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BT1100 2005

SUPPLEMENTARY SERVICE MANUAL

© 2004 by Yamaha Motor Italia S.p.A.

First edition, September 2004

All rights reserved. Any reproduction or

unauthorized use without the written

permission of Yamaha Motor Italia S.p.A.

is expressly prohibited.

Printed in Italy

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the Yamaha
BT1100 (2005).
For complete service information procedures it is necessary to use this Supplementary Service Manual to-
gether with the following manuals.

BT1100 SERVICE MANUAL: 5JN1-AE1

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Summary of Contents for 2005 BT1100

Page 1: ...BT1100 SUPPLEMENTARY SERVICE MANUAL 2005 5JN4 AE1 ...

Page 2: ......

Page 3: ...itten permission of Yamaha Motor Italia S p A is expressly prohibited Printed in Italy FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the Yamaha BT1100 2005 For complete service information procedures it is necessary to use this Supplementary Service Manual to gether with the following manuals BT1100 SERVICE MANUAL 5JN1 AE1 ...

Page 4: ...ications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will ap pear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means A...

Page 5: ...of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each re moval and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number indicate...

Page 6: ...ith engine mounted 0 Filling fluid q Lubricant w Special tool e Torque r Wear limit clearance t Engine speed y Electrical data Illustrated symbols u to s in the exploded dia grams indicate the types of lubricants and lubrica tion points u Apply engine oil i Apply gear oil o Apply molybdenum disulfide oil p Apply wheel bearing grease a Apply lightweight lithium soap base grease s Apply molybdenum d...

Page 7: ... PERIODIC MAINTENANCE LUBRICATION INTERVALS 29 CHASSIS ADJUSTING THE FRONT BRAKE 31 CHECKING THE FUSES 32 ENGINE ENGINE REMOVAL 34 CARBURETION CARBURETOR 36 CHASSIS FRONT BRAKE MASTER CYLINDER 37 FRONT BRAKE CALIPERS 39 HANDLEBAR 41 STEERING HEAD LOWER BRACKET 45 ELECTRICAL ELECTRICAL COMPONENTS 47 SWITCHES 49 CHECKING THE BULBS AND BULB SOCKETS 52 IMMOBILIZER SYSTEM 55 SELF DIAGNOSIS DEVICE 63 IG...

Page 8: ......

Page 9: ... load except motorcycle 200 kg Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement V type 2 cylinder Displacement 1 063 L Bore stroke 95 75 mm Compression ratio 8 3 1 Compression pressure STD 1 000 kPa 10 kg cm2 10 bar at 400 r min Starting system Electric starter Lubrication system Wet sump Engine oil Type Temp C SAE20W40SE or SAE10W30SE Recommended engine oil classification API Serv...

Page 10: ...nt mesh 5 speed Operation Left foot operation Gear ratio 1st 40 17 2 353 2nd 40 24 1 667 3rd 36 28 1 286 4th 32 31 1 032 5th 29 34 0 853 Chassis Frame type Twin tube Backbone Caster angle 25 Trail 106 mm Tire Type Tubeless Size front 120 70 ZR17 58W rear 170 60 ZR17 72W Manufacturer front DUNLOP METZELER rear DUNLOP METZELER Type front D205F TL MEZ3F TL rear D205 TL MEZ3 TL Tire pressure cold tire...

Page 11: ...eel travel 113 mm Electrical system Ignition system T C I digital Generator system A C magneto Battery type GT14B 4 Battery capacity 12V 12Ah Headlight type Quartz bulb halogen Bulb voltage wattage x quantity Headlight 12 V 60 W 55 W x 1 Auxiliary light 12 V 5 W x 1 Tail brake light 12 V 5 W 21 W x 1 License plate light 12 V 5 W x 1 Front turn signal indicator light 12 V 10 W x 2 Rear turn signal ...

