tank Refer to FUEL TANK on page 6 1 3 Hemove Air filter case cover 1 3 15 4 Remove e Air filter element 1 5 Check Air filter element Damage gt The air filter needs more frequent service if you are riding in unusually wet or dusty areas 6 Install e Air filter case cover EC1D71002 CAUTION Never operate the engine without the air filter element installed Unfiltered air will
140. 90 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful 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 ECA13540 CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 4 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 20 REAR BRAKE G 5 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 6 Adjust Brake position Refer to ADJUSTING THE REAR DISC BRAKE on page 3 20 7 Adjust Rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 22 4 54 HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 28 Nm 2 8 kg 20 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 32
141. 90 INCORRECT ENGINE IDLING SPEED Engine 1 Cylinder s and cylinder head s Incorrect valve clearance Damaged valve train components 2 Air filter Clogged air filter element Fuel system 1 Throttle body ies Damaged or loose throttle body joint Improperly synchronized throttle bodies Improper throttle cable free play Flooded throttle body Electrical system 1 Battery Discharged battery Faulty battery 2 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Faulty spark plug 3 Ignition coil s Broken or shorted primary or secondary coils Faulty spark plug lead Cracked or broken ignition coil 4 Ignition system Faulty ECU e Faulty crankshaft position sensor e Broken generator rotor woodruff key EAS28510 POOR MEDIUM AND HIGH SPEED PERFORMANCE Refer to STARTING FAILURES on page 8 1 Engine 1 Air filter Clogged air filter element Fuel system 1 Fuel pump Faulty fuel pump EAS28530 FAULTY GEAR SHIFTING Shifting is difficult Refer to Clutch drags EAS28540 SHIFT PEDAL DOES NOT MOVE Shift shaft Improperly adjusted shift rod Bent shift shaft Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide bar 8 2 TROUBLESHOOTING Transmission e Seized transmi
142. AAAAAAAAA 3 Install Throttle position sensor NOTE When installing the throttle position sensor ad just its angle properly Refer to ADJUSTING THE THROTTLE POSITION SENSOR on page 6 12 EAS28350 CHECKING THE FUEL PUMP 13850 Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire Be extremely careful and note the following points Stop the engine before refueling Do not smoke and keep away from open flames sparks or any other source of fire f you do accidentally spill gasoline wipe it up immediately with dry rags f gasoline touches the engine when it is hot a fire may occur Therefore make sure the engine is completely cool before per forming the following test 1 Disconnect Fuel pump coupler from the fuel pump 2 Check Fuel pump operation Faulty rough movement Replace a Fill the fuel tank b Put the end of the fuel hose 1 into an open container c Connect the battery DC 12 V to the fuel pump terminals as shown Positive battery lead red blue 2 Negative battery lead black 3 d Check the fuel pump operation DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE EXUP SERVO MOTOR 1 Check EXUP servo motor operation Out of specification Replace
143. AKE EAS22210 FRONT BRAKE Removing the front brake pads 10 Nm 1 0 m kg 7 2 ft Ib Order Job Partstoremove dob Partstoremove to remove REN us the front brake calipers pt MN IL 1700 4 5 Brake pad ip gt 6 Brake pad stim NE For installation reverse the removal proce dure 4 31 FRONT BRAKE Removing the front brake master cylinder Omer Job Parts to remove EAM Brake fluid Refer to BLEEDING THE HYDRAULIC SYSTEM on page 3 22 1 Right rearview mirror rearview mirror master cylinder reservoir 4 3 o BEDV Brake light switch connector 7 Brake light switch 77 0 3 Front brake master cylinder __ dure 4 32 FRONT BRAKE Disassembling the front brake master cylinder Dust boot 3 E _ 3 Brake master cylinder kit Brake master cylinder body For assembly reverse the disassembly pro cedure 4 33 FRONT BRAKE Removing the front brake calipers 40 Nm 4 0 kg 29 ft Ib 32 Nm 3 2 m kg 23 ft Ib 10 Nm 1 0 kg 7 2 ft Ib The following procedure applies to both of the front brake calipers Drain Brake fluid Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 2 Frontbateroseunionbor
144. AND VALVE SPRINGS b Install the new valve guide with the valve Valve stem to valve guide clear guide installer 2 and valve guide remover ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clear ance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 0039 in c After installing the valve guide bore the valve guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance NOTE After replacing the valve guide reface the valve seat UL Valve guide remover 06 90890 04064 2 Replace Valve guide remover 6 0 mm Valve guide YM 04064 A NOTE Valve guide installer 06 To ease valve guide removal and installation 90890 04065 and to maintain the correct fit heat the cylinder 6 0 mm head to 100 C 212 F in an oven Valve guide reamer 06 90890 04066 Remove the valve guide with the valve guide Valve guide reamer 6 0 mm remover 1 YM 04066 3 Eliminate Carbon deposits from the valve face and valve seat 4 Check Valve Pitting wear Grind the valve face 5 40 Valve stem end Mushroom shape or diameter larger than the body of the valve stem the valve
145. AS28240 CHECKING THE SPEED SENSOR 1 Check Speed sensor output voltage Out of specification Replace Output voltage reading cycle 0 6 V to 4 8 V to 0 6 Vto 4 8V a Connect the pocket tester DC 20 V to the speed sensor coupler as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe white 1 Negative tester probe black 2 b Turn the main switch to ON c Elevate the rear wheel and slowly rotate it d Measure the voltage of white and black With each full rotation of the rear wheel the volt age reading should cycle from 0 6 V to 4 8 V to 0 6 V to 4 8 V DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE THROTTLE POSITION SENSOR 1 Remove Throttle position sensor from the throttle body 2 Check Throttle position sensor maximum resistance Out of specification Replace the throttle position sensor Resistance 4 0 6 0 ko blue black a Connect the pocket tester Q x 1k to the throttle position sensor terminals as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe gt blue 1 Negative tester probe black 2 ELECTRICAL COMPONENTS b Measure the throttle position sensor maxi mum resistance DAAAAAAAAAAAAAAAAAAAAAA
146. BRAKE CALIPER BRACKET 4 28 CHECKING THE REAR WHEEL DRIVE 4 29 CHECKING AND REPLACING THE REAR WHEEL PULLEY 4 29 ASSEMBLING THE REAR WHEE 4 29 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 29 INSTALLING THE REAR WHEEL 15 4 29 FRONT BRAKE ptt 4 31 INTRODUC TION 4 36 CHECKING THE FRONT BRAKE 01 5 4 36 REPLACING THE FRONT BRAKE PADS 4 37 REMOVING THE FRONT BRAKE CALIPERS 4 38 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 38 CHECKING THE FRONT BRAKE 4 39 ASSEMBLING THE FRONT BRAKE CALIPERS 4 39 INSTALLING THE FRONT BRAKE 4 39 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 40 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 40 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 41 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 41 REAR BRAKE _ 4 43 INTRODUC O Gels 4 49 CHECKING THE REAR BRAKE DISC 4 49 REPLACING IHE REAR BRAKE PADS 4 49 REMOVING THE REAR BRAKE
147. CLUTCH PLATES 1 Check The following procedure applies to all of the e Friction plate clutch plates 1 Check Damage wear Replace the friction plates e Clutch plate as a set 2 Measure Damage Replace the clutch plates as a Friction plate thickness set 2 Measure Out of specification Replace the friction plates as a set NOTE Measure the friction plate at four places Clutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clutch plates as a set Friction plate 1 3 thickness 7 Thickness gauge 2 90 3 10 mm 0 114 0 122 in F 90890 03180 Wear limit Feeler gauge set 2 80 mm 0 110 in YU 26900 9 Friction plate 2 thickness 2 92 3 08 mm 0 115 0 121 in Wear limit Clutch plate thickness 2 82 mm 0 111 in mm 0 075 0 083 in 0 20 mm 0 0079 in EAS25130 CHECKING THE CLUTCH SPRING PLATE 1 Check Clutch spring plate Damage Replace 5 61 2 Check Clutch spring plate seat Damage Replace EAS25150 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE Pitting on the clutch housing dogs will cause er ratic clutch operation iir ATTE T E 2 Check Bearing Damage wear Replace the bearing and clutch housing EAS25160 CHECKING THE CLUTCH BOSS 1 Check
148. Check the cylinder 2 intake air Starting the en hose pressure sensor hose condition gine and oper Repair or replace the sensor ating it at idle hose Cylinder 2 intake air pressure sensor Check and repair the connec malfunction at intermediate electrical tion potential Replace it if there is a malfunc tion Connections Check the coupler for any pins Cylinder 2 intake air pressure sen that may be pulled out sor coupler Check the locking condition of Main wire harness ECU coupler the coupler f there is a malfunction repair it and connect the coupler se curely Defective cylinder 2 intake air pres Execute the diagnostic mode sure sensor Code No 04 Replace if defective Refer to CHECKING THE IN TAKE AIR PRESSURE SEN on page 7 90 7 49 FUEL INJECTION SYSTEM Fault code No ui Symptom Engine temperature sensor open or short circuit detect ed Diagnostic code No o Engine temperature sensor Item components and probable Check or maintenance job Reinstatement method Installed state of engine temperature Check for looseness or pinching Turning the sensor main switch to Connections Check the coupler for any pins ON e Engine temperature sensor coupler that may be pulled out Main wire harness ECU coupler Check the locking condition of Sub wire harness 2 coupler the coupler f there is a malfunction repair it and con
149. Clutch cover damper plate screw plate screw 10 Nm 1 0 10Nm 1 0 m kg 7 2 840 7 2 ft lb cover bolt eta toe 10 Nm 1 0 m kg 7 2 ft lb a Generator damper cover bolt 5 Nm 0 5 m kg 3 6 ft lb Engine oil filler plug 20 1 10 Nm 1 0 m kg 7 2 ft lb sprocket cover plate 10 Nm 1 0 m kg 7 2 ft lb plate bolt right crank EG 10 Nm 1 0 mg 7 2 16 ES 10 Nm 1 0 m kg 7 2 ft lb wi Camshaft sprocket coverbok W6 8 TONn DmmTZRE _ Starter clutch bolt M8 24 Nm 2 4 m kg 17 ft lb 10 46 21 Primary drive gear bolt 2 1 100 Nm 10 0 m kg 72 ft lb m O NO ol tak Clutch boss nut M20 1 105 Nm 10 5 m kg 75 ft lb 5 pn Clutch spring plate retainer bolt 6 6 8 Nm 0 8 m kg 5 8 ft lb Bleed screw clutch release cylin 8 1 6 Nm 0 6 m kg 4 3 ft lb der Clutch release cylinder bolt M63 10 Nm 1 0 m kg 7 2 ft lb Drive axle bearing retainer screw 20 Nm 2 0 m kg 14 ft lb Stake Main axle bearing retainer screw M6 2 10 Nm 1 0 m kg 7 2 ft lb Engine oil drain bolt oil tank 43 Nm 4 3 m kg 31 ft lb Transfer gear oil drain bolt M8 1 18 Nm 1 8 m kg 13 ft lb t L3 Middle drive gear nut LIU 140 Nm 14 0 m kg 100 ft lb Transfer gear case oil pump as Transfer gear case oil pump as sembly
150. E Prior to checking the ignition timing check the wiring connections of the entire ignition system Make sure all connections are tight and free of corrosion 1 Stand the vehicle on a level surface 2 Remove e Shift pedal assembly 1 3 Remove e Damper cover 1 e Damper 2 Timing mark accessing screw 3 4 Connect Timing light 1 e Tachometer L Timing light 90890 03141 Inductive clamp timing light YU 03141 3 10 ENGINE 5 Check Ignition timing Start the engine warm up for several min utes and then let it run at the specified en gine idling speed Check that pointer a on the clutch cover is within the firing range b on the crankshaft position sensor rotor Incorrect firing range Check the ignition system Engine idling speed 850 950 r min NOTE The ignition timing is not adjustable DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 6 Install Timing mark accessing screw Damper e Damper cover Damper cover bolt 10 Nm 1 0 m kg 7 2 ft Ib 7 Install Shift pedal assembly 1 Shift pedal bolt 18 Nm 1 8 m kg 13 ft lb AN NOTE Align the mark a on the shift pedal shaft with the slot in the shift pedal EAS20750 CHECKING THE ENGINE OIL LEVEL 1 Stand the vehicle on a level surface NOTE e Place the vehicle on a suitabl
151. EXUP valve pulley cover bolt 7 Nm 0 7 5 1 ft Ib EAS21140 CHASSIS EAS21190 ADJUSTING THE REAR DISC BRAKE 1 Check Brake position distance a from the top of the rider footrest to the top of the brake pedal Out of specification Adjust Brake pedal position 110 0 mm 4 33 in 2 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained Direction a Brake pedal is raised Direction b Brake pedal is lowered EWA13070 After adjusting the brake pedal position check that the end of the adjusting is visible through the hole gt f 2 S 3 20 CHASSIS c Tighten the locknut EW1D71005 A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance ECA13510 CAUTION After adjusting the brake pedal position make sure there is no brake drag DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Adjust Rear brake light switch Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 22 EAS21240 CHECKING THE BRAKE FLUID LEVEL
152. GINE OIL 1 Start the engine warm it up for several min utes and then turn it off 2 Place a container under the engine oil drain bolts 3 Remove Engine oil filler cap 1 4 Remove Engine oil drain bolt oil tank 1 along with the gasket 5 Remove Engine oil drain bolts crankcase 1 along with the gaskets 6 Drain Engine oil completely from the oil tank and crankcase 7 If the oil filter cartridge is also to be replaced perform the following procedure Remove the oil filter cartridge 1 with an oil filter wrench 2 Z Oil filter wrench gt 90890 01426 0 38411 A b Lubricate the O ring of the new oil filter cartridge with a thin coat of engine oil ECA13390 CAUTION Make sure the O ring 3 is positioned cor rectly in the groove of the oil filter cartridge OL ENGINE c Tighten the new oil filter cartridge to specifi cation with an oil filter wrench Syr filter cartridge 17 Nm 1 7 m kg 12 ft lb DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 8 Check e Engine oil drain bolt gaskets Damage Replace 9 Install e Engine oil drain bolt oil tank along with the gasket Syr Engine oil drain bolt oil tank 43 Nm 4 3 m kg 31 ft Ib 10 Install Engine oil drain bolts crankcase along with the gaskets Engine oil drain
153. Gta L VE RE 5 DA 69 9 Mn us A 69 _ TAM OD 18 wa WAS Ls Sac 5 5 EIS C o SSANYVH 805 M 3 adf 3 e 5 4 B T 24 e uM Ss um 9 L bom 2 Ss 1 lt 2 mW T 44 Nus ANN A 1 C 6 Ty 8 Gum 1 d x es m 9 5 it e ufo 6 u o 0 46 u H 9 9 EDEN ua 1 QM wa uet E E 449 W S MENS SS3NHVH 38 M SSS SSS 15 M 8 5 SS3NHVH3HM 7 63 Main switch Main fuse Battery 7 Fuel injection system fuse 11 Relay unit 13 Fuel pump relay 15 Diode 2 17 Fuel pump 27 ECU electronic control unit 68 Engine stop switch 77 gnition fuse 81 ECU fuse eu 7 64 FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate NOTE Before troubleshooting remove the following part s
154. HE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 1 Install Shift forks 1 1 Shift fork 2 2 Shift drum assembly 3 5 112 Shift fork guide bars 4 NOTE The embossed marks 107 on the shift forks should face towards the left side of the engine 2 Check Transmission Rough movement Repair NOTE Apply engine oil to each gear and bearing thor oughly Before assembling crankcase make sure that the transmission is in neutral and that the gears turn freely 5 113 TRANSMISSION FUEL SYSTEM 6 1 REMOVING THE FUEL TANK 6 3 REMOVING THE FEE PUMP 6 3 CHECKING THE F EE PUMIP BODY its 6 4 CHECKING THE FUEL PUMP OPERATION 6 4 THE FUEL 5 Fnit cun Go RIPE RS 6 4 INSTALLING TAE DANI cines 6 4 THROTILE BODIES Dante baleen iow 6 6 REMOVING THE PUELJAOSE 6 11 CHECKING THE MEG OPUS 6 11 CHECKING THE THROTTLE BODIES esee 6 11 CHECKING THE ROLLOVER VAL VIS 6 11 CHECKING THE PRESSURE 6 11 CHECKING THE PRESSURE REGULATOR OPERATION 6 11 ADJUSTING T
155. HE THROTTLE POSITION SENSOR 6 12 6 12 INSTALLING THE FUEL uei estere 6 13 ISC IDLE SPEED CONTROL 6 14 CHECKING THE ISC IDLE SPEED CONTROL SYSTEM 6 15 FUEL TANK 526620 FUEL TANK Removing the fuel tank Nm 0 7 m kg 5 1 ft Ib NEN Rider seat Rider seat bracket mE ID IEEE esit IRAM NN For installation reverse the removal proce dure 6 1 FUEL TANK Removing the fuel pump and sub fuel tank 10 Nm 1 0 m kg 7 2 ft Ib Omer Job Parts to remove seat Rider seat bracket EN Acid 1 1 Fuel tank Refer to FUEL TANK on page 6 1 EE NN Fuel outlet hose 1 Disconnect Air vent hose fuel pump to fuel hose join 1 O Disconnect 5 Fuel return hose fuel return pipe to sub fuel 1 tank p Seek _ For installation reverse the removal proce dure 1 2 Fuel hose connector cover 3 J j 6 2 EAS26630 REMOVING THE FUEL TANK 1 Extract the fuel in the fuel tank through the fuel tank cap with a pump
156. IAL TOOLS Reference Tool name Tool No pages Valve guide remover 26 90890 04064 Valve guide remover 6 0 mm YM 04064 A Valve guide installer 06 90890 04065 Valve guide installer 6 0 mm YM 04065 A Valve guide reamer 06 90890 04066 Valve guide reamer 6 0 mm YM 04066 Piston pin puller set 90890 01304 90890 01304 Piston pin puller YU 01304 Universal clutch holder 90890 04086 YM 91042 YM 91042 Sheave holder 90890 01701 Primary clutch holder YS 01880 A Yamaha bond No 1215 90890 85505 Three Bond No 121 5 Rotor puller 90890 01080 Stator rotor puller YM 01080 A Vacuum pressure pump gauge set 90890 06756 Pressure gauge 90890 03153 Fuel pressure adapter 90890 03176 YM 03176 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 SPECIAL TOOLS Reference SPECIAL TOOLS SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 ENGINE 85 2 2 CHASSIS SPECIFICATIONS eset 2 10 ELECTRICAL 8 2 13 TIGHTENING LOR QUES 2 16 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 16 ENGINE TIGHTENING
157. ISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR Battery Main fuse Main switch Ignition fuse Engine stop switch Diode 2 Helay unit starting circuit cut off relay Relay unit diode Clutch switch 10 Sidestand switch 11 Neutral switch 12 Start switch 13 Starter relay 14 Starter motor 15 ECU fuse 16 ECU electronic control unit 17 Diode 1 ELECTRIC STARTING SYSTEM 7 10 ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn NOTE Before troubleshooting remove the following part s 1 Rider seat 2 Tool kit tray 3 Headlight assembly 1 Check the fuses gt Main ignition and ECU Refer to CHECKING THE FUS ES on page 7 75 Check the battery gt Refer to CHECKING AND CHARGING THE BATTERY on page 7 76 OK Replace the fuse s Clean the battery terminals Recharge or replace the battery Check the starter motor operation OK Refer to CHECKING THE START ER MOTOR OPERATION on page 7 85 NG 4 Check starter motor NG Refer to CHECKING THE START Repair or replace the starter motor ER MOTOR on page 5 79 OK Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 Check the relay unit starting circuit 9 cut off relay Refer to CHECKING THE RE 5
158. KE MASTER CYLINDER 1 Check Brake master cylinder 1 Damage scratches wear Replace Brake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage scratches wear Replace 3 Check Brake master cylinder reservoir Cracks damage Replace Brake master cylinder reservoir diaphragm Damage wear Replace 4 Check e Brake hose Cracks damage wear Replace EAS22520 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents Recommended fluid DOT 4 EAS22530 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Front brake master cylinder 1 Front brake master cylinder holder 2 Front brake master cylinder hold er bolt 10 Nm 1 0 m kg 7 2 ft lb NOTE Align the end of the brake master cylinder hold er with the punch mark a on the handlebar FRONT BRAKE First tighten the rear bolt then the front bolt 2 Install Copper washers e Front brake hose 1 e Front brake hose union bolt 2 Front brake hose union 30 Nm 3 0 m kg 22 ft Ib 13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTI
159. L 5 18 US qt 4 31 Imp qt 60 0 kPa 900 r min 8 7 psi 900 r min 0 60 kgf cm 900 r min SAE80 GL 4 Hypoid gear oil 0 60 L 0 63 US qt 0 53 Imp qt 0 55 L 0 58 US qt 0 48 Imp qt Cartridge paper Trochoid Less than 0 12 mm 0 0047 in 0 20 mm 0 0079 in 0 09 0 19 mm 0 0035 0 0075 in 0 26 mm 0 0102 in 0 06 0 13 mm 0 0024 0 0051 in 0 20 mm 0 0079 in 80 0 120 0 kPa 11 6 17 4 psi 0 80 1 20 kgf cm 600 0 kPa 87 0 psi 6 00 kgf cm Trochoid Inner rotor to outer rotor tip clearance Limit Outer rotor to oil pump housing clearance Limit Oil pump housing to inner and outer rotor clearance Limit Spark plug s Manufacturer model Manufacturer model Spark plug gap Cylinder head Volume Warpage limit Camshaft Drive system Crankcase hole inside diameter Camshaft journal diameter crankcase side Camshaft to crankcase clearance Camshaft cover hole inside diameter Camshaft journal diameter camshaft cover side Camshaft to camshaft cover clearance Camshaft lobe dimensions Intake A Limit Intake B Limit Exhaust A Limit Exhaust B Limit 2 3 ENGINE SPECIFICATIONS Less than 0 12 mm 0 0047 in 0 20 mm 0 0079 in 0 10 0 15 mm 0 0039 0 0059 in 0 22 mm 0 0087 in 0 04 0 09 mm 0 0016 0 0035 in 0 160 mm 0 0063 in NGK DPR8EA 9 DENSO X24EPR U9 0 8 0 9 mm 0 031 0 035 in 80 90 84 90 4 94 5 18 cu in 0 03 mm 0 0012 in Gear dri
160. M 3 b DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 5 Install Upper bracket Refer to FRONT FORK on page 4 60 Mf Se d EAS21530 CHECKING THE FRONT FORK 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Check Inner tube Damage scratches Replace Oil seal Oil leakage Replace 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK on page 4 60 EAS21590 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EWA13120 Securely support the vehicle so that there is no danger of it falling over Spring preload ECA13590 CAUTION Never go beyond the maximum or minimum adjustment positions 1 Adjust e Spring preload NOTE Adjust the spring preload with the special wrench 1 Loosen the locknut 2 b Turn the adjusting ring 3 in direction D t 72 a Direction a Spring preload is increased suspen sion is harder Direction b Spring preload is decreased suspen sion is softer CHASSIS Spring preload adjusting posi tions Installed spring length Minimum 162 0 mm 6 38 in Standard XV19S C XV19
161. NG on page 2 45 NOTE Install the brake hose at a right angle to the front brake master cylinder as shown in the il lustration While holding the brake hose tighten the union bolt Turn the handlebar to the left and right to make sure the brake hose does not touch other parts e g wire harness cables leads Correct if necessary 2 V TN 3 Fill Brake master cylinder reservoir with the specified amount of the recom mended brake fluid Recommended fluid DOT 4 EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock ECA13540 CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 5 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 20
162. Nm 3 2 kg 23 ft Ib body a Refer to GENERAL CHASSIS on page mdp a 3 Frentbrakeightawien connector 2 4 tf Fewbaemeseronderawenhy 3 _ BE NN Throttle cable holder 7 handlebar switch IM ________ 22 Lm 7 2 C LLL Lo A DNI 4 55 HANDLEBAR Removing the handlebar 28 Nm 2 8 m kg 20 ft Ib Rm e S e S dure 4 56 EAS22860 REMOVING THE HANDLEBAR 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Remove Handlebar grip 1 NOTE Blow compressed air between the handlebar and the left handlebar grip and gradually push the grip off the handlebar VS EAS22880 CHECKING THE HANDLEBAR 1 Check Handlebar Bends cracks damage Replace EWA13690 Do not attempt to straighten a bent handle bar as this may dangerously weaken it EAS22930 INSTALLING THE HANDLEBAR 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Connect Throttle cable decelerator cable 1 to the right handlebar switch 2 NOTE Rotate the right handlebar switch and screw it onto
163. O pressure sensor NO O pressure sensor hose system Engine temperature sensor NO C2 Lean angle sensor latch up detected O Cylinder 2 intake air open or short circuit Cylinder 2 intake air open or short circuit Cylinder 2 intake air pressure sensor open or short circuit de tected Cylinder 2 intake air pressure sensor hose system malfunction clogged or detached hose Engine temperature sensor open or short circuit detected The vehicle has overturned 7 30 Fault code No Cylinder 1 left right ignition coil faulty ignition Cylinder 2 left or right ignition coil faulty ignition Cylinder 1 left or right ignition coil faulty ignition Cylinder 2 left or right ignition coil faulty ignition FUEL INJECTION SYSTEM Symptom Malfunction detected in the prima ry wire of the cylinder 1 left or right ignition coil Malfunction detected in the prima ry wire of the cylinder 2 left or right ignition coil Malfunction detected in the prima ry wire of the cylinder 1 left or right ignition coil Malfunction detected in the prima ry wire of the cylinder 2 left or right ignition coil Able un able to start Able depending on the number of faulty cylin ders Able depending on the number of faulty cylin ders Able depending on the number of faulty cylin
164. PE 5 27 INSTALLING THE CAMSHAFT Db 5 27 BLEEDING EISE 5 29 INSTALLING THE VALVE LIFTERS 5 30 INSTALLING THE ROCKER ARMS AND PUSH RODS 5 31 INSTALLING THE CYLINDER HEAD 85 2 2 5 32 INSTALLING THE SHIFT PEDAL 55 5 32 CYLINDER HEADS ese iara ves 5 33 REMOVING THE CYLINDER ABAD 5 35 CHECKING THE CYLINDER 5 seem 5 35 CHECKING TTE OIL TP E ds 5 35 INSTALLING THE CYLINDER 5 36 VALVES AND VALVE SPRINGS 5 38 THE VALVES 5 39 CHECKING THE VALVES AND VALVE GUIDES 5 39 CHECKING THE VALVE 5 5 41 CHECKING THE VALVE SPRINGS tree ea eot xe n ei epis 5 42 INSTALLING THE VALVES Ern mpi n rud 5 43 CYLINDERS AND PISTONS irene nee 5 45 REMOVING PISTON PUMP EE 5 46 CHECKING THE CYLINDERS AND PISTONS 5 46 CHECKING THE PISTON RINGS 5 47 CHECKING THE PISTON PINS 6
165. PIPES 1 Check Oil pipes Damage gt Replace EAS25520 ASSEMBLING THE TRANSFER GEAR OIL PUMP 1 Lubricate Transfer gear oil pump inner rotor Transfer gear oil pump outer rotor Transfer gear oil pump shaft with the recommended lubricant Recommended lubricant Engine oil 2 Install Transfer gear oil pump shaft 1 to the transfer gear oil pump housing 2 e Washer 3 e Pin 4 Transfer gear oil pump inner rotor 5 TRANSFER GEAR CASE e Transfer gear oil pump outer rotor 6 e Transfer gear oil pump cover 7 NOTE When installing the inner rotor align the pin in the oil pump shaft with the groove in the inner ro tor Syr Oil pump housing screw 4 Nm 0 4 m kg 2 9 ft lb 3 Check Transfer gear oil pump operation Refer to CHECKING THE TRANSFER GEAR OIL PUMP on page 5 86 EAS25530 INSTALLING THE TRANSFER GEAR CASE 1 Install Spacer 1 NOTE Install the spacer with its groove a towards the drive pulley 2 Install e Middle driven shaft 1 Middle drive gear 2 Primary chain into the transfer gear case Drive pulley nut NOTE Install the primary chain with its blue link facing outward TRANSFER GEAR CASE Install the middle drive gear 2 with its cham fered side facing b the transfer gear case Install the middle driven shaft middle drive gear and prima
166. R CYLINDER 1 Check Brake master cylinder Damage scratches wear Replace Brake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air 4 52 2 Check Brake master cylinder kit Damage scratches wear Replace 3 Check Brake fluid reservoir Cracks damage Replace Brake fluid reservoir diaphragm Cracks damage 4 Check Brake hoses Cracks damage wear Replace EAS22730 ASSEMBLING THE REAR BRAKE MASTER CYLINDER EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents EAS22740 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install Copper washers 1 e Rear brake hose 2 e Rear brake hose union bolt 3 Recommended fluid DOT 4 Rear brake hose union bolt 30 Nm 3 0 m kg 22 ft Ib EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 45 EC1D71009 CAUTION When installing the brake hose onto the brake master cylinder make sure the brake pipe touches the projection a on the brake caliper bracket as shown REAR BRAKE a eae je 2 N 2 Fill Brake fluid reservoir with the specified amount of the recom mended brake fluid Recommended fluid DOT 4 EWA130
