YAMAHA YZF-R1S 2004 User Guide

REAR SHOCK ABSORBER ASSEMBLY4-65 . . . . . . . . . . . . . . . . . . . . . . . .
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 CHAIN4-69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE SWINGARM 4-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE DRIVE CHAIN 4-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SWINGARM 4-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE DRIVE CHAIN 4-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE SWINGARM 4-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 5
ENGINE
ENGINE5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SPROCKET 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST PIPE 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEADS AND HOSES 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE ENGINE 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT5-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD COVER 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFTS 5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CAMSHAFTS 5-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CAMSHAFTS 5-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,
AND TIMING CHAIN GUIDES 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TIMING CHAIN TENSIONER 5-17. . . . . . . . . . . . . . . .
INSTALLING THE CAMSHAFTS 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD5-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CYLINDER HEAD 5-23. . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CYLINDER HEAD 5-23. . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CYLINDER HEAD 5-24. . . . . . . . . . . . . . . . . . . . . . . . .
VALVES AND VALVE SPRINGS5-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE VALVES 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE VALVES AND VALVE GUIDES 5-28. . . . . . . . . . . . . . .
CHECKING THE VALVE SEATS 5-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE VALVE SPRINGS 5-31. . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE VALVE LIFTERS 5-32. . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE VALVES 5-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ProCarManuals.com

STARTER CLUTCH AND GENERATOR5-35 . . . . . . . . . . . . . . . . . . . . . . . . .
STATOR COIL ASSEMBLY 5-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER CLUTCH 5-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE GENERATOR 5-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE STARTER CLUTCH 5-39. . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE DAMPER 5-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STARTER CLUTCH 5-40. . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE STARTER CLUTCH 5-41. . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE GENERATOR 5-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT POSITION SENSOR5-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CRANKSHAFT POSITION SENSOR 5-44. . . . . . . . .
INSTALLING THE CRANKSHAFT POSITION SENSOR 5-44. . . . . . . .
CLUTCH5-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH COVER 5-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PULL LEVER SHAFT 5-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH 5-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CLUTCH 5-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRICTION PLATES 5-52. . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH PLATES 5-52. . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH SPRINGS 5-53. . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH HOUSING 5-53. . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH BOSS 5-53. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PRESSURE PLATE 5-54. . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PULL LEVER SHAFT AND PULL ROD 5-54. . . . . . .
INSTALLING THE CLUTCH 5-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT SHAFT5-58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT SHAFT AND STOPPER LEVER 5-58. . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE SHIFT SHAFT 5-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT SHAFT 5-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STOPPER LEVER 5-61. . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE SHIFT SHAFT 5-61. . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PAN AND OIL PUMP5-63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE OIL PAN 5-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SPROCKET AND CHAIN 5-66. . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL PUMP 5-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE RELIEF VALVE 5-67. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL DELIVERY PIPE AND OIL PIPE 5-68. . . . . . . . .
CHECKING THE OIL STRAINER 5-68. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL NOZZLES 5-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE OIL PUMP 5-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE OIL / WATER PUMP ASSEMBLY 5-69. . . . . . . . . . . .
INSTALLING THE OIL PAN 5-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ProCarManuals.com

CRANKCASE5-72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE CRANKCASE 5-74. . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKCASE 5-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BEARINGS AND OIL SEALS 5-75. . . . . . . . . . . . . . . .
ASSEMBLING THE CRANKCASE 5-75. . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING RODS AND PISTONS5-77 . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CONNECTING RODS AND PISTONS 5-78. . . . . . . .
REMOVING THE CRANKSHAFT ASSEMBLY 5-79. . . . . . . . . . . . . . . . .
CHECKING THE CYLINDER AND PISTON 5-79. . . . . . . . . . . . . . . . . . .
CHECKING THE PISTON RINGS 5-80. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PISTON PINS 5-81. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BIG END BEARINGS 5-82. . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CONNECTING ROD AND PISTON 5-86. . . . . . . . . .
CRANKSHAFT5-92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKSHAFT 5-93. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKSHAFT DRIVE SPROCKET 5-93. . . . . . . . . .
CHECKING THE CRANKSHAFT JOURNAL BEARINGS 5-93. . . . . . . .
INSTALLING THE CRANKSHAFT 5-96. . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION5-97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION, SHIFT DRUM ASSEMBLY AND
SHIFT FORKS 5-97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE TRANSMISSION 5-103. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT FORKS 5-103. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT DRUM ASSEMBLY 5-104. . . . . . . . . . . . . . . . . . .
CHECKING THE TRANSMISSION 5-104. . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE TRANSMISSION 5-105. . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 6
COOLING SYSTEM
RADIATOR6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE RADIATOR 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE RADIATOR 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL COOLER6-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL COOLER 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE OIL COOLER 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTAT6-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE THERMOSTAT 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE THERMOSTAT ASSEMBLY 6-11. . . . . . . . . . . . . . .
INSTALLING THE THERMOSTAT ASSEMBLY 6-11. . . . . . . . . . . . . . . .
WATER PUMP6-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPELLER SHAFT 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE WATER PUMP 6-14. . . . . . . . . . . . . . . . . . . . . . .
ProCarManuals.com

