Yamaha YZF-R1 2002 User Manual [ru]

YZF-R1P
YZF-R1PC

SERVICE MANUAL

LIT-11616-15-47 5PW-28197-10

EAS00000

YZF-R1P/YZF-R1PC

SERVICE MANUAL

©2001 by Yamaha Motor Corporation, U.S.A.

First edition, December 2001

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-11616-15-47

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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 manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle 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
vehicle 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
significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal­ers and will appear in future editions of this manual where applicable.

NOTE:

_

• 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.

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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!

WARNING

CAUTION:

NOTE:

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
motorcycle.

A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.

A NOTE provides key information to make procedures easier or clearer.

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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)
appears.

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 sequen­tially.

6

4

5

12

3

8

7

12

GEN

SPEC

INFO

34

CHK

CHAS

ADJ

56

ENG

78

COOL

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SYMBOLS

The following symbols are not relevant to
every vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.

General information

1

Specifications

2

Periodic checks and adjustments

3

Chassis

4

Engine

5

Cooling system

6

Fuel injection system

7

Electrical system

8

Troubleshooting

9

FI

90

ELEC

–+

TRBL

SHTG

AB

CD

T

.

R

.

EFG

HIJ

Symbols 0 to G indicate the following.

Serviceable with engine mounted

0

Filling fluid

A

Lubricant

B

Special tool

C

Tightening torque

D

Wear limit, clearance

E

Engine speed

F

Electrical data

G

Symbols H to M in the exploded diagrams
indicate the types of lubricants and lubrication
points.

LS

G

M

M

E

KLM

B

NO

New

LT

Engine oil

H

Gear oil

I

Molybdenum-disulfide oil

J

Wheel-bearing grease

K

Lithium-soap-base grease

L

Molybdenum-disulfide grease

M

Symbols N to O in the exploded diagrams
indicate the following.

®

Apply locking agent (LOCTITE

N

Replace the part

O

)

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TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND
ADJUSTMENTS

CHASSIS

ENGINE

GEN

INFO

SPEC

CHK

ADJ

CHAS

ENG

1

2

3

4

5

COOLING SYSTEM

FUEL INJECTION SYSTEM

ELECTRICAL SYSTEM

TROUBLESHOOTING

COOL

FI

– +

ELEC

TRBL

SHTG

6

7

8

9

CHAPTER 1

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER ....................................................1-1

MODEL LABEL .........................................................................................1-1

FEATURES

OUTLINE OF FI SYSTEM ........................................................................1-2

FI SYSTEM ...............................................................................................1-3

COMPONENTS ........................................................................................1-5

FUEL INJECTION SYSTEM ...................................................................1-16

THREE-WAY CATALYTIC CONVERTER SYSTEM ..............................1-19

INSTRUMENT FUNCTION .....................................................................1-20

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND DISASSEMBLY ........................1-23

REPLACEMENT PARTS ........................................................................1-23

GASKETS, OIL SEALS AND O-RINGS .................................................1-23

LOCK WASHERS/PLATES AND COTTER PINS ..................................1-24

BEARINGS AND OIL SEALS .................................................................1-24

CIRCLIPS ...............................................................................................1-24

CHECKING THE CONNECTIONS

.....................................................................................................1-2

.................................................................1-1

.......................................................................1-23

...............................................................1-25

SPECIAL TOOLS

.........................................................................................1-26

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS

ENGINE SPECIFICATIONS

CHASSIS SPECIFICATIONS

ELECTRICAL SPECIFICATIONS

CONVERSION TABLE

.................................................................................2-17

........................................................................2-1

..........................................................................2-2

.......................................................................2-11

................................................................2-15

TIGHTENING TORQUES .............................................................................2-17

GENERAL TIGHTENING TORQUE SPECIFICATIONS ........................2-17

ENGINE TIGHTENING TORQUES ........................................................2-18

CHASSIS TIGHTENING TORQUES ......................................................2-21

LUBRICATION POINTS AND LUBRICANT TYPES ....................................2-23

ENGINE ..................................................................................................2-23

CHASSIS ................................................................................................2-24

COOLING SYSTEM DIAGRAMS .................................................................2-25

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 HOSE ...............................................................3-6