167. R SUSPENSION 3 30 ELECTRICAL SYSTEM apii gn UR oe Ups 3 31 CHECKING AND CHARGING THE 3 31 OHEONING LHE FUSES eite tete ni 3 31 REPLACING THE HEADLIGHT 3 31 ADJUSTING THE HEADLIGHT 3 32 PERIODIC MAINTENANCE EAS20450 PERIODIC MAINTENANCE EAS20460 INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments followed these preventive maintenance procedures will ensure more reliable vehicle operation a long er service life and reduce the need for costly overhaul work This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale All service technicians should be familiar with this entire chapter EAU17600 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM INITIAL ODOMETER READINGS ITEM ROUTINE or Check fuel hoses for cracks or damage y if necessary Check condition Adjust gap and clean Spark plugs Replace every 8000 mi 13000 km 12 months Check and adjust valve clear ave clearance _ clearance ance when engine is cold Every 16000 mi 25000 km Adjust if necessary
168. S EAS28150 CHECKING THE STATOR COIL 1 Disconnect e Stator coil coupler from the rectifier regulator 2 Check e Stator coil resistance Out of specification Replace the stator coil Stator coil resistance 0 112 0 168 a Connect the pocket tester x 1 to the stator coil coupler as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe gt white 1 Negative tester probe white 2 Positive tester probe gt white 1 Negative tester probe white 3 Positive tester probe white 2 Negative tester probe white 3 123 b Measure the stator coil resistance 528170 CHECKING THE RECTIFIER REGULATOR 1 Check Charging voltage Out of specification Replace the rectifi er regulator Charging voltage 14 V at 5000 r min Set the engine tachometer to the cylinder 1 left spark plug lead or right spark plug lead b Connect the pocket tester DC 20 V to the rectifier regulator coupler as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe gt red 1 Negative tester probe black 2 c Start the engine and let
169. TE J Do not allow the fuel tank to empty itself com pletely Fuel gauge 1 Fuel gauge 1 5 FEATURES The fuel gauge does not indicate the correct fuel level for the first 5 km h 3 mi h after refu eling Odometer tripmeter and clock modes 1 Odometer tripmeter fuel reserve tripmeter clock Push the SELECT switch to switch the display between the odometer mode the tripme ter modes TRIP 1 and TRIP 2 and the clock mode in the following order ODO TRIP 1 TRIP 2 gt Clock ODO If the fuel level warning light comes on the odometer display will automatically change to the fuel reserve tripmeter mode F TRIP and start counting the distance traveled from that point In that case push the SELECT switch to switch the display between the various tripme ter odometer and clock modes in the following order F TRIP gt TRIP 1 TRIP 2 gt Clock gt F TRIP To reset a tripmeter select it by pushing the SE LECT switch and then push the RESET switch for at least one second If you do not reset the fuel reserve tripmeter manually it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km 3 mi Clock mode To set the clock 1 Push the SELECT switch to change the dis play to the clock mode Push the SELECT and RESET switches together for at least two se
170. TE ubricate the primary drive gear bolt threads with engine oil While holding the generator rotor 3 with the sheave holder 4 tighten the primary drive gear bolt 02 Sheave holder 90890 01701 Primary clutch holder YS 01880 A CLUTCH e Washer Conical spring washer 2 Clutch boss nut 3 Clutch boss nut 105 Nm 10 5 m kg 75 ft lb NOTE ubricate the clutch boss nut threads and con ical spring washer mating surfaces with engine oil Install the conical spring washer 2 with the OUT mark a facing out While holding the clutch boss with the univer sal clutch holder 4 tighten the clutch boss nut e Stake the clutch boss nut 3 at a cutout b in the main axle Universal clutch holder 90890 04086 EAS25260 91042 INSTALLING THE CLUTCH 1 Install Clutch housing Thrust washer NOTE Lubricate the clutch housing bearings with en gine oil Make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly Make sure that the primary driven gear teeth and oil pump driven gear teeth mesh correctly 4 Lubricate 2 Install Friction plates Clutch boss assembly 1 Clutch plates NOTE 0 with the recommended lubricant Install the clutch damper spring 2 with the OUTSIDE mark facing out Recommended lubricant f the wire circlip 3 has been
171. THE CLUTCH MASTER CYLINDER 5 67 INSTALLING THE CLUTCH MASTER CYLINDER 5 67 REMOVING THE CLUTCH RELEASE CYLINDER 5 68 CHECKING THE CLUTCH RELEASE 5 68 ASSEMBLING THE CLUTCH RELEASE CYLINDER 5 68 INSTALLING THE CLUTCH RELEASE 5 69 SHIFT STW a vetns as De 5 70 CHECKING THE SHIFT SHAFT eene 5 71 CHECKING THE STOPPER a a 5 71 INSTALLING THE SHIFT SHAFT 5 71 GENERATOR AND STARTER CLUTCH 5 72 REMOVING THE 5 74 REMOVING THE STARTER CLUTCH 4 em 5 74 CHECKING THE STARTER CLUTOCH eene 5 74 CHECKING THE TORQUE 5 75 INSTALLING THE STARTER 5 75 INSTALLING THE GENERATOR otiosus gus 5 5 52 Ras 5 77 CHECKING THE STARTER ides teet 5 79 ASSEMBLING THE STARTER 5 80 TRANSFER GEAR CASE trim ex 5 81 REMOVING THE MIDDLE DRIVEN 5 86 CHECKING THE MIDDLE DRIVE HUS 5 86 CHECKING
172. TS EAS27970 7 67 9 OF ee Cylinder 2 right ignition coil Cylinder 2 left ignition coil Fuel sender Engine temperature sensor Cylinder 1 left ignition coil Cylinder 1 right ignition coil ECU electronic control unit EXUP servo motor Speed sensor 10 Rectifier regulator 11 Neutral switch 12 Horn 2 13 Horn 1 14 15 idle speed control unit 7 68 ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS 7 69 Air temperature sensor Main switch Cylinder 2 intake air pressure sensor Throttle position sensor Cylinder 1 intake air pressure sensor Fuse box Starter relay Fuel injection system fuse 9 Battery 10 Diode 2 11 Turn signal relay 12 Headlight relay 13 Relay unit 14 Diode 1 15 Main fuse 16 Lean angle cut off switch 17 Crankshaft position sensor 18 Rear brake light switch pO EX OD aes 7 70 ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 5 gt lt 7 71 Main switch Engine stop switch Start switch Accessory light switch Front brake light switch Neutral switch Sidestand switch Rear brake light switch 9 Clutch switch 10 Horn switch 11 Dimmer switch 12 Select switch 13 Turn signal switch poc OD ME IN 7 72 ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester If the continuity reading is incorrect check the wir
173. UE 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 emm w 85 er 22mm temm 130 180 96 2 16 EAS20340 ENGINE TIGHTENING TORQUES Thread Cylinder head nut head nut M12 2 60 Nm 6 0 43 ft lb Oris ren aT head stud bolt exhaust 15 Nm 1 5 m kg 11 ftlb mM me a TON mG tb Ergin temperate Roderambesebot 4 0Nm Omio72Rb lt wa gt Cylinder head cover bolt 10 Nm 0 m kg 7 2 ft Ib Connecting rod bolt 1st M8 15 Nm 1 5 m kg 11 ft lb Connecting rod bolt final M8 Specified angle 125 1352 Right balancer driven gear bolt 40 Nm 4 0 m kg 29 ft lb 4 t Left balancer drive gear bolt 40 Nm 4 0 m kg 29 ft lb lt O Left balancer driven gear housing Left balancer weight bolt 10 Nm 1 0 m kg 7 2 ft lb Left balancer
174. UTING on page 2 45 NOTE Install the clutch hose at 5 25 a angle to the clutch master cylinder as shown in the illustra tion While holding the clutch hose tighten the union bolt Turn the handlebar to the left and right to make sure the clutch hose does not touch other parts e g wire harness cables leads Correct if necessary 3 Fill Clutch master cylinder reservoir with the specified amount of the recom mended clutch fluid Recommended clutch fluid Brake fluid DOT 4 EWA13370 Use only the designated clutch fluid Other clutch fluids may cause the rubber seals to deteriorate causing leakage and poor clutch performance Refill with the same type of clutch fluid that is already in the system Mixing clutch flu ids may result in a harmful chemical reac tion leading to poor clutch performance When refilling be careful that water does not enter the clutch fluid reservoir Water Will significantly lower the boiling point of the clutch fluid and could cause vapor lock ECA13420 CAUTION Clutch fluid may damage painted surfaces or plastic parts Therefore always clean up any spilt clutch fluid immediately NOTE In order to ensure a correct reading of the clutch fluid level make sure the top of the reservoir is horizontal 4 Bleed Clutch system Hefer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 15 5 Check e Clutch fluid level Below the minimum
175. WA13290 Batteries generate explosive hydrogen gas and contain electrolyte which is made of poi sonous and highly caustic sulfuric acid Therefore always follow these preventive measures Wear protective eye gear when handling or working near batteries Charge batteries a well ventilated area Keep batteries away from fire sparks open flames e g welding equipment lighted cigarettes DO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion EC1D71020 CAUTION This is a sealed battery Never remove the sealing caps because the balance between cells will not be maintained and battery per formance will deteriorate Charging time charging amperage and charging voltage for an MF battery are dif ferent from those of conventional batteries The MF battery should be charged accord ing to the instructions for the charging method If the battery is overcharged the ELECTRICAL COMPONENTS electrolyte level will drop considerably
176. WA13620 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort Whenever a brake caliper 15 disassembled replace the brake caliper piston seals EAS22670 INSTALLING THE REAR BRAKE CALIPER 1 Install Rear brake caliper 1 temporarily Copper washers e Rear brake hose 2 e Rear brake hose union bolt 3 Syr Rear brake hose union bolt 30 Nm 3 0 m kg 22 ft Ib EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 45 ECA14170 CAUTION When installing the brake hose onto the brake caliper 1 make sure the brake pipe touches the projection b on the brake caliper 238 vi 3 2 Recommended fluid DOT 4 Im 1 2 Remove Rear brake caliper 3 Install Brake pads 4 51 Brake pad springs Rear brake caliper bolts Rear brake caliper Refer to REPLACING THE REAR BRAKE PADS on page 4 49 Rear brake caliper bolt 27 Nm 2 7 m kg 19 ft Ib 4 Fill Brake fluid reservoir with the specified amount of the recom mended brake fluid Recommended fluid DOT 4 EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals
177. XV19CT C XV19CTM C 48 Nm 4 8 kg 35 ft Ib 23 Nm 2 3 kg 17 ft Ib 48 Nm 4 8 kg 35 ft Ib 23 Nm 2 3 m 17 ft Ib Omer Job Parts to remove Sidebag Backrest to GENERAL CHASSIS on page footrest left and right NOTE Remove only one sidebag bracket at a time 3 Sidebag bracket left and right If both brackets are removed at the same time the rear fender will fall NOTE 4 O sensor lead guide Pass the sensor lead through the guide dure 4 7 ET1D71047 CHECKING THE SIDEBAG BRACKET SPRING NUTS 1 Check e Sidebag bracket spring nut height a Out of specification Adjust Sidebag bracket spring nut height 12 0 mm 0 47 in 2 Check e Sidebag bracket spring nuts Damage Replace 4 8 GENERAL CHASSIS GENERAL CHASSIS Removing the seats and side covers 16 Nm 1 6 kg 11 ft Ib 7 Nm 0 7 kg 5 1 ft Ib Job Parts to remove Q ty 2 Passenger seat 3 Toolkit NE Tool kit tray OU o 5 Rider seat bracket assembly 71 22 22 NEL EN Seat lock cable assembly dure 4 9 GENERAL CHASSIS Removing the headlight 7 Nm 0 7 m kg 5 1 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib Air temperature sensor coupler 1 Disconnect ae a I
178. Yamaha Service Manual Arranged by CycleHippie The best Service Manuals have been CycleHippied Over 30 Years of Powersports Industy Experience goes into the arrangement of the official Yamaha Factory Service Data If you obtained this manual from a source other than CycleHippie It may not have been properly CycleHippied Go to CycleHippie eBay Store _ PowerSeller www CycleHippie com YAMAHA XV19SW C XV19W C XV19MW C XV19CTSW C XV19CTW C XV19CTMW C SERVICE MANUAL EAS20050 XV19SW C XV19W C XV19MW C XV19CTSW CyXV19CTW C XV19CTMW C SERVICE MANUAL 92006 by Yamaha Motor Corporation U S A First edition July 2006 rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A 15 expressly prohibited Printed in U S A P N LIT 11616 20 40 EAS20070 NOTICE This manual was produced by the Yamaha Motor Company Ltd primarily for use by Yamaha dealers and their qualified mechanics It is not possible to include all the knowledge of a mechanic in one man ual Therefore anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi cle unsafe and unfit for use This model has been designed and man
179. _______ For assembly reverse the disassembly cedure I 5 59 REMOVING THE CLUTCH 1 Loosen e Clutch boss nut 1 NOTE While holding the clutch boss 2 with the univer sal clutch holder 3 loosen the clutch boss nut Universal clutch holder 90890 04086 YM 91042 Clutch boss nut 1 Conical spring washer 2 e Washer 3 Clutch boss assembly 4 NOTE There is a built in damper between the clutch boss and the clutch plate It is not necessary to remove the wire circlip 5 and disassemble the built in damper unless there is serious clutch chattering EAS25090 REMOVING THE PRIMARY DRIVE GEAR 1 Loosen Primary drive gear bolt 71 NOTE While holding the generator rotor 2 with the sheave holder 3 loosen the primary drive gear bolt 5 60 CLUTCH Va Sheave holder 90890 01701 Primary clutch holder YS 01880 A ET1D71021 REMOVING THE LEFT BALANCER DRIVE GEAR 1 Loosen Left balancer drive gear bolt 1 While the holding the generator rotor 2 with the primary sheave holder 3 loosen the left bal ancer drive gear bolt 2 Sheave holder 90890 01701 Primary clutch holder YS 01880 A CLUTCH A Friction plate 1 3 EAS25100 B Friction plate 2 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric EAS25110 tion plates CHECKING THE
180. air temperature 7 37 Checking method Check with throttle fully closed Check with throttle fully open Set the engine stop switch to and then push the start switch s If the dis play value changes the performance is OK Set the engine stop switch to O and then push the start switch If the dis play value changes the performance is OK Compare the actually mea sured air temperature with the meter display value Check that the number in creases when the rear wheel is rotated The num ber is cumulative and does not reset each time the wheel is stopped Remove the lean angle sensor and incline it more than 65 degrees Fuel system voltage battery voltage Engine temperature Sidestand switch e Stand retracted e Stand extended Neutral switch Neutral n gear EXUP servo motor EEPROM fault code dis play No history History exists Malfunction history code display No history History exists Malfunction history code erasure No history History exists FUEL INJECTION SYSTEM Meter display Approximately 12 0 Displays the engine tempera ture Displays the operating angle Engine trouble warning light comes on twice once when the EXUP valve is closing and once when it is opening 00 01 or 02 Cylinder fault code If both cylinders are defec tive the display alternates every two seconds 00
181. air the signaling system wiring 1 Check the fuel level warning light gt Refer to CHECKING THE FUEL the meter assembly or fuel pump LEVEL WARNING LIGHT on page assembly 7 88 OK 1 7 25 SIGNALING SYSTEM 2 Check the fuel sender fuel pump gt Refer to CHECKING THE FUEL SENDER FUEL PUMP on page Replace the fuel pump assembly 7 88 OK 4 Check the entire signaling system gt wiring Refer to CIRCUIT DIAGRAM on page 7 21 This circuit is OK The speedometer fails to operate 1 Check the speed sensor NG Refer to CHECKING THE SPEED the speed sensor SENSOR on page 7 88 OK Properly connect or repair the signaling system wiring 2 Check the entire signaling system gt wiring Properly connect or repair the signaling Refer to CIRCUIT DIAGRAM on page 7 21 OK Replace the meter assembly system wiring 7 26 FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM amp Bajau fo MJ SS3NuvH dH assaNuvH MENS ss3NuvH 5 8 Voto Pay SSANHVH 3H M Tay Eo 12 gt lt Sn F D 45 S QS Qi T Giove 69 09
182. air to enter the hydraulic brake system considerably lengthening the bleeding procedure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 2 Bleed Hydraulic brake system a Fill the brake fluid reservoir to the proper level with the recommended brake fluid b Install the diaphragm brake master cylinder reservoir or brake fluid reservoir c Connect a clear plastic hose 1 tightly to the bleed screw 2 XA SAS Q A Front B Rear d Place the other end of the hose into a con tainer e Slowly apply the brake several times f Fully pull the brake lever or fully press down the brake pedal and hold it in position g Loosen the bleed screw CHASSIS NOTE Loosening the bleed screw will release the pres sure and cause the brake lever to contact 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 Bleed screw front brake caliper 6 Nm 0 6 m kg 4 3 ft lb Bleed screw rear brake caliper 6 Nm 0 6 m kg 4 3 ft lb k Fill the brake
183. all e Rear cylinder camshaft gear 1 Front cylinder camshaft gear 2 e Washer 3 Conical spring washer 4 e Washer 5 Circlip 6 CAMSHAFTS NOTE Align the projection a on the washer 3 with the punch mark b on the front cylinder cam shaft gear Install the conical spring washer 4 as shown in the illustration Lubricate the front cylinder camshaft gear bolt threads with engine oil 6 Tighten Front cylinder camshaft gear bolt 1 Front cylinder camshaft gear bolt 40 Nm 4 0 m kg 29 ft Ib NOTE Place a folded copper washer 2 between the teeth of the front cylinder camshaft gear and rear cylinder camshaft gear in order to lock them Do not damage the teeth of the front cylinder camshaft and rear cylinder camshaft gears After tightening the front cylinder camshaft gear bolt remove the copper washer to clean the teeth of the front cylinder camshaft and rear cylinder camshaft gears CAMSHAFTS NOTE Place a folded copper washer 2 between the teeth of the camshaft drive gear and camshaft driven gear in order to lock them Do not damage the teeth of the camshaft drive and driven gears After tightening the camshaft driven gear bolt remove the copper washer to clean the teeth of the camshaft drive and camshaft driven gears 7 Install e Straight key driven gear 1 NOTE
184. and make sure the crankcase halves sepa rate evenly CRANKCASE EAS25580 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air ET1D71005 CHECKING THE BEARINGS AND OIL SEAL 1 Check Bearings Clean and lubricate the bearings then rotate the inner race with your finger Rough movement Replace Oil seals Damage wear Replace EAS25590 CHECKING THE OIL DELIVERY PIPE AND OIL PIPE 1 Check Oil delivery pipe Oil pipes Damage Replace Obstruction Wash and blow out with com pressed air ET1D71038 CHECKING THE OIL STRAINERS 1 Check e Oil strainers Damage Replace Contaminants Clean with solvent EAS25610 CHECKING THE ENGINE OIL PUMP DRIVEN GEAR 1 Check Engine oil pump driven gear Chips pitting roughness wear Replace ET1D71034 INSTALLING THE BEARING RETAINERS 1 Install Bearing retainers 1 NOTE Apply locking agent LOCTITES to the threads of the bearing retainer bolts e Stake the bearing retainer bolts 2 EAS25690 ASSEMBLING THE CRANKCASE 1 Apply e Sealant onto the crankcase mating surfaces 5 Yamaha bond No 1215 2 90890 85505 Three Bond No 12159 CRANKCASE Joint pipe 4 3 I
185. axle nut 1 ENS EE Loosen both locknuts 2 Turn both adjusting bolts 3 in direction a or b until the specified drive belt slack is ob tained Direction Drive belt is tightened Direction b Drive belt is loosened CHASSIS NOTE Using the alignment marks on each side of the swingarm make sure that both belt pullers are in the same position for proper wheel alignment d Tighten the locknuts to specification Locknut drive belt adjusting bolt 16 Nm 1 6 m kg 11 ft Ib e Tighten the rear wheel axle nut to specifica 3 25 tion Rear wheel axle nut 150 Nm 15 0 m kg 110 5 Install Muffler Refer to ENGINE REMOVAL on page 5 1 EWA12800 Always use a new gasket EAS21510 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 2 Check e Steering head Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head xs gt Q 3 Remove Upper bracket Refer to FRONT FORK on page 4 60 4 Adjust e Steering head
186. bearings and oil seals the reverse order of disassembly EC1D71011 gt 2 Check Do not contact the wheel bearing inner race e Tire 1 or balls 2 Contact should be made e Front wheel only with the outer race 3 Damage wear Replace NOTE Refer to CHECKING THE TIRES on page 3 27 and CHECKING THE WHEELS on page 3 29 3 Measure e Radial wheel runout 1 Lateral wheel runout 2 Over the specified limits Replace Use a socket 4 that matches the diameter of the wheel bearing outer race and oil seal Radial wheel runout limit 1 0 mm 0 04 in Lateral wheel runout limit 0 5 mm 0 02 in DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 2 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE After replacing the tire wheel or both the front wheel static balance should be adjusted Adjust the front wheel static balance with the brake disc installed 4 Check E Wheel bearings 4 iaht Front wheel turns roughly or is loose Re weight s place the wheel bearings Front wheel s heavy spot Oil seals Damage wear Replace Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X4 mark at the bottom of the wheel 4 19 FRONT WHEEL c Turn the front wheel 90
187. bolt crankcase 43 Nm 4 3 m kg 31 ft lb 11 Fill Oil tank with the specified amount of the recom mended engine oil Engine oil quantity Total amount 5 20 L 5 50 US qt 4 58 Imp qt Without oil filter cartridge re placement 4 10 L 4 33 US qt 3 61 Imp qt With oil filter cartridge replace ment 4 90 L 5 18 US qt 4 31 Imp qt NOTE Pour the engine oil in two stages First pour in 2 5 L of oil then start the engine and rev it 3 to 5 times Stop the engine and then pour in the re mainder of the specified amount EC1D71008 CAUTION When starting the engine make sure the dip stick is securely fitted into the oil tank 12 Fill when engine is disassembled Crankcase and oil tank with the specified amount of the recom mended engine oil Engine oil quantity Total amount 5 20 L 5 50 US qt 4 58 Imp qt Engine 3 2 L 3 38 US qt 2 82 Imp qt Oil tank 2 0 L 2 11 US qt 1 76 Imp qt 13 Install Engine oil filler cap 14 Start the engine warm it up for several min utes and then turn it off 15 Check Engine for engine oil leaks 16 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 11 17 Check Engine oil pressure a Slightly loosen the oil gallery bolts 1 A EE g X BIN b Start the engine and keep it idling until engine oil starts to seep fro
188. bolts right upper side NOTE Engine bracket left upper side Tighten the cylinder head nuts in the proper Engine bracket bolts left upper side tightening sequence as shown and torque them Engine mounting bolts left upper side in two stages NOTE Apply locking agent LOCTITES to the threads of the engine mounting bolts left upper side Do not fully tighten the bolts 6 Tighten Engine mounting bolts right upper side Engine mounting bolts left upper side Engine bracket bolts right upper side Engine bracket bolts left upper side 5 36 Engine mounting bolt right up per side 59 Nm 5 9 m kg 43 16 Engine mounting bolt left upper side 66 Nm 6 6 m kg 48 16 LOCTITE9 Engine bracket bolt right upper side 53 Nm 5 3 m kg 38 ft lb Engine bracket bolt left upper side 53 Nm 5 3 m kg 38 ft lb 5 37 CYLINDER HEADS VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs The following procedure applies to both inders Cylinder heads EE Refer to CYLINDER HEADS on page 5 33 I Valve spring 7 6 wesmam 8 NO For installation reverse the removal proce dure 5 38 EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components NOTE Before removing the internal par
189. brown 1 Negative tester probe ground b Turn the main switch to ON c Measure the turn signal relay input voltage DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 2 Check Turn signal relay output voltage Out of specification Replace lj Turn signal relay output voltage DC 12V a Connect the pocket tester DC 20 V to the turn signal relay terminal as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe brown white 1 yellow red 2 or white yel low 3 Negative tester probe ground b Turn the main switch to ON c Measure the turn signal relay output voltage DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS28050 CHECKING THE DIODES Relay unit diode 1 Check Relay unit diode Out of specification Replace Pocket tester 90890 03112 Analog pocket tester YU 03112 C NOTE The pocket tester or the analog pocket tester readings are shown in the following table ELECTRICAL COMPONENTS Continuity Positive tester probe sky blue 4 22 Negative tester probe black yellow 2 No continuity Positive tester probe black yellow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 4 33 Negative tester probe blue yellow 3 No continuity Positive tester probe blue yellow 3 N
190. cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect the throttle body synchronization leading to poor en gine performance and possible overheating NOTE When installing the air filter element into the air filter case make sure that the sealing surfaces are aligned to prevent any air leaks 7 Install Fuel tank Refer to FUEL TANK on page 6 1 Hider seat Refer to GENERAL CHASSIS on page 4 1 ENGINE EAS21010 CHECKING THE THROTTLE BODY JOINTS The following procedure applies to all of the throttle body joints and intake manifolds 1 Remove Rider seat Rider seat bracket assembly Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 2 Check Throttle body joints 1 Cracks damage Replace CS D L I lt 3 Install Air filter case Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 1 Rider seat bracket assembly e Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS21030 CHECKING THE FUEL LINE The following procedure applies to all of the fuel air vent and breather hoses 1 Remove Rider seat Rider seat bracket assembly Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 1 2 Check Fuel hoses 1
191. ce For XV19CTS C XV19CT C and XV19CTM NOTE 1 First tighten the lower ring to approximately 52 Nm 5 2 m kg 37 ft lb with a torque wrench then loosen the lower ring nut completely 2 Retighten the lower ring nut to 18 Nm 1 8 m kg 13 ft lb with a torque wrench ss Co CO 2 26 LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE lt lt lt a lt a a Gasket left balancer driven gear housing Flange bolts left balancer drive gear and right balancer driven gear iG Flange camshaft gear lt O Valve stems intake and exhaust 1 Valve stem ends intake and exhaust lt O lt lt a Camshaft front and rear cylinders 4 t Oil pump rotors inner and outer and oil pump housing lt lt 2 27 LUBRICATION POINTS AND LUBRICANT TYPES Transmission gears wheel and pinion and collar Yamaha bond No 1215 Three Bond No 12159 Yamaha bond No 1215 Three Bond No 12159 Yamaha bond Crankshaft position sensor lead grommet No 1215 Three Bond 12159 Crankcase mating surface Stator coil lead grommet 2 28 LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Steering bearings and upper bearing dust cover lip Lower bearing dust seal lip Front wheel oil seal lips left and right Rear wheel o
192. ce if there is an open or short circuit Between the crankshaft position sensor coupler and ECU cou pler gray gray black blue black blue Defective crankshaft position sensor Replace if defective Refer to CHECKING THE CRANKSHAFT POSITION SENSOR on page 7 84 7 41 FUEL INJECTION SYSTEM Fault code No Symptom Cylinder 1 intake air pressure sensor open or short cir cuit detected Diagnostic code No Cylinder 1 intake air pressure sensor Item components and probable Check or maintenance job cause Connections Cylinder 1 intake air pressure sen sor coupler Main wire harness ECU coupler Open or short circuit in wire harness Defective cylinder 1 intake air pres sure sensor Reinstatement method e Check the coupler for any pins that may be pulled out Check the locking condition of the coupler f there is a malfunction repair it and connect the coupler se curely Turning the main switch to ON Repair or replace if there 15 an open or short circuit Between cylinder 1 intake air pressure sensor coupler and ECU coupler black blue black blue pink white pink white blue blue Execute the diagnostic mode Code No 03 Replace if defective Refer to CHECKING THE IN TAKE AIR PRESSURE SEN on page 7 90 7 42 FUEL INJECTION SYSTEM Fault code No Symptom Cylinder 1 intake air pressure s
