Yamaha YZF-R1 (2002) — диагностика и устранение неисправностей системы впрыска топлива [369/439]

Содержание

• Yzf r1 service manual p.3
• Warning p.6
• Caution p.6
• Important manual information p.6
• Notice p.6
• How to use this manual p.7
• Trbl shtg p.8
• Gen info p.8
• Symbols p.8
• Chk adj p.8
• Table of contents p.10
• Chapter 1 general information p.11
• Chapter 2 specifications p.11
• Chapter 3 periodic checks and adjustments p.12
• Chapter 4 chassis p.14
• Chapter 5 overhauling the engine p.15
• Chapter 7 fuel injection system p.18
• Chapter 6 cooling system p.18
• Chapter 8 electrical p.19
• Chapter 9 troubleshooting p.20
• Motorcycle identification p.22
• General information p.22
• Gen info p.22
• Outline of fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the opti mum air fuel ratio in accordance with the engine operating conditions and the atmospheric tempera ture in the conventional carburetor system the air fuel ratio of the mixture that is supplied to the com bustion chamber is created by the volume of the intake air and the fuel that is metered by the jet that is used in the respective chamber despite the same volume of intake air the fuel volume requirement varies by the engine operating conditions such as acceleration deceleration or operating under a heavy load carburetors that meter the fuel through the use of jets have been provided with various auxiliary devices so that an optimum air fuel ratio can be achieved to accommodate the constant changes in the operating con ditions of the engine as the requirements for the engine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control p.23
• Gen info p.23
• Features p.23
• Fi system the fuel pump delivers fuel to the injector via the fuel filter the pressure regulator maintains the fuel pressure that is applied to the injector at only 284 kpa 2 4 kg c p.24
• 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 atmospheric pressure sensor intake temperature sensor and coolant temperature sensor enable the ecu to determine the injection duration the injection timing is determined through the signals from the crankshaft position sensor and the cylinder identification sensor as a result the volume of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions p.24
• 40 psi higher than the intake manifold pressure accordingly when the energizing signal from the ecu energizes the injector the fuel passage opens causing the fuel to be injected into the intake manifold only during the time the passage remains open therefore the longer the length of time the injector is energized injection duration the greater the volume of fuel that is supplied conversely the shorter the length of time the injector is energized injection duration the lesser the volume of fuel that is sup plied p.24
• Illustration is for reference only p.24
• Gen info p.24
• Features p.24
• Gen info p.25
• Features p.25
• Components ecu electronic control unit the ecu is mounted underneath the seat the main functions of the ecu are ignition control fuel control self diagnosis and load control ecu s internal construction and functions the main components and functions of the ecu can be broadly divided into the following four items a power supply circuit the power supply circuit obtains power from the battery 12 v to supply the power 5 v that is required for operating the ecu b input interface circuits the input interface circuits convert the signals output by all the sensors into digital signals which can be processed by the cpu and input them into the cpu c cpu central processing unit the cpu determines the condition of the sensors in accordance with the level of the signal that is output by the respective sensor then the signals are temporarily stored on the ram in the cpu based on those stored signals and the basic processing program on the rom the cpu calculates the fuel injection duration injection p.26
• Gen info p.26
• Features p.26
• Gen info p.27
• Features p.27
• Gen info p.28
• Features p.28
• Pressure regulator it regulates the fuel pressure that is applied to the injectors that are provided in the cylinders in order to maintain a constant pressure difference with the pressure in the intake manifold the fuel that is delivered by the fuel pump fills the fuel chamber through the fuel inlet of the regulator and exerts pressure on the diaphragm in the direction for opening the valve a spring that is provided in the spring chamber exerts pressure on the diaphragm in the direction for closing the valve in contrast to the pressure of the fuel thus the valve cannot open unless the fuel pressure overcomes the spring force an intake vacuum is applied to the spring chamber via a pipe when the pressure of the fuel exceeds the sum of the intake vacuum and the spring force the valve that is integrated with the diaphragm opens allowing the fuel to return from the fuel outlet to the fuel tank via the fuel return hose as a result because the intake vacuum fluctuates in accordance with the c p.29
• Gen info p.29
• Features p.29
• Fuel injector upon receiving injection signals from the ecu the fuel injector injects fuel in the normal state the core is pressed downward by the force of the spring as illustrated the plunger that is integrated with the bottom of the core keeps the fuel passage closed when the current flows to the coil in accordance with the signal from the ecu the core is drawn upward allowing the flange that is integrated with the plunger to move to the spacer since the dis tance of the movement of the needle is thus kept constant the opening area of the fuel passage also becomes constant because the pressure difference of the fuel to the intake manifold pressure is kept constant by the pressure regulator the fuel volume varies in proportion to the length of time the coil is energized the injector that has been recently adopted has a four hole type injection ori fice that enhances the atomization of fuel and improves combustion efficiency p.30
• Gen info p.30
• Features p.30
• Gen info p.31
• Features p.31
• Features p.32
