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EAS00010
YZF-R1S/YZF-R1SC
SERVICE MANUAL
2003 by Yamaha Motor
Corporation, U.S.A.
First edition, December 2003
All rights reserved. Any reproduction
or unauthorized use without the written
permission of Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-17-55
NOTE:
WARNING
CAUTION:
EAS00030
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 manu-
al. 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 ve-
hicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the ve-
hicle 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.
This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
Designs and specifications are subject to change without notice.
EAS00040
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person checking or repairing the mo-
torcycle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
1
2
4
8
3
5
6
7
EAS00007
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.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each
page indicate the current chapter.
Refer to “SYMBOLS”.
2 Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s) ap-
pears.
3 Sub-section titles appear in smaller print than the section title.
4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6 Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8 Jobs requiring more information (such as special tools and technical data) are described sequen-
tially.
22
1
3
5
7
9
2
4
8
6
24
25
23
21
19
20
18
16
17
15
14
13
11
12
10
GEN
INFO
SPEC
ENG
FI
ELEC
COOL
CHK
ADJ
TRBL
SHTG
CHAS
EAS00008
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.
1 General information
2 Specifications
3 Periodic checks and adjustments
4 Chassis
5 Engine
6 Cooling system
7 Fuel injection system
8 Electrical system
9 Troubleshooting
Symbols 10 to 17 indicate the following.
10 Serviceable with engine mounted
11 Filling fluid
12 Lubricant
13 Special tool
14 Tightening torque
15 Wear limit, clearance
16 Engine speed
17 Electrical data
Symbols 18 to 23 in the exploded diagrams indi-
cate the types of lubricants and lubrication
points.
18 Engine oil
19 Gear oil
20 Molybdenum-disulfide oil
21 Wheel-bearing grease
22 Lithium-soap- based grease
23 Molybdenum-disulfide grease
Symbols 24 to 25 in the exploded diagrams indi-
cate the following.
24 Apply locking agent (LOCTITE)
25 Replace the part
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
COOLING SYSTEM
FUEL INJECTION SYSTEM
ELECTRICAL SYSTEM
TROUBLESHOOTING
GEN
INFO 1
SPEC 2
3
ENG
4
COOL
5
FI
6
CHAS
7
ELEC 8
TRBL
SHTG 9
CHK
ADJ
EAS00012 TABLE OF CONTENTS
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
1-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBER
1-1
. . . . . . . . . . . . . . . . . . . . . . . .
MODEL LABEL
1-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FEATURES
1-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT FUNCTIONS
1-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT INFORMATION
1-6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR REMOVAL AND DISASSEMBLY
1-6
. . . . . . . . .
REPLACEMENT PARTS
1-6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKETS, OIL SEALS AND O-RINGS
1-6
. . . . . . . . . . . . . . . . . . . . . . .
LOCK WASHERS/PLATES AND COTTER PINS
1-7
. . . . . . . . . . . . . .
BEARINGS AND OIL SEALS
1-7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCLIPS
1-7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CONNECTIONS
1-8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS
1-9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS
2-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SPECIFICATIONS
2-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS SPECIFICATIONS
2-11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SPECIFICATIONS
2-15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONVERSION TABLE
2-18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL TIGHTENING TORQUE SPECIFICATIONS
2-18
. . . . . . . . . . . .
TIGHTENING TORQUES
2-19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE TIGHTENING TORQUES
2-19
. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS TIGHTENING TORQUES
2-23
. . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION POINTS AND LUBRICANT TYPES
2-25
. . . . . . . . . . . . . . .
ENGINE
2-25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS
2-26
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM DIAGRAMS
2-27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL LUBRICATION CHART
2-29
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION DIAGRAMS
2-30
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING
2-35
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
3-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM
3-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL MAINTENANCE AND LUBRICATION CHART
3-1
. . . . . . . . .
SEATS
3-3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL TANK
3-4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FUEL TANK
3-5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FUEL PUMP
3-5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FUEL PUMP
3-6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FUEL TANK
3-6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COWLINGS
3-7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT COWLING AND SIDE COWLINGS
3-7
. . . . . . . . . . . . . . . . . . .
REAR COWLING
3-8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL
3-9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION
3-9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR FILTER CASE
3-10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE
3-11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE VALVE CLEARANCE
3-11
. . . . . . . . . . . . . . . . . . . . . .
