YAMAHA YZF-R1LEVC, YZF-R1LEV, YZF-R1V, YZF-R1VC SERVICE MANUALS SUPPLEMENTARY
YZF-R1V
YZF-R1VC
YZF-R1LEV
YZF-R1LEVC
SUPPLEMENTARY
SERVICE MANUAL
LIT-11616-19-75
5VY-28197-11
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
YZF-R1V/YZF-R1VC/YZF-R1LEV / YZF-R1LEVC. For complete service information procedures it is
necessary to use this Supplementary Service Manual together with the following manual.
YZF-R1S/YZF-R1SC SERVICE MANUAL: LIT-11616-17-55 (5VY-28197-10)
EAS00001
YZF-R1V/YZF-R1VC
YZF-R1LEV/YZF-R1LEVC
SUPPLEMENTARY
SERVICE MANUAL
©2005 by Yamaha Motor
Corporation, U.S.A.
First edition, October 2005
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.
LIT-11616-19-75
EAS00030
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
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 deal
ers 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.
-
EAS00040
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or death
to the vehicle operator, a bystander or a person checking or repairing the
vehicle.
A CAUTION indicates special precautions that must be taken to avoid damage to the vehicle.
A NOTE provides key information to make procedures easier or clearer.
EAS00007
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are
laid out with the individual steps in sequential order.
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”.
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.
Sub-section titles appear in smaller print than the section title.
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
Jobs requiring more information (such as special tools and technical data) are described
sequentially.
EAS00008
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols to indicate the subject of each
chapter.
General information
Specifications
Periodic checks and adjustments
Chassis
Engine
Cooling system
Fuel injection system
Electrical system
Troubleshooting
Symbols to indicate the following.
Serviceable with engine mounted
Filling fluid
Lubricant
Special tool
Tightening torque
Wear limit, clearance
Engine speed
Electrical data
Symbols to in the exploded diagrams
indicate the types of lubricants and lubrication
points.
Engine oil
Gear oil
Molybdenum-disulfide oil
Wheel-bearing grease
Lithium-soap-based grease
Molybdenum-disulfide grease
Symbols to in the exploded diagrams
indicate the following.
Apply locking agent (LOCTITE®)
Replace the part with a new one.
CONTENTS
GENERAL INFORMATION
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHASSIS SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . 7
CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . 8
LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . 9
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
GENERAL MAINTENANCE AND LUBRICATION CHART . . . . . . . . 27
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ADJUSTING THE FRONT FORK LEGS. . . . . . . . . . . . . . . . . . . . . 29
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . 32
CHASSIS
FRONT WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . 35
REAR WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REAR BRAKE DISC AND REAR WHEEL SPROCKET . . . . . . . . . 36
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DISASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . 40
CHECKING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . 42
ASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . 43
REAR SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 47
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . 49
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . 50
SWINGARM AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
REMOVING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
CHECKING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
CHECKING THE CONNECTING ROD ASSEMBLY . . . . . . . . . . . 53
CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
ENGINE
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
REMOVING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
CHECKING THE FRICTION PLATES . . . . . . . . . . . . . . . . . . . . . . 67
CHECKING THE CLUTCH PLATES. . . . . . . . . . . . . . . . . . . . . . . . 68
CHECKING THE CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . 69
CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . 69
CHECKING THE PRESSUR PLATE 2 . . . . . . . . . . . . . . . . . . . . . . 70
CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . 70
CHECKING THE PRESSURE PLATE 1 . . . . . . . . . . . . . . . . . . . . . 70
CHECKING THE PULL LEVER SHAFT AND PULL ROD . . . . . . . 71
INSTALLING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
YZF-R1V/YZF-R1VC / YZF-R1LEV / YZF-R1LEVC 2006 WIRING DIAGRAM
GEN
SPECIAL TOOLS
EAS00027
INFO
GENERAL INFORMATION
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the
country.
When placing an order, refer to the list provided below to avoid any mistakes.
NOTE:
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part number starting with “90890-”.