• Gen info p.32
• Throttle position sensor the throttle position sensor measures the intake air volume by detecting the position of the throttle valve it detects the mechanical angle of the throttle valve through the positional relationship between the moving contact that moves in unison with the throttle shaft and the resistor board in actual operation the ecu supplies 5 v power to both ends of the resistor board and the voltage that is output by the throttle position sensor is used to determine the angle of the throttle valve p.33
• Gen info p.33
• Features p.33
• Intake air pressure sensor and atmospheric pressure sensor intake air pressure sensor the intake air pressure sensor is used for measuring the intake air volume the intake air volume of every intake stroke is proportionate to the intake air pressure therefore the intake air volume can be measured by measuring the intake air pressure the intake air pressure sensor converts the measured intake air pressure into electrical signals and sends those signals to the ecu when the intake air pressure is introduced into the sensor unit which contains a vacuum chamber on one side of the silicon diaphragm the silicon chip that is mounted on the silicon diaphragm con verts the intake air pressure into electrical signals then an integrated circuit ic amplifies and adjusts the signals and makes temperature compensations in order to generate electrical signals that are proportionate to the pressure atmospheric pressure sensor the atmospheric pressure sensor is used for making compensations to the chang p.34
• Gen info p.34
• Features p.34
• Gen info p.35
• Intake temperature sensor the intake temperature sensor corrects the deviation of the air fuel mixture that is associated with the changes in the intake air density which are created by the changes in the intake air temperature that occur due to atmospheric temperatures this sensor uses a semi conductor thermistor that has a large resistance at low temperatures and a small resistance at high temperatures the thermistor converts the temperature dependent changes in resistance into electrical resistance values which are then input into the ecu p.35
• Features p.35
• Coolant temperature sensor the signals from the coolant temperature sensor are used primarily for making fuel volume compen sations during starting and warm up the coolant temperature sensor converts the temperature of the coolant into electrical signals and sends them to the ecu this sensor uses a semi conductor thermistor that has a large resistance at low temperatures and a small resistance at high temperatures the thermistor converts the temperature dependent changes in resistance into electrical resistance values which are then input into the ecu p.35
• Gen info p.36
• Features p.36
• Fuel injection system operation and control the fuel injection timing injection duration ignition timing and the coil energizing duration are con trolled by the ecu to determine the basic injection timing the ecu calculates the intake air volume through the signals from the intake air pressure sensor throttle position sensor cylinder identifica tion sensor and crankshaft position sensor furthermore the ecu calculates the final injection timing by adding the following compensations to the aforementioned basic injection duration those obtained from the state of acceleration as well as those based on the signals from various sensors such as the coolant temperature intake tem perature and atmospheric at the same time the ecu assesses the crankshaft position through the signals from the cylinder identification sensor and the crankshaft position sensor then when the ecu determines that it is time to inject fuel it sends an injection command to the injectors further more the ecu also controls p.37
• Features p.37
• Detection of intake air volume the intake air volume is detected primarily through the signals from the throttle position sensor and the intake air pressure sensor the intake air volume is determined in accordance with the signals from the atmospheric pressure sensor intake temperature sensor and the engine speed data p.37
• Gen info p.37
• Gen info p.38
• Features p.38
• Determining the final injection duration the intake air volume determines the basic injection duration however at a given intake air vol ume the volume of fuel that is required varies by the engine operating conditions such as accelera tion or deceleration or by weather conditions this system uses various sensors to precisely check these conditions applies compensations to the basic injection duration and determines the final injection duration based on the operating condition of the engine p.38
• Composition of final injection duration p.38
• Gen info p.39
• Features p.39
• Three way catalytic converter system system outline this is a highly efficient exhaust gas cleaning system that effects air fuel control through a joint effort by the fi system and the three way catalytic converter system by effecting comprehensive control of the air fuel ratio in this manner this system reduces the co hc and nox in the exhaust gases the fi system controls the mixture to an optimal air fuel ratio basic air fuel ratio that matches the operating condition of the engine in order to realize an ideal combustion through the joint effort of these control systems the exhaust gas is cleaned in a highly efficient manner without sacrificing engine performance p.40
• Three way catalytic converter system diagram p.40
• Gen info p.40
• Features p.40
• Gen info p.41
• Features p.41
• Gen info p.42
• Features p.42
• Features p.43
• Gen info p.43
• Important information p.44
• Gen info p.44
• Important information p.45
• Gen info p.45
• Caution p.45
• Gen info p.46
• Checking the connections p.46
• Tool no tool name function illustration p.47
• The following special tools are necessary for complete and accurate tune up and assembly use only the appropriate special tools as this will help prevent damage caused by the use of inappropri ate tools or improvised techniques special tools part numbers or both may differ depending on the country when placing an order refer to the list provided below to avoid any mistakes p.47