COWLINGS .....................................................................................................3-7

AIR FILTER CASE ..........................................................................................3-8

ENGINE ...........................................................................................................3-9

ADJUSTING THE VALVE CLEARANCE ..................................................3-9

SYNCHRONIZING THE THROTTLE BODIES .......................................3-14

ADJUSTING THE ENGINE IDLING SPEED ..........................................3-16

ADJUSTING THE THROTTLE CABLE FREE PLAY ..............................3-17

CHECKING THE SPARK PLUGS ..........................................................3-19

MEASURING THE COMPRESSION PRESSURE .................................3-20

CHECKING THE ENGINE OIL LEVEL ...................................................3-23

CHANGING THE ENGINE OIL ...............................................................3-24

ADJUSTING THE CLUTCH CABLE FREE PLAY ..................................3-26

REPLACING THE AIR FILTER ELEMENT ............................................3-28

CHECKING THE FUEL AND BREATHER HOSES ................................3-29

CHECKING THE CRANKCASE BREATHER HOSE ..............................3-29

CHECKING THE EXHAUST SYSTEM ...................................................3-30

ADJUSTING THE EXUP CABLES .........................................................3-31

CHECKING THE COOLANT LEVEL ......................................................3-32

CHECKING THE COOLING SYSTEM ...................................................3-33

CHANGING THE COOLANT ..................................................................3-34

CHASSIS ......................................................................................................3-37

ADJUSTING THE FRONT BRAKE .........................................................3-37

ADJUSTING THE REAR BRAKE ...........................................................3-38

CHECKING THE BRAKE FLUID LEVEL ................................................3-39

CHECKING THE FRONT AND REAR BRAKE PADS ............................3-40

ADJUSTING THE REAR BRAKE LIGHT SWITCH ................................3-40

CHECKING THE FRONT AND REAR BRAKE HOSES .........................3-41

BLEEDING THE HYDRAULIC BRAKE SYSTEM ...................................3-41

ADJUSTING THE SHIFT PEDAL ...........................................................3-43

ADJUSTING THE DRIVE CHAIN SLACK ..............................................3-43

LUBRICATING THE DRIVE CHAIN .......................................................3-45

CHECKING AND ADJUSTING THE STEERING HEAD ........................3-45

CHECKING THE FRONT FORK ............................................................3-48

ADJUSTING THE FRONT FORK LEGS ................................................3-49

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY .................3-51

CHECKING THE TIRES .........................................................................3-53

CHECKING THE WHEELS ....................................................................3-56

CHECKING AND LUBRICATING THE CABLES ....................................3-57

LUBRICATING THE LEVERS AND PEDALS ........................................3-57

LUBRICATING THE SIDESTAND ..........................................................3-57

LUBRICATING THE REAR SUSPENSION ............................................3-57

ELECTRICAL SYSTEM ................................................................................3-58

CHECKING AND CHARGING THE BATTERY ......................................3-58

CHECKING THE FUSES ........................................................................3-63

REPLACING THE HEADLIGHT BULBS ................................................3-65

ADJUSTING THE HEADLIGHT BEAM ..................................................3-66

CHAPTER 4

CHASSIS

FRONT WHEEL AND BRAKE DISCS

FRONT WHEEL ........................................................................................4-2

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

REAR WHEEL ........................................................................................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 .........4-14