Page 12: ...in drive left right Cam cap inside diameter 25 000 25 021 mm Camshaft outside diameter 24 96 24 98 mm Shaft to cap clearance 0 020 0 061 mm Cam dimensions Intake A 39 112 39 212 mm 39 012 mm B 1 32 093 32 193 mm 1 31 993 mm 2 32 127 32 227 mm 2 32 027 mm C 7 162 mm 7 012 mm Exhaust A 39 145 39 245 mm 39 045 mm B 32 200 32 300 mm 32 100 mm C 7 195 mm 7 045 mm Camshaft runout limit 0 03 mm MAINTENAN...

Page 13: ...e guide Valve clearance cold IN 0 07 0 12 mm EX 0 12 0 17 mm Valve dimensions Head Diameter Face Width Seat Width Margin Thickness A head diameter IN 47 0 47 2 mm EX 39 0 39 2 mm B face width IN 2 1 mm EX 2 1 mm C seat width IN 1 2 1 4 mm 1 8 mm EX 1 2 1 4 mm 1 8 mm D margin thickness IN 1 1 1 5 mm 0 8 mm EX 1 1 1 5 mm 0 8 mm Stem outside diameter IN 7 975 7 990 mm 7 955 mm EX 7 960 7 975 mm 7 935...

Page 14: ... kg EX 160 7 N 16 4 kg Spring rate K1 IN 35 28 N mm 3 6 kgf mm EX 35 28 N mm 3 6 kgf mm Spring rate K2 IN 45 37 N mm 4 63 kgf mm EX 45 37 N mm 4 63 kgf mm Tilt limit IN 2 5 1 9 mm EX 2 5 1 9 mm Direction of winding top view IN Clockwise EX Clockwise Piston Piston to cylinder clearance 0 025 0 050 mm 0 15 mm Piston size D 94 960 94 975 mm Measuring point H 5 mm Piston off set 0 mm Piston pin bore i...

Page 15: ...ring Type Taper Dimensions B x T 1 2 3 8 mm End gap installed 0 30 0 45 mm 0 8 mm Side clearance 0 03 0 07 mm 0 1 mm Oil ring Dimensions B x T 2 5 3 4 mm End gap installed 0 2 0 7 mm Connecting rod Oil clearance 0 044 0 073 mm Color code corresponding size 1 Blue 2 Black 3 Brown 4 Green 5 Yellow Crankshaft Crank width A 101 95 102 00 mm Runout limit C 0 02 mm Big end side clearance D 0 320 0 474 m...

Page 16: ...m Shifter Shifter type Guide bar Shift fork thickness 5 76 5 89 mm Carburetor I D mark 5JN4 10 Main jet M J 1 128 8 2 127 5 Main air jet M A J 55 Jet needle J N 5DL49 3 Needle jet N J P 0M 826 Pilot air jet P A J 1 63 8 P A J 2 142 5 Pilot outlet P O 1 0 Pilot jet P J 17 5 Bypass 1 B P 1 0 8 Bypass 2 B P 2 0 8 Bypass 3 B P 3 0 8 Pilot screw P S 3 0 Valve seat size V S 1 2 Starter jet G S 1 45 Star...

Page 17: ...e Oil pump type Trochoid type Tip clearance A or B 0 03 0 09 mm 0 15 mm Side clearance 0 03 0 08 mm 0 15 mm Bypass valve opening pressure 80 120 kPa 0 8 1 2 kgf cm2 Relief valve operating pressure 450 550 kPa 4 5 5 5 kgf cm2 Shaft drive Middle gear backlash 0 1 0 2 mm Final gear backlash 0 1 0 2 mm ...

Page 18: ...hart Needle bearing starter Connecting rod big end Crankshaft Main axle Drive axle Pinin drive Middle driveshaft Rocker arm IN Camshaft IN Camshaft EX Rocker arm IN Rocker arm EX Rocker arm EX Oil filter Oil pump Relief valve Oil pan Pressure feed Splashed Orifice ...

Page 19: ...11 SPEC MAINTENANCE SPECIFICATIONS Cylinder head tightening sequence Crankcase tightening sequence Right crankcase Left crankcase ...

