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 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.

CAUTION: 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.

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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.

3Sub-section titles appear in smaller print than the section title.

4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.

5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step.

6Symbols indicate parts to be lubricated or replaced. Refer to “SYMBOLS”.

7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.

8Jobs requiring more information (such as special tools and technical data) are described sequentially.

6 2 1

3

4

8

5

7

1 2

GEN SPEC

INFO

3 4

CHK CHAS

ADJ

5 6

ENG COOL

7 8

FI	ELEC	–	+
9	0

TRBL

SHTG

A B

C D

T .

R .

E F G

H I J

E G M

K L M

B

LS

M

N O

New

LT

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SYMBOLS

The following symbols are not relevant to every vehicle.

Symbols 1 to 9 indicate the subject of each chapter.

1 General information

2Specifications

3Periodic checks and adjustments

4Chassis

5Engine

6Cooling system

7Fuel injection system

8Electrical system

9Troubleshooting

Symbols 0 to G indicate the following.

0 Serviceable with engine mounted A Filling fluid

BLubricant

CSpecial tool

DTightening torque

EWear limit, clearance

FEngine speed

GElectrical data

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

H Engine oil

I Gear oil

JMolybdenum-disulfide oil

KWheel-bearing grease

LLithium-soap-base grease

MMolybdenum-disulfide grease

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

NApply locking agent (LOCTITE®)

OReplace the part

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TABLE OF CONTENTS

GENERAL INFORMATION	GEN	1
	INFO

SPECIFICATIONS

SPEC 2

PERIODIC CHECKS AND	CHKADJ 3
ADJUSTMENTS

CHASSIS	4
CHAS

ENGINE

ENG 5

COOLING SYSTEM

COOL 6

	FUEL INJECTION SYSTEM
		FI				7
				–		+
	ELECTRICAL SYSTEM
		ELEC				8

TROUBLESHOOTING
	TRBL		9
	SHTG

CHAPTER 1

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION .................................................................	1-1
VEHICLE IDENTIFICATION NUMBER ....................................................	1-1
MODEL LABEL .........................................................................................	1-1
FEATURES .....................................................................................................	1-2
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 .......................................................................	1-23
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 ...............................................................	1-25
SPECIAL TOOLS .........................................................................................	1-26

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS ........................................................................	2-1
ENGINE SPECIFICATIONS ..........................................................................	2-2
CHASSIS SPECIFICATIONS .......................................................................	2-11
ELECTRICAL SPECIFICATIONS ................................................................	2-15

CONVERSION TABLE .................................................................................

2-17

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 ...........................................................	4-1
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 ................................................................	4-9
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 ......................................................................	4-16
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
FRONT FORK ...............................................................................................	4-45
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

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 .....................................................................................................	6-1
CHECKING THE RADIATOR ...................................................................	6-3
INSTALLING THE RADIATOR .................................................................	6-4
OIL COOLER ..................................................................................................	6-5
CHECKING THE OIL COOLER ................................................................	6-6
INSTALLING THE OIL COOLER ..............................................................	6-6
THERMOSTAT ...............................................................................................	6-7
CHECKING THE THERMOSTAT ...........................................................	6-10
ASSEMBLING THE THERMOSTAT ASSEMBLY ..................................	6-11
INSTALLING THE THERMOSTAT ASSEMBLY ....................................	6-11
WATER PUMP ..............................................................................................	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 ..................................................	7-3
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 ....................................................................................	7-29
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

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

GEN

MOTORCYCLE IDENTIFICATION INFO

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.

1

1 - 1

FEATURES

FEATURES

OUTLINE OF FI SYSTEM

GEN INFO

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.

1 Ignition coil	8 Intake air pressure	D Spark plug	J Fuel injection system
2 Air filter case	sensor	E Cylinder identification	relay
3 Intake temperature	9 Throttle position sensor	sensor	K Engine trouble warn-
sensor	0 Fuel injector	F Pressure regulator	ing light
4 Fuel delivery hose	A Catalytic converter	G Battery	L Lean angle cut-off
5 Fuel tank	B Crankshaft position	H ECU	switch
6 Fuel pump	sensor	I Atmospheric pressure	M Air cut-off valve
7 Fuel return hose	C Coolant temperature	sensor
	sensor

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FEATURES

FI SYSTEM

GEN INFO

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 (2.84 kg/cm2, 40.4 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 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.

1 Fuel pump	6 Throttle position sensor	0 Coolant temperature	È Fuel system
2 Pressure regulator	7 Intake air pressure	sensor	É Air system
3 Fuel injector	sensor	A Cylinder identification	Ê Control system
4 Throttle body	8 ECU	sensor
5 Intake temperature	9 Atmospheric pressure	B Crankshaft position
sensor	sensor	sensor

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FEATURES

Fuel control block

The fuel control block consists of the following main components:

GEN INFO

	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
	Air Induction system, air cut valve	Induction of secondary air

An engine trouble warning light is provided on meter panel.

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FEATURES

COMPONENTS

ECU (Electronic Control Unit)

GEN INFO

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.

		ECU	Battery
			Power
		Input	supply	Output
			circuit
		interface circuit		interface circuit
	Hall sensor	Waveform	CPU	Injector drive	Injector
		shaping circuit		output circuit
	signal
	(for cylinder
	identification)
	Pickup coil signal	Waveform		Ignition output circuit	Ignition coil
		shaping circuit
	(for identifying the
	crankshaft position)
	Switches	Digital input circuit
			RAM/ROM
		A/D converter	MEMORY	Relay drive
	Sensors				Relay
		input circuit		output circuit
			Serial comunication	Communication
			circuit	interface circuit

Meter unit

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GEN

FEATURES INFO

•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 trouble 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.

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FEATURES

Fuel pump

GEN INFO

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/cm2, 62.6 ~ 91.0 psi), and returns the fuel to the fuel tank.

1 Fuel filter

2 Fuel inlet strainer

3 Outlet

È Fuel

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FEATURES

Pressure regulator

GEN INFO

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.

1 Spring chamber	4 Fuel inlet	7 Valve	È Spring pressure
2 Spring	5 Fuel return	8 Intake manifold vac-	É Fuel pressure
3 Diaphragm	6 Fuel chamber	uum pressure	Ê Vacuum pressure

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FEATURES

Fuel injector

GEN INFO

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.

1 Fuel	4 Plunger
2 Coil	5 Inject
3 Core	6 Flange

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