INSTALLING THE REAR WHEEL ..........................................................4-14

ADJUSTING THE REAR WHEEL STATIC BALANCE ...........................4-15

FRONT AND REAR BRAKES

FRONT BRAKE PADS ...........................................................................4-16

REAR BRAKE PADS ..............................................................................4-17

REPLACING THE FRONT BRAKE PADS .............................................4-18

REPLACING THE REAR BRAKE PADS ................................................4-21

FRONT BRAKE MASTER CYLINDER ...................................................4-23

REAR BRAKE MASTER CYLINDER .....................................................4-26

DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER .............4-28

DISASSEMBLING THE REAR BRAKE MASTER CYLINDER ...............4-28

CHECKING THE FRONT

AND REAR BRAKE MASTER CYLINDERS ..........................................4-29

ASSEMBLING AND INSTALLING

THE FRONT BRAKE MASTER CYLINDER ..........................................4-30

ASSEMBLING THE REAR BRAKE MASTER CYLINDER .....................4-32

FRONT BRAKE CALIPERS ...................................................................4-34

REAR BRAKE CALIPER ........................................................................4-36

DISASSEMBLING THE FRONT BRAKE CALIPERS .............................4-38

DISASSEMBLING THE REAR BRAKE CALIPER ..................................4-39

CHECKING THE FRONT AND REAR BRAKE CALIPERS ....................4-40

ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS ....4-41

ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER .........4-43

......................................................................4-16

...........................................................4-1

................................................................4-9

FRONT FORK

REMOVING THE FRONT FORK LEGS .................................................4-48

DISASSEMBLING THE FRONT FORK LEGS .......................................4-48

CHECKING THE FRONT FORK LEGS ..................................................4-50

ASSEMBLING THE FRONT FORK LEGS .............................................4-51

INSTALLING THE FRONT FORK LEGS ................................................4-55

...............................................................................................4-45