(YZF-R1LE)
Tool No. Tool name/Function Illustration
Front fork cap bolt wrench
90890-01472
This tool is used to loosen or tighten the front
fork cap bolt.
Damper rod holder
90890-01504
Rod puller
90890-01437
YM-A8703
Rod puller
attachment
90890-01435
YM-A8703
This tool is used to loosening or tightening
the damper rod assembly.
Rod puller
Rod puller attachment
These tools are used to pull up the front fork
damper rod.
1
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Model code YZF-R1
5VYH (USA), 5VYL (USA) •
5VYJ (CAL), 5VYM (CAL)
YZF-R1LE
4B14 (USA), 4B15 (CAL) •
Dimensions
Overall length 2,085 mm (82.1 in) •
Wheelbase 1,415 mm (55.7 in) •
Weight
Wet (with oil and a full fuel tank) 194 kg (428 lb) (USA) (YZF-R1) •
195 kg (430 lb) (CAL) (YZF-R1) •
195 kg (430 lb) (USA) (YZF-R1LE) •
195 kg (430 lb) (CAL) (YZF-R1LE) •
Maximum load (except vehicle) 201 kg (443 lb) (USA) (YZF-R1) •
200 kg (441 lb) (CAL) (YZF-R1) •
200 kg (441 lb) (USA) (YZF-R1LE) •
200 kg (441 lb) (CAL) (YZF-R1LE) •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
2
ENGINE SPECIFICATIONS
SPEC
ENGINE SPECIFICATIONS
Item Standard Limit
Oil pump
Oil-pump-housing-to-inner-and-outerrotor clearance
Cylinder head
Volume 12.3 ~ 12.9 cm
Max. warpage •
Piston
Diameter D 76.975 ~ 76.990 mm (3.0305 ~ 3.0311 in) •
0.06 ~ 0.13 mm
(0.0024 ~ 0.0051 in)
3
(0.75 ~ 0.79 cu.in) • • •
• • 0.10 mm
0.20 mm
(0.0079 in)
(0.0039 in)
• •
Height H 12 mm (0.47 in) •
• •
Clutch
Friction plates
Color code Red •
• •
Thickness 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 2.8 mm
(0.110 in)
Plate quantity 7 •
Color code Red •
• •
• •
Thickness 2.9 ~ 3.1 mm (0.114~ 0.122 in) 2.8 mm
(0.110 in)
Plate quantity 1 •
Color code Red •
• •
• •
Thickness 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 2.8 mm
(0.110 in)
Plate quantity 1 •
• •
Clutch plates
Thickness 1.9 ~ 2.1 mm (0.07 ~ 0.08 in) •
Plate quantity 8 •
Max. warpage •
• • 0.1 mm
• •
• •
(0.0039 in)
Clutch springs
Free length 43.8 mm (1.72 in) (YZF-R1LE) 41.6 mm
(1.64 in)
Throttle bodies
ID mark 5VY1 30 (USA), 5VY1 40 (CAL) •
• •
3
CHASSIS SPECIFICATIONS
SPEC
CHASSIS SPECIFICATIONS
Item Standard Limit
Front wheel
Wheel type Forged wheel (YZF-R1LE) •
Rear wheel
Wheel type Forged wheel (YZF-R1LE) •
Front tire
Model (manufacturer) Pilot POWER (MICHELIN) (YZF-R1) •
D218FG (DUNLOP) (YZF-R1) •
DIABLO CORSA H (PIRELLI) (YZF-R1LE) •
Tire pressure (cold)
90 ~ 201 kg (198 ~ 443 lb) 250 kPa (2.5 kgf/cm
(USA) (YZF-R1)
~ 200 kg (198 ~ 441 lb) 250 kPa (2.5 kgf/cm
90
(CAL) (YZF-R1)
90 ~ 200 kg (198 ~ 441 lb) 250 kPa (2.5 kgf/cm
(USA) (YZF-R1LE)
90 ~ 200 kg (198 ~ 441 lb) 250 kPa (2.5 kgf/cm
(CAL) (YZF-R1LE)
Rear tire
Model (manufacturer) Pilot POWER/ Pilot POWER G
(MICHELIN) (YZF-R1)
D218G (DUNLOP) (YZF-R1) •
DIABLO CORSA (PIRELLI) (YZF-R1LE) •
Tire pressure (cold)
90 ~ 201 kg (198 ~ 443 lb) 290 kPa (2.9 kgf/cm