193. charge the MF battery A vari able voltage charger is recommended d Charge the battery until the battery s charg ing voltage is 15 V NOTE 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 ELECTRICAL COMPONENTS 12 8 V or more Charging is complete 12 7 V or less Recharging is required Pocket tester 90890 03112 Under 12 0 V Replace the battery Analog pocket tester YU 03112 C 8 Install 1 Disconnect the relay from the wire harness Battery 2 Connect the pocket tester 0 x 1 and battery 9 Connect 12 V to the relay terminals as shown Check the relay operation Out of specification Replace Battery leads to the battery terminals ECA13630 Starter rela First connect the positive battery lead 1 and then the negative battery lead 2 3 NOTE sure to route the negative battery lead to P wards the front of the vehicle and to install the C negative terminal cover 3 securely Positive battery terminal Negative battery terminal Positive tester probe Negative tester probe poo Result 10 Check Continuity Battery terminals between 3 and 4 Dirt Clean with a wire brush Loose connection C
194. ck e ire Hear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 27 and CHECKING THE WHEELS on page 3 29 3 Measure Radial wheel runout e Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 18 Radial wheel runout limit 1 0 mm 0 04 in Lateral wheel runout limit 0 5 mm 0 02 in ET1D71024 CHECKING THE REAR BRAKE CALIPER BRACKET 1 Check Rear brake caliper bracket Cracks damage Replace EAS22110 CHECKING THE REAR WHEEL DRIVE HUB 1 Check Rear wheel drive hub Cracks damage Replace Rear wheel drive hub dampers Damage wear Replace EAS22130 CHECKING AND REPLACING THE REAR WHEEL PULLEY 1 Check Rear wheel pulley Surface plating has come off Replace the rear wheel pulley Bent teeth Replace the rear wheel pulley 2 Replace Rear wheel pulley a Remove the self locking nuts and the rear wheel pulley b Clean the rear wheel drive hub with a clean cloth especially the surfaces that contact the pulley c Install the new rear wheel pulley Rear wheel pulley self locking nut 95 Nm 9 5 m kg 68 ft lb NOTE Tighten the self locking nuts in stages and in a crisscross pattern EAS22140 ASSEMBLING THE REAR WHEEL 1 Install Wheel bearin
195. ck Red B Y Black Yellow Br L Brown Blue Br W Brown White G L Green Blue G R Green Red G W Green White G Y Green Yellow Gy G Gray Green Gy R Gray Red Gy W Gray White L B Blue Black L G Blue Green L R Blue Red L W Blue White L Y Blue Yellow P L Pink Blue P W Pink White P Y Pink Yellow R B Red Black R G Red Green R L Red Blue R W Red White R Y Red Yellow Sb W Sky blue White W B White Black W G White Green W R White Red W Y White Yellow Y B Yellow Black Y G Yellow Green Y L Yellow Blue Y R Yellow Red YAMAHA YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN
196. ck that the sensor is in stalled in the specified position Connections Check the coupler for any pins hrottle position sensor coupler that may be pulled out Main wire harness ECU coupler Check the locking condition of Sub wire harness 2 coupler the coupler f there is a malfunction repair it and connect the coupler se curely Open or short circuit in wire harness Repair or replace if there is and or sub lead open or short circuit Between throttle position sen sor coupler and ECU coupler blue blue yellow yellow black black Throttle position sensor lead wire Check for open circuit and re open circuit output voltage check place the throttle position sen sor black yellow Open circuit Output voltage item Ground wire 5V open circuit Output wire open circuit Power supply wire open cir cuit Defective throttle position sensor Execute the diagnostic mode Code No 01 Replace if defective Refer to CHECKING THE 3 5 THROTTLE POSITION SEN on page 7 89 7 44 Fault code No Diagnostic code No Connections EXUP servo motor coupler Main wire harness ECU coupler Open or short circuit in wire harness Defective EXUP servo motor potenti ometer circuit FUEL INJECTION SYSTEM Symptom EXUP servo motor circuit open or short circuit detected 55 EXUP servo motor Check or maint
197. con NOTE O necting arms and rear shock absorber Be sure to face the FWD mark a on the relay A Install arm 1 toward the front of the vehicle and to r face the label b on the rear shock absorber 2 ushings downward to connecting arms 4 78 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM 6 Tighten Connecting arm to relay arm nut Connecting arm to relay arm nut 59 Nm 5 9 m kg 43 16 Rear shock absorber assembly to relay arm nut Rear shock absorber assembly to relay arm nut 40 Nm 4 0 m kg 29 ft Ib Helay arm to swingarm nut EAS28780 INSTALLING THE SWINGARM 1 Lubricate Bearings e Collars Oil seals Pivot shaft Relay arm to swingarm nut 59 Nm 5 9 m kg 43 16 Recommended lubricant Lithium soap based grease 2 Install Bearings 1 to swingarm Installed depth a 1 0 mm 0 04 in 2 Swingarm A Left side B Right side 3 Install Pivot shaft Washer Pivot shaft nut NOTE Temporarily tighten the pivot shaft nut 4 Install Connecting arm bolt front side NOTE When installing the connecting arm bolt hold the swingarm so that it does not drop down 5 Tighten Pivot shaft nut Engine mounting nut rear lower side Connecting arm nut front side Pivot shaft nut 125 Nm 12 5 m kg 90 ft lb Engine mounting nut rear lower side 98 Nm 9 8 m kg 71 ft lb Connecting arm nut fr
198. conds When the hour digits start flashing push the RESET switch to set the hours Push the SELECT switch and the minute digits will start flashing Push the RESET switch to set the minutes Push the SELECT switch and then release it to start the clock 2 Self diagnosis device This model is equipped with a self diagnosis de vice for various electrical circuits If any of those circuits are defective the engine trouble warning light will come on and then the odometer tripmeter clock display will indicate a two digit error code e g 12 13 14 If the odometer tripmeter clock display indicates any error codes note the code number and then check the vehicle Refer to FUEL INJEC TION SYSTEM on page 7 27 EC1D71018 CAUTION If the display indicates an error code the ve hicle should be checked as soon as possible in order to avoid engine damage Brightness control mode 1 196 Multi function meter unit panel LCD Speedometer needle Tachometer needle Fuel gauge needle 4 5 mo Ie c 5 The brightness be adjusted for the following e the multi function meter unit panel item num ber 1 the LCD item number 2 the speedometer tachometer and the fuel gauge needles item number 3 1 6 FEATURES Select the brightness control mode as follows 1 Turn the key to OFF 2 Push and hold the SELECT switch 3
199. connect ISC idle speed control unit inlet hose Disconnect Disconnect Cylinder 1 intake air pressure sensor bracket Disconnect 4 13 GENERAL CHASSIS Removing the air filter case Air filter case For installation reverse the removal proce dure 4 14 FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs 10 Nm 1 0 m kg 7 2 ft Ib 40 Nm 4 0 kg 29 ft Ib 40 Nm 4 0 kg 29 ft Ib Job Parts to remove Place the vehicle on a suitable stand so that the front wheel is elevated 2 3 4 Front brake hose guide 5 Right front brake hose guide bracket 10 Front brake caliper Front wheel axle pinch bolt Front wheel axle 13 Front wheel 4 15 FRONT WHEEL Removing the front wheel and brake discs 10 Nm 1 0 kg 7 2 ft Ib 40 Nm 4 0 kg 29 ft Ib 40 Nm 4 0 kg 29 ft Ib EO _ 35 Fewbwedecag p mE For installation reverse the removal proce dure 4 16 FRONT WHEEL Disassembling the front wheel For assembly reverse the disassembly pro cedure 4 17 EAS21900 REMOVING THE FRONT WHEEL 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Remove Right front fender stay 1 eft front fender stay 2 Front fender s
200. cylinder head b Measure the warpage If the limit is exceeded resurface the cylinder head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern NOTE To ensure an even surface rotate the cylinder head several times DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE OIL PIPE 1 Check Oil pipe 1 Damage Replace Obstruction Wash and blow out with com pressed air 5 35 CYLINDER HEADS EAS24250 INSTALLING THE CYLINDER HEADS 1 Install Cylinder head gasket 1 Dowel pins 2 NOTE The 7107 mark on the cylinder head gasket must face up and towards the left side of the cyl inder A Front cylinder ZZ lt lt B Rear cylinder 7 5 4 Install Copper washers Oil pipe 1 Oil pipe union bolt M8 Syr Cil pipe union bolt M8 T 18 Nm 1 8 m kg 13ft Ib 2 Install Cylinder heads Oil pipe union bolts M10 e Washers EN Cylinder head nuts pipe union bolt M10 NOTE 21 Nm 2 1 m kg 15 ft Ib Lubricate the cylinder head nuts and washers with engine oil adis Tighten the three union bolts evenly and then 3 Tighten torque them to specification Cylinder head nuts 5 Install Se Cylinder head nut Engine bracket right upper side 24 60 Nm 6 0 m kg 43 ft Ib Engine bracket bolts right upper side Engine mounting
201. cylinder is dis assembled replace the piston seal Recommended clutch fluid Brake fluid DOT 4 EAS25350 INSTALLING THE CLUTCH RELEASE CYLINDER 1 Install Copper washers Clutch pipe 71 Clutch pipe union bolt 2 Clutch pipe union bolt 26 Nm 2 6 m kg 19 ft Ib EW1D71003 Proper clutch pipe routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 45 EC1D71005 CAUTION When installing the clutch pipe onto the clutch release cylinder make sure the pipe touches the projection b on the clutch release cylinder NS v dp e 2 2 Fill Clutch master cylinder reservoir with the specified amount of the recom mended clutch fluid EWA13370 Recommended clutch fluid Brake fluid DOT 4 Use only the designated clutch fluid Other clutch fluids may cause the rubber seals to deteriorate causing leakage and poor clutch performance Refill with the same type of clutch fluid that is already in the system Mixing clutch flu ids may result in a harmful chemical reac tion leading to poor clutch performance CLUTCH When refilling be careful that water does not enter the clutch fluid reservoir Water Will significantly lower the boiling point of the clutch fluid and could cause vapor lock ECA13420 CAUTION Clutch fluid may damage painted surfaces or plastic parts Therefore always clean
202. d Repair or replace if there is an km h open circuit Between neutral switch coupler and relay unit coupler fuel pump relay sky blue sky blue Between relay unit coupler and main switch blue yellow blue yellow Between main switch and ECU coupler blue black blue black Faulty shift drum neutral detection ar Replace if defective ea Refer to TRANSMISSION on page 5 107 Defective neutral switch Execute the diagnostic mode Code No 21 Replace if defective Refer to CHECKING THE SWITCHES on page 7 71 7 58 FUEL INJECTION SYSTEM Fault code No Symptom is unable to monitor the battery voltage an open or short circuit in the line to the ECU Diagnostic code No oo Fuel system voltage Item components and probable Check or maintenance job Reinstatement cause method Connections Check the coupler for any pins Starting the en e Relay unit coupler fuel pump relay that may be pulled out gine and oper Main wire harness ECU coupler Check the locking condition of ating it at idle the coupler f there is a malfunction repair it and connect the coupler se curely 2 Open or short circuit in wire har Repair or replace if there is an ness open or short circuit Between relay unit coupler fuel pump relay and ECU coupler blue red blue red red blue red blue Between relay unit coupler fuel pump relay and
203. d Measure the valve clearance with a thickness gauge Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 Z AG DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 23 E 2056 LN SS BY aa Piston 2 TDC front cylinder a Turn the crankshaft counterclockwise from b Insert a thickness gauge 2 between the end the piston 1 TDC by 408 degrees of the adjusting screw and the valve tip b When piston 2 is at TDC on the compres 2 Thickness gauge sion stroke align the TDC mark e on the 2 90890 03180 crankshaft position sensor rotor with the Feeler gauge set pointer b on the clutch cover YU 26900 9 c the adjusting screw 3 in direction or b with the tappet adjusting tool 4 until the specified valve clearance is obtained Cz Tappet adjusting tool 4 mm 90890 04133 Valve adjustment wrench 3 mm amp 4 mm YM 08035 A C6 9 c Check the camshaft drive gear mark c posi tion and camshaft driven gear mark d posi mE Adjusting Slip side screw side tion as shown Valve clear Valve clear Direction ance is in ance is de creased creased Valve clear Valve clear Direction b ance is de ance Is in creased creased d Measure the valve clearance with a thickness gauge 3 6 ENGINE Cylinder 1 ignition coil cover Refer to ENGINE REMOVAL on page 5 1
204. d as an assem bly 4 During disassembly clean all of the parts and place them in trays in the order of disassem bly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality IMPORTANT INFORMATION EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals and O rings All gasket surfac es oil seal lips and O rings must be cleaned 2 During reassembly properly oil all mating parts and bearings and lubricate the oil seal lips with grease Oil Lip Spring Grease se uid EAS20220 LOCK WASHERS PLATES AND COTTER PINS After removal replace all lock washers plates 1 and cotter pins After the bolt or nut has been tightened to specification bend the lock tabs along a flat of the bolt or nut EAS20230 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu facturer s marks or numbers are visible When installing oil seals 1 lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appropri ate ECA13300 CAUTION Do not spin the bearing with compressed air
205. d fluid Steering Steering bearing type Lock to lock angle left Lock to lock angle right Front suspension Type Spring shock absorber type Front fork travel Fork spring free length Limit Collar length Installed length Spring rate K1 Spring stroke K1 Spring rate K2 Spring stroke K2 Inner tube outer diameter Inner tube bending limit Optional spring available CHASSIS SPECIFICATIONS Dual disc brake Right hand operation 298 0 x 5 0 mm 11 73 x 0 20 in 4 5 mm 0 18 in 0 10 mm 0 0039 in 5 5 mm 0 22 in 0 5 mm 0 02 in 5 5 mm 0 22 in 0 5 mm 0 02 in 14 00 mm 0 55 in 27 00 mm 1 06 in 30 23 mm 1 19 in DOT 4 oingle disc brake Right foot operation 110 0 mm 4 33 in 320 0 x 6 0 mm 12 60 x 0 24 in 5 5 mm 0 22 in 0 15 mm 0 0059 in 5 8 mm 0 23 in 0 8 mm 0 03 in 5 8 mm 0 23 in 0 8 mm 0 03 in 12 7 mm 0 50 in 41 30 mm 1 63 in DOT 4 Taper roller bearing 35 0 35 0 Telescopic fork Coil spring oil damper 130 0 mm 5 12 in 273 9 mm 10 78 in 268 4 mm 10 57 in 230 0 mm 9 06 in 268 9 mm 10 59 in 10 0 N mm 57 1 1 02 kgf mm 0 0 30 0 mm 0 00 1 18 in 12 0 N mm 68 5 Ib in 1 22 kgf mm 30 0 130 0 mm 1 18 5 12 in 46 0 mm 1 81 in 0 2 mm 0 01 in Recommended oil Quantity Level Rear suspension Type Spring shock absorber type Rear shock absorber assembly travel Spring free length Limit Installed length Spring rate K1 Spri
206. d into the hole in the headlight housing Face the end of the plastic band downward 2 48 CABLE ROUTING CABLE ROUTING N TU NA eo __ y So 279 TC 9 d ACAI ague K AREA US e N M Y 14 08 2 49 QNO Ur Im 13 14 15 16 17 18 19 20 21 22 23 24 29 26 27 28 EXUP servo motor Fuse box Wire harness Fuel outlet hose Cylinder 1 right spark plug cap Cylinder 1 right ignition coil Cylinder 2 intake air pressure sensor coupler Fuel sender fuel tank coupler Meter assembly coupler Throttle cable Front brake hose Cylinder 2 right spark plug cap Cylinder 1 left ignition coil Clutch pipe Neutral switch lead Stator coil lead Speed sensor lead O sensor lead EXUP cable Cylinder 1 right spark plug lead Cylinder 1 left spark plug lead ISC idle speed control unit inlet hose Cylinder 2 ISC idle speed control unit outlet hose Cylinder 1 ISC idle speed control unit outlet hose Sub wire harness 3 coupler Cylinder 2 right spark plug lead Sub wire harness 4 coupler Cylinder 2 left spark plug lead Fasten the cylinder 1 left and right spark plug leads fuel outlet hose wire harness and the fuel tank damper with the plastic locking tie Install the plastic locking tie in the rear sl
207. der 1 intake air pressure sensor Cylinder 1 intake air pressure sensor hose Air filter case breather hose 1 Fuel hose intake manifold assembly to pressure regulator Pressure regulator Air filter case breather hose 2 Canister purge hose for California only ISC idle speed control unit inlet hose Canister for California only Fuel tank breather overflow hose for California only Cylinder 2 ISC idle speed control unit outlet hose ISC idle speed control unit Cylinder 1 ISC idle speed control unit outlet hose Cylinder 2 intake air pressure sensor Cylinder 1 intake air pressure sensor hose Fuel outlet hose Cylinder head breather hose Hose joint cover Throttle position sensor Cylinder 1 injector coupler Engine temperature sensor coupler Sub wire harness 2 Face the ends of the hose clamp to the left angled 45 rearward Install the cylinder 1 intake air pressure sensor hose onto the throttle body pipe up to the bend in the pipe making sure to face the white paint mark on the hose upward Face the ends of the hose clamp forward Fasten the canister purge hose and the air filter case breather hose 2 with the hose clamp making sure to face the ends of the clamp upward for California only Face the ends of the hose clamp to the left Fasten the canister purge hose and fuel tank breather overflow hose with the holder 70 mm 2 76 in from the hose joints on the canister for California
208. e adapter 3 be tween the fuel hose 1 and pressure regula tor 2 d Connect the pressure gauge 4 to the fuel pressure adapter 3 e Connect the vacuum pressure pump gauge set 5 to the pressure regulator 6 11 Vacuum pressure pump gauge set 90890 06756 Pressure gauge 90890 03153 Fuel pressure adapter 90890 03176 YM 03176 f Start the engine 0 Measure the fuel pressure h Use the vacuum pressure pump gauge set to adjust the fuel pressure in relation to the vac uum pressure as described below NOTE Fuel pressure 392 kPa 3 92 2 55 7 psi The vacuum pressure should not exceed 100 kPa 760 mmHg Increase the vacuum pressure gt Fuel pressure is decreased Decrease the vacuum pressure Fuel pressure is increased Faulty Replace the pressure regulator DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 6 12 THROTTLE BODIES EAS27030 ADJUSTING THE THROTTLE POSITION SENSOR 1 Check Throttle position sensor Refer to CHECKING THE THROTTLE PO SITION SENSOR on page 7 89 2 Adjust hrottle position sensor angle Connect the throttle position sensor coupler to the throttle position sensor b Connect the digital circuit tester to the throttle position sensor Positive tester probe yellow terminal 1 Negative tester probe black terminal 2 Digital circuit
209. e entire lighting system gt wiring Properly connect or repair the lighting sys Refer to CIRCUIT DIAGRAM on tem wiring page 7 17 OK The lighting system circuit is OK 7 20 SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM amp novia 2553 805 SS3NHVH3H M YSSANYVH 15 SS3NHVH3H M pu su SS3NHVH3HM 8184 SS3NHVH3HM 1893 805 SS3NuvH3H M 24 bd 8 8 Kyowa wem 69 09 140 _ 9 Se owe 9 MOm 09 L Gn 2 em m ees en aul 42 8 za 00 erp TEREA 1 Sz epe 7 m 1 1 1 ANN 8 9 Fm 26 178 69 75 B _ 1 oova 4g L 4 19 Toot 62 7 21 Main switch Main fuse Backup fuse odometer and clock 6 Battery 11 Relay unit 14 Neutral switch 18 Fuel sender fuel pump 24 Speed sensor 27 ECU electronic control unit 39 Neutral indicator light 40 Multi function meter 43 Fuel level warning light 45 Left turn signal indicator light 46 Right turn signal indicator light 48 Fuel sender fuel tank 49 Horn 1 50 Horn 2
210. e front fork leg with a plastic bag to protect the oil seal during installation 8 Install Oil seal clip 1 NOTE Adjust the oil seal clip so that it fits into the outer tube s groove Y 9 Install Dust seal 1 with the fork seal driver weight 2 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 10 Fill Front fork leg with the specified amount of the recom mended fork oil FRONT FORK Quantity 571 0 cm 19 31 US oz 20 10 Imp oz Recommended oil Fork oil 10WT 11 Measure Front fork leg oil level from the top of the inner tube with the outer tube fully compressed and without the fork spring Out of specification Correct Level 124 0 mm 4 88 in NOTE While filling the front fork leg keep it upright After filling slowly pump the front fork leg up and down to distribute the fork oil 12 Install Spring 1 e Spring seat 2 Spacer Cap bolt with O ring NOTE Install the spring with the smaller pitch facing up Before installing the cap bolt lubricate its O ring with grease Temporarily tighten the cap bolt 4 67 9 523050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install ower front fork cover 1 Front fork leg 2 Upper bracket 3 Temporarily tighten the lowe
211. e lifter case Valve lifters Valve lifter case bolt 10 Nm 1 0 m kg 7 2 ft lb 5 30 Install the valve lifter in the correct place After installing the valve lifters fill the tops of them with engine oil 2 Install e Push rod covers 1 NOTE Install the push rod covers so that their paint marks a are facing towards the cylinder heads EAS24070 INSTALLING THE ROCKER ARMS AND PUSH RODS The following procedure applies to both cylin ders 1 Install Rocker arms 1 Rocker arm shafts 2 onto rocker arm base NOTE The thread hole of the rocker arm shaft must face to the outside 2 Install Rocker arm base with rocker arms Push rods CAMSHAFTS rocker arm base on the cylinder head b Install the push rods NOTE Be sure to correctly install the push rods be tween the rocker arms and valve lifters as shown The illustration is viewed from the right side of the vehicle The lengths of push rod 1 and push rod 2 are different Therefore be sure to install them in the proper position ubricate the push rod end balls with engine A Rear oylinder B Front cylinder 1 Exhaust side rocker arm 2 ntake side rocker arm 3 Exhaust valve lifter 4 ntake valve lifter 5 Push rod 11 2 286 5
212. e stand Make sure the vehicle is upright 2 Startthe engine warm it up for approximately 15 minutes until the oil temperature rises to 60 C 140 F and then turn it off 3 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 4 Remove Dipstick 1 5 Check Engine oil level The engine oil level should be between the minimum level mark and maximum level mark Below the minimum level mark Add the recommended engine oil to the proper level NOTE Before checking the engine oil level wait a few minutes until the oil has settled Do not screw the dipstick in when inspecting the oil level a 2 OR bo Er KIT d EYE OY ili ENGINE Type YAMALUBE 4 20W40 SAE20W40 Recommended engine oil grade API service SG type or higher JASO standard MA ECA13380 CAUTION Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives Do not allow foreign materials to enter the crankcase 6 Start the engine warm it up for several min utes and then turn it off 7 Check the engine oil level again NOTE Before checking the engine oil level wait a few minutes until the oil has settled 8 Install Dipstick 9 Install e Hider seat Refer to GENERAL CHASSIS on page 4 1 EAS20780 CHANGING THE EN
213. e the fuel sender float to maximum 9 minimum 4 level position c Measure the fuel sender resistance CHECKING THE FUEL SENDER FUEL PUMP 1 Drain the fuel 2 Disconnect Fuel pump coupler from the fuel pump 3 Hemove Fuel pump from the sub fuel tank 4 Check Fuel sender resistance Out of specification Replace the fuel pump assembly Fuel sender resistance 0 90 2 05 a Connect the pocket tester x 1 to the fuel sender terminals as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe green white 1 Negative tester probe black 2 7 88 ELECTRICAL COMPONENTS 1 b Measure the fuel sender resistance DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE FUEL LEVEL WARNING LIGHT This model is equipped with a self diagnosis de vice for the fuel level detection circuit 1 Check Fuel level warning light 1 Turn the main switch to ON Warning light comes on for a few seconds then goes off Warning light is OK Warning light does not come on Replace the meter assembly Warning light flashes eight times then goes off for three seconds in a repeated cycle mal function detected in fuel sender or thermistor Replace the fuel pump assembly E
214. e univer sal clutch holder 3 loosen the clutch boss nut 3 i Universal clutch holder T 90890 04086 YM 91042 4 2 Clutch boss nut 1 5 Conical spring washer 2 Washer 3 e Clutch boss assembly 4 2072 NOTE REMOVING THE LEFT BALANCER DRIVE 2 There is a built in damper between the clutch GEAR 5 lt 2 boss and the clutch plate It is not necessary to 1 Loosen s remove the wire circlip 5 and disassemble the Left balancer drive gear bolt 1 built in damper unless there is serious clutch NOTE chattering While the holding the generator rotor 2 with the 6 ler arts to remove Remarks primary sheave holder 3 loosen the left bal ancer drive gear bolt D Refer to CHANGING THE ENGINE OIL on age 3 11 P LOD Refer to GENERAL CHASSIS Sheave holder 5559 FPR 90890 01701 of 3 3 Primary clutch holder Refer to THROTTLE BODIES on page 6 6 For California only p YS 01880 A Fuel tank Sub fuel tank Refer to FUEL TANK on page 6 1 Left rider footrest assembly Shift rod Sidestand Refer to ENGINE REMOVAL on page 5 1 Refer to GENERATOR AND STARTER Generator cover CLUTCH on page 5 72 E EAS25090 Drive pulley case Refer to TRANSFER GEAR CASE on REMOVING THE PRIMARY DRIVE GEAR page 5 81 1 Loosen Crankshaft position sensor coupler Disconnect Primary drive gear bolt 1
215. eat bracket assembly and seat lock assembly bolt M6 7 Nm 0 7 m kg 5 1 ft lb 2 Tool kit and battery box bolt 7 Nm 0 7 m kg 5 1 ft lb Pressure regulator bracket bolt 13 Nm 1 3 m kg 9 4 ft lb Cylinder 1 ignition coil cover 2 7 Nm 0 7 m kg 5 1 ft lb bolt d s Cylinder 1 ignition coil bracket 7 Nm 0 7 m kg 5 1 ft lb bolt License plate bolt 16 Nm 1 6 m kg 11 ft lb Sidestand bolt M10 63 Nm 6 3 m kg 45 ft lb Rider footrest assembly bolt left and right M10 48 Nm 4 8 m kg 35 ft lb 48 Nm 4 8 m kg 35 ft lb HE M8 23 Nm 2 3 m kg 17 ft lb 2 Passenger footrest bolt left and right Rear brake master cylinder bracket and rear brake master 23 Nm 2 3 m kg 17 ft lb cylinder bolt Rear brake master cylinder bracket and frame bolt 23 Nm 2 3 m kg 17 ft lb 16 Nm 1 6 m kg 11 ft lb 7 Nm 0 7 m kg 5 1 16 30 Nm 3 0 m kg 22 ft lb 7 Nm 0 7 m kg 5 1 ft lb 12 Nm 1 2 m kg 8 7 ft lb 40 Nm 4 0 m kg 29 ft lb 7 Nm 0 7 m kg 5 1 16 140 Nm 14 0 m kg 100 ft lb Stake 10 Nm 1 0 m kg 7 2 ft lb 2 25 Rear brake master cylinder cover bolt Brake fluid reservoir and frame bolt Rear brake hose union bolt 0 Co gt Rear brake hose holder bolt Shift pedal shaft bracket bolt Locknut shift rod Shift arm bolt Shift pedal bolt toe side Shift pedal bolt heel side Lower bracket pinch bolt Cap bolt Damper rod assembly
216. ediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury FIRST AID FOR BRAKE FLUID ENTERING THE EYES Flush with water for 15 minutes and get im mediate medical attention EAS22570 CHECKING THE REAR BRAKE DISC 1 Remove Rear wheel Refer to REAR WHEEL on page 4 23 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 36 Brake disc deflection limit 0 15 mm 0 0059 in 4 Measure e Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 36 REAR BRAKE Brake disc thickness limit 5 5 mm 0 22 in 5 Adjust e Brake disc deflection Refer to CHECKING THE FRONT BRAKE DISCS on page 4 36 Brake disc bolt 18 Nm 1 8 m kg 13 ft Ib LOCTITE 4 49 6 Install Rear wheel Refer to REAR WHEEL on page 4 23 EAS22580 REPLACING THE REAR BRAKE PADS NOTE When replacing the brake pads it is not neces sary to disconnect the brake hose or disassem ble the brake caliper 1 Measure Brake pad wear limit a Out of specification Replace the brake pads as a Set Brake pad lining thickness in ner 5 8 mm 0 23 in Limit 0 8 mm 0 03