HANDLEBARS .............................................................................................4-56

REMOVING THE HANDLEBARS ...........................................................4-58

CHECKING THE HANDLEBARS ...........................................................4-58

INSTALLING THE HANDLEBARS .........................................................4-58

STEERING HEAD .........................................................................................4-61

REMOVING THE LOWER 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

OVERHAULING THE ENGINE

ENGINE ...........................................................................................................5-1

DRIVE SPROCKET ..................................................................................5-1

EXHAUST PIPE ........................................................................................5-2

LEADS AND HOSES ................................................................................5-4

ENGINE ....................................................................................................5-6

INSTALLING THE ENGINE ......................................................................5-7

CAMSHAFT ....................................................................................................5-8

CYLINDER HEAD COVERS ...................................................................5-8

CAMSHAFTS ............................................................................................5-9

REMOVING THE CAMSHAFTS .............................................................5-11

CHECKING THE CAMSHAFTS .............................................................5-12

CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,

AND TIMING CHAIN GUIDES ...............................................................5-14

CHECKING THE TIMING CHAIN TENSIONER .....................................5-15

INSTALLING THE CAMSHAFTS ...........................................................5-15

CYLINDER HEAD ........................................................................................5-19

REMOVING THE CYLINDER HEAD ......................................................5-20

CHECKING THE CYLINDER HEAD ......................................................5-20

INSTALLING THE CYLINDER HEAD ....................................................5-21

VALVES AND VALVE SPRINGS ................................................................5-22

REMOVING THE VALVES .....................................................................5-24

CHECKING THE VALVES AND VALVE GUIDES ..................................5-25

CHECKING THE VALVE SEATS ...........................................................5-27

CHECKING THE VALVE SPRINGS .......................................................5-28

CHECKING THE VALVE LIFTERS ........................................................5-29

INSTALLING THE VALVES ....................................................................5-29

GENERATOR ..............................................................................................5-32

REMOVING THE GENERATOR ............................................................5-33

INSTALLING THE GENERATOR ...........................................................5-33

PICKUP COIL ..............................................................................................5-36

REMOVING THE PICKUP COIL ROTOR ..............................................5-38

INSTALLING THE PICKUP COIL ROTOR .............................................5-38

CLUTCH ........................................................................................................5-40

CLUTCH COVER ..................................................................................5-40

PULL LEVER SHAFT .............................................................................5-41

CLUTCH .................................................................................................5-42

REMOVING THE CLUTCH ....................................................................5-44

CHECKING THE FRICTION PLATES ....................................................5-44

CHECKING THE CLUTCH PLATES ......................................................5-45

CHECKING THE CLUTCH HOUSING ...................................................5-45

CHECKING THE CLUTCH BOSS ..........................................................5-45

CHECKING THE PRESSURE PLATE ...................................................5-46

CHECKING THE PULL LEVER SHAFT AND PULL ROD ......................5-46

CHECKING THE STARTER CLUTCH ...................................................5-46

INSTALLING THE CLUTCH ...................................................................5-47

SHIFT SHAFT ...............................................................................................5-49

SHIFT SHAFT AND STOPPER LEVER ................................................5-49

CHECKING THE SHIFT SHAFT ............................................................5-50

CHECKING THE STOPPER LEVER ......................................................5-50

INSTALLING THE SHIFT SHAFT ..........................................................5-50

OIL PAN AND OIL PUMP ............................................................................5-51

OIL PUMP ...............................................................................................5-53

REMOVING THE OIL PAN .....................................................................5-54

CHECKING THE OIL PUMP ..................................................................5-54

CHECKING THE RELIEF VALVE ..........................................................5-55

CHECKING THE OIL DELIVERY PIPES ...............................................5-55

CHECKING THE OIL STRAINER ...........................................................5-55

ASSEMBLING THE OIL PUMP ..............................................................5-56

INSTALLING THE OIL PUMP ................................................................5-56

INSTALLING THE OIL STRAINER .........................................................5-57

INSTALLING THE OIL PAN ...................................................................5-57

CRANKCASE ...............................................................................................5-58

DISASSEMBLING THE CRANKCASE ...................................................5-60

CHECKING THE CRANKCASE .............................................................5-61

CHECKING THE BEARINGS AND OIL SEALS .....................................5-61

CHECKING THE SPROCKET AND CHAINS .........................................5-61

ASSEMBLING THE CRANKCASE .........................................................5-62

CONNECTING RODS AND PISTONS .........................................................5-64

REMOVING THE CONNECTING RODS AND PISTONS ......................5-65

REMOVING THE CRANKSHAFT ASSEMBLY ......................................5-66

CHECKING THE CYLINDER AND PISTONS ........................................5-66

CHECKING THE PISTON RINGS ..........................................................5-68

CHECKING THE PISTON PINS .............................................................5-69

CHECKING THE BIG END BEARINGS .................................................5-69

INSTALLING THE CONNECTING ROD AND PISTON ..........................5-72

CRANKSHAFT .............................................................................................5-76

CHECKING THE CRANKSHAFT ...........................................................5-77

CHECKING THE CRANKSHAFT JOURNAL BEARINGS ......................5-77

INSTALLING THE CRANKSHAFT .........................................................5-80

TRANSMISSION ...........................................................................................5-81

REMOVING THE TRANSMISSION ........................................................5-87

CHECKING THE SHIFT FORKS ............................................................5-87

CHECKING THE SHIFT DRUM ASSEMBLY .........................................5-88

CHECKING THE TRANSMISSION ........................................................5-88

INSTALLING THE TRANSMISSION ......................................................5-89

CHAPTER 6

COOLING SYSTEM

RADIATOR

CHECKING THE RADIATOR ...................................................................6-3

INSTALLING THE RADIATOR .................................................................6-4

OIL COOLER

CHECKING THE OIL COOLER ................................................................6-6

INSTALLING THE OIL COOLER ..............................................................6-6

THERMOSTAT

CHECKING THE THERMOSTAT ...........................................................6-10

ASSEMBLING THE THERMOSTAT ASSEMBLY ..................................6-11

INSTALLING THE THERMOSTAT ASSEMBLY ....................................6-11

WATER PUMP

DISASSEMBLING THE WATER PUMP .................................................6-14

CHECKING THE WATER PUMP ...........................................................6-14

ASSEMBLING THE WATER PUMP .......................................................6-15

.....................................................................................................6-1

..................................................................................................6-5

...............................................................................................6-7

..............................................................................................6-12

CHAPTER 7

FUEL INJECTION SYSTEM

FUEL INJECTION SYSTEM

WIRING DIAGRAM ...................................................................................7-2

ECU’S SELF-DIAGNOSTIC FUNCTION ..................................................7-3

SUBSTITUTE CHARACTERISTICS OPERATION CONTROL

(FAIL-SAFE ACTION) ..............................................................................7-4

FAIL-SAFE ACTIONS TABLE ..................................................................7-4

TROUBLESHOORING CHART ................................................................7-5

DIAGNOSTIC MODE ................................................................................7-6

TROUBLESHOOTING DETAILS ............................................................7-12

THROTTLE BODIES

CHECKING THE INJECTOR ..................................................................7-33

CHECKING THE THROTTLE BODY .....................................................7-33

CHECKING THE PRESSURE REGULATOR .........................................7-34

CHECKING THE FUEL PUMP

AND PRESSURE REGULATOR OPERATION .....................................7-34

CHECKING AND ADJUSTING

THE THROTTLE POSITION SENSOR .................................................7-35

....................................................................................7-29