Page 20: ...oner Bolt M6 4 10 1 0 Timing chain tentioner cap Bolt M6 2 8 0 8 Timing chain guide Bolt M6 4 10 1 0 Oil pump Bolt M6 3 10 1 0 Oil strainer cover Bolt M6 3 10 1 0 Oil filter cover Bolt M6 5 10 1 0 Oil pump gear Bolt M6 1 12 1 2 Oil pump cap Bolt M6 1 10 1 0 Oil delivery pipe cylinder head Union M16 2 20 2 0 bolt crankcase Union M10 1 20 2 0 bolt Oil drain bolt M14 1 43 4 3 Air filter Air filter co...

Page 21: ...Push lever axle Screw M8 1 12 1 2 Middle drive pinion gear Nut M44 1 110 11 0 Stake Bearing retainer middle driven shaft Nut M88 1 110 11 0 Stake Yoke middle driven shaft Nut M14 1 Stake Bearing housing middle drive shaft Bolt M8 4 25 2 5 Shift lever stopper Bolt M8 1 22 2 2 Use lock washer Guide bar stopper Screw M6 2 7 0 7 Shift dram segment Screw M5 1 4 0 4 Shift arm Bolt M6 1 10 1 0 Shift peda...

Page 22: ...o Oil capacity 0 537 L Oil level 117 mm Oil grade Fork oil 10W or equivalent Rear suspension Shock absorber travel 60 mm Spring free length 175 mm Fitting length 162 mm Spring rate K1 120 N mm 12 23 kg mm Stroke K1 0 60 mm Optional spring No Swingarm Free play limit End 0 mm Front wheel Rim size Cast wheel Dimensioni cerchio 17 MT3 50 Rim material Aluminium Rim runout limit radial 1 0 mm lateral 0...

Page 23: ... cylinder inside diameter 30 2 mm Caliper cylinder inside diameter 27 mm Brake fluid type DOT 4 Rear brake Type Single disc Disc outside diameter thickeness 267 5 mm 4 5 mm Disc deflection limit 0 15 mm Pad thickness inner 5 5 mm 0 5 mm outer 5 5 mm 0 5 mm Master cylinder inside diameter 13 mm Caliper cylinder inside dimeter 42 85 mm Brake fluid type DOT 4 Brake pedal position 43 mm Clutch lever f...

Page 24: ...astening screw M6 7 0 7 Front wheel Front brake caliper right and left M10 42 4 2 Front brake disc right and left M8 25 2 5 Front wheel axle M18 75 7 5 Front wheel axle pinch bolt M8 25 2 5 Rear wheel Rear brake disc M8 25 2 5 Rear brake caliper M10 35 3 5 Rear wheel axle nut M16 110 11 0 Rear wheel axle pinch bolt M8 22 2 2 Dust cover fastening screw M5 4 0 4 Swingarm assembly Pivot shaft M16 92 ...

Page 25: ...7 Rear footrest bracket fastening screw M8 23 2 3 Rear lights Rear fender Panel assembly Side panel fastening screw M6 7 0 7 Battery receptacle fastening screws M6 7 0 7 Battery receptacle cover fastening screws M6 7 0 7 Plastic rear fender fastening screws M6 7 0 7 Plastic license bracket fastening screws M6 7 0 7 Rear fender cover fastening screw aluminium M8 23 2 3 Seat lock fastening screw M6 ...

Page 26: ...tput 14V 350W at 5 000 r min Stator coil resistance color 0 36 0 44 Ω at 20 C White White Voltage regulator Type Semi conductor short circuit type Model manufacturer SH650D 11 SHINDENGEN No load regulated voltage 14 1 14 9 V Rectifier Model manufacturer SH650D 11 SHINDENGEN Capacity 18 A Withstand voltage 200 V Battery Specific gravity 1 320 Electric starter system Type Constant mesh type Starter ...