217. egative tester probe sky blue 1 Continuity Positive tester probe sky blue 4 22 Negative tester probe sky blue white 4 No continuity Positive tester probe sky blue white 4 Negative tester probe sky blue 1 Continuity Positive tester probe blue green 5 Negative tester probe blue yellow 3 No continuity Positive tester probe blue yellow 3 Negative tester probe blue green 5 Disconnect the relay unit from the wire ness b Connect the pocket tester Q x 1 to the relay unit terminals as shown c Check the relay unit diode for continuity d Check the relay unit diode for no continuity DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Diode 1 1 Check Diode 1 Out of specification gt Replace Pocket tester 90890 03112 Analog pocket tester YU 03112 C NOTE The pocket tester and the analog pocket tester readings are shown in the following table Continuity Positive tester probe red yel low 4 22 Negative tester probe red white 2 or red white 3 No continuity Positive tester probe red white 2 or red white 3 Negative tester probe red yel low 4 22 vVYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY a Disconnect the diode 1 from the wire har ness Connect the pocket tester Q x 1 to the diode 1 terminals as shown c C
218. elivery passage NOTE ___ o oOo ooo o clutch master cylinder body Install the shift arm 1 with its slot a aligned Obstruction Blow out with compressed air with the mark b in end of the shift shaft 2 Check Clutch master cylinder kit Damage scratches wear Replace 3 Check Clutch master cylinder reservoir Cracks damage Replace 5 66 Clutch master cylinder reservoir diaphragm Damage wear Replace 4 Check Clutch hose Cracks damage wear Replace EAS25300 ASSEMBLING THE CLUTCH MASTER CYLINDER EW1D71010 Before installation all internal clutch com ponents must be cleaned and lubricated with clean or new clutch fluid e Never use solvents on internal clutch com ponents EAS25310 INSTALLING THE CLUTCH MASTER CYLINDER 1 Install Clutch master cylinder 1 Clutch master cylinder holder 2 Recommended clutch fluid Brake fluid DOT 4 Clutch master cylinder holder bolt 10 Nm 1 0 m kg 7 2 ft lb NOTE Align the end of the clutch lever holder with the punch mark a on the handlebar First tighten the rear bolt then the front bolt 1 2 Install Copper washers e Clutch hose 1 e Clutch hose union bolt 2 Clutch hose union bolt 30 Nm 3 0 m kg 22 ft Ib 5 67 CLUTCH EW1D71002 Proper clutch hose routing is essential to in sure safe vehicle operation Refer to CABLE RO
219. em Damaged ball bearing or bearing race 3 Front fork leg s Uneven oil levels both front fork legs Unevenly tensioned fork spring both front fork legs Broken fork spring Bent or damaged inner tube Bent or damaged outer tube 4 Swingarm Worn bearing or bushing Bent or damaged swingarm 5 Rear shock absorber assembly Faulty rear shock absorber spring eaking oil or gas 6 Tire s Uneven tire pressures front and rear Incorrect tire pressure Uneven tire wear 7 Wheel s Incorrect wheel balance Deformed cast wheel Damaged wheel bearing Bent or loose wheel axle Excessive wheel runout 8 Frame Bent frame Damaged steering head pipe Improperly installed bearing race EAS28710 FAULTY LIGHTING OR SIGNALING SYSTEM Headlight does not come on Wrong headlight bulb oo 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 Improperly grounded circuit Faulty main switch Headlight bulb life expired Tail brake light does not come on Wrong tail brake light LED oo many electrical accessories Incorrect connection Burnt out tail brake light LED Tail brake light LED burnt out Wrong tail brake light LED Faulty batt
220. enance job Reinstatement method Check the coupler for any pins that may be pulled out Check the locking condition of the coupler f there is a malfunction repair it and connect the coupler se curely Turning the main switch to ON Repair or replace if there is an open or short circuit Between servo motor coupler and ECU coupler blue blue white red white red black blue black blue Execute the diagnostic mode Code No 53 Replace if defective Refer to CHECKING THE EXUP SERVO MOTOR page 7 90 Fault code No 18 Symptom EXUP servo motor is stuck Diagnostic code No 53 EXUP servo motor Item components and probable Check or maintenance job Reinstatement cause method 1 Connections EXUP servo motor coupler Main wire harness ECU coupler Open or short circuit in wire harness Defective EXUP servo motor 4 Check the coupler for any pins that may be pulled out Check the locking condition of the coupler f there is a malfunction repair it and connect the coupler se curely Turning the main switch to It takes 120 seconds at the maximum be fore the origi nal state Repair or replace if there is an returns open or short circuit Between the EXUP servo motor coupler and the ECU coupler black green black green black red black red Execute the diagnostic mode Code No 53 Replace
221. engine temperature sensor detected Malfunction in ECU Improperly installed sensor Open or short circuit in wire harness Malfunction detected in the Malfunction in cylinder 1 left or right igni 33 primary wire of the cylin tion coil der 1 left or right ignition Malfunction in ECU coil Malfunction in a component of ignition cut off circuit system Open or short circuit in wire sub lead Open or short circuit in wire harness Malfunction in cylinder 22 left or right igni tion coil Malfunction in ECU Malfunction in a component of ignition cut off circuit system Open or short circuit in wire harness Malfunction detected in the Malfunction in cylinder 1 left or right igni 35 primary wire of the cylin tion coil Malfunction detected in the primary wire of the cylin 2 left or right ignition coil der 1 left or right ignition Malfunction ECU coil Malfunction in a component of ignition cut off circuit system 7 35 Symptom Malfunction detected in the primary wire of the cylin 2 left or right ignition coil Engine speed is high when the engine is idling Lean angle sensor open or short circuit detected No normal signals are re ceived from the speed sen sor Open circuit is detected in the neutral switch The ECU is unable to moni tor the battery voltage an open or short circuit in the line to the ECU
222. ensor hose system mal function clogged or detached hose Diagnostic code No Cylinder 1 intake air pressure sensor Item components and probable Check or maintenance job Reinstatement cause method Cylinder 1 intake air pressure sensor Check the cylinder 1 intake air Starting the en hose pressure sensor hose condition gine and oper Repair or replace the sensor ating it at idle hose Cylinder 1 intake air pressure sensor Check and repair the connec malfunction at intermediate electrical tion potential Replace it if there is malfunc tion Connections e Check the coupler for any pins Cylinder 1 intake air pressure sen that may be pulled out sor coupler Check the locking condition of Main wire harness ECU coupler the coupler f there is a malfunction repair it and connect the coupler se curely Defective cylinder 1 intake air pres Execute the diagnostic mode sure sensor Code No 03 Replace if defective Refer to CHECKING THE IN TAKE AIR PRESSURE SEN on page 7 90 7 43 FUEL INJECTION SYSTEM Fault code No 15 Symptom Throttle position sensor open or short circuit detected Diagnostic code No 0 Throttle position sensor Item components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position Check for looseness or pinch Turning the 2 4 Sensor ing main switch to Che
223. er to GENERAL CHASSIS on page 4 1 2 Remove Headlight cover 1 3 Disconnect e Air temperature sensor coupler 1 LE NI ZA 4 Remove Headlight assembly 1 ELECTRICAL SYSTEM 5 Replace Low beam headlight bulb Disconnect Headlight coupler 1 b Remove Headlight bulb 2 EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down a IFRS 2 c Install Headlight bulb Secure the new headlight bulb with the head light bulb holder ECA13690 CAUTION Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner d Connect Headlight coupler DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 6 Replace High beam headlight bulb a Remove Headlight bulb cover 1 b Disconnect Headlight coupler 1 c Detach Headlight bulb holder 2 221 KS ar d Remove Headlight bulb EWA13320 Since the headlight bulb gets extremely
224. ery Incorrectly adjusted rear brake light switch light LED life expired Turn signal does not come on Faulty turn signal switch e Faulty turn signal relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signal flashes slowly Faulty turn signal relay Faulty main switch Faulty turn signal switch Incorrect turn signal bulb Turn signal remains lit Faulty turn signal relay Burnt out turn signal bulb Turn signal flashes quickly Incorrect turn signal bulb 8 4 TROUBLESHOOTING Faulty turn signal relay Burnt out turn signal bulb Horn does not sound Improperly adjusted horn Damaged or faulty horn e Faulty main switch Faulty horn switch Faulty battery Blown damaged or incorrect fuse Faulty wire harness XV19SW C XV19W C XV19MW C XV19CTSW C XV19CTW C XV19CTMW C 2007 WIRING DIAGRAM lt m CE 18 _ BB ee fX me fa 49 WIRE HARNESS SUB WIRE HARNESS CON BLACK WIRE HARNESS SUB WIRE HARNESS WIRE HARNESS SUB WIRE HARNESS WIRE HARNESS SUB WIRE HARNESS WIRE HARNESS SUB WIRE HARNESS 6 0 Hm B c
225. est lock 1 GENERAL CHASSIS NOTE Align the projection a on the lock 1 with the slot b in the left backrest lower bracket 2 2 Install Backrest lower brackets 1 Backrest upper bracket 2 Backrest plate Before tightening the bolts S to specification temporarily install the backrest lower brackets on backrest holders making sure not to push down on the rear of the brackets The lower bolts cannot be tightened when the backrest lower brackets are installed completely ET1D71042 INSTALLING THE BACKREST 1 Install Backrest 6 I a Fit the slot a on each backrest bracket left and right side into the groove of its holder b EC1D71026 CAUTION Be careful not to scratch the rear fender when fitting the slot into the groove b Push the rear of the backrest down smoothly but forcefully to lock it in place and make sure that the lever hook 1 on each side is secure ly fit over its holder 2 EW1D71017 Both lever hooks must be securely fitted over their holder If the backrest is loose a passenger might lose balance and fall c Insert the key into the backrest lock turn it clockwise and then remove the key DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 4 6 GENERAL CHASSIS GENERAL CHASSIS Removing the sidebag brackets For XV19CTS C
226. et tester YU 03112 C NOTE Before checking for continuity set the pocket tester to O and to the Q x 1 range VVVVV VV VV VV VV VV VV VV VV VV VV VV VV VY a Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 2 and check the continuity b Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 3 and check the continuity c If either of the readings indicate no continuity replace the bulb DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 7 74 Checking the condition of the bulb sockets The following procedure applies to all of the bulb sockets 1 Check Bulb socket for continuity with the pocket tester No continuity Replace Pocket tester 90890 03112 Analog pocket tester ELECTRICAL COMPONENTS NOTE Set the pocket tester selector to Q x 1 Pocket tester 90890 03112 Analog pocket tester YU 03112 C NOTE Check each bulb socket for continuity in the same manner as described in the bulb section however note the following b Install a good bulb into the bulb socket Connect the pocket tester probes to the re spective leads of the bulb socket Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb socket DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE FUSES
227. etting the diagnostic mode 1 Turn the main switch to OFF and set the engine stop switch to O 2 Disconnect the wire harness coupler from the fuel pump 3 Press and hold the RESET switch turn the main switch to ON and continue to press the switch for 8 seconds or more SELECT HESET NOTE All displays on the meter disappear except the clock and odometer trip meter fuel reserve trip meter clock displays appears on the odometer trip meter fuel reserve trip meter clock LCD 4 Simultaneously press the SELECT and RESET switches for 2 seconds or more to activate the diagnostic mode The diagnostic code number 401 appears on the clock LCD 5 Set the engine stop switch to iss 6 Select the diagnostic code number corresponding to the fault code number by pressing the SE LECT and RESET switches NOTE decrease the selected diagnostic code number press the RESET switch Press the RESET switch for 1 second or longer to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the SELECT switch Press the SELECT switch for 1 second or longer to automatically increase the diagnostic code numbers 7 33 FUEL INJECTION SYSTEM 401 470 470 901 7 Merify the operation of the sensor or actuator e Sensor operation The data representing the operating conditions of the sensor appears o
228. g 54 ISC valve Check or maintenance job Reinstatement method ISC valve re turns to its orig inal position by turning the main switch to ON and back to OFF Reinstated if the engine idle speed is within specification af ter starting the engine Fault code No FUEL INJECTION SYSTEM a Symptom angle sensor open or short circuit detected Diagnostic code No 08 o Lean angle sensor Connections ean angle sensor coupler Main wire harness ECU coupler Open or short circuit in lead wire Defective lean angle sensor Check or maintenance job Reinstatement method Check the coupler for any pins Turning that may be pulled out main switch to Check the locking condition of ON the coupler f there is a malfunction repair it and connect the coupler se curely Repair or replace if there is an open or short circuit Between lean angle sensor coupler and ECU coupler blue blue yellow green yellow green black blue black blue Execute the diagnostic mode Code No 08 Replace if defective Refer to CHECKING THE LEAN ANGLE SENSOR on page 7 84 7 56 FUEL INJECTION SYSTEM Fault code No Symptom No normal signals are received from the speed sensor B Open circuit is detected in the neutral switch Diagnostic code No A Speed sensor Connections Speed sensor coupler Main wire harness ECU coupler Open
229. gh beam indicator light taillight license light position light meter light or accessory light OPTION NOTE Before troubleshooting remove the following part s 1 Rider seat 2 Tool kit tray 3 Headlight assembly Check the condition of each bulb and bulb socket Refer to CHECKING THE BULBS AND BULB SOCKETS on page 7 74 OK Check the fuses Main headlight signaling system taillight and ECU Refer to CHECKING THE FUS ES on page 7 75 OK 4 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 76 OK Check the main switch Refer to CHECKING THE SWITCHES on page 7 71 OK 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 7 71 OK Check the accessory light switch Refer to CHECKING THE SWITCHES on page 7 71 OK Check the headlight relay Refer to CHECKING THE RE LAYS on page 7 79 OK 4 gt gt gt gt gt gt gt 7 19 Replace the bulb s and bulb socket s Replace the fuse s Clean the battery terminals Recharge or replace the battery Replace the main switch The dimmer switch is faulty Replace the left handlebar switch The accessory light switch is faulty Re place the right handlebar switch Replace the headlight relay LIGHTING SYSTEM 8 Check th
230. gine temperature sensor resis tance 0 90 1 10 at 100 C 212 F a Connect the pocket tester Q x 1 k to the en gine temperature sensor terminals as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C ELECTRICAL COMPONENTS D 0 56 b Immerse the engine temperature sensor 1 in a container filled with water 2 NOTE Make sure that the engine temperature sensor terminals do not get wet Place a thermometer 3 in the water Slowly heat the water then let it cool down to the specified temperature Measure the engine temperature sensor re sistance 3 Install Engine temperature sensor Syr Engine temperature sensor 20 Nm 2 0 m kg 14 ft Ib ET1D71014 CHECKING THE FUEL SENDER FUEL TANK 1 Remove Fuel sender from the fuel tank 2 Check Fuel sender resistance Out of specification Replace C d e Fuel sender fuel tank Sender unit resistance full 9 11 Q Sender unit resistance empty 213 219 Q a Connect the pocket tester Q x 100 to the fuel sender coupler as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C 7 87 Positive tester probe green 1 Negative tester probe black 2 b Mov
231. gnition coil cover Refer to ENGINE REMOVAL on page 5 1 1 r 2 Cylinder 1 intake air pressure sensor hose Cylinder 2 intake air pressure sensor hose For California only EC1D71013 CAUTION 7 Throttle body The throttle bodies should not be disas sembled dure 6 8 THROTTLE BODIES Removing the intake manifolds 3 10 Nm 1 0 m kg 7 2 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib Job Parts to remove Q ty 4 1 2 Fuel hose intake manifold assembly to pres 1 sure regulator ose ose dure 6 9 THROTTLE BODIES Disassembling the intake manifolds 30 Nm 3 0 kg 22 ft Ib Job Parts to remove Q ty E a a TP memi p p For assembly reverse the disassembly pro cedure 6 10 ET1D71026 REMOVING THE FUEL HOSE 1 Disconnect Fuel hose intake manifold assembly to pres sure regulator EC1D71014 CAUTION Although the fuel has been removed from the fuel tank be careful when removing the fuel hose since there may be fuel remaining in it NOTE remove the fuel hose from the fuel pipe or pressure regulator slide the fuel hose connec tor cover 1 on the end of the hose in the direc tion of the arrow shown press the two buttons 2 on the sides of the connector and then re move the hose the fuel hose manually withou
232. gs Oil seals Refer to ASSEMBLING THE FRONT WHEEL on page 4 19 REAR WHEEL EAS22150 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust Hear wheel static balance Hefer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 19 EAS28770 INSTALLING THE REAR WHEEL DISC 1 Lubricate e Hear wheel axle Oil seal lips Recommended lubricant Lithium soap based grease 2 Install e Rear brake disc e Rear brake disc cover Rear brake disc bolt 18 Nm 1 8 m kg 13 ft lb LOCTITE NOTE Apply locking agent LOCTITE to the threads of the brake disc bolts e Tighten the brake disc bolts in stages and ina crisscross pattern Rear brake disc Refer to CHECKING THE REAR BRAKE DISC on page 4 49 4 Install e Rear wheel axle e Washer e Hear wheel axle nut 4 29 NOTE Temporarily tighten the wheel axle nut 5 Adjust e Drive belt slack Hefer to ADJUSTING THE DRIVE BELT SLACK on page 3 24 6 Tighten Hear wheel axle nut gt Rear wheel axle nut 150 Nm 15 0 m kg 110 16 7 Install Rear brake caliper Rear brake caliper 27 Nm 2 7 m kg 19 ft Ib 13500 Make sure the brake hose is routed properly 4 30 REAR WHEEL FRONT BR
233. gs with the notches b in the connecting rod and connecting rod cap A c Put a piece of Plastigauge 1 on the crank shaft pin 5 102 d Assemble the connecting rod halves NOTE Do not move the connecting rod or crankshaft until the clearance measurement has been completed ubricate the bolts threads with molybdenum disulfide grease Make sure the projection c on the connecting rod faces towards the left side of the crank shaft Make sure the characters d on both the con necting rod and connecting rod cap are aligned e Tighten the connecting rod bolts EWA12890 Replace the connecting rod bolts with new ones Clean the connecting rod bolts NOTE The tightening procedure of the connecting rod bolts is angle controlled therefore tighten the bolts using the following procedure f Tighten the connecting rod bolts to the spec ified torque Connecting rod 1st 15 Nm 1 5 m kg 11 ft Ib g Puta mark 1 on the connecting rod bolts 2 and the connecting rod cap 3 CRANKSHAFT h Tighten the connecting rod bolts further to reach the specified angle 125 1352 Connecting rod bolt final Specified angle 125 135 lt gt 125 135 EW1D71011 When a bolt is tightened more than the spec ified angle do not loosen and then retighten it Replace the bolt with a new one and perform the procedure
234. h 58 Select switch 64 Headlight high beam 65 Headlight low beam 68 Engine stop switch 77 gnition fuse 78 Headlight fuse 79 Signaling system fuse 81 ECU fuse Se 7 28 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 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 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 f a malfunction is detected in the system by the self diagnostic function the ECU provides an appro priate substitute characteristic operation and alerts the rider of the detected malfunction by illuminat ing the engine trouble warning light After the engine has been stopped the lowest fault code number appears on the odometer tripme ter fuel reserve tripmeter clock LCD Once a fault code has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation Wa
235. h rod CAMSHAFTS Push rod end Bends damage Replace 2 Measure Push rod runout Out of specification Replace Valve push rod runout 0 3 mm 0 012 in EAS23920 CHECKING THE VALVE LIFTERS AND VALVE LIFTER CASES 1 Check Valve lifter Blue discoloration excessive wear pitting scratches Replace and check the lubrica tion system 2 Check Valve lifter case 1 Damage wear Replace the valve lifter case O rings 2 Damage wear Replace the O ring 3 Measure e Valve lifter outside diameter Out of specification Replace Valve lifter outside diameter in take 22 962 22 974 mm 0 9040 0 9045 in Valve lifter outside diameter ex haust 22 962 22 974 mm 0 9040 0 9045 in 4 Measure e Valve lifter case inside diameter Out of specification Replace Valve lifter hole inside diameter intake 23 000 23 021 mm 0 9055 0 9063 1 Valve lifter hole inside diameter exhaust 23 000 23 021 mm 0 9055 0 9063 1 5 Calculate e Valve lifter to valve lifter case clearance NOTE Calculate the clearance by subtracting the valve lifter outside diameter from the valve lifter case inside diameter Above 0 072 mm 0 0028 Replace the defective part s 5 26 CAMSHAFTS Valve lifter to valve lifter hole clearance 0 026 0 059 mm 0 0010 0 0023 in EAS23930 CHECKING THE PUSH ROD COVER 1 Check Push
236. he camshaft cover hole inside diameter Camshaft to camshaft cover clearance 0 020 0 064 mm 0 0008 0 0025 in 9 Check Camshaft drive gears Camshaft driven gears Front cylinder camshaft gears Rear cylinder camshaft gears Chips pitting roughness wear Replace the defective part s EAS23890 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts 1 Check Rocker arm Damage wear Replace 2 Check Rocker arm shaft Blue discoloration excessive wear pitting scratches Replace or check the lubrication system 3 Measure Rocker arm inside diameter a Out of specification Replace Rocker arm inside diameter 18 000 18 018 mm 0 7087 0 7094 in 4 Measure e Rocker arm shaft outside diameter Out of specification Replace Rocker arm shaft outside diame ter 17 976 17 991 mm 0 7077 0 7083 in 5 Calculate e Rocker arm to rocker arm shaft clearance NOTE Calculate the clearance by subtracting the rock er arm shaft outside diameter from the rocker arm inside diameter Above 0 08 mm 0 003 in Replace the de fective part s Rocker arm to rocker arm shaft clearance 0 009 0 042 mm 0 0004 0 0017 in EAS23900 CHECKING THE ROCKER ARM BASES 1 Check Rocker arm base Cracks damage Replace EAS23910 CHECKING THE PUSH RODS 1 Check e Pus
237. he handle bar First tighten the rear bolt then the front bolt 8 Install hrottle grip hrottle cables Right handlebar switch 1 Grip end 2 NOTE Align the projection a on the right handlebar switch with the hole b in the handlebar HANDLEBAR There should be 1 3 mm 0 04 0 12 in of clearance c between the throttle grip and the grip end 9 Install Front brake master cylinder 1 Front brake master cylinder holder 2 Front brake master cylinder hold er bolt 10 Nm 1 0 m kg 7 2 ft lb NOTE gt Align the end of the front brake master cylinder holder with the punch mark a on the handle bar First tighten the rear bolt then the front bolt 10 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 8 HANDLEBAR Throttle cable free play 4 0 6 0 mm 0 16 0 24 in 4 59 FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 10 Nm 1 0 m kg 7 2 ft Ib 1115 Nm 11 5 m kg 85 ft Ib 19 Nm 1 9 kg 13 ft Ib 16 Nm 1 6 m kg 11 ft Ib 7 Nm 0 7 kg 5 1 ft Ib 23 Nm 2 3 kg 17 ft Ib The following procedure applies to both of the front fork legs Windshield bracket left and right 2 jJRentfnder Refer to WHEEL on page 4 15 Upper bracket cover 3 NE NM A Upper brac
238. heck the diode 1 for continuity d Check the diode 1 for no continuity DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Diode 2 1 Check Diode 2 Out of specification gt Replace b ELECTRICAL COMPONENTS Pocket tester 90890 03112 Analog pocket tester YU 03112 C 7 82 NOTE The pocket tester and the analog pocket tester readings are shown in the following table Continuity Positive tester probe red white 1 Negative tester probe black red 2 No continuity Positive tester probe black red 2 Negative tester probe red white 1 Disconnect the diode 2 from the wire har ness Connect the pocket tester 1 to the diode 2 terminals as shown Check the diode 2 for continuity Check the diode 2 for no continuity DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE IGNITION SPARK GAP 1 Check Ignition spark gap Out of specification Perform the ignition system troubleshooting starting with step 5 Refer to TROUBLESHOOTING on page 7 4 Minimum ignition spark gap 6 0 mm 0 24 in NOTE 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 Ignition checker 90890 06754 Opama pet
239. hot keep flammable products and your hands away from the bulb until it has cooled down e Install Headlight bulb Secure the new headlight bulb with the head light bulb holder ECA13690 CAUTION Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner f Attach Headlight bulb holder g Connect Headlight coupler h Install Headlight bulb cover DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA ELECTRICAL SYSTEM 7 Install Headlight assembly 8 Connect e Air temperature sensor coupler 9 Install Headlight cover Syr Headlight cover bolt 7 Nm 0 7 m kg 5 1 16 10 Install Windshield For XV19CTS C XV19CT C XV19CTM C Refer to GENERAL CHASSIS on page 4 1 EAS21810 ADJUSTING THE HEADLIGHT BEAMS 1 Adjust Headlight beam vertically the adjusting bolt 1 in direction a or Direction Headlight beam is raised Direction b Headlight beam is lowered DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 2 Adjust Headlight beam horizontally the adjust
240. hrottle body ies Damaged or loose throttle body joint 2 Air filter Clogged air filter element Chassis 1 Brake s Dragging brake Electrical system 1 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range 2 Ignition system Faulty ECU 528620 POOR BRAKING PERFORMANCE Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper kit Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level 528660 FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal TROUBLESHOOTING Damaged oil seal lip Incorrect oil level high Loose damper rod assembly bolt Damaged damper rod assembly bolt copper washer Cracked or damaged cap bolt O ring Malfunction Bent or damaged inner tube Bent or damaged outer tube Damaged fork spring Worn or damaged outer tube bushing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS28670 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handlebar 2 Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tightened ring nut Bent steering st
241. ial gauge 1 Out of specification Replace the drive axle Drive axle runout limit 0 08 mm 0 0032 in 5 111 3 Check Transmission gears Blue discoloration pitting wear Replace the defective gear s e Transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect gt Reassemble the transmission axle assemblies 5 Check ransmission gear movement Rough movement Replace the defective part s 6 Check Circlips Bends damage looseness Replace ET1D71006 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1 Install Toothed washer 1 Circlip 2 NOTE Be sure the circlip sharp edged corner a is positioned opposite side to the toothed washer and gear For main axle TRANSMISSION Install the circlip so that both ends b rest on the sides of a spline c with both axles aligned 2 Install e Toothed lock washer retainer 1 e Toothed lock washer 2 NOTE e With the toothed lock washer retainer 1 in the groove a in the axle align the projection c on the retainer with an axle spline b and then install the toothed lock washer 2 Be sure to align the projection on the toothed lock washer that is between the alignment marks e with the alignment mark d on the retainer EAS26320 INSTALLING T