...........................................................................7-1

AIR INDUCTION SYSTEM ...........................................................................7-37

AIR INDUCTION .....................................................................................7-37

AIR CUT-OFF VALVE ............................................................................7-37

AIR INDUCTION SYSTEM DIAGRAMS .................................................7-38

CHECKING THE AIR INDUCTION SYSTEM .........................................7-39

CHAPTER 8

ELECTRICAL

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 .......................................8-6

CHECKING THE CONDITION OF THE BULB SOCKETS .......................8-7

CHECKING THE LEDs .............................................................................8-7

IGNITION SYSTEM .........................................................................................8-8

CIRCUIT DIAGRAM .................................................................................8-8

TROUBLESHOOTING ..............................................................................8-9

ELECTRIC STARTING SYSTEM .................................................................8-13

CIRCUIT DIAGRAM ...............................................................................8-13

STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .......................8-14

TROUBLESHOOTING ............................................................................8-15

STARTER MOTOR .................................................................................8-18

CHECKING THE STARTER MOTOR ....................................................8-20

ASSEMBLING THE STARTER MOTOR ................................................8-21

CHARGING SYSTEM ...................................................................................8-22

CIRCUIT DIAGRAM ...............................................................................8-22

TROUBLESHOOTING ............................................................................8-23

LIGHTING SYSTEM .....................................................................................8-25

CIRCUIT DIAGRAM ...............................................................................8-25

TROUBLESHOOTING ............................................................................8-27

CHECKING THE LIGHTING SYSTEM ...................................................8-29

SIGNALING SYSTEM ...................................................................................8-32

CIRCUIT DIAGRAM ...............................................................................8-32

TROUBLESHOOTING ............................................................................8-34

CHECKING THE SIGNALING SYSTEM ................................................8-34

COOLING SYSTEM ......................................................................................8-41

CIRCUIT DIAGRAM ...............................................................................8-41

TROUBLESHOOTING ............................................................................8-42

FUEL PUMP SYSTEM ..................................................................................8-45

CIRCUIT DIAGRAM ...............................................................................8-45

FUEL PUMP SYSTEM ...........................................................................8-46

TROUBLESHOOTING ............................................................................8-47

CHECKING THE FUEL PUMP ...............................................................8-49

CHAPTER 9

TROUBLESHOOTING

STARTING FAILURES ...................................................................................9-1

ENGINE ....................................................................................................9-1

FUEL SYSTEM .........................................................................................9-1

ELECTRICAL SYSTEMS .........................................................................9-2

INCORRECT ENGINE IDLING SPEED ..........................................................9-2

ENGINE ....................................................................................................9-2

FUEL SYSTEM .........................................................................................9-2

ELECTRICAL SYSTEMS .........................................................................9-2

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ................................9-3

ENGINE ....................................................................................................9-3

FUEL SYSTEM .........................................................................................9-3

FAULTY GEAR SHIFTING .............................................................................9-3

SHIFTING IS DIFFICULT .........................................................................9-3

SHIFT PEDAL DOES NOT MOVE ...........................................................9-3

JUMPS OUT OF GEAR ............................................................................9-3

FAULTY CLUTCH ..........................................................................................9-3

CLUTCH SLIPS ........................................................................................9-3

CLUTCH DRAGS .....................................................................................9-3

OVERHEATING ..............................................................................................9-4

ENGINE ....................................................................................................9-4

COOLING SYSTEM .................................................................................9-4

FUEL SYSTEM .........................................................................................9-4

CHASSIS ..................................................................................................9-4

ELECTRICAL SYSTEMS .........................................................................9-4

OVERCOOLING .............................................................................................9-4

COOLING SYSTEM .................................................................................9-4

POOR BRAKING PERFORMANCE ...............................................................9-4

FAULTY FRONT FORK LEGS .......................................................................9-5

LEAKING OIL ...........................................................................................9-5

MALFUNCTION ........................................................................................9-5

UNSTABLE HANDLING .................................................................................9-5

FAULTY LIGHTING OR SIGNALING SYSTEM .............................................9-6

HEADLIGHT DOES NOT COME ON .......................................................9-6

HEADLIGHT BULB BURNT OUT .............................................................9-6

TAIL/BRAKE LIGHT DOES NOT COME ON ...........................................9-6

TAIL/BRAKE LIGHT BULB BURNT OUT .................................................9-6

TURN SIGNAL DOES NOT COME ON ....................................................9-6

TURN SIGNAL BLINKS SLOWLY ............................................................9-6

TURN SIGNAL REMAINS LIT ..................................................................9-6

TURN SIGNAL BLINKS QUICKLY ...........................................................9-6

HORN DOES NOT SOUND .....................................................................9-6

MOTORCYCLE IDENTIFICATION

EAS00014

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

EAS00017

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is
stamped into the right side of the steering head
pipe.