• Special tools p.47
• Gen info p.47
• Tool no tool name function illustration p.48
• Special tools p.48
• Gen info p.48
• Gen info p.49
• Tool no tool name function illustration p.49
• Special tools p.49
• Tool no tool name function illustration p.50
• Special tools p.50
• Gen info p.50
• Specifications p.51
• General specifications p.51
• Engine specifications p.52
• Engine p.52
• Engine specifications p.53
• Engine specifications p.54
• Engine specifications p.55
• Engine specifications p.56
• Engine specifications p.57
• Engine specifications p.58
• Engine specifications p.59
• Engine specifications p.60
• Chassis specifications p.61
• Chassis p.61
• Chassis specifications p.62
• Chassis specifications p.63
• Chassis specifications p.64
• Electrical p.65
• Electrical specifications p.65
• Electrical specifications p.66
• General tightening torques p.67
• General tightening torque specifications this chart specifies tightening torques for stan dard fasteners with a standard iso thread pitch tightening torque specifications for spe cial components or assemblies are provided for each chapter of this manual to avoid warpage tighten multi fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached unless otherwise specified tightening torque specifications require clean dry threads com ponents should be at room temperature p.67
• Conversion table tightening torques p.67
• Conversion table p.67
• All specification data in this manual are listed in si and metric units use this table to convert metric unit data to imperial unit data p.67
• Tightening torques p.67
• A width across flats b thread diameter p.67
• Nm m kg p.67
• A nut b bolt p.67
• Mm 8 mm 15 1 p.67
• Mm 6 mm 6 0 p.67
• Mm 16 mm 130 13 p.67
• Mm 14 mm 85 8 p.67
• Mm 12 mm 55 5 p.67
• Mm 10 mm 30 3 p.67
• Mm 0 3937 in p.67
• Mm 0 3937 0 8 in p.67
• Metric multiplier imperial p.67
• Tightening torques p.68
• Tightening torques p.69
• Tightening torques p.70
• Tightening torques p.71
• Tightening torques p.72
• Lubrication points and types p.73
• Lubrication points and lubricant types p.73
• Lubrication points and lubricant types p.74
• Cooling system diagrams p.75
• Cooling system diagrams p.76
• Cooling system diagrams p.77
• Engine oil lubrication chart p.79
• Lubrication diagrams p.80
• Lubrication diagrams p.81
• Lubrication diagrams p.82
• Lubrication diagrams p.83
• Lubrication diagrams p.84
• Cable routing p.85
• Cable routing p.86
• Cable routing p.87
• Cable routing p.88
• Cable routing p.89
• Cable routing p.90
• Cable routing p.91
• Cable routing p.92
• Cable routing p.93
• Cable routing p.94
• For california p.95
• Cable routing p.95
• Periodic maintenance chart for the emission control system p.96
• Periodic checks and adjustments p.96
• Introduction p.96
• General maintenance and lubrication chart p.96
• Chk adj p.96
• Engine oil type yamalube 4 20w 40 or engine oil sae 20w 40 api se for temperatures of 5 c 40 f or above yamalube 4 10w 30 or engine oil sae 10w 30 api se for temperatures of 15 c 60 f or below p.97
• Chk adj p.97
• 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 p.97
• Since these items require special tools data and technical skills have a yamaha dealer perform the service p.97
• Note from 24 000 mi 37 000 km or 36 months repeat the maintenance intervals starting from 4 000 mi 7 000 km or 6 months p.97
• Hydraulic brake service after disassembling the brake master cylinders and calipers always change the fluid regularly check the brake fluid levels and fill the reservoirs as required every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid replace the brake hoses every four years and if cracked or damaged p.97
• General maintenance and lubrication chart p.97
• Chk adj p.98
• Fuel tank p.99
• Chk adj p.99
• Fuel tank p.100
• Chk adj p.100
• Caution p.100
• Fuel tank p.101
• Chk adj p.101
• Caution p.101
• Cowlings p.102
• Chk adj p.102
• Air filter case p.103
• Chk adj p.103
• Engine p.104
• Chk adj p.104
• Adjusting the valve clearance p.104
• Chk adj p.105
• Adjusting the valve clearance p.105
• Chk adj p.106
• Adjusting the valve clearance p.106
• Chk adj p.107
• Adjusting the valve clearance p.107
• Valve pad selection table intake p.108
• Exhaust p.108
• Example valve clearance 0 1 0 7 mm installed is 175 measured clearance is 0 5 mm replace 175 pad with 185 pad p.108
• Example valve clearance 0 1 0 0 mm installed is 150 measured clearance is 0 5 mm replace 150 pad with 160 pad p.108
• Chk adj p.108
• Adjusting the valve clearance p.108
• Chk adj p.109
• Adjusting the valve clearance synchronizing the throttle bodies p.109
• Synchronizing the throttle bodies p.110
• Chk adj p.110
• Caution p.110
• Synchronizing the throttle bodies adjusting the engine idling speed p.111
• Chk adj p.111
• Chk adj p.112
• Adjusting the engine idling speed adjusting the throttle cable free play p.112
• Chk adj p.113
• Adjusting the throttle cable free play p.113
• Warning p.114
• Chk adj p.114
• Caution p.114
• Adjusting the throttle cable free play checking the spark plugs p.114
• Checking the spark plugs measuring the compression pressure p.115
• Chk adj p.115
• Measuring the compression pressure p.116
• Chk adj p.116
• Caution p.116
• Warning p.117
• Measuring the compression pressure p.117
• Chk adj p.117
• Measuring the compression pressure checking the engine oil level p.118
• Chk adj p.118
• Chk adj p.119
• Checking the engine oil level changing the engine oil p.119
• Caution p.119
• Chk adj p.120
• Changing the engine oil p.120
• Adjusting the clutch cable free play 1 check clutch cable free play a out of specification adjust p.121
• A slightly loosen the oil gallery bolt 1 b start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt 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 pan and oil pump in chapter 5 d start the engine after solving the problem s and check the engine oil pressure again e tighten the oil gallery bolt to specification p.121