(USA) (YZF-R1)
90
~ 200 kg (198 ~ 441 lb) 290 kPa (2.9 kgf/cm
(CAL) (YZF-R1)
90
~ 200 kg (198 ~ 441 lb) 290 kPa (2.9 kgf/cm
(USA) (YZF-R1LE)
~ 200 kg (198 ~ 441 lb) 290 kPa (2.9 kgf/cm
90
(CAL) (YZF-R1LE)
2
, 2.5 bar, 35.6 psi)
2
, 2.5 bar, 35.6 psi)
2
, 2.5 bar, 35.6 psi)
2
, 2.5 bar, 35.6 psi)
2
, 2.9 bar, 41.3 psi)
2
, 2.9 bar, 41.3 psi)
2
, 2.9 bar, 41.3 psi)
2
, 2.9 bar, 41.3 psi)
• •
• •
• •
• •
• •
• • •
• • •
• • •
• • •
•
• •
• •
• •
• • •
• • •
• • •
• • •
4
CHASSIS SPECIFICATIONS
SPEC
Item Standard Limit
Front brakes
Master cylinder inside diameter 16 mm (0.63 in) •
Caliper cylinder inside diameter 30.2 mm and 27 mm (1.19 in and 1.06 in) •
• •
• •
Front suspension
(YZF-R1)
Fork oil
Quantity (each front fork leg) 0.52 L (0.46 Imp qt, 0.55 US qt) •
Level (from the top of the outer tube,
90 mm (3.54 in) •
• •
• •
with the outer tube fully compressed,
and without the fork spring)
Spring preload adjusting positions
Minimum 8 •
Standard 4.5 •
Maximum 0 •
• •
• •
• •
(YZF-R1LE)
Spring
Free length 260 mm (10.24 in) 254.8 mm
(10.03 in)
Coller length 42 mm (1.653 in) •
Installed length 248.0 mm (9.76 in) •
Spring rate (K1) 9.50 N/mm (0.97 kg/mm, 54.22 lb/ in) •
• •
• •
• •
Fork oil
Recommended oil Suspension oil “Ohlins R&T 43”
•
• •
(ACC-RT43F-00-00)
Quantity (each front fork leg) 0.43 L (0.38 Imp qt, 0.45 US qt) •
Level (from the top of the outer tube,
145 mm (5.71 in) •
• •
• •
with the outer tube fully compressed,
and without the fork spring)
Spring preload adjusting positions
Minimum* 11 turns out* •
Maximum* 2 turns in* •
• •
• •
*from the standard position
Rebound damping adjusting positions
Minimum** 17 •
Standard** 12 •
Maximum** 1 •
• •
• •
• •
Compression damping adjusting
positions
Minimum** 20 •
Standard** 12 •
Maximum** 1 •
• •
• •
• •
**from the fully turned-in direction
5
CHASSIS SPECIFICATIONS
SPEC
Item Standard Limit
Rear suspension
(YZF-R1)
Spring preload adjusting positions
Minimum 1 •
Standard 5 •
Maximum 9 •
• •
• •
• •
(YZF-R1LE)
Spring
Free length 150.0 mm (5.91 in) •
Installed length 139.0 mm (5.47 in) •
Spring rate (K1) 95.0 N/mm (9.68 kg/ mm, 542.18 lb / in) •
• •
• •
• •
Spring preload adjusting positions
Minimum* 0 •
Standard* 6 •
Maximum* 20 •
• •
• •
• •
Rebound damping adjusting positions
Minimum* 18 •
Standard* 14 •
Maximum* 1 •
• •
• •
• •
Compression damping adjusting
positions (fast compression damping)
Minimum* 42 •
Standard* 30 •
Maximum* 1 •
• •
• •
• •
Compression damping adjusting
positions (slow compression damping)
Minimum* 17 •
Standard* 10 •
Maximum* 1 •
• •
• •
• •
*from the fully turned-in position
Drive chain
Model (manufacturer) 50VA8 (DAIDO) •
Link quantity 118 •
Drive chain slack 20 ~ 25 mm (0.79 ~ 0.98 in) •
• •
• •
• •
Maximum 15-link section ••• 239.3 mm
(9.42 in)
6
ELECTRICAL SPECIFICAT IONS / TIGHTENING TORQUES
SPEC