CHECKING THE WATER PUMP 6-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE WATER PUMP 6-15. . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 7
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ECU’S SELF-DIAGNOSTIC FUNCTION 7-4. . . . . . . . . . . . . . . . . . . . . .
SUBSTITUTE CHARACTERISTICS OPERATION CONTROL
(FAIL-SAFE ACTION) 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAIL-SAFE ACTIONS TABLE 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING CHART 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC MODE 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING DETAILS 7-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THROTTLE BODIES7-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INJECTORS 7-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE INJECTORS 7-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE THROTTLE BODIES 7-39. . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE THROTTLE BODY JOINTS 7-39. . . . . . . . . . . . . . . . . .
CHECKING THE PRESSURE REGULATOR 7-40. . . . . . . . . . . . . . . . . .
CHECKING THE FUEL PUMP AND PRESSURE REGULATOR
OPERATION 7-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR 7-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE SUB-THROTTLE POSITION
SENSOR 7-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE THERMO WAX 7-45. . . . . . . . . . . .
AIR INDUCTION SYSTEM7-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INJECTION 7-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CUT-OFF VALVE 7-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION SYSTEM DIAGRAMS 7-47. . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE AIR INDUCTION SYSTEM 7-48. . . . . . . . . . . . . . . . . .
CHAPTER 8
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING SWITCH CONTINUITY8-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SWITCHES8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BULBS AND BULB SOCKETS8-5 . . . . . . . . . . . . . . . . .
TYPES OF BULBS 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CONDITION OF THE BULBS 8-5. . . . . . . . . . . . . . . .
ProCarManuals.com

CHECKING THE CONDITION OF THE BULB SOCKETS 8-6. . . . . . .
CHECKING THE LEDs 8-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION SYSTEM8-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 8-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRIC STARTING SYSTEM8-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 8-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION 8-15. . . . . . . . .
TROUBLESHOOTING 8-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER MOTOR8-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STARTER MOTOR 8-21. . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE STARTER MOTOR 8-22. . . . . . . . . . . . . . . . . . . . . .
CHARGING SYSTEM8-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 8-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 8-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTING SYSTEM8-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 8-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 8-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE LIGHTING SYSTEM 8-31. . . . . . . . . . . . . . . . . . . . . . . .
SIGNALING SYSTEM8-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 8-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 8-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SIGNALING SYSTEM 8-36. . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM8-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 8-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 8-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP SYSTEM8-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 8-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP SYSTEM 8-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 8-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL PUMP 8-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SELF-DIAGNOSIS8-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 8-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 9
TROUBLESHOOTING
STARTING FAILURES9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ProCarManuals.com

ELECTRICAL SYSTEMS 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INCORRECT ENGINE IDLING SPEED9-2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE9-2 . . . . . . . . . . . . .
ENGINE 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY GEAR SHIFTING9-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFTING IS DIFFICULT 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT PEDAL DOES NOT MOVE 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
JUMPS OUT OF GEAR 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY CLUTCH9-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH SLIPS 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH DRAGS 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHEATING9-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERCOOLING9-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POOR BRAKING PERFORMANCE9-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY FRONT FORK LEGS9-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEAKING OIL 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MALFUNCTION 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNSTABLE HANDLING9-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY LIGHTING OR SIGNALING SYSTEM9-6 . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ProCarManuals.com

1-1
MOTORCYCLE IDENTIFICATION
GEN
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.
ProCarManuals.com

1-2
1
1 Clock
2 Speedometer
3 “SELECT” button
4 “RESET” button
5 Tachometer
6 Coolant temperature display / air intake
temperature display
7 Odometer / tripmeters / fuel reserve tripme-
ter / stopwatch
8 Shift timing indicator light
1 Clock
2 Speedometer
FEATURES
GEN
INFO
NOTE:
EAS00019
FEATURES
INSTRUMENT FUNCTIONS
Multi-function display
The multi-function meter unit is equipped with
the following:

a speedometer (which shows the riding
speed)

a tachometer (witch shows engine speed)

an odometer (which shows the total distance
traveled)

two tripmeters (which show the distance
traveled since they were last set to zero)

a fuel reserve tripmeter (which shows the
distance traveled since the fuel level warning
light came on)

a stopwatch

a clock

a coolant temperature display

an air intake temperature display

a self-diagnosis device

a display brightness and shift timing indicator
light control mode

Be sure to turn the key to “ON” before using the “SELECT” and “RESET” buttons.
Clock mode
Turn the key to “ON”.
To set the clock
1. Push the “SELECT” button and “RESET”
button together for at least two seconds.
2. When the hour digits start flashing, push the
“RESET” button to set the hours.
3. Push the “SELECT” button, and the minute
digits will start flashing.
4. Push the “RESET” button to set the minutes.
5. Push the “SELECT” button and then release
it to start the clock.
ProCarManuals.com