SYNCHRONIZING THE THROTTLE BODIES
3-17
. . . . . . . . . . . . . . . . .
ADJUSTING THE ENGINE IDLING SPEED
3-20
. . . . . . . . . . . . . . . . . . .
ADJUSTING THE THROTTLE CABLE FREE PLAY
3-21
. . . . . . . . . . . .
CHECKING THE SPARK PLUGS
3-22
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING THE COMPRESSION PRESSURE
3-23
. . . . . . . . . . . . . .
CHECKING THE ENGINE OIL LEVEL
3-25
. . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE ENGINE OIL
3-27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING THE ENGINE OIL PRESSURE
3-28
. . . . . . . . . . . . . . . . .
ADJUSTING THE CLUTCH CABLE FREE PLAY
3-30
. . . . . . . . . . . . . . .
REPLACING THE AIR FILTER ELEMENT
3-31
. . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL AND BREATHER HOSES
3-32
. . . . . . . . . . . . .
CHECKING THE CRANKCASE BREATHER HOSE
3-33
. . . . . . . . . . . .
CHECKING THE EXHAUST SYSTEM
3-34
. . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE EXUP CABLES
3-35
. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLANT LEVEL
3-36
. . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLING SYSTEM
3-37
. . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE COOLANT
3-38
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS
3-41
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT BRAKE
3-41
. . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE
3-42
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE FLUID LEVEL
3-43
. . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE LIGHT SWITCH
3-44
. . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE PADS
3-44
. . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE HOSES
3-45
. . . . . . . . .
BLEEDING THE HYDRAULIC BRAKE SYSTEM
3-46
. . . . . . . . . . . . . . .
ADJUSTING THE SHIFT PEDAL
3-47
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE DRIVE CHAIN SLACK
3-48
. . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE DRIVE CHAIN
3-49
. . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE STEERING HEAD
3-50
. . . . . . . . .
CHECKING THE FRONT FORK
3-52
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT FORK LEGS
3-53
. . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
3-55
. . . . .
CHECKING THE TIRES
3-57
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE WHEELS
3-59
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND LUBRICATING THE CABLES
3-60
. . . . . . . . . . . . . . .
LUBRICATING THE LEVERS AND PEDALS
3-60
. . . . . . . . . . . . . . . . . .
LUBRICATING THE SIDESTAND
3-60
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE REAR SUSPENSION
3-60
. . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM
3-61
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND CHARGING THE BATTERY
3-61
. . . . . . . . . . . . . . . . .
CHECKING THE FUSES
3-66
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE HEADLIGHT BULBS
3-68
. . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE HEADLIGHT BEAMS
3-69
. . . . . . . . . . . . . . . . . . . . . .
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISCS
4-1
. . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT WHEEL
4-3
. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT WHEEL
4-3
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE DISCS
4-5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT WHEEL
4-6
. . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT WHEEL STATIC BALANCE
4-7
. . . . . . . . .
REAR WHEEL AND BRAKE DISC
4-9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WHEEL
4-9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE DISC AND REAR WHEEL SPROCKET
4-10
. . . . . . . . .
REMOVING THE REAR WHEEL
4-12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL
4-13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL DRIVE HUB
4-13
. . . . . . . . . . . . . . . . .
CHECKING AND REPLACING THE REAR WHEEL
SPROCKET
4-13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE REAR WHEEL
4-14
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR WHEEL STATIC BALANCE
4-14
. . . . . . . . . . .
FRONT AND REAR BRAKES
4-15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE PADS
4-15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE PADS
4-16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE FRONT BRAKE PADS
4-18
. . . . . . . . . . . . . . . . . . . . .
REPLACING THE REAR BRAKE PADS
4-20
. . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE MASTER CYLINDER
4-22
. . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE MASTER CYLINDER
4-25
. . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT BRAKE MASTER
CYLINDER
4-27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE REAR BRAKE MASTER
CYLINDER
4-27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE MASTER
CYLINDERS
4-28
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING AND INSTALLING THE FRONT BRAKE
MASTER CYLINDER
4-29
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE REAR BRAKE MASTER CYLINDER
4-31
. . . . . . .
FRONT BRAKE CALIPERS
4-33
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE CALIPER
4-35
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT BRAKE CALIPERS
4-37
. . . . . . . . . . .