242. iate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques Special tools part numbers or both may differ depending on the country When placing an order refer to the list provided below to avoid any mistakes NOTE For U S A and Canada use part number starting with Y M YU or ACC For others use part number starting with 90890 Reference Pocket tester 90890 03112 Analog pocket tester YU 03112 C Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 Tappet adjusting tool 4 mm 90890 04133 Valve adjustment wrench 3 mm amp 4mm YM 08035 A 90890 04133 YM 08035 A Vacuum gauge 90890 03094 Carburetor synchronizer YU 44456 90890 03094 YU 44456 SPECIAL TOOLS Reference Timing light 90890 03141 Inductive clamp timing light YU 03141 90890 01426 YU 38411 Oil filter wrench Belt tension gauge 3 24 90890 03170 s Rear drive belt tension gauge 3 03170 Steering nut wrench 3 26 4 71 90890 01403 Spanner wrench YU 33975 Damper rod holder 4 64 4 66 90890 01460 T handle 4 64 4 66 90890 01326 T handle 3 8 drive 60 cm long YM 01326 Fork seal driver 4 66 4 67 90890 01442 gt Adjustable fork seal driver 36 46 mm L Ne YM 01442 7 12 Pivot shaft wrench 5 90890 01485 Frame mount insert wrench YM 01485 Valve spring compressor 5 39 5 44 90890 04019 YM 04019 SPEC
243. ide with the holder Align the paint mark on the hose with the hose joint as shown in the illustration Fasten the fuel tank breather overflow hose and starter motor lead with the holder To the fuel injector Align the yellow paint mark on the air vent hose fuel hose joint to fuel tank with the round indentation on the bend in the fuel hose joint Face the fastener of the clamp to the left Face the ends of the hose clamp forward Install the air vent hose fuel pump to fuel hose joint with its white paint mark facing upward Face the ends of the hose clamp upward Face the fastener of the clamp upward making sure that the projections on the clamp are positioned as shown in the illustration 2 56 lt lt om o CABLE ROUTING Install the fuel hose fuel tank to fuel hose joint with its white paint mark facing downward Tothe pressure regulator Install the air vent hose fuel hose joint to fuel tank with its white paint mark facing downward For California only To the fuel tank To the intake manifold assembly Fasten the canister purge hose and fuel tank breather overflow hose with the holder making sure to align the paint mark on the breather overflow hose with the holder Fasten the canister purge hose and throttle cable guide with the holder CABLE ROUTING 2 57 moo mmc qu ED I 12 13 14 15 16 17 18 19 20 21 22 Cylin
244. if defective Refer to CHECKING THE EXUP SERVO page 7 90 Defective EXUP valve pulley cables Replace if defective 7 45 FUEL INJECTION SYSTEM Fault code No Symptom break or disconnection of the blue black lead of the ECU is detected Diagnostic code No 0 Sidestand switch Item components and probable Check or maintenance job Reinstatement cause method Connections Execute the diagnostic mode If the transmis Main wire harness ECU coupler Code No 20 sion is in gear Check the coupler for any pins retracting the that may be pulled out sidestand Check the locking condition of If the transmis the coupler sion is in neu f there is a malfunction repair it tral and connect the coupler se reconnecting curely the wiring Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between ECU and blue black lead Defective sidestand switch Replace if defective Refer to CHECKING THE SWITCHES on page 7 71 Fault code No 22 Symptom temperature sensor open or short circuit detected Diagnostic code No 05 temperature sensor Item components and probable Check or maintenance job Reinstatement cause method 1 Installed condition of air temperature Check for looseness or pinching Turning the Sensor main switch to 2 Connections Check the coupler for any pins Air temperature sensor coupler that
245. ight handlebar switch Replace the neutral switch Replace the sidestand switch the clutch switch The start switch is faulty Replace the right handlebar switch Properly connect or repair the starting sys tem wiring 7 12 CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 6 1 1 1 3 8 9 m Q m o 7 13 ORD AC magneto Rectifier regulator Main fuse Battery 7 14 CHARGING SYSTEM CHARGING SYSTEM EAS27220 TROUBLESHOOTING The battery is not being charged NOTE Before troubleshooting remove the following part s 1 Rider seat 2 Rectifier regulator cover 3 Lead cover 1 Check the fuse gt Main Refer to CHECKING THE FUS ES on page 7 75 OK Check the battery gt Refer to CHECKING AND CHARGING THE BATTERY on page 7 76 OK Check the stator coil gt Refer to CHECKING THE STATOR COIL on page 7 85 OK Replace the fuse Clean the battery terminals Recharge or replace the battery the stator coil 4 Check the rectifier regulator Refer to CHECKING THE RECTI Replace the rectifier regulator FIER REGULATOR on page 7 85 OK Check the entire charging system gt wiring Properly connect or repair the charging Refer to CIRCUIT DIAGRAM on page 7 13 OK
246. il seal lips Rear wheel drive hub oil seal lip Rear wheel drive hub mating surface Tube guide throttle grip inner surface and throttle cables Brake lever pivoting point and metal to metal moving parts Clutch lever pivoting point and metal to metal moving parts Brake pedal shaft pivoting point Passenger footrest pivoting point and ball Sidestand pivoting point and metal to metal moving parts Dowel pins rear fender stay Pivot shaft Swingarm pivoting point collar flange circumference and oil seal inner surface Rear shock absorber bushings and O rings Swingarm relay arm bearings and oil seal lips Connecting arm bushings and O rings Rear wheel axle Shift pedal pivoting point Clutch master cylinder push rod pin and contact surface 2 29 LUBRICATION POINTS AND LUBRICANT TYPES 2 30 LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION SYSTEM CHART AND DIAGRAMS ENGINE OIL LUBRICATION CHART m QI OU ct HH HH HSH HSH HS SH 0 LUBRICATION SYSTEM CHART AND DIAGRAMS Oil strainer transfer gear case Oil pump Cil tank Drive axle Main axle Oil strainer crankcase Balancer Front cylinder head cover Rear cylinder head cover Rear cylinder camshaft Front cylinder camshaft Rear valve lifter case Front valve lifter case Push rod Crankshaft Camshaft sprocket cover Generator shaft Generator co
247. ing bolt 1 in direction a or Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left 3 32 ELECTRICAL SYSTEM 3 33 CHASSIS GENERAL CHASSIS 4 1 REMOVING Sa potest 4 2 ASSEMBLING THE WINDSHIELD eue in 4 2 INSTALLING EFIE WINDSHIELD s dei Pom nis PIU 4 2 REMOVING THE BAUNRBRES utantur eae 4 5 AoSEMBEING THE BACKREST eie Rute RES 4 5 INSTALLING THE BACKAES Ti ni EH E FR 4 5 CHECKING THE SIDEBAG BRACKET SPRING NUTS 4 8 FHONT 4 15 REMOVING THE FRONT WEBEL 4 18 DISASSEMBLING THE FRONT 4 18 CHECKING THE FRONT WHEE 4 18 ASSEMBLING THE 4 19 ADJUSTING THE FRONT WHEEL STATIC BALANCE 4 19 INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS 4 20 REAR WHEE E eb e ees cca enc a tt 4 23 REMOVING THE REAR WHEEL 0 15 4 28 DISASSEMBLING THE REAR 4 28 CHECKING THE REAR WHEEL de cup eos 4 28 CHECKING THE REAR
248. ing connections and if necessary replace the switch ECA14370 CAUTION Never insert the tester probes into the coupler terminal slots Always insert the probes from the opposite end of the coupler taking care not to loosen or damage the leads Pocket tester 90890 03112 Analog pocket tester YU 03112 C NOTE Before checking for continuity set the pocket tester to O and to the Q x 1 range e When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch position is indicated by _ There is continuity between red and brown blue yellow and blue black when the switch is set to ON 7 73 EAS27990 CHECKING THE BULBS AND BULB SOCKETS NOTE Do not check any of the lights that use LEDs Check each bulb and bulb socket for damage or wear proper connections and also for continuity between the terminals Damage wear Repair or replace the bulb bulb socket or both Improperly connected Properly connect No continuity Repair or replace the bulb bulb socket or both Types of bulbs The bulbs used on this vehicle are shown
249. ing tie between the air filter case damper and the frame Route the crankshaft position sensor lead sidestand switch lead neutral switch lead starter motor lead and speed sensor lead under the fuel outlet hose Inside of frame Outside of frame View with tray removed Route the negative battery lead under the starter motor lead and battery positive lead Route the positive battery lead main fuse to starter relay over the tray Route the negative battery lead towards the front of the vehicle Route the positive battery lead battery to starter relay under the tray with tray installed To the tail brake light View with ECU removed Wrap the protective covering around the couplers crankshaft position sensor coupler auxiliary DC jack coupler neutral switch coupler sub wire harness 1 coupler speed sensor coupler and sidestand switch coupler and the wire harness When installing the ECU be sure not to pinch the leads in the areas shown in the illustration with oblique lines CABLE ROUTING ps ape NA ER WIRE p 3 Sy nea OO Ni A TAS K 9 Wa 2 55 pro 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 cU U O Fuel tank breather hose Fuel sender
250. ion coil Diagnostic code No 30 32 Cylinder 1 left or right ignition coil Item components and probable Check or maintenance job Reinstatement cause method Connections Check the connector and cou Starting the en Cylinder 1 left or right ignition coil pler for any pins that may be gine and oper connector primary coil side pulled out ating it at idle Main wire harness ECU coupler Check the locking condition of the connector and coupler f there is a malfunction repair it and connect the coupler se curely Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between cylinder 1 left or right ignition coil connector and ECU coupler main wire harness black red blue red orange orange Defective cylinder 1 left or right igni Execute the diagnostic mode tion coil Code No 30 or 32 Test the primary and secondary coils for continuity Replace if defective Refer to CHECKING THE IG NITION COILS on page 7 83 7 51 FUEL INJECTION SYSTEM Fault code No Symptom Malfunction detected in the primary wire of the cylinder 2 left or right ignition coil Diagnostic code No 31 33 Cylinder 2 left or right ignition coil Reinstatement method Connections Check the connector and cou Starting the en Cylinder 2 left or right ignition coil pler for any pins that may be gine and oper connector primary coil side pulled ou
251. ir or replace if there is an open or short circuit Between cylinder 1 left or right ignition coil connector and ECU coupler main wire harness black red blue red orange orange Defective cylinder 1 left or right igni Execute the diagnostic mode tion coil Code No 30 or 32 Test the primary and secondary coils for continuity Replace if defective Refer to CHECKING THE IG NITION COILS on page 7 83 7 53 FUEL INJECTION SYSTEM Fault code No Symptom Malfunction detected in the primary wire of the cylinder 2 left or right ignition coil Diagnostic code No 31 33 Cylinder 2 left or right ignition coil Reinstatement method Connections Check the connector and cou Starting the en Cylinder 2 left or right ignition coil pler for any pins that may be gine and oper connector primary coil side pulled out ating it at idle Main wire harness ECU coupler Check the locking condition of Sub wire harness coupler the connector and coupler f there is a malfunction repair it and connect the coupler se curely Open or short circuit in wire harness Repair or replace if there is an and or sub lead open or short circuit Between cylinder 2 left or right ignition coil connector and ECU coupler main wire harness black red blue red gray red gray red Defective cylinder 2 left or right igni Execute the diagnostic mode tion coil Code No 31 or 33
252. ith your finger c Tighten the bleed screw Bleed screw front brake caliper 6 Nm 0 6 m kg 4 3ft Ib d Install a new brake pad shim onto each new brake pad e Install new brake pads and a new brake pad spring NOTE The arrow mark a on the brake pad spring must point in the direction of disc rotation DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Install Brake pad pin Brake pad clips e Front brake caliper Front brake caliper bolt 40 Nm 4 0 m kg 29 ft Ib 4 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 20 5 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 EAS22300 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers NOTE Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove e Brake hose holder 1 e Front brake hose union bolt 2 Copper washers 3 FRONT BRAKE e Front brake hose 4 NOTE Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22350 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Remove Brake caliper pistons 1
253. ive belt that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive belt slack within the specified lim its NOTE Measure the drive belt slack when the engine is cold and when the drive belt is dry CHASSIS 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on the sidestand and or on a suitable stand so that the rear wheel is elevated 2 Check Drive belt slack Out of specification Adjust Drive belt slack on the side stand 7 5 13 mm 0 30 0 51 in Drive belt slack on a suitable stand 14 21 mm 0 55 0 83 in Belt tension gauge 90890 03170 Rear drive belt tension gauge YM 03170 NOTE The level marks of the level window on the low er drive belt cover are in units of 5 mm 0 20 in Use them as a standard for measuring the drive belt slack Measure the drive belt slack when the drive belt has been pushed with 4 5 kg 10 16 of pressure using belt tension gauge 1 3 24 3 Hemove e Muffler Refer to ENGINE REMOVAL on page 5 1 4 Adjust Drive belt slack Place the vehicle on a suitable stand so that the rear wheel is elevated a Loosen the wheel
254. ket pinch bolt Loosen Loosen Lower front fork cover nut Lower bracket pinch bolt 11 Lower front fork cover 4 60 Loosen FRONT FORK Removing the front fork legs 10 Nm 1 0 m kg 7 2 ft Ib 1115 Nm 11 5 m kg 85 ft Ib 19 Nm 1 9 kg 13 ft Ib 16 Nm 1 6 kg 11 ft Ib 7 Nm 0 7 kg 5 1 ft Ib 23 Nm 2 3 kg 17 ft Ib Rm sme For installation reverse the removal proce dure 4 61 FRONT FORK Disassembling the front fork legs 23 Nm 2 3 kg 17 ft Ib LM J 9 52 16 17 40 Nm 4 0 kg 29 ft Ib Omer Job Parts to remove E aw uL ee procedure applies to both of front fork 2 O ring J a 7 4 EE E RE 4 62 e e I FRONT FORK Disassembling the front fork legs 23 Nm 2 3 kg 17 ft Ib lt 6 S mmm Job Parts to remove Q ty For assembly reverse the disassembly pro cedure 4 63 EAS22960 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place
255. l unit 34 EXUP servo motor 35 Injector 1 36 Injector 2 37 sensor 38 Meter assembly 39 Neutral indicator light 40 Multi function meter 41 Reset switch 42 Engine trouble warning light 43 Fuel level warning light 44 Meter light 45 Left turn signal indicator light 46 Right turn signal indicator light 47 High beam indicator light 48 Fuel sender fuel tank 49 Horn 1 50 Horn 2 51 Turn signal relay GLa CO 52 Headlight relay 53 Left handlebar switch 54 Clutch switch 55 Dimmer switch 56 Turn signal switch 57 Horn switch 58 Select switch 59 Front right turn signal position light 60 Front left turn signal position light 61 Rear right turn signal light 62 Rear left turn signal light 63 Headlight assembly 64 Headlight high beam 65 Headlight low beam 66 Right handlebar switch 67 Front brake light switch 68 Engine stop switch 69 Start switch 70 Accessory light switch 71 Accessory light OPTION 72 Tail brake light 73 License plate light 74 Rear brake light switch 75 Auxiliary DC coupler 76 Auxiliary DC connector fuse 77 gnition fuse 78 Headlight fuse 79 Signaling system fuse 80 Taillight fuse 81 ECU fuse EAS28750 COLOR CODE B Black Br Brown Ch Chocolate Dg Dark green G Green Gy Gray L Blue O Orange P Pink R Red Sb Sky blue W White Y Yellow B Br Black Brown B G Black Green B L Black Blue B R Bla
256. lace the valve spring 3 Install Valve guide 1 5 43 VALVES AND VALVE SPRINGS Lower spring seat 2 Valve stem seal 3 Valve 4 Valve spring 5 Upper spring seat 6 into the cylinder head NOTE Make sure each valve is installed in its original place Install the valve springs with the larger pitch facing up 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer a n ECA13800 CAUTION Hitting the valve tip with excessive force could damage the valve gt b Smaller pitch 4 Install e Valve cotters NOTE Install the valve cotters by compressing the valve springs with the valve spring compressor set 1 Cz Valve spring compressor gt 90890 04019 04019 5 44 CYLINDERS AND PISTONS Mog SSE NDA Omer Job Parts to remove Cylinder heads Refer to CYLINDER HEADS on page 5 33 Front cylinder LEN 9 7 Piston 10 Oil ring For installation reverse the removal proce ure EAS24380 REMOVING THE PISTON 1 Remove e Piston clips 1 Piston pin 2 Piston 3 ECA13810 CAUTION Do not use a hammer to drive the piston pin out NOTE Before removing the piston pin clip cover the crankcase opening with a clean rag to prevent the piston pin clip from falli
257. lder bolt 7 Nm 0 7 m kg 5 1 ft lb Air filter case bracket bolt M8 16 Nm 1 6 m kg 11 ft lb M6 7 Nm 0 7 m kg 5 1 ft lb fornia Canister bolt only 3 2 Front wheel axle 72 Nm 7 2 m kg 52 ft lb Front wheel axle pinch bolt 23 Nm 2 3 m kg 17 ft lb Rear wheel axle nut M18 150 Nm 15 0 m kg 110 ft lb Locknut drive adjusting bolt 16 Nm 1 6 m kg 11 ft lb Front brake caliper bolt 40 Nm 4 0 m kg 29 ft lb Front brake hose union bolt front 2 32 Nm 3 2 m kg 23 ft lb T gt gt For Cali brake caliper side Rear brake caliper bolt 2 27 Nm 2 7 m kg 19 ft lb Front brake disc bolt 12 23 Nm 2 3 m kg 17 ft Ib d SN OSmig Left side cover and sub fuel tank side co Tummasi Left side cover bolt M6 10 Nm 1 0 m kg 7 2 ft lb 6 Seat lock cable assembly bolt M 10 Nm 1 0 m kg 7 2 ft lb Lead holder bracket bolt 10 Nm 1 0 m kg 7 2 ft lb Right side cover bolt 10 Nm 1 0 m kg 7 2 ft lb Starter motor lead bolt starter Positive battery lead bolt starter Rear fender bracket and frame 40 Nm 4 0 m kg 29 ft lb bolt ux TIGHTENING TORQUES Thread a Tightening torque Rear fender bracket and frame 0 2 40 Nm 4 0 m kg 29 10 bolt Rear fender bracket and rear fender bolt Passenger seat bolt 2 16 Nm 1 6 m kg 11 ft Ib Rider s
258. le grip housing and cable Lights signals Check operation Since these items require special tools data and technical skills have a Yamaha dealer perform the service PERIODIC MAINTENANCE NOTE From 24000 mi 37000 km or 36 months repeat the maintenance intervals starting from 8000 mi 13000 km or 12 months EAU38440 NOTE Air filter This model s air filter is equipped with a disposable oil coated paper element which must not be cleaned with compressed air to avoid damaging it The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas Hydraulic brake and clutch systems After disassembling the brake or clutch master cylinders caliper cylinders or clutch release cylinder always change the fluid Regularly check the brake and clutch fluid levels and fill the reservoirs as required Replace the oil seals on the inner parts of the brake or clutch master cylinders caliper cylinders and clutch release cylinder every two years Replace the brake and clutch hoses every four years or if cracked or damaged 3 3 EAS20470 ENGINE EAS20530 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves NOTE he valve clearance is automatically adjusted by the hydraulic valve lifter However there are times when the valve clearance needs to be adjusted manually If this is the case adjust the clearance of the two
259. lts in stages and in a crisscross pattern 2 Check e Front brake discs Refer to CHECKING THE FRONT BRAKE DISCS on page 4 36 3 Lubricate Oil seal lips Recommended lubricant Lithium soap based grease 4 Install e Front wheel axle NOTE Install the tire and wheel with the mark 1 point ing in the direction of wheel rotation LER D 5 Tighten Front wheel axle Front wheel axle pinch bolt Front wheel axle 72 Nm 7 2 m kg 52 ft Ib Front wheel axle pinch bolt 23 Nm 2 3 m kg 17 ft Ib CAUTION Before tightening the wheel axle push down hard on the handlebar several times and check if the front fork rebounds smoothly 6 Install Front brake calipers 4 21 FRONT WHEEL Front brake caliper bolt 40 Nm 4 0 m kg 29 ft Ib EWA13500 Make sure the brake hose is routed properly 7 Install Front fender Left front brake hose guide bracket e Right front brake hose guide bracket NOTE Temporarily tighten the front fender bolts Apply locking agent LOCTITES to the threads of the front fender bolts 8 Install Front fender stay rod 1 eft front fender stay 2 Right front fender stay 3 NOTE Insert the rod into the front wheel axle from the right side of the vehicle Tighten the left front fender stay bolt front side 4 to specification while holding the rod with a wrench 5 and then
260. lve seat and valve face contacted one another the blueing will have been re moved 5 41 4 Lap e Valve face e Valve seat NOTE After replacing the cylinder head or replacing the valve and valve guide the valve seat and valve face should be lapped a Apply a coarse lapping compound a to the valve face ECA13790 CAUTION Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem 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 the lapping compound NOTE For the best lapping results lightly tap the valve seat while rotating the valve back and forth be tween your hands VALVES AND VALVE SPRINGS 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 0 onto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear impres sion Measure the valve seat width c again
261. m kg 9 4 ft Ib CT t 48 Nm 4 8 kg 35 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 18 Nm 1 8 m kg 13 ft Ib Cylinder 1 ignition coil bracket EE NE L3 mE 3 3 RE a menwewaww m e ees Sit ea a MUI I NN RR RN md 3 E reverse the removal proce 5 4 ET1D71029 INSTALLING THE SHIFT PEDAL ASSEMBLY 1 Assemble Shift pedal heel side 1 Shift pedal toe side 2 Syr Shift pedal heel side bolt 13 Nm 1 3 m kg 9 4 ft lb NOTE Align the mark a on the pin on the toe side with the mark b on the heel side 3 2 Install Shift pedal assembly 1 Syr Shift pedal bolt 18 Nm 1 8 m kg 13 ft Ib NOTE Align the mark a on the shift pedal shaft with the slot in the shift pedal 3 Adjust Shift rod length Refer to ADJUSTING THE SHIFT PEDAL on page 3 23 5 5 ENGINE REMOVAL ENGINE REMOVAL Removing the oil cooler and oil filter bracket Nm 0 7 kg 5 1 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib Sw SS 2 SA ae 5 Bw y 5 Oil cooler inlet hose a 0 2 dure 5 6 ET1D71028 CHECKING THE OIL COOLER 1 Check Oil cooler fins Obstruction Clean Apply compressed air to the rear of the oil cooler Damage
262. m kg 32 ft lb 8 See NOTE 10 Nm 1 0 m kg 7 2 ft lb 24 Nm 2 4 m kg 17 146 10 Nm 1 0 m kg 7 2 ft lb 1 See NOTE 0 5 Nm 0 05 m kg 0 36 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb c 20 Nm 2 0 m kg 14 ft lb aq M1 43 Nm 4 3 m kg 31 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 2 18 Oil pump housing cover 2 screw crankcase Throttle body joint clamp screw NO Pressure regulator bolt NO Intake manifold assembly bolt Fuel pipe bolt NO Rear exhaust pipe joint nut Rear exhaust pipe rear exhaust pipe joint cover and rear exhaust pipe joint nut Front exhaust pipe nut Front exhaust pipe and rear ex haust pipe bolt Rear exhaust pipe and muffler bolt Locknut EXUP cable EXUP valve pulley cover bolt Rear exhaust pipe joint cover bolt lt BO 51 09 o o aA a Muffler and muffler bracket bolt Muffler bracket and frame bolt O sensor gt Crankcase stud bolt Crankcase bolt Crankcase bolt Cil baffle plate bolt left crank case Crankcase stud bolt Nozzle NO Oil gallery screw B Bearing housing bolt torque lim iter Oil gallery bolt Engine oil drain bolt crankcase Stator coil lead holder screw Crankshaft position sensor lead holder screw TIGHTENING TORQUES Thread Clutch cover
263. m the oil gallery bolts If no engine oil comes out after one minute turn the engine off so that it will not seize c Check the engine oil passages the oil filter cartridge and the oil pump for damage or leakage Refer to OIL PUMP on page 5 95 d Start the engine after solving the problem s and check the engine oil pressure again e Tighten the oil gallery bolts to specification ENGINE Cil gallery bolt 10 Nm 1 0 m kg 7 2 ft Ib AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE TRANSFER GEAR OIL LEVEL 1 Stand the vehicle on a level surface NOTE e Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Remove Transfer gear oil check bolt 1 3 Check Transfer gear oil level The transfer gear oil level should be up to the brim 1 of the hole Below the brim Add the recommended transfer gear oil to the proper level Type 5 80 GL 4 Hypoid gear oil EC1D71024 CAUTION Do not allow foreign materials to enter the transfer gear case 4 Install e Transfer gear oil check bolt Syr Transfer gear oil check bolt 8 Nm 0 8 m kg 5 8 ft lb EAS20850 CHANGING THE TRANSFER GEAR OIL 1 Remove Muffler Exhaust pipes Refer to ENGINE REMOVAL on page 5 1 2 Place a container under the transfer gear oil 8 Install drain bolt Straight plug 3 Remove 9 Check e Straight plug 1 e Transfer gear oil drain bolt
264. maged 0 1 p DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check Inner tube Outer tube Bends damage scratches Replace 13650 Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure Spring free length a Out of specification Replace Fork spring free length 273 9 mm 10 78 in Limit 268 4 mm 10 57 in 3 Check e Damper rod Damage wear Replace Obstruction Blow out all of the oil passag es with compressed air Oil flow stopper Damage Replace FRONT FORK ECA14200 CAUTION The front fork leg has a built in damper ad justing rod and a very sophisticated inter nal construction which are particularly sensitive to foreign material When disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork 4 Check Cap bolt O ring Damage wear Replace EAS23020 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs EWA13660 Make sure the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability NOTE When assembling the front fork leg be sure 10 replace the following parts Inner tube bushing Outer tube bushing Oil seal Dust seal Before a
265. maladjusted or worn valves using the adjusting screw on the rocker arm If clearance is on the slip side 1 loosen the adjusting screw and bring the valve clearance within specification Check if the valve clearance b on the adjusting screw 2 side is within specification 1 2 LE If clearance is on the adjusting screw 2 side tighten the adjusting screw and bring the valve clearance b within specification 2 Valve clearance adjustment should be made on a cold engine at room temperature When the valve clearance is to be measured or adjusted the piston must be attop dead center TDC on the compression stroke 1 Remove Rider seat e Rider seat bracket assembly Refer to GENERAL CHASSIS on page 4 1 ENGINE Fuel tank Refer to FUEL TANK on page 6 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Muffler Exhaust pipes Refer to ENGINE REMOVAL on page 5 1 2 Disconnect e Spark plug caps 3 Remove e Spark plugs 4 Remove Shift pedal assembly 1 5 Remove Damper cover 1 Damper 2 Timing mark accessing screw 3 Crankshaft end screw 4 6 Remove Camshaft sprocket cover 1 7 Remove Wire harness guide bolt 1 8 Fuel tank damper 1 Cylinder head breather hose 2 9 Disconnect e Oil tank breather hose 3 F
266. mark 1 on the camshaft driven gear aligns with the punch mark on the camshaft drive gear as shown This is the condition in which piston 1 is at top dead center TDC NOTE d e f The crankshaft can be rotated smoothly when the spark plugs are removed EWA12880 Be careful since the engine is hot 9 With piston 1 at TDC count the indicated number of gear teeth and place marks 2 through 5 on the camshaft driven gear as shown When these marks align between the centers of the camshaft drive and driven gears the corresponding valve lifter is at its highest point Piston 1 TDC punch mark Cylinder 2 intake valve at its highest point Cylinder 1 exhaust valve at its highest point Cylinder 1 intake valve at its highest point Cylinder 2 exhaust valve at its highest point CAMSHAFTS h Rotate the crankshaft until the mark on the camshaft driven gear for the valve lifter to be bled aligns with the camshaft drive gear as shown Example For bleeding the cylinder 2 intake valve lift er align mark 2 as shown 1 Piston 1 TDC punch mark 2 Cylinder 2 intake valve at its highest point i Leave the camshaft drive and driven gears aligned for five minutes to allow the valve lift er to bleed If necessary repeat steps h and i to bleed other valve lifters DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS24060 INSTALLING THE VALVE LIFTERS 1 Install Front valve lifter case Rear valv