• Oil gallery bolt 10 nm 1 m kg 7 ft lb p.121
• Clutch cable free play at the pivot bolt of the clutch lever 10 15 mm 0 9 0 9 in p.121
• Chk adj p.121
• Check engine oil pressure p.121
• Changing the engine oil adjusting the clutch cable free play p.121
• Remove bottom cowling refer to cowlings p.122
• If the specified clutch cable free play cannot be obtained as described above perform the mechanism adjustment procedure described below p.122
• Handlebar side a turn the adjusting dial 1 in direction a or b until the specified clutch cable free play is obtained p.122
• Engine side a loosen the locknut 1 b turn the adjusting nut 2 in direction a or b until the specified clutch cable free play is obtained p.122
• Direction b clutch cable free play is decreased p.122
• Direction a clutch cable free play is increased p.122
• Chk adj p.122
• C tighten the locknut d check the clutch cable free play again and adjust it if necessary p.122
• Adjusting the clutch cable free play p.122
• Adjust clutch mechanism p.122
• Adjust clutch cable free play p.122
• Replacing the air filter element p.123
• Chk adj p.123
• Caution p.123
• Chk adj p.124
• Checking the fuel and breather hoses checking the crankcase breather hose p.124
• Caution p.124
• Chk adj p.125
• Checking the crankcase breather hose checking the exhaust system p.125
• Chk adj p.126
• Check exup system operation p.126
• Check exup cable free play at the exup valve pulley a p.126
• Adjusting the exup cables 1 remove bottom cowling refer to cowlings 2 remove exup valve pulley cover 1 p.126
• Adjusting the exup cables p.126
• Adjust exup cable free play p.126
• A turn the main switch on b check that the exup valve operates prop erly p.126
• A loosen both locknuts 1 b insert a 4 mm long pin through the notch in the exup valve pulley and into the hole in the exup valve cover c turn both adjusting bolts 2 counterclock wise until there is no exup cable free play d turn both adjusting bolts 1 2 of a turn clock wise e tighten both locknuts and then remove the pin p.126
• Maximum exup cable free play at the exup valve pulley 1 mm 0 59 in p.126
• Install exup valve pulley cover p.126
• Exup valve pulley cover bolt 10 nm 1 m kg 7 ft lb p.126
• Chk adj p.127
• Caution p.127
• Adjusting the exup cables checking the coolant level p.127
• Chk adj p.128
• Checking the cooling system p.128
• Warning p.129
• Chk adj p.129
• Changing the coolant p.129
• Warning p.130
• Chk adj p.130
• Changing the coolant p.130
• Caution p.130
• Changing the coolant p.131
• Chk adj p.131
• Warning p.132
• Chk adj p.132
• Chassis p.132
• Caution p.132
• Adjusting the front brake p.132
• Warning p.133
• Chk adj p.133
• Caution p.133
• Adjusting the rear brake p.133
• Warning p.134
• Chk adj p.134
• Caution p.134
• Adjusting the rear brake checking the brake fluid level p.134
• Chk adj p.135
• Checking the front and rear brake pads adjusting the rear brake light switch p.135
• Warning p.136
• Chk adj p.136
• Checking the front and rear brake hoses bleeding the hydraulic brake system p.136
• Warning p.137
• Chk adj p.137
• Bleeding the hydraulic brake system p.137
• Warning p.138
• Chk adj p.138
• Caution p.138
• Adjusting the shift pedal adjusting the drive chain slack p.138
• Chk adj p.139
• Caution p.139
• Adjusting the drive chain slack p.139
• Warning p.140
• Lubricating the drive chain checking and adjusting the steering head p.140
• Chk adj p.140
• Warning p.141
• Chk adj p.141
• Checking and adjusting the steering head p.141
• Chk adj p.142
• Checking and adjusting the steering head p.142
• Warning p.143
• Chk adj p.143
• Checking and adjusting the steering head checking the front fork p.143
• Warning p.144
• Chk adj p.144
• Caution p.144
• Adjusting the front fork legs p.144
• Adjusting positions minimum 26 clicks in direction b standard 13 clicks in direction b maximum 1 click in direction b with the adjusting screw fully turned in direction a p.145
• Adjust rebound damping p.145
• Adjust compression damping p.145
• A turn the adjusting screw 1 in direction a or b p.145
• Rebound damping p.145
• Never go beyond the maximum or mini mum adjustment positions p.145
• Direction b rebound damping is decreased suspension is softer p.145
• Direction a rebound damping is increased suspension is harder p.145
• Compression damping p.145
• Chk adj p.145
• Caution p.145
• Adjusting the front fork legs p.145
• Warning p.146
• Chk adj p.146
• Caution p.146
• Adjusting the front fork legs adjusting the rear shock absorber assembly p.146
• Adjusting positions minimum 20 clicks in direction b standard 15 clicks in direction b maximum 1 click in direction b with the adjusting screw fully turned in direction a p.147
• Adjusting positions minimum 1 standard 4 maximum 9 p.147
• Adjust rebound damping p.147
• A turn the adjusting screw 1 in direction a or b p.147
• Rebound damping p.147
• Never go beyond the maximum or mini mum adjustment positions p.147
• Direction b spring preload is decreased suspension is softer p.147
• Direction b rebound damping is decreased suspension is softer p.147
• Direction a spring preload is increased suspension is harder p.147
• Direction a rebound damping is increased suspension is harder p.147
• Compression damping p.147
• Chk adj p.147
• Caution p.147
• Adjusting the rear shock absorber assembly p.147
• Warning p.148
• Chk adj p.148
• Adjusting the rear shock absorber assembly checking the tires p.148
• Warning p.149
• Chk adj p.149
• Checking the tires p.149
• Warning p.150
• Chk adj p.150
• Checking the tires p.150
• Warning p.151
• Chk adj p.151
• Checking the tires checking the wheels p.151
• Warning p.152
• Chk adj p.152
• Warning p.153
• Electrical system p.153
• Chk adj p.153
• Checking and charging the battery p.153
• Caution p.153
• Chk adj p.154
• Checking and charging the battery p.154
• Caution p.154
• Warning p.155
• Chk adj p.155
• Checking and charging the battery p.155
• Caution p.155
• Chk adj p.156
• Checking and charging the battery p.156