EAS00018

MODEL LABEL

The model label 1 is affixed to the frame. This
information will be needed to order spare
parts.

GEN

INFO

1

1 - 1

GEN

FEATURES

FEATURES

OUTLINE OF FI 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 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 con­ditions of the engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases
increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned man­ner. To accommodate this need, this model has adopted an electronically controlled fuel injection
(FI) system, in place of the conventional carburetor system. This system can achieve an optimum
air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel
injection volume according to the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine
response, better fuel economy, and reduced exhaust emissions. Furthermore, the air induction sys­tem (AI system) has been placed under computer control together with the FI system in order to
realize cleaner exhaust gases.

INFO

Ignition coil

1

Air filter case

2

Intake temperature

3

sensor
Fuel delivery hose

4

Fuel tank

5

Fuel pump

6

Fuel return hose

7

Intake air pressure

8

sensor
Throttle position sensor

9

Fuel injector

0

Catalytic converter

A

Crankshaft position

B

sensor
Coolant temperature

C

sensor

Spark plug

D

Cylinder identification

E

sensor
Pressure regulator

F

Battery

G

ECU

H

Atmospheric pressure

I

sensor

1 - 2

Fuel injection system

J

relay
Engine trouble warn-

K

ing light
Lean angle cut-off

L

switch
Air cut-off valve

M

GEN

FEATURES

FI SYSTEM

The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the

2

fuel pressure that is applied to the injector at only 284 kPa (2.84 kg/cm
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 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, 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.

Illustration is for reference only.

, 40.4 psi) higher than the

INFO

Fuel pump

1

Pressure regulator

2

Fuel injector

3

Throttle body

4

Intake temperature

5

sensor

Throttle position sensor

6

Intake air pressure

7

sensor
ECU

8

Atmospheric pressure

9

sensor

Coolant temperature

0

sensor
Cylinder identification

A

sensor
Crankshaft position

B

sensor

1 - 3

Fuel system

È

Air system

É

Control system

Ê

GEN

FEATURES

Fuel control block

The fuel control block consists of the following main components:

Component Function

Control block ECU Total FI system control

Throttle body Air volume control

Pressure regulator Fuel pressure detection

Sensor block Intake air pressure sensor Intake air pressure detection

Atmospheric pressure sensor Atmospheric pressure detection

Coolant temperature sensor Coolant temperature detection

Intake temperature sensor Intake temperature detection

Throttle position sensor Throttle angle detection

Cylinder identification sensor Reference position detection

Crankshaft position sensor Crankshaft position detection and engine

RPM detection

Speed sensor Speed detection

Actuator block Injector Fuel injection

Fuel pump Fuel feed

INFO

Air Induction system, air cut valve Induction of secondary air

An engine trouble warning light is provided on meter panel.

1 - 4

GEN

FEATURES

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 timing, and ignition timing, and then sends con­trol commands to the respective output interface circuits.

D. Output interface circuits

The output interface circuits convert the control signals output by the CPU into actuating sig­nals for the respective actuators in order to actuate them. They also output commands to the
indicator and relay output circuits as needed.

INFO

Hall sensor

signal

(for cylinder

identification)

Pickup coil signal

(for identifying the

crankshaft position)

Switches

Sensors

ECU

Input

interface circuit

Waveform

shaping circuit

Waveform

shaping circuit

Digital input circuit

A/D converter

input circuit

Battery

Power
supply

circuit

CPU

RAM/ROM

MEMORY

Output

interface circuit

Injector drive
output circuit

Ignition output circuit

Relay drive

output circuit

Injector

Ignition coil

Relay

Serial comunication

circuit

Meter unit

1 - 5

Communication
interface circuit

GEN

FEATURES

• Ignition control
The ignition control function of the ECU controls the ignition timing and the duration of ignition
energizing. The ignition timing control uses the signals from the throttle position sensor (to detect
the angle of the throttle), and the crankshaft position sensor and speed sensor (to detect the
speed of the engine). This control establishes an ignition timing that suits the operating condition
of the engine through compensations made to the basic ignition timing control map. The ignition
energizing duration control establishes the energizing duration to suit the operating conditions by
calculating the energizing duration in accordance with the signal received from the crankshaft
position sensor and the battery voltage.