Page 27: ... Model manufacturer G8R 30Y U0 OMRON Coil resistance 162 198 Ω at 20 C Throttle position sensor Resistance 4 0 6 0 kΩ at 20 C Blue Black Fuel pump relay Model manufacturer G8R 30Y U0 OMRON Coil resistance 162 198 Ω at 20 C Thermostat switch Model manufacturer 5FU NIPPON THERMOSTAT Circuit breaker Circuit breaker type Fuse Amperage for fuses Main fuse 30 A Headlight fuse 15 A Signaling system fuse ...

Page 28: ...ifications N m m kg 10 mm 6 mm 6 0 6 12 mm 8 mm 15 1 5 14 mm 10 mm 30 3 0 17 mm 12 mm 55 5 5 19 mm 14 mm 85 8 5 22 mm 16 mm 130 13 0 CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS Use this table to convert METRIC unit data to IMPERIAL unit data Ex METRIC MULTIPLIER IMP mm 0 03937 in 2 mm 0 03937 0 08 in CONVERSION TABLE METRIC TO IMP Known Multiplier Resul...

Page 29: ...nal big end Piston surface Piston pin Camshaft cam lobe journal Rocker arm shaft Valve stem IN EX Valve stem end IN EX Timing chain drive gear shafts sprokets Oil pump rotor inner outer housing Idle gear surface Starter idle gear Starter idle gear shaft Starter oneway cam Middle drive gear Primary driven gear Push rod 1 2 Transmission gear wheel pinion Shift cam Shift fork guide bar Shift shaft as...

Page 30: ...lip Clutch hub fitting area Rear brake pedal shaft Shift pedal shaft Sidestand bolt sidestand sliding surface Tube guide throttle grip inner surface Brake lever pivot bolt contact surface Clutch lever pivot bolt contact surface Rear shock absorber lower oil seal lip Swingarm pivot bearing inner surface Swingarm pivot oil seal lip Relay arm bearing collar and oil seal Drive shaft spline Drive shaft...

Page 31: ...23 SPEC LUBRICATION DIAGRAMS EB205000 LUBRICATION DIAGRAMS 1 Rocker arm shaft intake 2 Rocker arm shaft exhaust 3 Oil filter 4 Oil pump 5 Drive axle 6 Middle drive shaft ...

Page 32: ...24 SPEC LUBRICATION DIAGRAMS 1 Oil pump 2 Releaf valve 3 Oil filter 4 Middle drive shaft ...

Page 33: ...25 SPEC LUBRICATION DIAGRAMS 1 Camshaft 2 Crankshaft 3 Main axle 4 Middle drive shaft 5 Drive axle 6 Connecting rod big end ...

Page 34: ... tank cap fuel drain pipe q Fuel hose carburetor 3 way w Handlebar switch leads left e Rectifier regulator r Spark plug cap front cilinder t Throttle cables y Wireharness u Clutch cable i Front brake cable left o Carburetor pipe vent p Pipe drain å Fix the wires of the left swicth assy to the handlebar by means of no 2 plastic clamps Fix the headlight leads to the clamp 3 4 9 0 5 8 6 i u r 7 1 2 o...

Page 35: ...arter relay assy x Depression fuel cock c Spark plug cap rear cylinder v A I S pipe to the rear cylinder b A I S system n Throttle position sensor TPS m Ignition coil front cylinder Handlebar switch leads right Throttle cables Brake cable front master cylinder Thermo swicth ç Check that the wires of the igni tion coil do not remain tensioned Fix the wires of the right switch assy to the handlebar ...

Page 36: ...rminal Fuse box Battery negative terminal Igniter unit Q Fuel filter W Fuel pump E Fuel sender R Air intake pipe A I S system T Anti theft alarm connectors Y Rubber cap for front wiring connections U Spark plug lead front I Throttle cable Position the spark plug wire of the rear cylinder below the fuel hose I Y R E W Q U T ...