• Charging method using a variable current voltage charger p.156
• Chk adj p.157
• Checking and charging the battery p.157
• Charging method using a constant voltage charger p.157
• Chk adj p.158
• Checking and charging the battery checking the fuses p.158
• Caution p.158
• Warning p.159
• Chk adj p.159
• Checking the fuses p.159
• Warning p.160
• Replacing the headlight bulbs p.160
• Chk adj p.160
• Caution p.160
• Direction b headlight beam moves to the left p.161
• Direction b headlight beam is low ered p.161
• Direction a headlight beam moves to the right p.161
• Direction a headlight beam is raised p.161
• Chk adj p.161
• Adjusting the headlight beam 1 adjust headlight beam vertically p.161
• Adjusting the headlight beam p.161
• Adjust headlight beam horizontally p.161
• A turn the adjusting screw 2 in direction a or b p.161
• A turn the adjusting screw 1 in direction a or b p.161
• Front wheel and brake discs p.162
• Chassis p.162
• Front wheel and brake discs p.163
• Warning p.164
• Front wheel and brake discs p.164
• Front wheel and brake discs p.165
• Caution p.165
• Tighten the brake disc bolts in stages and in a crisscross pattern p.166
• Measure brake disc thickness measure the brake disc thickness at a few different locations out of specification replace p.166
• Front wheel and brake discs p.166
• Checking the brake discs the following procedure applies to all of the brake discs 1 check brake disc damage galling replace 2 measure brake disc deflection out of specification correct the brake disc deflection or replace the brake disc p.166
• Brake disc thickness limit minimum front 4 mm 0 8 in rear 4 mm 0 8 in p.166
• Brake disc deflection limit maximum front 0 mm 0 4 in rear 0 5 mm 0 6 in p.166
• Adjust brake disc deflection p.166
• A remove the brake disc b rotate the brake disc by one bolt hole c install the brake disc p.166
• A place the motorcycle on a suitable stand so that the wheel is elevated b before measuring the front brake disc deflection turn the handlebars to the left or right to ensure that the front wheel is sta tionary c remove the brake caliper d hold the dial gauge at a right angle against the brake disc surface e measure the deflection 2 3 mm below the edge of the brake disc p.166
• Front wheel and brake discs p.167
• Front wheel and brake discs p.168
• Start with the lightest weight p.169
• Mark is positioned as shown d release the front wheel e when the wheel stops put an p.169
• Mark at the bottom of the wheel f repeat steps d through f several times until all the marks come to rest at the same spot g the spot where all the marks come to rest is the front wheel s heavy spot x p.169
• Mark at the bottom of the wheel c turn the front wheel 90 so that the p.169
• Front wheel and brake discs p.169
• Check front wheel static balance p.169
• 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 p.169
• Adjust front wheel static balance p.169
• A turn the 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 p.169
• A spin the front wheel b when the front wheel stops put an p.169
• A install a balancing weight 1 onto the rim exactly opposite the heavy spot x p.169
• Rear wheel and brake disc p.170
• Rear wheel and brake disc p.171
• Rear wheel and brake disc p.172
• Warning p.173
• Rear wheel and brake disc p.173
• Rear wheel and brake disc p.174
• Tighten the self locking nuts in stages and in a crisscross pattern p.175
• Replace rear wheel sprocket p.175
• Recommended lubricant lithium soap based grease p.175
• Rear wheel sprocket self locking nut 100 nm 10 m kg 72 ft lb p.175
• Rear wheel and brake disc p.175
• Installing the rear wheel 1 lubricate wheel axle wheel bearings oil seal lips p.175
• Checking and replacing the rear wheel sprocket 1 check rear wheel sprocket more than 1 4 tooth a wear replace the rear wheel sprocket bent teeth replace the rear wheel sprocket p.175
• A remove the self locking nuts and the rear wheel sprocket b clean the rear wheel drive hub with a clean cloth especially the surfaces that contact the sprocket c install the new rear wheel sprocket p.175
• Warning p.176
• Rear wheel and brake disc p.176
• Caution p.176
• Front and rear brakes p.177
• Front and rear brakes p.178
• Front and rear brakes p.179
• Caution p.179
• Warning p.179
• Front and rear brakes p.180
• Front and rear brakes p.181
• Front and rear brakes p.182
• Front and rear brakes p.183
• Front and rear brakes p.184
• Front and rear brakes p.185
• Front and rear brakes p.186
• Front and rear brakes p.187
• Front and rear brakes p.188
• Front and rear brakes p.189
• Front and rear brakes p.190
• Warning p.191
• Front and rear brakes p.191
• Front and rear brakes p.192
• Caution p.192
• Warning p.192
• Warning p.193
• Front and rear brakes p.193
• Caution p.193
• Front and rear brakes p.194
• Front and rear brakes p.195
• Front and rear brakes p.196
• Front and rear brakes p.197
• Front and rear brakes p.198
• Warning p.199
• Front and rear brakes p.199
• Disassembling the rear brake caliper p.200
• Cover the brake caliper piston 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 p.200
• Before disassembling the brake caliper drain the brake fluid from the entire brake system p.200
• B remove the brake caliper piston seals p.200
• A blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper p.200
• Warning p.200
• Remove union bolt 1 copper washers 2 brake hose p.200
• Remove brake caliper pistons 1 brake caliper piston seals 2 p.200
• Put the end of the brake hose into a container and pump out the brake fluid carefully p.200
• Front and rear brakes p.200
• Warning p.201
• Front and rear brakes p.201
• Warning p.202
• Front and rear brakes p.202
• Caution p.202
• Warning p.203
• Front and rear brakes p.203
• Caution p.203
• Warning p.204
• Front and rear brakes p.204
• Caution p.204
• Warning p.205
• Front and rear brakes p.205
• Caution p.205
• Front fork p.206
• Front fork p.207
• Front fork p.208
• Warning p.209
• Front fork p.209
• Warning p.210
• Front fork p.210
• Caution p.210
• Warning p.211
• Front fork p.211
• Caution p.211
• Front fork p.212