• Fuel control
The fuel control function of the ECU controls the injection timing and injection duration. The injec­tion timing control controls the injection timing during the starting of the engine and the injection
timing during the normal operation of the engine, based on the signals received from the crank­shaft position sensor and the cylinder identification sensor. The injection duration control deter­mines the duration of injection based on the signals received from the atmospheric pressure
sensors, temperature sensors, and the position sensors, to which compensations are made to suit
various conditions such as the weather, atmospheric pressure, starting, acceleration, and deceler­ation.

• Load control
The ECU effects load control in the following manner:

1. Stopping the fuel pump and injectors when the motorcycle overturns

The ECU turns OFF the fuel injection system relay when the lean angle cut-off switch is oper­ated.

2. Operating the headlight illumination relay

The ECU controls the headlight relay 2 in accordance with the engine speed as required by the
daytime illumination specification.

3. Operating the radiator fan motor in accordance with the coolant temperature

The ECU controls the radiator fan motor relay ON/OFF in accordance with the coolant temper­ature.

4. Operating the AI system solenoid valve

The ECU controls the energizing of the solenoid valve in accordance with the driving condi­tions.

• Self-diagnosis function
The ECU is equipped with a self-diagnosis function to ensure that the engine control system is
operating normally. The ECU mode functions include a diagnosis mode in addition to the normal
mode.
Normal mode

• To check for any blown bulbs, this mode illuminates a engine trouble warning light while the

main switch is turned ON, and while the starter switch is being pressed.

• If the starting disable warning is activated, this mode alerts the rider by blinking the engine trou-

ble warning light while the start switch is being pressed.

• If a malfunction occurs in the system, this mode provides an appropriate substitute characteristic

operation, and alerts the rider of the malfunction by illuminating an engine trouble warning light.
After the engine is stopped, this mode displays a fault code on the clock LCD.

Diagnosis mode

• In this mode, a diagnostic code is input into the ECU through the operation of the operating

switch on the meter, and the ECU displays the values output by the sensors or actuates the
actuators in accordance with the diagnostic code. Whether the system is operating normally can
be checked by observing the illumination of the engine trouble warning light, the values dis­played on the meter, or the actuating state of the actuators.

INFO

1 - 6

GEN

FEATURES

Fuel pump

The fuel pump, which is mounted in the fuel tank, draws the fuel directly from the tank and pumps it
to the injector.
A filter that is provided in the fuel pump prevents any debris in the fuel tank from entering the fuel
system downstream of the pump.
The pump consists of a pump unit, electric motor, filter, and valves.
The pump unit is a Wesco type rotary pump that is connected to the motor shaft.
A relief valve is provided to prevent the fuel pressure from rising abnormally if the fuel hose
becomes clogged. This valve opens when the fuel pressure at the discharge outlet reaches
between 440 ~ 640 kPa (4.4 ~ 6.4 kg/cm

2

, 62.6 ~ 91.0 psi), and returns the fuel to the fuel tank.

INFO

Fuel filter

1

Fuel inlet strainer

2

Outlet

3

Fuel

È

1 - 7

GEN

FEATURES

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 changes in the operating
conditions in contrast to the constant volume of fuel supplied by the pump, the valve opening/clos­ing pressure also changes to regulate the return fuel volume. Thus, the difference between the fuel
pressure and the intake manifold pressure remains constant at a prescribed pressure.

INFO

Spring chamber

1

Spring

2

Diaphragm

3

Fuel inlet

4

Fuel return

5

Fuel chamber

6

Valve

7

Intake manifold vac-

8

uum pressure

1 - 8

Spring pressure

È

Fuel pressure

É

Vacuum pressure

Ê

GEN

FEATURES

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 dis­tance 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 ori­fice that enhances the atomization of fuel and improves combustion efficiency.

INFO

1
2
3

Fuel
Coil
Core

4
5
6

Plunger
Inject
Flange

1 - 9