267. mm 11 280 in 6 Push rod 21 288 5 mm 11 358 in c Install the rocker arm base bolts M6 1 and rocker arm base bolts 8 2 and 3 NOTE Tighten the rocker arm base bolts in stages and in a crisscross pattern Rocker arm base bolt M6 10 Nm 1 0 m kg 7 2 ft lb Rocker arm base bolt M8 24 Nm 2 4 m kg 17ft Ib 5 31 Bolts 2 45 mm 1 77 in Bolts 3 70 mm 2 76 in DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA INSTALLING THE CYLINDER HEAD COVERS 1 Install e Rear cylinder head cover 1 e Front cylinder head cover 2 NOTE Due to the small clearance between the frame and the rear cylinder head cover the three bolts 3 cannot be installed when the cover is in place Set the bolts in the cylinder head cover and then install the cover from the right side of the vehicle Cylinder head cover bolt 10 Nm 1 0 m kg 7 2 ft lb Bolts 4 40 mm 1 57 in Bolts 5 60 mm 2 36 in CAMSHAFTS 5 S eA 1 ET1D71032 INSTALLING THE SHIFT PEDAL ASSEMBLY 1 Install Shift pedal assembly 1 NOTE Align the mark a on the shift pedal shaft with the slot in the shift pedal 5 32 CYLINDER HEADS EAS24110 CYLINDER HEADS Removing the cylinder heads Job Parts to remove Q ty D Cylinder 1 ignition coil bracket ZEE Refer to ENGINE REMOVAL on page 5 1 RENE Throttle bodies Intake manifolds Refer
268. n the brake disc bolts in stages and in a crisscross pattern Measure the brake disc deflection If out of specification repeat the adjustment steps until the brake disc deflection is within specification If the brake disc deflection cannot be brought within specification replace the brake disc 6 Install Front wheel Refer to FRONT WHEEL on page 4 15 EAS22270 REPLACING THE FRONT BRAKE PADS The following procedure applies to both brake calipers NOTE When replacing the brake pads it is not neces sary to disconnect the brake hose or disassem ble the brake caliper 1 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set Brake pad lining thickness in ner 5 5 mm 0 22 in Limit 0 5 mm 0 02 in Brake pad lining thickness out er 5 5 mm 0 22 in Limit 0 5 mm 0 02 in 4 37 FRONT BRAKE 2 Install Brake pad shims onto the brake pads Brake pads Brake pad spring NOTE Always install new brake pads brake pad shims and a brake pad spring as a set Connect a clear plastic hose 1 tightly to the bleed screw 2 Put other end of the hose into an open container Loosen the bleed screw and push the brake caliper pistons into the brake caliper w
269. n the brake pedal so the drive pulley does not move Stake the drive pulley nut 1 at a cutout a in the middle driven shaft 5 Adjust Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 24 4 83 BELT DRIVE ENGINE ENGINE REMOVAL ius ad 5 1 INSTALLING THE SHIFT PEDAL 55 5 5 CHECKING THE Ol COOLER 5 7 REMOVING THE zc 2 5 12 INSTALLING THE ENGINE 5 12 5 14 REMOVING THE CYLINDER HEAD COVERS 5 21 REMOVING THE ROCKER ARMS PUSH RODS AND VALVE n 5 21 REMOVING tantem pe 5 21 CHECKING THE CAMSHAFTS 5 23 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 5 24 CHECKING THE ROCKER ARM 5 25 CHECKING THE PUSH RODS s tete itte ondes 5 25 CHECKING THE VALVE LIFTERS AND VALVE LIFTER CASES 5 25 CHECKING THE PUSH ROD COVER 5 26 CHECKING THE DECOMPRESSION SYSTEM 5 26 CHECKING THE DECOMPRESSION SPRING 5 26 CHECKING THE OIL DELIVERY PI
270. n the odometer trip meter fu el reserve trip meter clock LCD Actuator operation Set the engine stop switch to to operate the actuator NOTE If the engine stop switch is set to set it to sq and then set it to O again 8 Turn the main switch to OFF to cancel the diagnostic mode Diagnostic code table Symptom No normal signals are re ceived from the crankshaft position sensor Cylinder 1 intake air pres sure sensor open or short circuit detected Cylinder 1 intake air pres sure sensor hose system malfunction clogged or de tached hose Throttle position sensor open or short circuit detect ed EXUP servo motor circuit open or short circuit detect ed EXUP servo motor is stuck Diagnostic Probable cause of malfunction coda Open or short circuit in wire harness Defective crankshaft position sensor Malfunction in crankshaft position sensor rotor Malfunction in ECU Improperly installed sensor Open or short circuit in wire harness Defective cylinder 1 intake air pressure sensor Malfunction in ECU Cylinder 1 intake air pressure sensor hose is detached clogged kinked or pinched Malfunction in ECU Open or short circuit in wire sub lead Open or short circuit in wire harness Defective throttle position sensor Malfunction in ECU Improperly installed throttle position sensor
271. nce Out of specification Replace the piston pin and piston as a set Piston pin to piston pin bore clearance Piston pin bore diameter b Piston pin outside diameter a Piston pin to piston pin bore clearance 0 004 0 024 mm 0 00016 0 00094 in EAS24460 INSTALLING THE PISTONS AND CYLINDERS The following procedure applies to all of the pis tons and cylinders 1 Install Top ring 1 2nd ring 2 Lower oil ring rail 3 Upper oil ring rail 4 5 48 Oil ring expander 5 NOTE Be sure to install the piston rings so that the manufacturer s marks or numbers face up 1 2 4 5 3 2 Install Piston 1 Piston pin 2 Piston pin clips 3 NOTE Apply engine oil onto the piston pin Make sure the arrow mark a on the piston fac es towards the front of the vehicle Before installing the piston pin clips cover the crankcase opening with a clean rag to prevent the clip from falling into the crankcase Install the piston pin clips so that the clip ends are 3 mm 0 12 in b or more from the cutout in the piston Reinstall each piston into its original cylinder numbering order starting from the left 1 to 2 CYLINDERS AND PISTONS 3 Lubricate Piston Piston rings Cylinder with the recommended lubricant Recommended lubricant Engine oil 4 Offset Piston ring end gaps 90 d e 1 b
272. nect the coupler se curely Open or short circuit in wire harness Repair or replace if there is an and or sub lead open or short circuit Between engine temperature sensor coupler and ECU cou pler brown brown black black Defective engine temperature sensor Execute the diagnostic mode Code No 11 Replace if defective Refer to CHECKING THE EN GINE TEMPERATURE SEN on page 7 87 Fault code No 80 Symptom vehicle has overturned Diagnostic code No 08 Lean angle sensor Item components and probable Check or maintenance job Reinstatement cause method The vehicle has overturned Raise the vehicle upright Turning the 2 Installed condition of the lean angle Check for looseness or pinching switch to sensor ON however the engine can 3 Connections Check the coupler for any pins notbe restarted ean angle sensor coupler that may be pulled out unless the main Main wire harness ECU coupler Check the locking condition of switch is first the coupler turned f there is a malfunction repair it and connect the coupler se curely 4 Defective lean angle sensor Execute the diagnostic mode Code No 08 Replace if defective Refer to CHECKING THE LEAN ANGLE SENSOR on page 7 84 7 50 FUEL INJECTION SYSTEM Fault code No Symptom Malfunction detected in the primary wire of the cylinder 1 left or right ignit
273. ned turn the crank shaft counterclockwise 360 degrees and re check step b CAMSHAFTS 2 Hemove e Hocker arm bases with the rocker arms 3 Hemove e Valve lifters NOTE Make a note of the position of each valve lifter so that they can be installed in the correct place EAS23830 REMOVING THE CAMSHAFTS 1 Loosen Camshaft driven gear bolt 1 NOTE Place a folded copper washer 2 between the teeth of the camshaft drive gear and camshaft driven gear in order to lock them Do not damage the teeth of the camshaft drive and camshaft driven gears 2 Remove Camshaft driven gear e Straight key NOTE Cover the crankcase hole with a clean rag to prevent the straight key from falling into the crankcase 3 Loosen Front cylinder camshaft gear bolt 71 NOTE Place a folded copper washer 2 between the teeth of the front cylinder camshaft gear and rear cylinder camshaft gear in order to lock them Do not damage the teeth of the front cylinder camshaft and rear cylinder camshaft gears 4 Remove Rear cylinder camshaft gear Front cylinder camshaft gear e Straight key NOTE Cover the crankcase hole with a clean rag to prevent the straight key from falling into the crankcase 5 Loosen Camshaft drive gear bolt 1 Right balancer driven gear bolt 2 CAMSHAFTS NOTE
274. ng into the crank case For reference during installation put an identi fication mark on each piston crown Before removing the piston pin deburr the pis ton pin clip s groove and the piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 4 Piston pin puller set 90890 01304 Piston pin puller YU 01304 a NEN 7 7 ee AP a C X a ur uo sinon mE i e e o A A nd 2 Remove op ring 2nd ring Oil ring 5 46 CYLINDERS AND PISTONS NOTE J J When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS24410 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the inders and pistons 1 Check Piston wall Cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance VYYVVYYYYYYYYYYYYYYYYYYYYYYYYYYYY a Measure cylinder bore with the cylinder bore gauge NOTE Measure cylinder bore by taking side to side and front to back measurements of the cylinder Then find the average of the measurements Bore 100 000 100 010 mm 3 9370 3 9374 in Taper limit 0 050 mm 0 0020
275. ng stroke K1 Optional spring available Enclosed gas air pressure STD opring preload adjusting positions Minimum Standard Maximum Swingarm owingarm end free play limit radial owingarm end free play limit axial Drive belt Model manufacturer Drive belt slack on the sidestand Drive belt slack on a suitable stand CHASSIS SPECIFICATIONS Fork oil 10WT 571 0 cm 19 31 US oz 20 10 Imp oz 124 0 mm 4 88 in owingarm link suspension Coil spring gas oil damper 50 0 mm 1 97 in 180 0 mm 7 09 in 176 4 mm 6 94 in XV19S C XV19 C XV19M C 171 0 mm 6 73 in XV19CTS C XV19CT C XV19CTM C 165 0 mm 6 50 in 176 50 N mm 1007 82 Ib in 18 00 kgf mm 0 0 50 0 mm 0 00 1 97 in NO 0 98 MPa 139 4 psi 9 8 kgf cm Installed spring length 162 0 mm 6 38 in XV19S C XV19 C XV19M C 171 0 mm 6 73 in XV19CTS C XV19CT C XV19CTM C 165 0 mm 6 50 in 171 0 mm 6 73 in 1 0 mm 0 04 in 1 0 mm 0 04 in UBD 0732 GATES CORPORATION 7 5 13 mm 0 30 0 51 14 21 mm 0 55 0 83 in EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage Ignition system Ignition system Advancer type Ignition timing B T D C Engine control unit Model manufacturer Ignition coil Model manufacturer Minimum ignition spark gap Primary coil resistance Secondary coil resistance Spark plug cap Material Hesistance AC magneto Model manufacturer Standard output Stator coil resistance
276. nstall eft crankcase onto the right crankcase NOTE Tap lightly on the left crankcase with a soft face hammer 4 Install Crankcase bolts 6 Crankcase bolts M8 Crankcase bolt M6 10 Nm 1 0 m kg 7 2 ft lb Crankcase bolt M8 24 Nm 2 4 m kg 17 ft lb NOTE Do not allow any sealant to come into contact with the oil gallery 2 Install e Oil pipe F mark 1 Oil pipe R mark 2 Dowel pins 3 5 93 NOTE Lubricate the bolt threads with engine oil Tighten each bolt 1 4 of a turn at a time stag es and in a crisscross pattern Tighten the bolts in numerical order refer to the numbers in the illustration e M8 x 90 mm bolts 1 2 e M8 x 65 mm bolt 3 M6 100 mm bolts 4 07 411 M6 x 80 mm bolt 12 e x 70 mm bolts 13 16 e M6 x 60 mm bolts 5 8 e M6 x 35 mm bolts 17 424 9 21 20 16 1510 14 19 A Right crankcase B Left crankcase 5 Apply Engine oil onto the crankshaft pin bearings and oil de livery holes 6 Check Crankshaft and transmission operation Rough movement Repair 5 94 CRANKCASE OIL PUMP EAS24910 OIL PUMP Removing the oil pump 24 Nm 2 4 kg 17 ft Ib Separate el pane sem dure 5 95 OIL PUMP Disassembling the oil pump Nm 0 7 kg 5 1 ft Ib 7 Nm 0 7 kg 5 1 ft Ib
277. ntainer and pump out the brake fluid carefully EAS22600 DISASSEMBLING THE REAR BRAKE CALIPER 1 Remove Brake caliper piston Brake caliper piston seals a Blow compressed air into the brake hose joint opening a to force out the piston from the brake caliper 13550 Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton 4 50 b Remove the brake caliper piston seals DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS22640 CHECKING THE REAR BRAKE CALIPER Recommended brake component replace ment schedule Brake pads Brake fluid 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air EWA13610 If necessary Every two years Every four years Every two years and whenever the brake is disassembled Whenever a brake caliper is disassembled replace the brake caliper piston seals 7 2 3 522650 ASSEMBLING THE REAR BRAKE CALIPER E
278. o avoid dam CAUTION age to the vehicle NOTE A NOTE provides key information to make procedures easier or clearer EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy easy to read reference book for the mechanic Comprehensive explanations of all installation removal disassembly assembly repair and check procedures are laid out with the individual steps in sequential order The manual is divided into chapters and each chapter is divided into sections The current section title is shown at the top of each page 1 Sub section titles 2 appear in smaller print than the section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a disas sembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction chart 6 accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc Jobs 7 requiring more information such as special tools and technical data are described sequen tially CLUTCH CLUTCH REMOVING THE CLUTCH Sheave holder 1 Loosen 90890 01701 Removing the clutch cover Clutch boss nut 1 en Primary clutch holder NOTE _ YS 01880 A While holding the clutch boss 2 with th
279. of the fuse box starter relay bracket AC For California only AD Route the horn 1 lead to the rear of the canister CABLE ROUTING E Ed SS ill a ih x pios SLM avt NY 1 A De _ O Ww i 2 CSS z 4 144 t x T AS 4 Ar 441 lt lt eX p V V EN LTE 7f rr rs 4 70 1 5 a Ek dm d 2 53 oo Noct 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Meter assembly coupler Cylinder 2 intake air pressure sensor coupler Cylinder 1 right spark plug cap Wire harness Negative battery lead EXUP servo motor Fuse box Starter motor lead Positive battery lead Sub wire harness 1 ECU electronic control unit Cylinder 1 left spark plug cap Cylinder 1 intake air pressure sensor coupler Fuel sender fuel tank coupler Neutral switch lead Sidestand switch lead Crankshaft position sensor lead Speed sensor lead Fuel hose fuel tank to fuel hose joint Fuel return hose fuel return pipe to sub fuel tank Air vent hose fuel pump to fuel hose joint Fuel outlet hose Frame Cil tank Sub fuel tank Battery Main fuse Fuel pump lead Do not pinch the leads between the fuel tank bracket and the frame when in
280. oil seals Swingarm side play at the end of the swingarm 1 0 mm 0 04 in d Check the swingarm vertical movement B by moving the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the spacers bear ings washers and oil seals REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM vu vv o cw Uy NI Uf 4 DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Check Rear shock absorber rod Bends damage Replace the rear shock absorber assembly Rear shock absorber Gas leaks oil leaks Replace the rear shock absorber assembly Spring Damage wear Replace the rear shock ab sorber assembly Bushing Damage wear Replace the rear shock ab sorber assembly Spacer Damage scratches Bolts Bends damage wear Replace EAS23260 CHECKING THE CONNECTING ARM AND RELAY ARM 1 Check Connecting arms Relay arm Damage wear Replace 2 Check Bearings Oil seals Damage pitting Replace 3 Check Bushings Damage wear Replace 4 Check e Spacers e Collars Damage scratches EAS23360 CHECKING THE SWINGARM 1 Check e Swingarm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash Pivot shaft
281. onnect properly 11 Lubricate Battery terminals Recommended lubricant Dielectric grease 12 Install Coupler tray ECU band NOTE Make sure the leads are routed correctly 1 Positive battery terminal 13 Install 2 Negative battery terminal Rider seat i Positive tester probe Refer to GENERAL CHASSIS on page 4 1 CHECKING THE RELAYS poem Check each switch for continuity with the pocket between 3 and 4 tester If the continuity reading is incorrect re place the relay 7 79 Relay unit fuel pump relay Positive battery terminal Negative battery terminal Positive tester probe Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 ET1D71011 CHECKING THE TURN SIGNAL RELAY 1 Check Turn signal relay input voltage Out of specification The wiring circuit from the main switch to the turn signal relay cou pler is faulty and must be repaired Turn signal relay input voltage DC 12V 7 80 ELECTRICAL COMPONENTS a Connect the pocket tester DC 20 V to the turn signal relay terminal as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe
282. ont side 59 Nm 5 9 m kg 43 ft Ib 6 Adjust Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 24 BELT DRIVE EAS23510 BELT DRIVE Removing the drive belt and drive pulley 53 Nm 5 3 m kg 38 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 63 Nm 6 3 kg 45 ft Ib 10 Nm 1 0 kg 7 2 ft Ib Omer Job Parts to remove Rearwheel Referto REAR WHEEL on 4 23 _ BRE RRA SHOOK ABSORBER 2 7 3 7 4 S 7 6 poan 39 2 I i 4 80 BELT DRIVE Removing the drive belt and drive pulley 53 Nm 5 3 m kg 38 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 63 Nm 6 3 kg 45 ft Ib 10 Nm 1 0 kg 7 2 ft Ib mE For installation reverse the removal proce dure 4 81 EAS23520 REMOVING THE DRIVE BELT AND DRIVE PULLEY NOTE Loosen the drive pulley nut before removing the rear wheel 1 Loosen Drive pulley nut 1 When loosening the drive pulley nut press down on the brake pedal so the drive pulley does not move EAS23530 CHECKING THE DRIVE BELT 1 Clean e Drive belt vYVVYYYYYYYYYYYYYYYYYYYYYYYYYYYY a Wipe the drive belt with a clean cloth b Put the
283. or setting the brightness control mode switch the odometer the tripmeters and the fuel reserve tripmeter displays between kilo meters and miles press the SELECT switch for at least two seconds For USA and Califor nia only 1 4 FEATURES 1 SELECT switch 2 HESET switch Speedometer 1 Speedometer The speedometer shows the riding speed When the key is turned to ON the speedome ter needle will sweep once across the speed range and then return to zero in order to test the electrical circuit Tachometer 1 Tachometer 2 Tachometer red zone The electric tachometer allows the rider to mon itor the engine speed and keep it within the ideal power range When the key is turned to ON the tachometer needle will sweep once across the r min range and then return to zero r min in order to test the electrical circuit EC1D71017 CAUTION Do not operate the engine in the tachometer red zone Red zone 5000 r min and above lt The fuel gauge indicates the amount of fuel in the fuel tank The needle moves towards E Empty as the fuel level decreases When the needle reaches E approximately 3 0 L 0 79 US gal 0 66 Imp gal remain in the fuel tank this occurs refuel as soon as possible When the key is turned to ON the fuel gauge needle will sweep once across the fuel level range and then return to the current amount in order to test the electrical circuit NO
284. or 3 5 minutes to check the battery 7 78 ELECTRICAL COMPONENTS e Standard charging current is reached Battery is good e Standard charging current is not reached Replace the battery d Adjust the voltage so that the current is at the standard charging level e Set the time according to the charging time suitable for the open circuit voltage f If charging requires more than 5 hours it is advisable to check the charging current after a lapse of 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging current g Measure the battery open circuit voltage after leaving the battery unused for more than 30 minutes 12 8 V or more Charging is complete 12 7 V or less Recharging is required Under 12 0 V Replace the battery Charging method using constant volt age charger a Measure the open circuit voltage prior to charging NOTE Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery NOTE If the current is lower than the standard charging current written on the battery this type of battery charger cannot
285. ot of the fuel tank damper Fasten the fuel outlet hose wire harness and fuel tank damper with the plastic locking tie Install the plastic locking tie in the front slot of the fuel tank damper and make sure that the end of the damper is aligned with the edge of the flat section on the outside of the frame Fasten the cylinder 1 left and right ignition coil leads engine temperature sensor lead and throttle position sensor lead to the guide on the engine bracket right upper side with the plastic locking tie Face the end of the plastic locking tie rearward and then cut off the excess end of the tie Fasten sub wire harness 2 with the plastic locking tie Align the positioning tape on the wire harness with the top of the frame 0 15 mm 0 0 59 in Route the throttle cables behind the front brake hose Make sure that the wire harness is not twisted between the fuel tank and the headlight assembly Position the cylinder 2 left and right spark plug leads sub wire harness 2 coupler and sub wire harness 4 coupler on top of the guide 2 50 Ou EE A O U lt lt CH Z CABLE ROUTING Fasten the wire harness and the cylinder 2 left and right spark plug leads with a plastic locking tie making sure to install the tie just past the end of the protective tube of the wire harness Face the end of the plastic locking tie inward and then cut off the excess end of the tie To the throttle position sen
286. ow shown 6 13 THROTTLE BODIES ISC IDLE SPEED CONTROL UNIT ET1D71009 ISC IDLE SPEED CONTROL UNIT Removing the ISC idle speed control unit 7 Nm 0 7 kg 5 1 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib 7 Nm 0 7 kg 5 1 ft Ib 7 Nm 0 7 kg 5 1 ft Ib Job Parts to remove Q ty Front cylinder head 7 Refer to CYLINDER HEADS on page 5 33 1 Sub wire harness ES NN S _________ ____________ Cylinder 2 ISC idle speed control unit outlet 3 h 2 ose Cylinder 1 ISC idle speed control unit outlet 2 2 ISC idle speed control unit inlet hose ELM omes cot 3 1 EB NM ISC idle speed control unit bracket dure 6 14 ET1D71010 CHECKING THE ISC IDLE SPEED CONTROL SYSTEM 1 Check e Hoses Loose connections Connect properly Cracks damage Replace ISC IDLE SPEED CONTROL UNIT 6 15 ELECTRICAL SYSTEM IGNITION SY E Re 7 1 eiie Tim 7 1 ENGINE STOPPING DUE TO SIDESTAND OPERATION 7 3 TROUBLESHOOTING Er 7 4 ELECTRIC STARTING 5 7 7 eie TI CSI rc 7 7 STARTING CIRCUIT CUT OFF SYSTEM 7 9 TROUBLESHOOTING ao 7 11 CHARGING SVS die
287. p may generate heat in the contact area and a weak clip spring may cause sparks f the battery becomes hot to the touch at any time during the charging process dis connect the battery charger and let the bat tery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of an MF battery stabi lizes about 30 minutes after charging has been completed Therefore wait 30 min utes after charging is completed before measuring the open circuit voltage voltage V Time minutes Charging Ambient temperature 20 68 F Check the open circuit voltage gt Charging method using a variable current voltage charger a Measure the open circuit voltage prior to charging NOTE Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging NOTE set the charging voltage at 16 17 V If the set ting is lower charging will be insufficient If too high the battery will be over charged c Make sure that the current is higher than the standard charging current written on the bat tery NOTE If the current is lower than the standard charging current written on the battery set the charging voltage adjust dial at 20 24 V and monitor the amperage f
288. page 7 40 Monitor the opera ble tion of the sensors and actuators in the diagnostic mode Re fer to Sensor opera tion table and Actuator operation table 3 Perform ECU reinstatement action Refer to Reinstatement method of table in TROUBLESHOOTING DETAILS 4 Turn the main switch to OFF and back to ON then check that no fault code number is displayed NOTE If fault codes are displayed repeat steps 1 to 4 until no fault code number is displayed 7 32 FUEL INJECTION SYSTEM 5 Erase the malfunction history in the diagnos The engine operation is not normal but the tic mode Refer to Sensor operation table engine trouble warning light does not come Diagnostic code No 62 on NOTE 1 Check the operation of following sensors and Turning the main switch to OFF will not erase actuators in the Diagnostic mode Refer to the malfunction history Sensor operation table and Actuator oper ation table 01 Throttle position sensor throttle angle 30 Cylinder 1 ignition coil 31 Cylinder 2 ignition coil 32 Cylinder 1 ignition coil 33 Cylinder 2 ignition coil 36 Injector 1 3 Injector 2 If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in the sensors and actuators check and repair inner parts of the engine EAS27420 DIAGNOSTIC MODE S
289. pe Model manufacturer Built in self canceling device Turn signal blinking frequency Wattage Fuel gauge Model manufacturer Sender unit resistance full Sender unit resistance empty Starting circuit cut off relay Model manufacturer Coil resistance Headlight relay Model manufacturer ELECTRICAL SPECIFICATIONS LED LED LED LED LED Constant mesh 1D7 MORIC 0 90 kW 0 0081 0 0099 9 8 mm 0 39 in 5 00 mm 0 20 in 7 36 11 04 26 49 39 74 oz 750 1126 gf 28 5 mm 1 12 in 27 5 mm 1 08 in 1 50 mm 0 06 in 2 68079 A JIDECO 180 0A 4 18 4 62 Eddy 2 pcs YP 12 NIKKO 2 0A 0 94 0 98 Q 95 115 dB 2m Semi transistor FB246H DENSO Yes 75 0 95 0 cycles min 21 23 W x2 LED x2 1D7 YAMAHA 9 110 213 219 G8R 30Y V3 OMRON 162 198 ACM33211M05 MATSUSHITA 2 14 ELECTRICAL SPECIFICATIONS Fuel pump relay Model manufacturer G8HR 30Y V3 OMRON Coil resistance 162 198 Thermo unit Model manufacturer 5PX DENSO Hesistance at 100 C 898 4 1098 0 Fuses Main fuse 50 0 A Headlight fuse 20 0A Taillight fuse 10 0A Signaling system fuse 10 0A Ignition fuse 25 0A Auxiliary DC connector fuse 3 0A ECU fuse 10 0A Fuel injection system fuse 15 0A Backup fuse 10 0A Heserve fuse 25 0 Heserve fuse 20 0 A Heserve fuse 15 0A Heserve fuse 10 0A Heserve fuse 3 0 A 2 15 TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQ
290. r bracket pinch bolts and steering stem nut NOTE Make sure the inner tube end is flush with the top of the upper bracket 2 Tighten Lower bracket pinch bolts Lower bracket pinch bolt 23 Nm 2 3 m kg 17 ft Ib 3 Hemove Upper bracket 4 Tighten Lower front fork cover nuts Lower front fork cover nut 7 Nm 0 7 m kg 5 1 ft Ib 5 Install Upper front fork cover 1 Upper bracket FRONT FORK NOTE Align the groove a in the upper front fork cover 1 with the lower front fork cover nut 2 6 Tighten e Steering stem nut Steering stem nut 115 Nm 11 5 m kg 85 16 Cap bolt Upper bracket pinch bolts Cap bolt 23 Nm 2 3 m kg 17 ft lb Upper bracket pinch bolt 10 Nm 1 0 m kg 7 2 ft Ib LOCTITE NOTE Tighten the upper bracket pinch bolts to specifi cation twice Tighten the upper and lower bolts alternately starting with the upper bolts Upper bracket cover bolts Upper bracket cover bolt 19 Nm 1 9 m kg 13 ft lb LOCTITE Upper bracket cover bolts Upper bracket cover bolt 16 Nm 1 6 m kg 11 ft Ib LOCTITE EWA13680 Make sure the brake hoses are routed prop erly STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 52 Nm 5 2 m kg 37 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib pes cer BUE 16 Nm 1 6 kg 11 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib Job Pa