• Caution p.212
• Warning p.212
• Front fork p.213
• Caution p.213
• Front fork p.214
• Warning p.215
• Front fork p.215
• Warning p.216
• Front fork p.216
• Handlebars p.217
• Handlebars p.218
• Warning p.219
• Handlebars p.219
• Handlebars p.220
• Caution p.220
• Adjust clutch cable free play refer to adjusting the clutch cable free play in chapter 3 p.221
• A apply a thin coat of rubber adhesive onto the end of the left handlebar b slide the handlebar grip over the end of the left handlebar c wipe off any excess rubber adhesive with a clean rag p.221
• Warning p.221
• Throttle cable free play at the flange of the throttle grip 3 5 mm 0 2 0 0 in p.221
• Install left handlebar switch 1 p.221
• Install handlebar grip p.221
• Handlebars p.221
• Do not touch the handlebar grip until the rubber adhesive has fully dried p.221
• Clutch cable free play at the end of the clutch lever 10 15 mm 0 9 0 9 in p.221
• Align the projection a on the left handlebar switch with the hole b in the left handlebar p.221
• Adjust throttle cable free play refer to adjusting the throttle cable free play in chapter 3 p.221
• Steering head p.222
• Steering head p.223
• Warning p.224
• Steering head p.224
• Steering head p.225
• Caution p.225
• Rear shock absorber assembly p.226
• Warning p.227
• Rear shock absorber assembly p.227
• Warning p.228
• Rear shock absorber assembly p.228
• Rear shock absorber assembly p.229
• Swingarm and drive chain p.230
• Swingarm and drive chain p.231
• Warning p.232
• Swingarm and drive chain p.232
• Warning p.233
• Swingarm and drive chain p.233
• Swingarm and drive chain p.234
• Swingarm and drive chain p.235
• Caution p.235
• Swingarm and drive chain p.236
• Engine p.237
• Overhauling the engine p.237
• Engine p.238
• Order job part q ty remarks 7 exhaust valve pipe 1 8 muffler 1 for installation reverse the removal procedure p.239
• Engine p.239
• Engine p.240
• Caution p.240
• Engine p.241
• Engine p.242
• Engine p.243
• Camshaft p.244
• Camshaft p.245
• Order job part q ty remarks 13 pin 1 14 timing chain guide intake side 1 for installation reverse the removal procedure p.246
• Camshaft p.246
• Camshaft p.247
• Caution p.248
• Camshaft p.248
• Camshaft p.249
• Camshaft p.250
• Camshaft p.251
• Caution p.252
• Camshaft p.252
• Warning p.253
• Camshaft p.253
• Caution p.254
• Camshaft p.254
• Order job part q ty remarks removing the cylinder head remove the parts in the order listed engine refer to engine intake and exhaust camshafts refer to camshafts 1 cylinder head 1 2 cylinder head gasket 1 3 dowel pin 2 for installation reverse the removal procedure p.255
• Cylinder head p.255
• Cylinder head p.256
• Cylinder head p.257
• Valves and valve springs p.258
• Valve and valve springs p.258
• Valves and valve springs p.259
• Valves and valve springs p.260
• Valves and valve springs p.261
• Valves and valve springs p.262
• Valves and valve springs p.263
• Valves and valve springs p.264
• Caution p.264
• Valves and valve springs p.265
• Valves and valve springs p.266
• Valves and valve springs p.267
• Caution p.267
• Generator p.268
• Warning p.269
• Generator p.269
• Warning p.270
• Generator p.270
• Caution p.270
• When the bolt are tightened more than the specified angle do not loosen the bolt and then retighten it replace the bolt with a new one and per form the procedure again p.271
• Warning p.271
• Note when using a hexagon bolt note that the angle from one corner to another is 60 p.271
• Note tighten the generator rotor cover bolts in stages and in a crisscross pattern p.271
• Install generator rotor cover p.271
• Generator p.271
• Do not use a torque wrench to tighten the bolt to the specified angle tighten the bolt until it is at the specified angle p.271
• Caution p.271
• Pickup coil p.272
• Pickup coil p.273
• Order job part q ty remarks 7 crankshaft position sensor coupler 1 disconnect 8 crankshaft position sensor 1 9 pickup coil rotor 1 for installation reverse the removal procedure p.273
• Pickup coil p.274
• Pickup coil p.275
• Clutch p.276
• Clutch p.277
• Clutch p.278
• Clutch p.279
• Clutch p.280
• Clutch p.281
• Clutch p.282
• Clutch p.283
• Clutch p.284
• Shift shaft p.285
• Shift shaft p.286
• Order job part q ty remarks removing the oil pan and oil pump remove the parts in the order listed engine oil drain refer to changing the engine oil in chapter 3 coolant drain refer to changing the coolant in chapter 3 radiator assembly and water pump outlet pipe refer to radiator and oil cooler in chapter 6 exhaust pipe assembly refer to engine 1 oil level switch connector 1 disconnect 2 oil level switch 1 3 oil level switch lead holder 1 4 oil pan 1 5 oil pan gasket 1 6 dowel pin 2 p.287
• Oil pan and oil pump p.287
• Order job part q ty remarks 7 drain pipe 1 8 oil strainer 1 9 oil pipe 1 10 oil delivery pipe 1 11 oil water pump assembly drive sprocket cover 1 p.288
• Oil pan and oil pump p.288
• Dowel pin 1 13 oil water pump assembly 1 14 relief valve assembly 1 for installation reverse the removal procedure p.288
• Oil pan and oil pump p.289
• Oil pan and oil pump p.290
• Oil pan and oil pump p.291
• Oil pan and oil pump p.292
• Warning p.293
• Oil pan and oil pump p.293
• Crankcase p.294
• Crankcase p.295
• Crankcase p.296
• Caution p.296
• Crankcase p.297
• Crankcase p.298
• Crankcase p.299
• Caution p.299
• Connecting rods and pistons p.300
• Connecting rods and pistons p.301
• Caution p.301
• Connecting rods and pistons p.302
• Connecting rods and pistons p.303
• Connecting rods and pistons p.304
• Connecting rods and pistons p.305
• Connecting rods and pistons p.306
• Caution p.306
• Warning p.307
• Connecting rods and pistons p.307
• Caution p.307
• Connecting rods and pistons p.308
• Connecting rods and pistons p.309
• Connecting rods and pistons p.310
• Caution p.310
• Note when using a hexagonal nut note that the angle from one corner to another is 60 p.311
• E tighten the nut further to reach the speci fied angle 120 p.311
• Do not use a torque wrench to tighten the nut to the specified angle tighten the nut until it is at the specified angles p.311