Page 37: ...r filter Clean element Replace 6 Clutch Check operation Adjust Check operation fluid level and vehicle for fluid 7 Front brake leakage Replace brake pads Whenever worm to the limit Check operation fluid level and vehicle for 8 Rear brake fluid leakage Replace brake pads Whenever worm to the limit 9 Brake Check for cracks or damage hoses Replace Every 4 years 10 Wheels Check runout and for damage C...

Page 38: ...nnual N0 ITEM CHECK OR MAINTENANCE JOB 1 10 20 30 40 check Rear suspension relay Check operation 20 arm and connecting arm pivoting Lubricate with lithium soap based grease points Check starter choke operation 21 Carburators Adjust engine idling speed and synchronization Change 22 Engine oil Check oil level and vehicle for oil leakage 23 Engine oil Replace filter element Check oil level and vehicl...

Page 39: ...ted in the hole in the adjusting dial WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the brake sys tem Before the vehicle is operated the air must be removed by bleeding the brake sys tem Air in the brake system will considerably reduce braking performance and could result in loss of control and possibly an accident Therefore inspect and if necessary bleed ...

Page 40: ...Check fuse CAUTION a Connect the pocket tester to the fuse and check it for continuity NOTE Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace blown fuse a Turn off the ignition b Install a new fuse of the correct amperage rat ing c Turn on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the ...

Page 41: ... fuse 5 A 1 9 Reserve fuse 30 A 1 0 Reserve fuse 15 A 1 q Reserve fuse 10 A 1 w Reserve fuse 5 A 1 INSP ADJ CHECKING THE FUSES WARNING Never use a fuse with an amperage rating other than that specified Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical sys tem cause the lighting and ignition systems to malfunction and could possibly cause a fire...

Page 42: ...TEM Order Job name Part name Q ty Remarks Removing the seat storage Remove the parts in the order listed compartment side covers fuel tank Stand the motorcycle on a level surface air filter case assembly carburetor assembly and exhaust system Seat 1 Storage compartment 1 WARNING Securely support the motorcycle so there is no danger of it falling over ...

Page 43: ...r case assembly Carburetor assembly 3 A I S system cover 1 4 A I S system 1 5 Muffler assembly 2 6 Exhaust pipes 2 For installation reverse the removal procedure Refer to SEAT SIDE COVERS AND FUEL TANK in Chapter 3 Refer to CARBURETOR in Chapter 5 NOTE First disconnect the negative lead then disconnect the positive lead ...

Page 44: ...r 3 1 Air filter case assembly 1 2 Air ducts 2 3 Cylinder head breather hose 1 Disconnect 4 Cover 1 5 Throttle position sensor lead 1 Disconnect 6 Carburetor heater lead 1 Disconnect 7 Fuel hoses 2 Disconnect 8 Carburetor assembly 1 9 Starter cable 1 10 Throttle cables 2 For installation reverse the removal procedure NOTE After removing the carburetor assembly remove the starter cable and throttle...

Page 45: ...e the parts in the order listed cylinder Drain the brake fluid 1 Brake lever 1 2 Front brake switch lead 2 3 Front brake switch 1 4 Union bolt 1 5 Copper washers brake hose 2 1 6 Master cylinder bracket 1 7 Master cylinder 1 For installation reverse the removal procedure Refer to REMOVING INSTALLING THE FRONT BRAKE MASTER CYLINDER ...

Page 46: ...er Job name Part name Q ty Remarks Disassembling the front brake Remove the parts in the order listed master cylinder 1 Dust boot 1 2 Circlip 1 3 Master cylinder cup 1 4 Spring 1 For assembly reverse the disassembly procedure ...

Page 47: ...marks Removing the front brake calipers Remove the parts in the order listed Drain the brake fluid 1 Union bolt 1 2 Copper washers 2 3 Brake hose 1 4 Brake caliper assembly 1 For installation reverse the removal procedure Refer to REMOVING INSTALLING THE FRONT BRAKE CALIPERS ...