291. r lead and wire harness with the holders Route sub wire harness 1 to the inside of the frame the tail brake light Fasten the starter motor lead horn 1 lead rear brake light switch lead sidestand switch lead and crankshaft position sensor lead with the plastic locking tie Make sure that there is no slack in the stator coil lead and rectifier regulator lead in the area shown in the illustration 2 52 CABLE ROUTING Fasten the stator coil lead and rectifier regulator lead with the plastic locking tie Face the end of the plastic locking tie outward and then cut off the excess end of the tie Fasten the lean angle sensor lead starter motor lead horn 1 lead rear brake light switch lead and sidestand switch lead with the holder Route the starter motor lead horn 1 lead rear brake light switch lead and sidestand switch lead to the inside of the frame boss Fasten the starter motor lead horn 1 lead rear brake light switch lead and sidestand switch lead with the plastic locking tie Face the end of the plastic locking tie outward and then cut off the excess end of the tie Fasten the starter motor lead horn 1 lead and rear brake light switch lead with the plastic locking tie and then face the end of the tie outward Be sure to install the plastic locking tie behind the frame cross member and to fasten the rear brake light switch lead at the white tape Houte the starter motor lead
292. r replace if there is an open or short circuit Between meter assembly cou pler and ECU coupler yellow blue yellow blue Malfunction in meter assembly Replace the meter assembly Malfunction in ECU Replace the ECU Fault code No Symptom No signals are received from the ECU within the specified duration Reinstatement method Connections Check the coupler for any pins Turning e Main wire harness ECU coupler that may be pulled out main switch to e Main wire harness meter assembly Check the locking condition of ON coupler the coupler f there is a malfunction repair it and connect the coupler se curely Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between meter assembly cou pler and ECU coupler yellow blue yellow blue Malfunction in meter assembly Replace the meter assembly Malfunction in ECU Replace the ECU 7 61 FUEL INJECTION SYSTEM Fault code No Era Symptom Data from the ECU cannot be received correctly Reinstatement method Connections Check the coupler for any pins Turning Main wire harness ECU coupler that may be pulled out main switch to Main wire harness meter assembly Check the locking condition of ON coupler the coupler f there is a malfunction repair it and connect the coupler se curely Open or short circuit in wire harness Repair or replace if there is an open o
293. r rotor 2 with the sheave holder 3 loosen the generator rotor bolt v Sheave holder gt 90890 01701 Primary clutch holder YS 01880 A 2 Remove e Generator rotor 1 with the rotor puller 72 Woodruff key Rotor puller 90890 01080 Stator rotor puller YM 01080 A EAS24560 REMOVING THE STARTER CLUTCH 1 Remove e Starter clutch bolts e Starter clutch NOTE While holding the generator rotor 1 with the sheave holder 2 loosen the starter clutch bolts Sheave holder AA 90890 01701 Primary clutch holder YS 01880 A EAS24570 CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers Damage wear Replace 2 Check e Starter clutch idle gear e Starter clutch gear Burrs chips roughness wear Replace the defective part s 3 Check e Starter clutch gear s contacting surfaces Damage pitting wear Replace the starter clutch gear 4 Check e Starter clutch operation a Install the starter clutch gear 1 onto the starter clutch and hold the generator rotor 2 b When turning the starter clutch gear clock wise the starter clutch and the starter clutch gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter clutch gear counter clockwise B it should turn freely otherwise the starter clutch is faulty and must be re
294. r short circuit Between meter assembly cou pler and ECU coupler yellow blue yellow blue Malfunction in meter assembly Replace the meter assembly Malfunction in ECU Replace the ECU Connections Check the coupler for any pins Turning Main wire harness ECU coupler that may be pulled out main switch to e Main wire harness meter assembly Check the locking condition of ON coupler the coupler f there is a malfunction repair it and connect the coupler se curely Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between meter assembly cou pler and ECU coupler yellow blue yellow blue Malfunction in meter assembly Replace the meter assembly Malfunction in ECU Replace the ECU 7 62 FUEL PUMP SYSTEM FUEL PUMP SYSTEM CIRCUIT DIAGRAM EAS27550 EAS27560 T E 8 40 de um pen 69 9 GIDI 9 1 eue 4 av m dien dio UA gu r D avo IXY vo a 1 1 aS A Ta PNIS i anjur Brew eor v 3018 PEt O C v faa FT Sano 02 69 69 Gove 51 Gp
295. r side 5 Engine mounting nut front lower side 7 Engine bracket nuts rear upper side 10 Engine mounting nut rear upper side 12 Engine mounting bolts left upper side 14 Engine bracket bolts left upper side 15 Engine mounting bolts right upper side 17 Engine bracket bolts right upper side 18 Engine mounting nut rear lower side 98 Nm 9 8 m kg 71 ft lb Engine mounting nut front lower side 105 Nm 10 5 m kg 75 ft lb Engine bracket nut rear upper side 53 Nm 5 3 m kg 38 ft lb Engine mounting nut rear upper side 98 Nm 9 8 m kg 71 ft lb Engine mounting bolt left upper side 66 Nm 6 6 m kg 48 ft lb LOCTITE Engine mounting bolt right up per side 59 Nm 5 9 m kg 43 ft lb Engine bracket bolt left upper side 53 Nm 5 3 m kg 38 ft lb Engine bracket bolt right upper side 53 Nm 5 3 m kg 38 ft lb 5 Install e Engine brackets front upper side 1 e Engine bracket bolts front upper side 2 Engine bracket nuts front upper side 3 e Engine cross member bracket 4 Engine cross member bracket bolts 5 Engine mounting front upper side 6 Engine mounting nut front upper side 7 NOTE Do not fully tighten the bolts and nuts 6 Install Lead holder bracket Lead removed during engine removal NOTE To install and route the leads refer to
296. re 4 1 ET1D71039 REMOVING THE WINDSHIELD 1 Remove e Windshield a Insertthe key 1 into the windshield lock turn it clockwise and then remove the key 2 Unlock b Remove the windshield by pushing it forward and then pulling it upward as shown EW1D71016 Be careful not to push the vehicle forward when removing the windshield The vehicle could fall off the sidestand EC1D71025 CAUTION Securely hold the windshield to prevent it from falling when removing 1 CN ET1D71045 ASSEMBLING THE WINDSHIELD 1 Install e Windshield lock 1 NOTE Align the projection a on the lock 1 with the slot b in the windshield bracket 2 GENERAL CHASSIS ET1D71040 INSTALLING THE WINDSHIELD 1 Install Right windshield holder bracket assembly 1 NOTE Pass the throttle cables 2 between the front fork and the right windshield holder bracket as sembly 554 SOM 2 Install e Windshield a Fit the slot in each windshield bracket left and right side into its holder b NOTE Make sure that the throttle cables 1 are not pinched b Push the windshield backward until it snaps into place
297. rear shock absorber at a point 15 20 mm 0 59 0 79 in from its end as shown A WARNING Wear eye protection to prevent eye damage from released gas or metal chips ET1D71002 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over 4 76 NOTE Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Loosen Engine mounting nut rear lower side Refer to ENGINE REMOVAL on page 5 1 NOTE Because there is force being exerted on the en gine mounting bracket left and right rear lower sides it is necessary to loosen the engine mounting nut rear lower side in order to create some space between the connecting arms and engine bracket before removing the rear shock absorber and swingarm 3 Remove Connecting arm bolt frame side NOTE When removing the connecting arm bolt frame side hold the swingarm so that it does not drop down 4 Measure Swingarm side play e Swingarm vertical movement Measure the tightening torque of the pivot shaft nut Pivot shaft nut 125 Nm 12 5 m kg 90 ft Ib b Measure the swingarm side play A by mov ing the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bearings washers and
298. removed care Engine oil fully install a new one 5 Install Friction plates 2 1 Clutch plates Friction plate 1 2 NOTE First install a friction plate and then alternate between a clutch plate and a friction plate Align a projection on each friction plate 2 1 with the A mark on the clutch housing and align a projection on friction plate 1 2 with the punch mark b on the housing 3 Install e Clutch boss 1 5 65 CLUTCH 6 Install Sue tai DISASSEMBLING THE CLUTCH MASTER utch spring plate retainer CYLINDER Clutch spring plate retainer bolt NOTE gt 8 Nm 0 8 m kg 5 8 16 Before disassembling the clutch master cylinder drain the clutch fluid from the entire clutch sys NOTE gt tem Tighten the clutch spring plate retainer bolts in 1 Remove stages and in a crisscross pattern Clutch hose union bolt 4 7 Apply Copper washers 2 e Sealant e Clutch hose 3 onto the crankshaft position sensor lead NOTE grommet To collect any remaining clutch fluid place a container under the master cylinder and the end 7 Yamaha bond No 1215 90890 85505 Three Bond No 12159 ET1D71037 CHECKING THE CLUTCH MASTER 8 Install Shift arm 1 i r ES Shift arm bolt Clutch master cylinder 24 12 Nm 1 2 m kg 8 7 1 Damage scratches wear gt Replace Clutch fluid d
299. riorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful 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 ECA13540 CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Hefer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 6 Check e Brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level FRONT BRAKE Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 20 7 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 22 EAS22490 REMOVING THE FRONT BRAKE MASTER CYLINDER NOTE Before removing the front brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Front brake hose union bolt 1 Copper washers 2 Front brake hose 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS22500 CHECKING THE FRONT BRA
300. rning operation nue opera Vehicle operation Warning provided Flashing when unable to start Operation stopped Cannot be operated engine Operated with substi tute characteristics Can or cannot be oper Remains on Malfunction detected accordance with the ated depending on the description of the mal fault code function The warning light flashes when any one of the conditions listed below is present and the start switch is pushed d Lean angle sensor 12 Crankshaft position sensor 41 open or short circuit 19 Blue black ECU lead 50 ECU internal malfunction broken or disconnected memory check error 30 Lean angle sensor latch up detected Checking the engine trouble warning light The engine trouble warning light comes on for 1 4 seconds after the main switch has been turned to ON and it comes on while the start switch is being pushed If the warning light does not come on under these conditions the warning light may be defective a b Main switch 5 Engine trouble warning light off Engine trouble warning light on for 1 4 seconds Main switch OFF 7 29 EAS27380 FUEL INJECTION SYSTEM 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
301. rts to remove Q ty Lower handlebar holder Refer to HANDLEBAR on page 4 55 OW NENNEN Upper bracket Front fork legs Refer to FRONT FORK on page 4 60 2 Front brake hose guide 6 7 8 9 OO 4 69 STEERING HEAD Removing the lower bracket 52 Nm 5 2 kg 37 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib pee dms 16 Nm 1 6 kg 11 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib mE For installation reverse the removal proce dure 4 70 EAS23110 REMOVING THE LOWER BRACKET 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Remove Upper ring nut e Rubber washer Lower ring nut 1 Lower bracket EWA13730 Securely support the lower bracket so that there is no danger of it falling NOTE Remove the lower ring nut with the steering nut wrench 2 Steering nut wrench 90890 01403 Spanner wrench YU 33975 EAS23120 CHECKING THE STEERING HEAD 1 Wash Bearings Bearing races Recommended cleaning solvent Kerosene 2 Check Bearings Bearing races Damage pitting Replace 3 Replace Bearings Bearing races 4 71 STEERING HEAD Remove the bearing races from
302. ry chain at the same time Align the splines on the middle drive gear with the splines on the drive axle Temporarily install the drive pulley nut onto the middle driven shaft 4 Remove 1 Drive pulley nut 3 Install Conical spring washer 1 Middle drive gear nut 2 Middle drive gear nut 140 Nm 14 0 m kg 100 NOTE ubricate the middle drive gear nut threads and conical spring washer mating surfaces with engine oil Install the conical spring washer 1 with the OUT mark a facing out Stake the middle drive gear nut 2 at a cutout b in the drive axle 5 88 CRANKCASE EAS25540 CRANKCASE Separating the crankcase X 24 Nm 2 4 kg 17 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 43 Nm 4 3 kg 31 ft Ib 10 Nm 1 0 kg 7 2 ft Ib Refer to CYLINDERS AND PISTONS on NEN Left balancer driven gear housing Refer to CLUTCH on page 5 50 HERI Shift shaft Refer to SHIFT SHAFT on page 5 70 CLUTCH on page 5 72 4 ees 8 Emmeolpmpdengersoper 3 Engine oil pump driven gear 4 0j 7 Cil baffle plate left crankcase 8 Left crankcase T 5 89 CRANKCASE Separating the crankcase wee QS 0 2 24 Nm 2 4 kg 17 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib Job Parts to remove LM For installa
303. shaft Improperly assembled crankcase e Seized crankshaft Fuel system 1 Fuel tank Empty fuel tank Clogged fuel filter Clogged fuel tank overflow breather hose Clogged rollover valve Clogged rollover valve hose Deteriorated or contaminated fuel 2 Fuel pump Faulty fuel pump Faulty relay unit fuel pump relay 3 Throttle body ies Deteriorated or contaminated fuel 8 1 TROUBLESHOOTING e Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Faulty spark plug cap 4 Ignition coil s Cracked or broken ignition coil body Broken or shorted primary or secondary coils Faulty spark plug lead 5 Ignition system Faulty ECU Faulty crankshaft position sensor Broken generator rotor woodruff key 6 Switches and wiring Faulty main switch Faulty engine stop switch Broken or shorted wiring Faulty neutral switch Faulty start switch Faulty sidestand switch Faulty clutch switch Improperly grounded circuit Loose connections 7 Starting system e Faulty starter motor e Faulty starter relay e Faulty relay unit starting circuit cut off relay Faulty starter clutch EAS284
304. side of the crank shaft Make sure the characters d on both the con necting rod and connecting rod cap are aligned 4 Tighten Connecting rod bolts 1 1010 A WARNING Replace the connecting rod bolts with new ones Clean the connecting rod bolts NOTE The tightening procedure of the connecting rod bolts is angle controlled therefore tighten the bolts using the following procedure 5 105 a Tighten the connecting rod bolts with a torque wrench Connecting rod bolt 1st 15 Nm 1 5 m kg 11 ft Ib b Puta mark 1 on the corner of the connecting rod bolts 2 and the connecting rod 3 c Tighten the connecting rod bolts further to reach the specified angle 125 135 Connecting rod bolt final Specified angle 125 135 gt 125 1357 EW1D71011 When a bolt is tightened more than the spec ified angle do not loosen and then retighten it Replace the bolt with a new one and perform the procedure again EC1D71001 CAUTION Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angle AA4AAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS26210 INSTALLING THE CRANKSHAFT ASSEMBLY 1 Install e Generator shaft 1 CRANKSHAFT Crankshaft assembly 2 ECA1397
305. so that the X4 mark is positioned as shown d Release the front wheel When the wheel stops put an X5 mark at the bottom of the wheel f Repeat steps d through f several times un til all marks come to rest at the same spot g The spot where all the marks come to rest is the front wheel s heavy spot X DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Adjust Front wheel static balance a Install a balancing weight 1 onto the rim ex actly opposite the heavy spot X NOTE Start with the lightest weight b Turn the front wheel 90 so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wheel is balanced DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 4 Check Front wheel static balance vYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY a Turn front wheel and make sure it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS The following procedure applies to both of the front brake discs 1 Install Front brake disc Front brake disc cover Front brake disc bolt 23 Nm 2 3 m kg 17 ft lb LOCTITE 4 20 NOTE Tighten the front brake disc bo
306. sor To the fuel injector and engine temperature sensor To the neutral switch speed sensor Fasten the stator coil lead with the plastic locking ties Face the end of each plastic locking tie outward and then cut off the excess end of the tie To the rear brake caliper Install the sensor coupler completely onto the O sensor bracket Outside of the frame Position the buckle of the plastic locking tie to the inside of the frame Face the end of the plastic locking tie upward and then cut off the excess end of the tie Inside of the frame Position the buckle of the plastic locking tie to the inside of the frame To the wire harness To the cylinder 2 right spark plug side Position the sub wire harness 3 coupler and the sub wire harness 4 coupler between the cylinder 2 right spark plug lead and the cylinder 1 ISC unit outlet hose Face the ends of the hose clamp outward angled 45 downward AA Route the cylinder 2 right spark plug lead under the sub wire harness 4 AB Face the ends of the hose clamp downward AC Route the cylinder 2 left spark plug lead under the cylinder 2 ISC unit outlet hose AD Left side AE To the cylinder 2 left spark plug AF Install the clutch pipe onto the clutch release cylinder making sure that the pipe contacts the projection on the cylinder AG the sensor AH Align the cutout in the clutch pipe union bolt cap
307. sor 20 Cylinder 2 right ignition coil 7 Cylinder 1 left ignition coil 21 Cylinder 22 left ignition coil 8 Cylinder 1 intake air pressure sensor 9 Fuel pump 10 ECU electronic control unit 11 Relay unit fuel pump relay 12 EXUP servo motor 13 Speed sensor 14 sensor 1 2 FEATURES ET1D71018 SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 392 kPa 3 92 kg cm 55 7 psi Accordingly when the energizing signal from the ECU energizes the fuel injector the fuel passage opens causing the fuel to be injected into the intake manifold only during the time the passage remains open There fore the longer the length of time the fuel injector is energized injection duration the greater the vol ume of fuel that is supplied Conversely the shorter the length of time the fuel injector is energized injection duration the lesser the volume of fuel that is supplied The injection duration and the injection timing are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor air temperature sensor engine temperature sensor speed sensor and 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 f
308. ssembling the front fork leg make sure all of the components are clean 1 Install Inner tube bushing 1 e Damper rod 2 Rebound spring e Spring 3 Oil flow stopper 4 EC1D71012 CAUTION Allow the damper rod to slide slowly down the inner tube 5 until it protrudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate e Inner tube s outer surface Recommended oil Fork oil 10WT 3 Install Inner tube in the outer tube 4 Install Copper washer Damper rod bolt 5 Tighten Damper rod bolt 1 Damper rod bolt 40 Nm 4 0 m kg 29 ft lb LOCTITE NOTE While holding the damper rod assembly with the damper rod holder 2 and T handle 3 tighten the damper rod bolt Damper rod holder 90890 01460 T handle 90890 01326 T handle 3 8 drive 60 cm long YM 01326 6 Install e Outer tube bushing 1 FRONT FORK Washer with the fork seal driver 2 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 7 Install Oil seal 1 with the fork seal driver 2 ECA14220 CAUTION Make sure the numbered side of the oil seal faces up NOTE Before installing the oil seal lubricate its lips with lithium soap based grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of th
309. ssion gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks e Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS28570 FAULTY CLUTCH Clutch slips 1 Clutch Improperly assembled clutch Improperly assembled clutch master cylinder Improperly assembled clutch release cylinder Incorrect clutch fluid level Damaged clutch hose oose or fatigued clutch spring Loose union bolt Worn friction plate Worn clutch plate Damaged clutch release cylinder 2 Engine oil Incorrect oil level Incorrect oil viscosity low Deteriorated oil Clutch drags 1 Clutch Air in hydraulic clutch system Unevenly tensioned clutch springs Warped pressure plate Bent clutch plate Swollen friction plate Bent clutch push rod Damaged clutch boss Burnt primary driven gear bushing Damaged clutch release cylinder Match marks not aligned 2 Engine oil Incorrect oil level Incorrect oil viscosity high Deteriorated oil EAS28590 OVERHEATING Engine 1 Cylinder head s and piston s Heavy carbon buildup 2 Engine oil Incorrect oil level Incorrect oil viscosity Inferior oil quality Fuel system 1 Throttle body ies Faulty t
310. stalling the bracket Pass the plastic locking ties through the holes in the frame damper and then fasten the wire harness and damper with the ties Face the end of each plastic locking tie upward and then cut off the excess end of the tie Align the white tape on the wire harness with the frame cross member 20 mm 0 79 in Fasten the wire harness with the plastic locking tie Face the end of the plastic locking tie upward and then cut off the excess end of the tie Route the wire harness along the frame Fasten the wire harness with the plastic locking tie making sure to align the tie with the line on the rubber damper Face the end of the plastic locking tie upward and then cut off the excess end of the tie Connect the ECU couplers and then fasten the ECU with the band Fasten the fuel return hose fuel return pipe to sub fuel tank with the plastic locking tie Face the end of the plastic locking tie inward and then cut off the excess end of the tie Route the cylinder 1 intake air pressure sensor lead so that it does not protrude past the top of the frame Fasten the fuel tank damper with the plastic locking tie Install the plastic locking tie in the middle slot of the fuel tank damper 2 54 D OVOZ CABLE ROUTING Fasten the air filter case damper with the plastic locking tie so that the rubber part of the damper contacts the frame Be sure to pass the plastic lock
311. t ating it at idle Main wire harness ECU coupler Check the locking condition of Sub wire harness coupler the connector and coupler f there is a malfunction repair it and connect the coupler se curely Open or short circuit in wire harness Repair or replace if there is an and or sub lead open or short circuit Between cylinder 2 left or right ignition coil connector and ECU coupler main wire harness black red blue red gray red gray red Defective cylinder 2 left or right igni Execute the diagnostic mode tion coil Code No 31 or 33 Test the primary and secondary coils for continuity Replace if defective Refer to CHECKING THE IG NITION COILS on page 7 83 7 52 FUEL INJECTION SYSTEM Fault code No Symptom Malfunction detected in the primary wire of the cylinder 1 left or right ignition coil Diagnostic code No 30 32 Cylinder 1 left or right ignition coil Item components and probable Check or maintenance job Reinstatement cause method Connections Check the connector and cou Starting the en Cylinder 1 left or right ignition coil pler for any pins that may be gine and oper connector primary coil side pulled out ating it at idle Main wire harness ECU coupler Check the locking condition of the connector and coupler f there is a malfunction repair it and connect the coupler se curely Open or short circuit in wire harness Repa
312. t LU 5 18 CAMSHAFTS Removing the camshafts and right balancer 10 Nm 1 0 m kg 7 2 ft Ib 19 Rear cylinder camshaft BM 1 For installation reverse the removal proce dure 5 19 CAMSHAFTS Disassembling the camshafts RU 3 e peos 7 5 Decompression pin 6 ream 7 meris For assembly reverse the disassembly pro cedure 5 20 ET1D71030 REMOVING THE CYLINDER HEAD COVERS 1 Remove Front cylinder Rear cylinder 1 NOTE Due to the small clearance between the frame and the rear cylinder head cover the three bolts 2 cannot be removed when the cover is in place Loosen the bolts and then remove the cover from the right side of the vehicle making sure that the bolts do not scratch the rocker arms or other engine parts EAS23790 REMOVING THE ROCKER ARMS PUSH RODS AND VALVE LIFTERS 1 Align mark on the crankshaft position sen Sor rotor with the pointer b on the clutch cover VYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY a the crankshaft counterclockwise b When piston 1 is at TDC on compres sion stroke align the TDC mark a on the crankshaft position sensor rotor with the pointer b on the clutch cover 6627 c Check the camshaft drive gear mark posi tion and camshaft driven gear mark d posi tion as shown If the marks are not alig
313. t idling The ECU automatically stops the en gine after 20 minutes if it is left idling Communication error with the meter Fault code No ECU internal malfunc Er 1 tion output signal error ECU internal malfunc Er 2 tion output signal error ECU internal malfunc Er 3 tion output signal error ECU internal malfunc 4 tion input signal error EAS27400 TROUBLESHOOTING METHOD The engine operation is not normal and the engine trouble warning light comes on 1 Check e Fault code number Symptom No signals are received from the ECU No signals are received from the ECU within the specified duration Data from the ECU cannot be re ceived correctly Non registered data has been re ceived from the meter Able un able to drive Able un able to start Able un able to drive Able un able to start 2 Check and repair the probable cause of mal function SHOOTING DE Fault code No Check and repair Refer to TROUBLE No fault code No Check and repair Refer to Self Diag nostic Function ta a Check the fault code number displayed on the meter b Identify the faulty system with the fault code Refer to Self Diagnostic Function table c Identify the probable cause of the malfunc tion Refer to Diagnostic code table DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA TAILS on
314. t using any tools Before removing the hoses place few rags in the area under where they will be removed t 1 526980 CHECKING THE INJECTORS 1 Check Injectors Damage Replace EAS26990 CHECKING THE THROTTLE BODIES 1 Check hrottle bodies Cracks damage Replace the throttle bod les as a set 2 Check Fuel passages Obstructions Clean vVYVYVYYYYYYYYYYYYYYYYYYYYYYYYYYYY a Wash the throttle bodies in a petroleum based solvent Do not use any caustic carburetor cleaning solution THROTTLE BODIES b Blowoutall of the passages with compressed air DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE ROLLOVER VALVES 1 Check Rollover valve 1 1 Rollover valve 2 2 Damage faulty Replace Check that air flows smoothly only in the direc tion of the arrow shown in the illustration he rollover valves must be in an upright posi tion when checking the airflow na c EAS27000 CHECKING THE PRESSURE REGULATOR 1 Check Pressure regulator Damage Replace EAS27010 CHECKING THE PRESSURE REGULATOR OPERATION 1 Check Pressure regulator operation Remove the pressure regulator cover Refer to THROTTLE BODIES on page 6 6 b Disconnect the fuel hose 1 from the pres sure regulator 2 c Connect the fuel pressur
315. t voltage and the charging time at 20 C 68 F These values vary with the temperature the condition of the battery plates and the electrolyte level OU 7 77 ELECTRICAL COMPONENTS A Open circuit voltage V B Charging condition of the battery 96 C Ambient temperature 20 68 F DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 7 Charge Battery refer to the appropriate charging method il lustration EWA13300 Do not quick charge a battery ECA13670 CAUTION Never remove the MF battery sealing caps Do not use a high rate battery charger since it forces a high amperage current into the battery quickly and can cause bat tery overheating and battery plate damage If it is impossible to regulate the charging current on the battery charger be careful not to overcharge the battery When charging a battery be sure to remove it from the vehicle If charging has to be done with the battery mounted on the vehi cle disconnect the negative battery lead from the battery terminal To reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded bat tery charger lead cli