DISASSEMBLING THE REAR BRAKE CALIPER
4-38
. . . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE CALIPERS
4-39
. . . . . .
ASSEMBLING AND INSTALLING THE FRONT BRAKE
CALIPERS
4-40
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING AND INSTALLING THE REAR
BRAKE CALIPER
4-42
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK
4-44
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK LEGS
4-44
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT FORK LEGS
4-47
. . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT FORK LEGS
4-48
. . . . . . . . . . . . . . . . .
CHECKING THE FRONT FORK LEGS
4-49
. . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE FRONT FORK LEGS
4-50
. . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT FORK LEGS
4-55
. . . . . . . . . . . . . . . . . . . . . .
HANDLEBARS
4-56
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE HANDLEBARS
4-58
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE HANDLEBARS
4-58
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE HANDLEBARS
4-58
. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STEERING DAMPER
4-60
. . . . . . . . . . . . . . . . . . . . . . .
STEERING HEAD
4-61
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNDER BRACKET
4-61
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE UNDER BRACKET
4-63
. . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STEERING HEAD
4-63
. . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE STEERING HEAD
4-64
. . . . . . . . . . . . . . . . . . . . . . . . .
REAR SHOCK ABSORBER ASSEMBLY
4-65
. . . . . . . . . . . . . . . . . . . . . . . .
HANDLING THE REAR SHOCK ABSORBER AND
GAS CYLINDER
4-66
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPOSING OF A REAR SHOCK ABSORBER AND
GAS CYLINDER
4-66
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY
4-67
. . . . .
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY
4-68
. . . . . .
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY
4-68
. . . . .
SWINGARM AND DRIVE CHAIN
4-69
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE SWINGARM
4-71
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE DRIVE CHAIN
4-72
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SWINGARM
4-72
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE DRIVE CHAIN
4-73
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE SWINGARM
4-75
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 5
ENGINE
ENGINE
5-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SPROCKET
5-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST PIPE
5-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEADS AND HOSES
5-5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE
5-7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE ENGINE
5-9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT
5-11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD COVER
5-11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFTS
5-13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CAMSHAFTS
5-14
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CAMSHAFTS
5-15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,
AND TIMING CHAIN GUIDES
5-17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TIMING CHAIN TENSIONER
5-17
. . . . . . . . . . . . . . . .
INSTALLING THE CAMSHAFTS
5-19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD
5-22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CYLINDER HEAD
5-23
. . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CYLINDER HEAD
5-23
. . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CYLINDER HEAD
5-24
. . . . . . . . . . . . . . . . . . . . . . . . .
VALVES AND VALVE SPRINGS
5-25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE VALVES
5-27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE VALVES AND VALVE GUIDES
5-28
. . . . . . . . . . . . . . .
CHECKING THE VALVE SEATS
5-30
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE VALVE SPRINGS
5-31
. . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE VALVE LIFTERS
5-32
. . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE VALVES
5-32
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER CLUTCH AND GENERATOR
5-35
. . . . . . . . . . . . . . . . . . . . . . . . .
STATOR COIL ASSEMBLY
5-35
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER CLUTCH
5-37
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE GENERATOR
5-38
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE STARTER CLUTCH
5-39
. . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE DAMPER
5-39
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STARTER CLUTCH
5-40
. . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE STARTER CLUTCH
5-41
. . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE GENERATOR
5-41
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT POSITION SENSOR
5-43
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CRANKSHAFT POSITION SENSOR
5-44
. . . . . . . . .
INSTALLING THE CRANKSHAFT POSITION SENSOR
5-44
. . . . . . . .
CLUTCH
5-46
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH COVER
5-46
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PULL LEVER SHAFT
5-47
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH
5-48
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CLUTCH
5-50
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRICTION PLATES
5-52
. . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH PLATES
5-52
. . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH SPRINGS
5-53
. . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH HOUSING
5-53
. . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH BOSS
5-53
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PRESSURE PLATE
5-54
. . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PULL LEVER SHAFT AND PULL ROD
5-54
. . . . . . .
INSTALLING THE CLUTCH
5-54
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT SHAFT
5-58
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT SHAFT AND STOPPER LEVER
5-58
. . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE SHIFT SHAFT
5-60
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT SHAFT
5-61
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STOPPER LEVER
5-61
. . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE SHIFT SHAFT
5-61
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PAN AND OIL PUMP
5-63
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE OIL PAN
5-66
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SPROCKET AND CHAIN
5-66
. . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL PUMP
5-67
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE RELIEF VALVE
5-67
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL DELIVERY PIPE AND OIL PIPE
5-68
. . . . . . . . .