ELECTRICAL SPECIFICATIONS
Item Standard Limit
Ignition system
T.C.I. unit model (manufacturer) F8T82075 (MITSUBISHI) • • •
Battery
Manufacturer GS-YUASA • • •
Ten hour rate amperage 0.9 A • • •
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Item Fastener
Exhaust pipe and exhaust valve pipe
assembly
EXUP servo motor Bolt M6 2 6 0.6 4.3
Crankcase Bolt M6 10 10 1.0 7.2
Drive sprocket cover Bolt M6 2 12 1.2 8.7
Drive sprocket cover Bolt M6 1 12 1.2 8.7
Plate Bolt M6 2 12 1.2 8.7
Bolt M6 5 12 1.2 8.7
Thread
size
Q’ty
Tightening torque
Nm m•kg ft•lb
Remarks
7
CHASSIS TIGHTENING TORQUES
TIGHTENING TORQUES
SPEC
Item
Horn bracket and under bracket M6 7 0.7 5.1
Connecting rod assembly (YZF-R1LE) M6 8 0.8 5.8
Side cover and fuel tank M5 4 0.4 2.9
Front fork and stay (YZF-R1LE) M5 6 0.6 4.3
Front fork and bracket (YZF-R1LE) M5 6 0.6 4.3
Rear brake master cylinder and foot rest bracket M6 13 1.3 9.4
Front brake disc and front wheel (YZF-R1LE) M6 23 2.3 17
Front wheel axle pinch bolt (YZF-R1LE) M8 26 2.6 19 See NOTE
Cap bolt (YZF-R1LE) – 20 2.0 14
Cap bolt and lock nut (YZF-R1LE) M12 25 2.5 18
Damper rod assembly (YZF-R1LE) – 48 4.8 35
Thread
size
NOTE:NOTE:
1. Insert the front wheel axle from the right
side and tighten it with the flange bolt from
the left side to 91 Nm (9.1 m•kg, 65.8 ft•lb).
2. In the order from the pinch bolt → pinch
bolt → pinch bolt , tighten each bolt to
26 Nm (2.6 m•kg, 19 ft•lb) without perform-
ing temporary tightening.
3. Check that the end face of the axle head
and the end face of the fork side are flushmounted. If they are out of alignment, make
sure to fit them by adding the external force
by hand or with a plastic hammer, etc.
If the end face of the axle is not parallel to
the end face of the fork, align them so that
one point of the axle circumference is positioned on the end face of the fork.
At this stage, it can be accepted if the end
face of the axle becomes partially concave
to the end face of the fork.
4. In the order from the pinch bolt → pinch
bolt → pinch bolt , tighten each bolt to
26 Nm (2.6 m•kg, 19 ft•lb) without perform-
ing temporary tightening.
Tightening
Remarks
Nm m•kg ft•lb
8
LUBRICATION POINTS AND LUBRICANT TYPES
EAS00031
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication point Lubricant
Valve lifter surfaces (intake and exhaust)
Valve stem ends (intake and exhaust)
EAS00032
CHASSIS
Lubrication point Lubricant
Pivot shaft
SPEC
9
LUBRICATION DIAGRAMS
Main axle
Oil delivery pipe
Drive axle
LUBRICATION DIAGRAMS
SPEC
10
EAS00035
CABLE ROUTING
Ground lead
Meter lead
Stay 1
Auxiliary light lead (right)
Headlight lead
Auxiliary light lead (left)
Console panel 1
Duct 1
Console panel 2
Duct 2
Headlight lead (right)
Headlight lead (left)
CABLE ROUTING
Insert to the rib of the head
light. (Either location of the right
and left relays is acceptable.)