316. tand under the frame and engine Refer to TRANSFER GEAR CASE on Fre nina na want 3 e mening bt 2 erie aca bot an 2 5 Engine bracket bolt left upper side erates fot myers 3 era mine ut ton S Erie mening bt ton a eese 2 eese i 4 Erie aca bt er a Erare 2 5 10 ENGINE REMOVAL Removing the engine 105 Nm 10 5 kg 75 ft Ib 59 Nm 5 9 kg 43 ft Ib 53 Nm 5 3 kg 38 ft Ib 18 Nm 1 8 m kg 13 ft Ib 66 Nm 6 6 m kg 48 ft Ib 198 Nm 9 8 m kg 71 ft Ib 53 Nm 5 3 kg 38 ft Ib 30 Nm 3 0 kg 22 ft Ib 53 Nm 5 3 kg 38 ft Ib Engine mounting nut rear upper side 18 Engine bracket rear upper side 19 Engine mounting nut front lower side 20 Spacer bolt LINE For installation reverse the removal proce dure 5 11 ET1D71019 REMOVING THE ENGINE 1 Loosen e Spacer bolt NOTE Loosen the spacer bolt with the pivot shaft wrench 1 Pivot shaft wrench 90890 01485 Frame mount insert wrench YM 01485 EAS23720 INSTALLING THE ENGINE 1 Install Spacer bolt 1 Engine 2
317. tanda utate 7 13 CIRCUIT DIAGRAM 7 13 TROUBLESHOOTING srianan a a 7 15 LIGHTING SYS TEM irrisa a A 7 17 DIAGRAM E 7 17 TROUBLESHOOTING 7 19 SIGNALING SYSTEM esep a a E 7 21 7 21 TROUBLESHOOTING 5 bes 7 23 FUEL INJECTION SYSTEM grados 7 27 CIRCUM DAGRAM a eiii eus eurn 7 27 ECU SELF DIAGNOSTIC 7 29 SELF DIAGNOSTIC FUNCTION 7 30 7 32 DIAGNOS TIO MODE iata ditione npa aiias Santa massif 7 33 TROUBLESHOOTING DETAIL S 7 40 FUEL PUMP SYSTEM a eam a rS 7 63 CIRCUIT DIAGRAM 7 63 IeOlcrm eem 7 65 ELECTRICAL 2 7 67 CHECKING THE SVU GIES 7 71 CHECKING THE BULBS AND BULB 7 74 CHECKING THE FUSES 7 75 CHECKING AND CHARGING THE 7 76 CHECKING THE bep
318. tank damper Fuel outlet hose Cylinder head cover bolt Cylinder head cover bolt EE EE Rear cylinder head cover Disconnect 40 mm 1 57 in 20 2 60 mm 2 36 in Front cylinder head cover Cylinder head cover gasket For installation reverse the removal proce dure 5 15 CAMSHAFTS Removing the push rods and rocker arms Rear rocker arm base assembly Front rocker arm base assembly Rocker arm base gasket Dowel pin Pull rod 1 INE NE WE EM NN LO E M 286 5 mm 11 280 in pink painting Pull rod 2 288 5 mm 11 358 in sky blue painting Rocker arm shaft 32 Rermderambme Frntreckerarmbase For installation reverse the removal proce dure 5 16 CAMSHAFTS Removing the valve lifters For installation reverse the removal proce dure 5 17 CAMSHAFTS Removing the camshafts and right balancer 10 Nm 1 0 m kg 7 2 ft Ib 40 Nm 4 0 m kg 29 ft Ib 60 Nm 6 0 kg 43 ft Ib Job Parts to remove Camshaft driven gear lt NE EN Straight key _ 3 Circlip iste NUN S Front cylinder camshaft gear VENE NUNL I erate 13 Right balancer drive gear wj N 16 Camshaft cover 17 Camshaft cover gaske
319. tay rod 3 NOTE Hemove the right front fender stay bolts and left front fender stay bolt rear side then hold the rod with a wrench 4 and remove the left front fender stay bolt front side 5 Remove the rod from the right side of the vehi cle 3 Loosen Front wheel axle pinch bolt 1 4 Remove Front brake calipers NOTE Do not apply the brake lever when removing the brake calipers 5 Elevate e Front wheel NOTE Place the vehicle on a suitable stand so that the front wheel is elevated FRONT WHEEL EAS21910 DISASSEMBLING THE FRONT WHEEL 1 Remove Oil seals Wheel bearings a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flathead screwdriver NOTE To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a gener al bearing puller CHECKING THE FRONT WHEEL 1 Check Front wheel axle Roll the wheel axle on a flat surface Bends Replace A WARNING Do not attempt to straighten a bent wheel ax le FRONT WHEEL EAS21960 ASSEMBLING THE FRONT WHEEL 1 Install Wheel bearings Oil seals a Install the new wheel
320. the spark plugs 1 Remove e Rider seat Rider seat bracket assembly Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 2 Disconnect e Spark plug cap 3 Remove e Spark plug ECA13320 CAUTION Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders 3 9 ENGINE 4 Check e Spark plug type Incorrect Change Manufacturer model NGK DPR8EA 9 Manufacturer model DENSO X24EPR U9 5 Check e Electrode 1 Damage wear Replace the spark plug Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 6 Clean e Spark plug with a spark plug cleaner or wire brush 7 Measure Spark plug gap with a wire thickness gauge Out of specification Spark plug gap 0 8 0 9 mm 0 031 0 035 in 8 Install Spark plug Spark plug 18 Nm 1 8 m kg 13 NOTE Before installing the spark plug clean the spark plug and gasket surface 9 Connect e Spark plug cap 10 Install e Air filtrer case Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 1 Rider seat bracket assembly Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS20700 CHECKING THE IGNITION TIMING NOT
321. the vehicle on a suitable stand so that the front wheel is elevated 2 Loosen ower bracket pinch bolts EW1D71007 Before loosening the lower bracket pinch bolts support the front fork leg EAS22980 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Drain Fork oil NOTE Stroke the outer tube several times while drain ing the fork oil 2 2 Remove Dust seal 1 Oil seal clip 2 with a flathead screwdriver ECA14180 CAUTION Do not scratch the inner tube 7 4 64 FRONT FORK 3 Remove Damper rod bolt 1 Copper washer NOTE While holding the damper rod with the damper rod holder 2 and T handle S loosen the damper rod bolt Damper rod holder 90890 01460 T handle 90890 01326 T handle 3 8 drive 60 cm long YM 01326 4 Remove e tube b Hold the front fork leg horizontally Securely clamp the brake caliper bracket in a vise with soft jaws Separate the inner tube from the outer tube by pulling the inner tube forcefully but careful ly ECA14190 CAUTION Excessive force will damage the oil seal and bushing A damaged oil seal or bush ing must be replaced Avoid bottoming the inner tube into the out er tube during the above procedure as the oil flow stopper will be da
322. ting rods Big end bearings Identify the position of each big end bearing so that it can be reinstalled in its original place lt 526090 CHECKING THE CRANKSHAFT AND CONNECTING RODS 1 Measure Crankshaft runout Out of specification Replace the crank shaft Runout limit C 0 040 mm 0 0016 in 2 Check Crankshaft journal surfaces Crankshaft pin surfaces Bearing surfaces Scratches wear the crankshaft Generator shaft drive gear 1 Damage wear Replace the crankshaft CRANKSHAFT 3 Measure Crankshaft pin to big end bearing clearance Out of specification Replace the big end bearings Journal oil clearance using plas tigauge9 0 030 0 060 mm 0 0012 0 0024 in The following procedure applies to all of the connecting rods ECA13930 CAUTION Do not interchange the big end bearings and connecting rods To obtain the correct crankshaft pin to big end bearing clear ance and prevent engine damage the big end bearings must be installed in their origi nal positions a Clean the big end bearings crankshaft pins and the inside of the connecting rod halves b Install the big end upper bearing into the con necting rod and the big end lower bearing into the connecting rod cap NOTE Align the projections a on the big end bearin
323. tion reverse the removal proce dure 5 90 CRANKCASE Removing the oil seals and bearings 10 Nm 1 0 m kg 7 2 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib Omer Job Parts to remove 7 pump Refer to PUMP on page 5 95 Refer to CRANKSHAFT on page 5 101 Transmission Refer to TRANSMISSION on page 5 107 1 jOWfepweWghcancme ____ 1 2 gt 8 For installation reverse the removal proce dure NI N N 5 91 EAS25570 DISASSEMBLING THE CRANKCASE 1 Remove e Crankcase bolts NOTE oosen each bolt 1 4 of a turn at a time in stag es and in a crisscross pattern After all of the bolts are fully loosened remove them oosen the bolts in decreasing numerical order refer to the numbers in the illustration M8 x 90 mm bolts 1 2 e M8 x 65 mm bolt 3 M6 x 100 mm bolts 4 07 411 e M6 x 80 mm bolt 12 e M6 x 70 mm bolts 137 16 e M6 x 60 mm bolts 57 48 e M6 x 35 mm bolts 17 924 7 1 NAPA 5 ore 9 OG 9 21 20 16 1510 14 19 A Right crankcase B Left crankcase 2 Remove e Left crankcase ECA13900 CAUTION Tap on one side of the crankcase with a soft face hammer Tap only on reinforced por tions of the crankcase not on the crankcase mating surfaces Work slowly and carefully
324. tion coils does not flow to the ECU when both the neutral switch and sidestand switch are set to OFF thereby preventing the spark plugs from producing a spark However the engine continues to run under the following conditions he transmission is in gear the neutral switch circuit is open and the sidestand is up the sidestand switch circuit is closed The transmission is in neutral the neutral switch circuit is closed and the sidestand is down the sid estand switch circuit is open i gt Battery Main fuse Main switch Ignition fuse Engine stop switch Ignition coil Spark plug ECU electronic control unit 9 Sidestand switch 10 Relay unit diode 11 Neutral switch It 7 3 IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate no spark or intermittent spark NOTE Before troubleshooting remove the following part s Rider seat Tool kit tray Rider seat bracket assembly Fuel tank Air filter case Headlight assembly Exhaust pipes Front cylinder Check the fuses gt Main ignition and Replace the fuse s Refer to CHECKING THE FUS ES on page 7 75 OK 2 Check the battery gt Refer to CHECKING AND Clean the battery terminals CHARGING THE BATTERY on Recharge or replace the battery page 7 76 OK Check the spark plugs NG
325. to THROTTLE BODIES on page 6 6 Cylinder head covers Rocker arms Refer to CAMSHAFTS on page 5 14 Engine bracket right upper side 1 Oil pipe 1 6 Copper washer 7 Rear cylinder head Front cylinder head E MM Cylinder head gasket Rear exhaust pipe joint cover 12 Hear exhaust pipe joint 5 33 CYLINDER HEADS Removing the cylinder heads 10 Nm 1 0 m kg 7 2 ft Ib 5 For installation reverse the removal dure 5 34 EAS24140 REMOVING THE CYLINDER HEADS 1 Remove Cylinder head nuts NOTE oosen the nuts in the proper sequence as shown Loosen each nut 1 2 of a turn ata time After all of the nuts are fully loosened remove them A Front cylinder B Rear cylinder EAS24170 CHECKING THE CYLINDER HEADS The following procedure applies to all of the inder heads 1 Eliminate Combustion chamber carbon deposits with a rounded scraper NOTE Do not use a sharp instrument to avoid damag ing or scratching e Spark plug bore threads Valve seats CYLINDER HEADS as Ub 8 Q E ho A 2 Check e Cylinder head Damage scratches Replace 3 Measure Cylinder head warpage Out of specification gt Resurface the cylinder head Warpage limit 0 03 mm 0 0012 in Place straightedge a thickness gauge across the
326. ts of the cylinder head e g valves valve springs valve seats make sure the valves properly seal 1 Check Valve sealing Leakage the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS on page 5 41 a Pour a clean solvent into the intake and exhaust ports b Check that the valves properly seal NOTE There should be no leakage at the valve seat 1 2 Remove e Valve cotters NOTE the valve cotters by compressing the valve springs with the valve spring compressor set 1 Valve spring compressor 90890 04019 YM 04019 VALVES AND VALVE SPRINGS 3 Remove Upper spring seat 1 Valve spring 2 Valve 3 Valve stem seal 4 ower spring seat 5 NOTE Identify the position of each part very carefully so that it can be reinstalled in its original place 5 4 E 3 N EAS24290 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides 1 Measure Valve stem to valve guide clearance Out of specification Replace the valve guide Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b 5 39 VALVES
327. uel outlet hose 4 10 Remove Front cylinder head cover 1 Rear cylinder head cover 2 NOTE Due to the small clearance between the frame and the rear cylinder head cover the three bolts 9 cannot be removed when the cover is in place Loosen the bolts and then remove the cylinder head cover from the right side of the ve hicle making sure that the bolts do not scratch the rocker arms or other engine parts 2 ENGINE 11 Measure e Valve clearance Out of specification Adjust Valve clearance cold Intake 0 00 0 04 mm 0 0000 0 0016 in Exhaust 0 00 0 04 mm 0 0000 0 0016 in Piston 1 TDC rear cylinder a Turn the crankshaft counterclockwise b When piston 1 is at TDC on the compres sion stroke align the TDC mark a on the crankshaft position sensor rotor with the pointer b on the clutch cover 66 mI c Check the camshaft drive gear mark posi tion and camshaft driven gear mark d posi tion as shown If the marks are not aligned turn the crank shaft counterclockwise 360 degrees and re check step b ENGINE K Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 12 Adjust e Valve clearance Loosen the locknut 1
328. uel that is required by the engine can be supplied at all times in accordance with the driving conditions Illustration is for reference only 1 Pressure regulator 13 Intake air pressure sensor 2 Fuel pump 14 Throttle body 3 Fuel injector 15 Air filter case 4 Ignition coil A Fuel system 5 ECU electronic control unit y B Air system 6 Air temperature sensor C Control system 7 SC idle speed control unit 8 Throttle position sensor 9 Oo sensor 10 Catalytic converter 11 Engine temperature sensor 12 Crankshaft position sensor 1 3 ET1D71036 INSTRUMENT FUNCTIONS Multi function meter unit EW1D71008 Be sure to stop the vehicle before making any setting changes to the multi function meter unit 4 NC Speedometer Fuel gauge Odometer tripmeter fuel reserve tripmeter clock Tachometer wW 4 The multi function meter unit is equipped with the following a speedometer which shows the riding speed a tachometer which shows the engine speed a fuel gauge an odometer which shows the total distance traveled two tripmeters which show the distance trav eled since they were last set to zero a fuel reserve tripmeter which shows the dis tance traveled on the fuel reserve a clock a self diagnosis device a brightness control mode NOTE Be sure to turn the key to ON before using the SELECT and RESET switches except f
329. ufactured to perform within certain specifications in regard to performance and emissions Proper service with the correct tools is necessary to ensure that the vehi cle will operate as designed If there is any question about a service procedure it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE 4 his Service Manual contains information regarding periodic maintenance to the emission control sys tem Please read this material carefully Designs and specifications are subject to change without notice EAS20080 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR A SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death WARNING to the vehicle operator a bystander or a person checking or repairing the ve hicle A CAUTION indicates special precautions that must be taken t
330. uid Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals Recommended fluid DOT 4 EAS22440 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Install e Front brake caliper 1 temporarily Copper washers e Front brake hose 2 e Front brake hose union bolt 3 Front brake hose union bolt 32 Nm 3 2 m kg 23 ft Ib EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 45 ECA14170 CAUTION When installing the brake hose onto the brake caliper 1 make sure the brake pipe touches the projection b on the brake caliper 2 Remove Front brake caliper 3 Install Brake pads Brake pad spring Brake pad pin Brake pad clips Front brake caliper Brake hose guide Brake caliper bolt 40 Nm 4 0 m kg 29 ft Ib Brake hose holder bolt 10 Nm 1 0 m kg 7 2 ft lb Refer to REPLACING THE FRONT BRAKE PADS on page 4 37 4 Fill Brake master cylinder reservoir with the specified amount of the recom mended brake fluid Recommended fluid DOT 4 EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to dete
331. up any spilt clutch fluid immediately NOTE In order to ensure a correct reading of the clutch fluid level make sure that the top of the reservoir is horizontal 3 Bleed Clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 15 4 Check Clutch fluid level Below the minimum level mark a Add the recommended clutch fluid to the proper level Hefer to CHECKING THE CLUTCH FLUID LEVEL on page 3 14 5 Check Clutch lever operation Soft or spongy feeling Bleed the clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 15 5 69 SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever 10 Nm 1 0 m kg 7 2 ft Ib Clutch housing Refer to CLUTCH on page 5 50 Shift shaft spring stopper For installation reverse the removal proce dure SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1 Check Shift shaft Bends damage wear Replace Shift shaft spring Damage wear Replace EAS25430 CHECKING THE STOPPER LEVER 1 Check e Stopper lever Bends damage Replace Roller turns roughly Replace the stopper lever e Stopper lever spring Damage wear Replace EAS25450 INSTALLING THE SHIFT SHAFT 1 Install e Stopper lever 1 Collar e Stopper lever bolt 2 Stopper lever spring 3 Stopper lever bolt 10 Nm 1 0 m kg 7 2 ft lb LOCTITE
332. urer and of the same design No guarantee con cerning handling characteristics can be giv en if a tire combination other than one approved by Yamaha is used on this vehicle Front tire Size 130 70R18M C 63H Manufacturer model DUNLOP D251F Manufacturer model BRIDGESTONE G851 RADIAL G Rear tire Size 190 60R17M C 78H Manufacturer model DUNLOP D251 Manufacturer model BRIDGESTONE G850 RADIAL G EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done NOTE For tires with a direction of rotation mark 1 CHASSIS Install the tire with the mark pointing in the di rection of wheel rotation Align the mark 2 with the valve installation point EAS21670 CHECKING THE WHEELS The following procedure applies to both of the wheels 1 Check e Wheel Damage out of round Replace 13260 Never attempt to make any repairs to the wheel NOTE After a tire or wheel has been changed or re placed always balance the wheel EAS21690 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in ner and outer cables EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement Re place damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage
333. ut ed correctly 3 Install Right side cover Refer to GENERAL CHASSIS on page 4 1 EAS21080 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex haust pipes and gaskets 1 Check Front exhaust pipe 1 Rear exhaust pipe 2 Muffler 3 Muffler bracket 4 Cracks damage Replace Gaskets 5 Exhaust gas leaks Replace 2 Check Tightening torque Front exhaust pipe nuts 6 Front exhaust pipe and rear exhaust pipe bolt Rear exhaust pipe nuts 8 Rear exhaust pipe and muffler bolt 9 Muffler and muffler bracket bolts 10 Muffler bracket and frame bolts 11 Front exhaust pipe nut 20 Nm 2 0 m kg 14 ft Ib Front exhaust pipe and rear ex haust pipe bolt 20 Nm 2 0 m kg 14 ft Ib Rear exhaust pipe nut 24 Nm 2 4 m kg 17 16 Rear exhaust pipe and muffler bolt 20 Nm 2 0 m kg 14 ft Ib Muffler and muffler bracket bolt 29 Nm 2 9 m kg 21 ft Ib Muffler bracket and frame bolt 53 Nm 5 3 m kg 38 ft lb 521090 CHECKING THE CANISTER for California only 1 Remove e Horn 1 Refer to THROTTLE BODIES on page 6 6 2 Check Canister 1 Canister purge hose 2 e Canister breather hose 3 e Fuel tank breather overflow hose 4 Cracks damage Replace 7 3 Install Horn 1 Refer to THROTTLE BODIES on page 6 6 EAS
334. utward Install the cylinder 2 ISC idle speed control unit outlet hose hose joint to intake manifold assembly completely onto the intake manifold making sure to face the green paint mark on the hose to the left Face the ends of the hose clamp outward angled 45 forward Install the cylinder 1 ISC idle speed control unit outlet hose hose joint to intake manifold assembly completely onto the intake manifold making sure to face the blue paint mark on the hose to the left Face the ends of the hose clamp upward Position the sub wire harness 4 coupler on top of the guide To the wire harness Install the cylinder 1 ISC idle speed control unit outlet hose onto the ISC unit pipe making sure to align the blue paint mark on the hose with the blue paint mark on the pipe Install the ISC idle speed control unit inlet hose onto the ISC unit pipe making sure to align the white paint mark on the hose with the white paint mark on the pipe Install the 2 ISC idle speed control unit outlet hose onto the ISC unit pipe making sure to align the green paint mark on the hose with the green paint mark on the pipe 2 60 CABLE ROUTING CABLE ROUTING 2 61 PERIODIC CHECKS AND ADJUSTMENTS PERIODIC 4 4 4 22 1 3 1 INTRODUCTION M 3 1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL ui
335. uunt E 3 1 GENERAL MAINTENANCE AND LUBRICATION CHART 3 1 3 4 ADJUSTING THE VALVE CLEARANCE 3 4 SYNCHRONIZING THE THROTTLE BODIES 3 7 ADJUSTING THE THROTTLE CABLE FREE PLAY 3 8 CHECKING THE SRARK PEUG 5 3 9 CHECKING THE IGNITION 3 10 CHECKING THE ENGINE OIL VEL 3 11 CHANGING THE ENGINE OIL 3 11 CHECKING THE TRANSFER GEAR OIL LEVEL 3 13 CHANGING THE TRANSFER GEAR 3 14 CHECKING THE CLUTCH FLUID 3 14 BLEEDING THE HYDRAULIC CLUTCH 5 3 15 REPLACING THE AIR FILTER 3 15 CHECKING THE THROTTLE BODY JOINTS 3 16 CHECKING THE 8 5 3 16 CHECKING THE CYLINDER HEAD BREATHER HOSE 3 17 CHECKING THE OIL TANK BREATHER 3 17 CHECKING THE EXHAUST SYSTEM nerui corn 3 17 CHECKING THE CANISTER for California only 3 18 ADJUSTING TTHE EAUP CABLES uit divom tei 3 18 CHASSIS
336. ve 25 000 25 021 mm 0 9843 0 9851 24 957 24 980 mm 0 9826 0 9835 in 0 020 0 064 mm 0 0008 0 0025 in 28 000 28 021 mm 1 1024 1 1032 in 27 957 27 980 mm 1 1007 1 1016 in 0 020 0 064 mm 0 0008 0 0025 in 42 532 42 632 mm 1 6745 1 6784 in 42 432 mm 1 6705 in 35 950 36 050 mm 1 4154 1 4193 in 35 850 mm 1 4114 in 42 530 42 630 mm 1 6744 1 6783 in cylinder 1 42 531 42 631 mm 1 6744 1 6784 in cylinder 2 42 430 mm 1 6705 in cylinder 1 42 431 mm 1 6705 in cylinder 2 35 950 36 050 mm 1 4154 1 4193 in 35 850 mm 1 4114 in B Rocker arm rocker arm shaft Hocker arm inside diameter Limit Hocker arm shaft outside diameter Hocker arm to rocker arm shaft clearance Limit Valve valve seat valve guide Valve clearance cold Intake Exhaust Valve dimensions Valve head diameter A intake Valve head diameter A exhaust A Valve seat width C intake Limit Valve seat width C exhaust Limit C X Valve margin thickness D intake Limit Valve margin thickness D exhaust Limit ed Valve stem diameter intake Limit Valve stem diameter exhaust Limit Valve guide inside diameter intake Limit ENGINE SPECIFICATIONS 18 000 18 018 mm 0 7087 0 7094 18 036 mm 0 7101 in 17 976 17 991 mm 0 7077 0 7083 in 0 009 0 042 mm 0 0004 0 001 7 in 0 080 mm 0 0032 in 0 00 0 04 mm 0 0000 0 0016 in 0 00 0 04 mm 0 0000 0 0016 in
337. ver Left crankcase Oil filter cartridge bracket Oil filter cartridge Right crankcase Oil cooler 2 32 LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION DIAGRAMS boves 242 9 NETS v A L BENE en ET NS 4 UR c en SNS Cil A OS 9 Ne D 7 6 5 9 Im Oil tank Dipstick Oil pipe 2 Oil delivery pipe 1 Oil filter cartridge Oil delivery pipe 2 Oil pipe 3 Oil pipe 4 Oil pipe 5 10 Oil strainer oil tank 11 Oil delivery pipe 3 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 NOR OND Valve lifter Push rod Rocker arm shaft Oil pipe 1 Crankshaft Oil pipe mark Oil pipe R mark LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 LUBRICATION SYSTEM CHART AND DIAGRAMS ax He COS M 2 37 RON Oil pipe 1 Oil pump Oil strainer crankcase Joint pipe LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 LUBRICATION SYSTEM CHART AND DIAGRAMS of H ITH D JANE Surio AH ui 73 gt pun gt Main axle Drive axle Oil strainer crankcase Oil pump To the oil filter cartridge LUBRICATION SYSTEM CHART AND DIAGRAMS 2
338. ving the clutch 1100 Nm 10 0 kg 72 ft Ib 8 Nm 0 8 kg 5 8 ft Ib iy Rema S C S TP 3 _ e S o Wee 39 qWmadp p 3 _ 16 Clutch damper spring seat 17 Clutch boss EE 5 53 CLUTCH Removing the clutch 1100 Nm 10 0 kg 72 ft Ib 8 Nm 0 8 kg 5 8 ft Ib _ 3 fam m E 5 25 Ca 39 ff 3 Sms p Waster 3 dure 5 54 CLUTCH Removing the left balancer 10 Nm 1 0 m kg 7 2 ft 16 10 Nm 1 0 m kg 7 2 ft Ib 40 Nm 4 0 m kg 29 ft Ib Job Parts to remove Left balancer idle gear shaft holder lt O ring 3 4 Left balancer idle gear 5 Left balancer idle gear shaft Left balancer drive gear 7 Straight key __________ NENNEN m dure gt I 5 55 CLUTCH Removing the clutch master cylinder X 30 Nm 3 0 kg 22 ft 1b P gt 13 7 99 e 7 Y
339. witch Refer to CHECKING THE SWITCHES on page 7 71 3 Check the turn signal relay Refer to CHECKING THE TURN SIGNAL RELAY on page 7 80 OK o the bulb s and bulb socket s NG The turn signal switch is faulty Replace the left handlebar switch Replace the turn signal relay 7 24 SIGNALING SYSTEM 4 Check the entire signaling system gt wiring Properly connect or repair the signaling Refer to CIRCUIT DIAGRAM on system wiring page 7 21 OK This circuit is OK The neutral indicator light fails to come on 1 Check the neutral switch gt Refer to CHECKING THE the neutral switch SWITCHES on page 7 71 OK 2 Check the relay unit diode NG Refer to CHECKING THE DI Replace the relay unit ODES page 7 81 OK Check the entire signaling system gt wiring Refer to CIRCUIT DIAGRAM on page 7 21 OK This circuit is OK The fuel level gauge fails to operate 1 Check the fuel sender fuel tank NG Refer to CHECKING THE FUEL SENDER FUEL TANK on page the fuel sender 7 87 OK Properly connect or repair the signaling system wiring Check the entire signaling system gt wiring Refer to CIRCUIT DIAGRAM on page 7 21 OK Replace the meter assembly The fuel level warning light fails to come on Properly connect or rep
340. y lower the boiling point of the clutch fluid and could cause vapor lock ECA13420 CAUTION Clutch fluid may damage painted surfaces or plastic parts Therefore always clean up any spilt clutch fluid immediately NOTE In order to ensure a correct reading of the clutch fluid level make sure the top of the reservoir is horizontal EAS20900 BLEEDING THE HYDRAULIC CLUTCH SYSTEM EWA13000 Bleed the hydraulic clutch system whenever the system was disassembled a clutch hose was loosened or removed the clutch fluid level is very low clutch operation is faulty NOTE Be careful not to spill any clutch fluid or allow the clutch master cylinder reservoir to over flow When bleeding the hydraulic clutch system make sure there is always enough clutch fluid before applying the clutch lever Ignoring this precaution could allow airto enter the hydraulic clutch system considerably lengthening the bleeding procedure If bleeding is difficult it may be necessary to let the clutch fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed Hydraulic clutch system vVYVYYYYYYYYYYYYYYYYYYYYYYYYYYYYY a Add the recommended clutch fluid to the proper level b Install the clutch master cylinder reservoir di aphragm c Connect a clear plastic hose 1 tightly to the bleed screw 2 ENGINE
341. y red 2 c Measure the primary coil resistance DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 2 Check e Secondary coil resistance Out of specification Replace Secondary coil resistance 8 64 12 96 Disconnect the spark plug cap from the igni tion coil b Connect the pocket tester Q x 1k to the ig nition coil as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Negative tester probe black red 1 Positive tester probe gt spark plug lead 2 c Measure the secondary coil resistance DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace the crank shaft position sensor Crankshaft position sensor resis tance 248 372 0 ELECTRICAL COMPONENTS Positive tester probe gray 4 Negative tester probe gt black 2 2 1 b Measure the crankshaft position sensor re sistance DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE LEAN ANGLE SENSOR 1 Remove Lean angle sensor 2 Check Lean angle sensor output voltage Out of specification Replace Lean angle sensor output voltage Less than 65 0 4 1 4 V More than 65 3 7 4 4 V

2007 Yamaha XV1900 Roadliner & Stratoliner Service Manual

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2007 Yamaha XV1900 Roadliner &amp; Stratoliner Service Manual

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2007 Yamaha XV1900 Roadliner & Stratoliner Service Manual