1-3
FEATURES
GEN
INFO
1 Coolant temperature display / air intake
temperature display
2 Odometer / tripmeters / fuel reserve tripme-
ter / stopwatch
3 Shift timing indicator light
NOTE:
NOTE:Odometer, tripmeter, and stopwatch modes
Push the “SELECT” button to switch the display
between the odometer mode “ODO”, the trip-
meter modes “TRIP A” and “TRIP B” and the
stopwatch mode in the following order:
TRIP A
TRIP B
ODO
Stopwatch

TRIP A
If the fuel level warning light comes on, the
odometer display will automatically change to
the fuel reserve tripmeter mode ”F-TRIP” and
start counting the distance traveled from that
point. In that case, push the ”SELECT” button to
switch the display between the various tripme-
ter, odometer, and stopwatch modes in the fol-
lowing order:
F-TRIP
Stopwatch
TRIP A
TRIP B

ODO
F-TRIP
To reset a tripmeter, select it by pushing the “SE-
LECT” button, and then push the “RESET” button
for at least one second. If you do not reset the fuel
reserve tripmeter manually, it will reset itself auto-
matically and the display will return to the prior
mode after refueling and traveling 5 km (3 mi).
Stopwatch mode
Standard measurement
1. Push the “RESET” button to start the stopwatch.
2. Push the “SELECT” button to stop the stopwatch.
3. Push the “SELECT” button again to reset the stopwatch.
Split-time measurement
1. Push the “RESET” button to start the stopwatch.
2. Push the “RESET” button to measure split-times. (The colon “:” will start flashing.)
3. Push the “RESET” button to display the final split-time or push the “SELECT” button to stop the stop-
watch and display total elapsed time.
4. Push the “SELECT” button to reset the stopwatch.
Coolant temperature display
The coolant temperature display indicates the temperature of the coolant. Push the “RESET” button to
switch the coolant temperature display to the air intake temperature display.
When the coolant temperature display is selected, “C” is displayed before the coolant temperature.
Air intake temperature display
The air intake temperature display indicates the temperature of the air drawn into the air filter case. Push
the “RESET” button to switch the coolant temperature display to the air intake temperature display.

Even if the air intake temperature is set to be displayed, the coolant temperature warning light comes
on when the engine overheats.

When the key is turned to “ON”, the coolant temperature is automatically displayed, even if the air
intake temperature was displayed prior to turning the key to “OFF”.

When the air intake temperature display is selected, “A” is displayed before thetemperature.
ProCarManuals.com

1-4
FEATURES
GEN
INFO
NOTE: Self-diagnosis devices
The model is equipped with a self-diagnosis device for various electrical circuits. If any of those circuits
are defective, the engine trouble warning light will come on, and then the right display will indicate a
two-digit error code (e.g.,11,12,13).
Display brightness and shift timing indicator light control mode
This mode cycles through five control functions, allowing you to make the following settings in the order
listed below.

Display brightness:
This function allows you to adjust the brightness of the displays and tachometer to suit the outside
lighting conditions.

Shift timing indicator light activity:
This function allows you to choose whether or not the indicator light should be activated and whether
it should flash or stay on when activated.

Shift timing indicator light activation:
This function allows you to select the engine speed at which the indicator light will be activated.

Shift timing indicator light deactivation:
This function allows you to select the engine speed at which the indicator light will be deactivated.

Shift timing indicator light brightness:
This function allows you to adjust the brightness of the indicator light to suit your preference.

To make any settings in this mode, you have to cycle through all of its functions. However, if the key is
turned to “OFF” or the engine is started before completing the procedure, only the settings made be-
fore the “SELECT” button was last pushed will be applied.

In this mode, the right display shows the current setting for each function (except the shift timing indi-
cator light activity function).
To adjust the brightness of the multifunction meter displays and tachometer
1. Turn the key to “OFF”.
2. Push and hold the “SELECT” button.
3. Turn the key to “ON”, and then release the “SELECT” button after five seconds.
4. Push the “RESET” button to select the desired brightness level.
5. Push the “SELECT” button to confirm the selected brightness level. The control mode changes to
the shift timing indicator light activity function.
To set the shift timing indicator light activity function
1. Push the “RESET” button to select one of the following indicator light activity settings:

The indicator light will stay on when activated. (This setting is selected when the indicator light stays
on.)

The indicator light will flash when activated. (This setting is selected when the indicator light flashes
four times per second.)

The indicator light is deactivated; in other words, it will not come on or flash. (This setting is selected
when the indicator light flashes once every two seconds.)
2. Push the ”SELECT” button to confirm the selected indicator light activity. The control mode changes
to the shift timing indicator light activation function.
ProCarManuals.com