The lead should not stretch too
much.
Direction of the ground terminal
can be either top side or flip
side.
Make sure to insert the coupler
and boot to the stay 1 hole.
The speedometer lead should
not be strained.
To the stay 1 hole
SPEC
Connect after passing over the
upper side of the duct.
Clamp the head light lead by
wrapping and insert it to the
intake air grill hole. (only at the
right side.)
Do not connect the wire to the
coupler with the plug for
options.
To the turn signal light
To the wire harness
Cut the tip of the clamp.
Clamp the headlight lead to the
positioning white tape section.
11
There should be no slack when
clamping. Point the tip of the
clamp (excessive part) to the
front side of the vehicle. Fasten
the head light lead with a clamp.
Feed a lead wire through the U
shape cutout of the console
panel.
CABLE ROUTING
SPEC
12
CABLE ROUTING
SPEC
Right handlebar switch lead
Clutch cable
Main switch lead
Left handlebar switch lead
Horn lead
Horn
Throttle cables
Brake hose
Throttle cable (return side)
Throttle cable (pull side)
Route the clutch cable so as to
get along the front side of the
main switch after passing it
through the guide.
Pass the main switch lead
through the guide wire.
Pass the left handlebar switch
lead through the guide wire.
Point the tip of the band (excessive part) to the left side of the
vehicle and cut the surplus sec
tion.
Clamp the section between 0
and 20 mm (0 and 0.79 in) from
the split of the under bracket.
-
Clamp the leads inside the front
fork of the vehicle. Point the exit
of the horn lead to the left front
fork side.
Route two throttle cables behind
the brake hose, pass between
the inside of the under bracket’s
upper side front fork and guide
wire assembly, and then pass it
through the clamp that is
inserted to the cover 3 under
the frame.
13
Contact the wire guide to the
top face of the under bracket
boss. The throttle cable should
not be caught between the wire
guide and under bracket. The
throttle cable (pull side) should
be positioned above the vehicle
wen the wire guide is installed.
Clamp should be positioned at
the protector lower end of the
brake hose and wrapped on the
protector.
Cut the tip leaving 2 to 4mm
0.08 ~ 0.16 in).
CABLE ROUTING
SPEC
14
CABLE ROUTING
SPEC
Wire harness
Crankshaft position sensor lead
Heat protector
Right handlebar switch lead
Positioning guide
Rear brake light switch lead
Coolant reservoir tank
Speed sensor lead
Clutch cable
Radiator
Oil cooler outlet hose
Coolant reservoir tank drain
hose
Breather pipe
Fuel tank drain hose
A.C. magneto lead
Wire harness
Throttle body lead
Clamp it after passing between
the frame and radiator stay.
Point the tip of the clamp
(excessive part) to the front side
of the vehicle. Fasten the right
handlebar switch lead with a
clamp.
To the wire harness
The clutch cable positioning
guide should be above the
upper end of the clamp. Fasten
the clutch cable with a clamp.
(Refer to
Position relation between the
clamp and guide.
)
Clamp the clamp upper end
along the line of lower end of
the hose clamp assembly. Point
the tip of the clamp (excessive
part) to the front side of the
vehicle. Clutch cable is what the
clamp fastens.
The clutch cable doesn’t project
outside the water hose and the
cylinder head in the box part in
the figure.
To the engine
Clamp behind the bracket 3.
Cut the tip of the clamp.
for CAL
15
CABLE ROUTING
SPEC
The coupler for the air induction
solenoid lead and camshaft
sensor lead should be con
nected above the ignition coil
sub wire harness and it should
not drop on the cylinder head
cover behind the ignition coil.
Pass the right handlebar switch
lead between the frame and
heat protector.
Coolant reservoir tank drain
hose should cross with the
speed sensor lead under the
swingarm bracket. Route the
coolant reservoir tank drain
hose over the up side of the
vehicle.
-
Pass the rear brake light switch
lead between the swingarm
bracket and coolant reservoir
tank.