CHECKING THE OIL STRAINER
5-68
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL NOZZLES
5-68
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE OIL PUMP
5-68
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE OIL/WATER PUMP ASSEMBLY
5-69
. . . . . . . . . . . .
INSTALLING THE OIL PAN
5-71
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE
5-72
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE CRANKCASE
5-74
. . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKCASE
5-75
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BEARINGS AND OIL SEALS
5-75
. . . . . . . . . . . . . . . .
ASSEMBLING THE CRANKCASE
5-75
. . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING RODS AND PISTONS
5-77
. . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CONNECTING RODS AND PISTONS
5-78
. . . . . . . .
REMOVING THE CRANKSHAFT ASSEMBLY
5-79
. . . . . . . . . . . . . . . . .
CHECKING THE CYLINDER AND PISTON
5-79
. . . . . . . . . . . . . . . . . . .
CHECKING THE PISTON RINGS
5-80
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PISTON PINS
5-81
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BIG END BEARINGS
5-82
. . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CONNECTING ROD AND PISTON
5-86
. . . . . . . . . .
CRANKSHAFT
5-92
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKSHAFT
5-93
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKSHAFT DRIVE SPROCKET
5-93
. . . . . . . . . .
CHECKING THE CRANKSHAFT JOURNAL BEARINGS
5-93
. . . . . . . .
INSTALLING THE CRANKSHAFT
5-96
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION
5-97
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION, SHIFT DRUM ASSEMBLY AND
SHIFT FORKS
5-97
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE TRANSMISSION
5-103
. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT FORKS
5-103
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT DRUM ASSEMBLY
5-104
. . . . . . . . . . . . . . . . . . .
CHECKING THE TRANSMISSION
5-104
. . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE TRANSMISSION
5-105
. . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 6
COOLING SYSTEM
RADIATOR
6-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE RADIATOR
6-3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE RADIATOR
6-4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL COOLER
6-5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL COOLER
6-7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE OIL COOLER
6-7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTAT
6-8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE THERMOSTAT
6-10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE THERMOSTAT ASSEMBLY
6-11
. . . . . . . . . . . . . . .
INSTALLING THE THERMOSTAT ASSEMBLY
6-11
. . . . . . . . . . . . . . . .
WATER PUMP
6-12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPELLER SHAFT
6-12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE WATER PUMP
6-14
. . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE WATER PUMP
6-14
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE WATER PUMP
6-15
. . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 7
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
7-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM
7-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ECU’S SELF-DIAGNOSTIC FUNCTION
7-4
. . . . . . . . . . . . . . . . . . . . . .
SUBSTITUTE CHARACTERISTICS OPERATION CONTROL
(FAIL-SAFE ACTION)
7-5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAIL-SAFE ACTIONS TABLE
7-5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING CHART
7-7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC MODE
7-8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING DETAILS
7-15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THROTTLE BODIES
7-35
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INJECTORS
7-37
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE INJECTORS
7-39
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE THROTTLE BODIES
7-39
. . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE THROTTLE BODY JOINTS
7-39
. . . . . . . . . . . . . . . . . .
CHECKING THE PRESSURE REGULATOR
7-40
. . . . . . . . . . . . . . . . . .
CHECKING THE FUEL PUMP AND
PRESSURE REGULATOR OPERATION
7-40
. . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE
THROTTLE POSITION SENSOR
7-41
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE
SUB-THROTTLE POSITION SENSOR
7-43
. . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE THERMO WAX
7-46
. . . . . . . . . . . .
AIR INDUCTION SYSTEM
7-47
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INJECTION
7-47
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CUT-OFF VALVE
7-47
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION SYSTEM DIAGRAMS
7-48
. . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE AIR INDUCTION SYSTEM
7-49
. . . . . . . . . . . . . . . . . .
CHAPTER 8
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS
8-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING SWITCH CONTINUITY
8-3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SWITCHES
8-4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BULBS AND BULB SOCKETS
8-5
. . . . . . . . . . . . . . . . .
TYPES OF BULBS
8-5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CONDITION OF THE BULBS
8-5
. . . . . . . . . . . . . . . .
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