Page 48: ... in the order listed calipers 1 Pad pin clips 2 2 Pad pin 1 3 Pad spring 1 4 Brake pads 2 5 Bleed screw 1 6 Brake caliper pistons 4 7 Dust seals 4 8 Caliper piston seals 4 For assembly reverse the disassembly procedure Refer to DISASSEMBLING THE FRONT BRAKE CALIPER Refer to REPLACING THE FRONT BRAKE PADS ...

Page 49: ... cable 1 3 Handlebar switch left 1 4 Grip left 1 5 Clutch lever assembly rear view mirror 1 1 6 Master cylinder bracket 1 7 Master cylinder assembly rear 1 1 view mirror 8 Handlebar switch right 1 9 Throttle cables 2 Refer to INSTALLING THE HANDLEBAR Refer to INSTALLING THE HANDLEBAR Refer to REMOVING THE HANDLEBAR WARNING Securely support the motorcycle so that there is no danger of it falling ov...

Page 50: ...Order Job name Part name Q ty Remarks 10 Throttle grip assembly 1 11 Handlebar holders upper 2 12 Handlebar 1 13 Handlebar holders lower 2 For installation reverse the removal procedure Refer to INSTALLING THE HANDLEBAR ...

Page 51: ...ay to the left and right If there is any contact with the fuel tank adjust the handlebar position NOTE Align the match marks on the handlebar with the upper surface of the lower handlebar holders CAUTION 23 Nm 2 3 m kg 3 Install throttle grip 1 throttle cable WARNING Make sure that the pin a on the throttle cable housing is aligned with the hole b in the han dlebar 4 Install master cylinder 1 Refe...

Page 52: ... on the handlebar switches with the punch mark a on the handle bar 8 Install clutch cable 9 Connect clutch switch coupler 10 Adjust clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY in Chapter 3 11 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in Chapter 3 Clutch cable free play at the end of the clutch lever 5 10 mm Throttle cable free play at ...

Page 53: ...T WHEEL AND BRAKE DISCS Front fork legs Refer to FRONT FORK Handlebar Refer to HANDLEBAR 1 Crown nut washer plate 1 1 2 Upper bracket 1 3 Special washer 1 4 Upper ring nut 1 5 Rubber seal 1 6 Lower ring nut 1 7 Lower bracket 1 8 Rubber washer 1 9 Bearing cover 1 10 Bearing 1 Refer to REMOVING THE LOWER BRACKET INSTALLING THE STEERING HEAD Refer to INSTALLING THE STEERING HEAD ...

Page 54: ...46 CHAS STEERING HEAD Order Job name Part name Q ty Remarks 11 Bearing 1 12 Dust seal 1 13 Lower handlebar holder 2 For installation reverse the removal procedure ...

Page 55: ...LECTRICAL ELECTRICAL COMPONENTS 1 Main switch 2 Igniter unit 3 Ignition coil rear cylinder 4 Ignition coil front cylinder 5 Horn 6 Oil level gauge assembly 7 Neutral switch 8 Sidestand switch 9 Speed sensor 0 Immobilizer control unit ...

Page 56: ...ELECTRICAL COMPONENTS 48 ELEC q Fuel meter senser unit w Battery e Starter relay r Relay assembly t Flasher relay y Relay assembly u Fuse assembly i Rectifier regulator o Thermo switch ...

Page 57: ...th between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illus tration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration NOTA The symbol indicates a continuity of elec tricity between switch terminals i e a...

Page 58: ...heck each switch for damage or wear proper connections and also for continuity between the termi nals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace the switch Improperly connected Properly connect Incorrect continuity reading Replace the switch ...

Page 59: ... 51 1 Clutch switch 2 Pass switch 3 Horn switch 4 Dimmer switch 5 Turn switch 6 Main switch 7 Front brake switch 8 Hazard switch 9 Engine stop switch 0 Start switch q Fuses w Rear brake switch e Sidestand switch r Neutral switch ...