Release the tip of the clamp and
install it to the clutch cable.
Insert the clamp to the hole
located on the right back side of
the radiator.
Radiator fan motor lead should
not be caught while inserting
the clamp.
Push the clamp until it hits the
radiator side stay. Radiator fan
motor lead should not be
caught.
Clamp the clutch cable so that it
is within this specified clamp.
To the air filter
Route the fuel tank drain hose
over the canister stay and
between the breather hose 2
and wire harness. On the front
side of the canister stay, let
though the bottom of the
A.C.magneto lead and the wire
harness.
Route by the upside of vehicle
away from the canister stay.
for CAL
16
CABLE ROUTING
SPEC
Heat protector
Main switch lead
Left handlebar switch lead
EXUP servo motor lead
Coolant reservoir tank drain hose
Fuel tank drain hose
Coolant outlet pipe
Sidestand switch lead
Oil level switch lead
A.C.magneto lead
Fuse box stay
Water hose
Stay 1
Chain case cover
Clamp the leads so that they
are positioned inner of the vehicle than the washer position
after routing them between the
frame and radiator stay. Align
the clamp position with the tap
ing sections of leads. Point the
tip of the clamp (excessive part)
to the down front side of the
vehicle. What the clamp fas
tens at this stage are the handlebar switch and main switch
leads.
Pass the main switch lead and
left handlebar switch lead
between the frame and the heat
protector.
-
-
To the coolant reservoir tank
Fold back the clamp and secure
it after passing the lead through
the clamp.
To the EXUP servo motor
Pass the coolant reservoir tank
drain hose and fuel tank drain
hose through the clamp from
the outer side of the water pump
inlet pipe after routing it behind
the water pump breather hose.
The lengths of two hose ends
are allowed to be random. Any
direction of cut edges can be
accepted. (Only for the fuel tank
drain hose)
17
CABLE ROUTING
SPEC
Clamp the fuel tank drain hose
and fuel tank breather hose.
Route the lead by the inside of
the water hose and water pipe.
Route the lead by the inside of
the water hose and water pipe.
There should be no exposure of
bared conductors due to the
displacement of the tube.
Route by the outside of vehicle
away from the water hose.
Point the tip of the clamp
(excessive part) to the down
rear side of the vehicle. Fasten
the wire harness with a clamp.
The outside of the vehicle.
Inner most section of the vehicle.
Can be routed in any order.
Route the water hose so that it is
placed at the outermost position
finally after routing other leads
and hoses in the guide.
Route the coolant reservoir tank
drain hose so that it is routed at
the innermost position to each
hose and lead.
Arrange so as not for each hose
to cross in the part between
“BB” from the section “AA”
which is in the illustration.
Align the molded part of the fuel
tank drain hose with the stay 1.
Routing of the fuel tank drain
hose.
EXUP servo motor, oil level
switch and sidestand switch
leads are omitted in this drawing.
18
CABLE ROUTING
SPEC
Heat protector
Crankshaft position sensor lead
Neutral switch lead
Ground lead
Coolant reservoir tank
Battery positive lead
Starter relay
Turn signal relay
Main fuse
Lean angle sensor
Atmospheric pressure sensor
Tail /brake light lead
Rear fender
Seat lock cable
Anti safety alarm coupler
Starting circuit cut-off relay
Battery negative lead
Starter motor lead
A.C.magneto lead
Oil level switch lead
Sidestand switch lead
Throttle body lead
Coolant reservoir tank drain hose
Fuel tank drain hose
Cover 7
Radiator fan motor lead (left)
Radiator fan motor lead (right)
Wire harness
Pipe 3
Frame
Coolant reservoir tank hose
Thermo stat assembly breather
hose
Throttle body side cap
Mud guard
Turn signal light lead
License plate light lead
Rear fender rib
Speed sensor lead
Rear brake light switch lead
Rear frame
Swingarm bracket
Main fuse lead
Starting circuit cut-off relay lead
Turn signal light relay lead
Starter relay lead
Main fuse lead (To the battery
positive lead)
Right handlebar switch lead
19
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