• Connecting rods and pistons p.311
• Caution p.311
• When the nut is tightened more than the specified angle do not loosen the nut and then retighten it replace the bolt with a new one and per form the procedure again p.311
• Warning p.311
• Crankshaft p.312
• Crankshaft p.313
• Caution p.313
• Crankshaft p.314
• Crankshaft p.315
• Crankshaft p.316
• Transmission p.317
• Transmission p.318
• Transmission p.319
• Transmission p.320
• Transmission p.321
• Transmission p.322
• Warning p.323
• Transmission p.323
• Transmission p.324
• Transmission p.325
• Radiator p.326
• Cooling system p.326
• Radiator p.327
• Radiator p.328
• Radiator p.329
• Oil cooler p.330
• Oil cooler p.331
• Thermostat p.332
• Thermostat p.333
• Order job part q ty remarks 5 thermostat assembly 1 6 thermostat assembly inlet pipe left 1 for installation reverse the removal procedure p.333
• Thermostat p.334
• Checking the thermostat 1 check thermostat does not open at 71 85 c 160 185 f replace p.335
• Check thermostat housing cover 1 thermostat housing 2 cracks damage replace p.335
• A suspend the thermostat in a container filled with water b slowly heat the water c place a thermometer in the water d while stirring the water observe the ther mostat and thermometer s indicated tem perature p.335
• Thermostat p.335
• Thermometer 2 water 3 thermostat 4 container è fully closed é fully open p.335
• If the accuracy of the thermostat is in doubt replace it a faulty thermostat could cause seri ous overheating or overcooling p.335
• Thermostat p.336
• Caution p.336
• Water pump p.337
• Water pump p.338
• Water pump p.339
• Water pump p.340
• Caution p.340
• Water pump p.341
• Caution p.341
• Fuel injection system p.342
• Wiring diagram p.343
• Main switch 5 battery 6 fuse main 7 fuse fuel injection system 0 starting circuit cut off relay a side stand switch c ecu d ignition coil e spark plug f fuel injector h exup servo motor i speed sensor j lean angle cut off switch k cylinder identification sensor l atmospheric pressure sensor m intake air pressure sensor n throttle position sensor o crankshaft position sensor p intake air temperature sensor q coolant temperature sensor r neutral switch b multi function meter s engine stop switch w fuse ignition p.343
• Fuel injection system p.343
• Fuel injection system p.344
• Substitute characteristics operation control fail safe action if the ecu detects an abnormal signal from a sensor while the motorcycle is being driven the ecu illuminates the engine trouble warning light and provides the engine with substitute characteristic operation instructions that are appropriate for the type of the malfunction when an abnormal signal is received from a sensor the ecu processes the specified values that are programmed for every sensor in order to provide the engine with substitute characteristics operation instructions that enable the engine to continue to operate or to stop its operation depending on circumstances the ecu takes fail safe actions in two ways one in which the sensor output is set to a prescribed value and the other in which the ecu directly operates an actuator details on the fail safe actions are given in the table below fail safe actions table p.345
• Fuel injection system p.345
• Troubleshooring chart p.346
• Fuel injection system p.346
• Fuel injection system p.347
• Fuel injection system p.348
• Diagnostic fault code table p.348
• Fuel injection system p.349
• Note check the intake temperature and coolant temperature as close as possible to the area in which the respective sensor is mounted if it is not possible to check it with an atmospheric pressure gauge judge it by using 760 mmhg 29 inhg as the standard if it is not possible to check the intake temperature use the ambient temperature as reference use the compared values for reference p.350
• Fuel injection system p.350
• Diagnostic mode table set the meter display from the regular mode to the diagnosis mode for the setting method refer to diagnostic mode p.350
• Fuel injection system p.351
• Fuel injection system p.352
• Troubleshooting details this section describes the measures per fault code number displayed on the meter carry out check and maintenance on items or components that could be a cause of malfunction in accordance with the order when the check and maintenance of malfunctioned part is completed restore the meter display according to the restore method fault code no fault code number displayed on the meter when the engine failed to work normally refer to diagnostic fault code table diagnostic code no code number to be used when the diagnostic monitoring mode is operated refer to diag nostic mode p.353
• Fuel injection system p.353
• Fuel injection system p.354
• Fuel injection system p.355
• Fuel injection system p.356
• Fuel injection system p.357
• Fuel injection system p.358
• Caution p.358
• Fuel injection system p.359
• Fuel injection system p.360
• Fuel injection system p.361
• Fuel injection system p.362
• Fuel injection system p.363
• Fuel injection system p.364
• Fuel injection system p.365
• Fuel injection system p.366
• Fuel injection system p.367
• Fuel injection system p.368
• Fuel injection system p.369
• Throttle bodies p.370
• Throttle bodies p.371
• Throttle bodies p.372
• Throttle bodies p.373
• Throttle bodies p.374
• The throttle bodies should not be disas sembled unnecessarily p.374
• Checking the throttle body 1 check throttle body cracks damage replace the throttle bodies p.374
• Checking the injector 1 check injector damage replace p.374
• Check fuel passages obstruction clean p.374
• Caution p.374
• A wash the throttle body in a petroleum based solvent do not use any caustic carburetor cleaning solution b blow out all of passages with compressed air p.374
• Throttle bodies p.375
• Throttle bodies p.376
• Adjust throttle position sensor angle p.377
• A connect the throttle position sensor coupler to the wire harness b connect the digital circuit tester to the throt tle position sensor p.377
• Throttle position sensor voltage 0 3 0 3 v yellow blue p.377