Page 60: ...ra The bulbs used on this motorcycle are shown in the illustration on the left Bulbs A and B are used for headlights and usually use a bulb holder which must be de tached before removing the bulb The majority of these bulbs can be removed from their respec tive socket by turning them counterclockwise Bulb C is used for turn signal and tail brake lights and can be removed from the socket by pushing...

Page 61: ...and the luminous flux will be adversely affect ed If the headlight bulb gets soiled thor oughly clean it with a cloth moistened with alcohol or lacquer thinner CAUTION 2 Check bult for continuity with the pocket tester No continuity Replace NOTE Before checking for continuity set the pocket tester to 0 and to the Ω x 1 range a Connect the tester positive probe to terminal 1 and the tester negative...

Page 62: ...er No continuity Replace NOTE Check each bulb socket for continuity in the same manner as described in the bulb section howev er note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the respective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb socket Pocket tester 90890 03...

Page 63: ...y B BL W W W W W W W W W W W W OFF ON P BrR BrR BrL RW B B B B B R R RW L RW L L LW BY Sb SbW RB LY LG LR LB LB YL RW RB Gy2 G B B LB LB Lg LR YB Y L Gy1 LY RB RW B Br Or RL BL W Sb WB YL SbW RB L LB LR LW BY Sb LY LG B B LG B B B W YB L Y BL LY WB RL Sb Br G NS SL1 SL2 SP RPM GND G G Br Br B GL B Y HI BEAM IMOBILIZER RG Br B GW Dg Ch GL W YB Y BW SbW Sb Sb Sb B W W L L B BL B L W BL GW GW BrB BrB...

Page 64: ...e a standard key for driving See caution below NOTE Each standard key is registered during production therefore re registering at purchase is not necessary CAUTION DO NOT LOSE THE CODE RE REGISTERING KEY If the code re registering key is lost registering new codes in the standard keys is impossible The standard keys can still be used to start the vehi cle however if code re registering is required...

Page 65: ...istering key registration is finished 2 Check that the engine can be started 3 Consequently carry out the standard key registration according the section below Standard key registration When you lose a standard key and need a new one Or when the code re registering key is re registered after the immobilizer unit or igniter unit are replaced NOTE It is prohibited to start the engine with the standa...

Page 66: ... 4 In the condition as mentioned above while the indicator light continues rapid flashing after the main switch is turned ON with the first new standard key turn OFF the main switch before 5 seconds elapses and then turn ON the main switch with the standard key that you want to register which is the second new key or the standard key remained in hand 5 When the registration is finished the indicat...

Page 67: ...738 EAS00781 TROUBLESHOOTING Check 1 Main ignition and backup fuses 2 Battery 3 Main switch 4 Wiring of the entire immobilizer system NOTE Before troubleshooting remove the following part s 1 Seat 2 Side covers 3 Fuel tank lift 4 Cowling lift forward 5 Storage compartment battery cover Troubleshoot with the following special tool s The immobilizer system fail to operate The immobilizer system indi...

Page 68: ...unit couplers as shown Tester positive probe red green 1 Tester negative probe black 2 RG B2 B RW GL YL B B2 RG YL GL RW 2 1 3 Voltage Connect the pocket tester DC 20 V to the immobilizer unit couplers as shown Tester positive probe red white 1 Tester negative probe black 2 Set the main switch to ON Measure the voltage 12 V between red white and black on the immobilizer unit Are the voltage within...

Page 69: ...ester negative probe black 2 Set the main switch to ON Measure the voltage 12 V between green blue and black on the immobilizer unit Are the voltage within specification RG B2 B RW GL YL B B2 RG YL GL RW 2 1 Replace the immobi lizer unit The wiring circuit from the immobilizer unit to the multi function dis play is faulty and must be repaired YES NO ...