• Throttle position sensor resis tance 0 5 1 k ω at 20 c 68 f yellow black p.377
• Throttle bodies p.377
• Tester positive probe blue terminal 1 tester negative probe yellow terminal 2 p.377
• Note check mainly that the resistance changes gradually when turning the throttle since the readings from closed to wide open throttle may differ slightly from those specified p.377
• F while slowly opening the throttle check that the throttle position sensor resistance is within the specified range the resistance does not change or it changes abruptly replace the throttle position sensor the slot is worn or broken replace the throttle position sensor p.377
• E after adjusting the throttle position sensor angle tighten the throttle position sensor screws p.377
• C measure the throttle position sensor volt age d adjust the throttle position sensor angle so the measured voltage is within the specified range p.377
• Air induction system p.378
• Air induction system diagrams p.379
• Air induction system p.379
• Air induction system p.380
• C measure the ai system solenoid resistance p.381
• Al system solenoid resistance 18 22 ω at 20 c 68 f p.381
• Air induction system p.381
• A remove the ai system solenoid coupler from the wire harness b connect the pocket tester ω 1 to the ai system solenoid terminal as shown p.381
• Tester positive probe orange 1 tester negative probe green 2 p.381
• D out of specification replace p.381
• Check al system solenoid p.381
• Electrical components p.382
• Electrical p.382
• Electrical components p.383
• Checking switch continuity p.384
• Caution p.384
• Checking the switches p.385
• Check each switch for damage or wear proper connections and also for continuity between the ter minals refer to checking switch continuity damage wear repair or replace improperly connected properly connect incorrect continuity reading replace the switch p.385
• Checking the bulbs and bulb sockets p.386
• Warning p.387
• Checking the bulbs and bulb sockets p.387
• Caution p.387
• A install a good bulb into the bulb socket b connect the pocket tester probes to the respective leads of the bulb socket c check the bulb socket for continuity if any of the readings indicate no continuity replace the bulb socket p.388
• A disconnect the meter assembly coupler meter assembly side b connect two jumper leads 1 from the bat tery terminals to the respective coupler ter minal as shown p.388
• Warning p.388
• Pocket tester ym 03112 p.388
• Checking the leds the following procedures applies to all of the leds 1 check led for proper operation improper operation replace p.388
• 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 p.388
• Checking the bulbs and bulb sockets p.388
• Check each bulb socket for continuity in the same manner as described in the bulb section however note the following p.388
• C when the jumper leads are connected to the terminals the respective led should illuminate does not light replace the meter assembly p.388
• A 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 p.388
• Main switch 5 battery 6 fuse main 0 starting circuit cut off relay a side stand switch c ecu d ignition coil e spark plug j lean angle cut off switch o crankshaft position sensor r neutral switch s engine stop switch w fuse ignition p.389
• Ignition system p.389
• Circuit diagram p.389
• Ignition system p.390
• Ignition system p.391
• Ignition system p.392
• Ignition system p.393
• Circuit diagram p.394
• Main switch 5 battery 6 fuse main 8 starter relay 9 starter motor 0 starting circuit cut off relay a side stand switch r neutral switch e clutch switch s engine stop switch t start switch w fuse ignition p.394
• Electric starting system p.394
• Electric starting system p.395
• Warning p.396
• Electric starting system p.396
• Electric starting system p.397
• Electric starting system p.398
• Electric starting system p.399
• Electric starting system p.400
• Electric starting system p.401
• Electric starting system p.402
• Circuit diagram p.403
• Charging system p.403
• Charging system p.404
• Charging system p.405
• Circuit diagram p.406
• Lighting system p.406
• Lighting system p.407
• Lighting system p.408
• Lighting system p.409
• Lighting system p.410
• Lighting system p.411
• Lighting system p.412
• Signaling system p.413
• Circuit diagram p.413
• Signaling system p.414
• Signaling system p.415
• Signaling system p.416
• Signaling system p.417
• Signaling system p.418
• Signaling system p.419
• Signaling system p.420
• Signaling system p.421
• Z fuse fan motor fan motor relay fan motor p.422
• Main switch 5 battery 6 fuse main p.422
• Cooling system p.422
• Circuit diagram p.422
• C ecu q coolant temperature sensor w fuse ignition p.422
• Cooling system p.423
• Cooling system p.424
• Warning p.425
• Cooling system p.425
• Main switch 5 battery 6 fuse main 7 fuse fuel injection 0 starting circuit cut off relay b fuel pump c ecu s engine stop switch w fuse ignition p.426
• Fuel pump system p.426
• Circuit diagram p.426
• Fuel pump system the ecu includes the control unit for the fuel pump p.427
• Fuel pump system p.427
• Fuel pump system p.428
• Fuel pump system p.429
• Warning p.430
• Fuel pump system p.430
• Troubleshooting p.431
• Trbl shtg p.431
• Starting failures p.431
• Trbl shtg p.432
• Starting failures incorrect engine idling speed p.432
• Incorrect engine idling speed p.432
• Trbl shtg p.433
• Poor medium and high speed performance faulty gear shifting faulty clutch p.433
• Poor medium and high speed performance p.433
• Faulty gear shifting p.433
• Faulty clutch p.433
• Overheating p.434
• Overcooling p.434
• Trbl shtg p.434
• Poor braking performance p.434
• Overheating overcooling poor braking performance p.434
• Unstable handling p.435
• Trbl shtg p.435
• Faulty front fork legs unstable handling p.435
• Faulty front fork legs p.435
• Trbl shtg p.436
• Faulty lighting or signaling system p.436
• Wiring diagram p.437
• Yzf r1p yzf r1pc wiring diagram p.437
• Yzf r1p yzf r1pc wiring diagram p.438
• Color code p.438
• Q r s t p.438