Page 70: ... the immobilizer unit 3 Replace the ignitor unit 54 IMMOBILIZER UNIT Codes do not match be tween ignitor unit and im mobilizer unit Noise interference or disconnected lead cable 1 Obstruction due to radio wave noise 2 Immobilizer unit failure 3 Ignitor unit failure When the used parts from other vehicles are used the code re registering key ID is not registered to the ECU 1 Register the code re re...

Page 71: ...e the circuit specific number of r min and check the oper ation of the system according to the following procedure 0 r min for 3 seconds 0 r min for 0 5 second Current engine speed for 3 seconds Indication of the r min corresponding to the first figure of error code for 2 5 seconds Indication of the r min corresponding to the second figure of error code for 2 5 seconds r min r min r min r min r mi...

Page 72: ...ttle posi tion sensor speed sensor error code LR LB LB YL RW RB Gy2 G B B LB LB Lg LR YB Y L Gy1 LY RB RW B Br Or RL BL W Sb WB YL B W YB L Y BL LY WB RL Sb Br G NS SL1 SL2 SP RPM GND 10 9 13 Or Gy1 Gy2 PU VCC TPS S GND HD SS B L Y B PUMP LR L Y B L Y BL B BLACK BLACK 1 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM Is the wire harness OK Repair or replace the wire har...

Page 73: ...IGHT MAIN HARNESS RB Or Or RB Gy1 Gy2 Gy2 PU VCC TPS S GND HD SS B L Y B PUMP LR L Y B L Y BL B BLACK BLACK B LG 1 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM Is the wire harness OK Repair or replace the wire harness YES NO 2 Speed sensor Place the motorcycle on a suitable stand so that the rear wheel is elevated Connect the pocket tester DC 20 V to the speed sensor...

Page 74: ...nectors from the ignition coil terminals Connect the pocket tester 1 to the igni tion coil as shwon Tester positive probe Red Black Tester negative probe Orange Gray Measure the primary coil resistance Primary coil resistance 3 57 4 83 at 20 C 68 F Connect the pocket tester 1k to the ignition coil as shown Measure the secondary coil resistance Tester positive probe spark plug lead 1 Tester negativ...

Page 75: ...L BL W Sb WB L L LB LR LW BY Sb B B W YB L Y BL LY WB RL Sb Br G NS SL1 SL2 SP RPM GND G G Br Br 10 11 9 12 14 UE RB Or Or RB Gy1 Gy2 Gy2 PU VCC TPS S GND HD SS B L Y B PUMP LR L Y B L Y BL CK BLACK 49 48 1 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM Is the wire harness OK Repair or replace the wire harness Replace the fuel cut solenoid 1 or 2 YES NO ...

Page 76: ... B B R R RW L RW L L LW BY Sb SbW RB LY LG LR LB LB YL RW RB Gy2 G B B LB LB Lg LR YB Y L Gy1 LY RB RW B Br Or RL BL W Sb WB YL SbW RB L LB LR LW BY Sb LY LG B B LG B B B W YB L Y BL LY WB RL Sb Br G NS SL1 SL2 SP RPM GND G G Br Br B GL B Y HI BEAM IMOBILIZER RG Br B GW Dg Ch GL W YB Y BW SbW Sb Sb Sb B W W L L B BL B L W BL GW GW BrB BrB B B B G Y LR G B Y LR BLUE 40 4 10 11 39 5 6 7 8 9 12 13 14...

Page 77: ...ce the spark plug Ignition checker 90890 06754 Pocket tester 90890 03112 1 Main and ignition fuses Check the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in Chapter 3 Are the main and ignition fuses OK Replace the fuse s EAS00738 EASB0030 TROUBLESHOOTING Check 1 Main and ignition fuses 2 Battery 3 Spark plugs 4 Ignition spark gap 5 Spark plug cap resistance 6 Ignition coil r...

Page 78: ...k plug Connect the pocket tester 1k to the spark plug cap as shown Measure the spark plug cap resistance The ignition system is OK NO YES EAS00745 Spark plug cap resistance 10 k at 20 C 68 F Is the spark plug cap OK Replace the spark plug cap YES NO 6 Ignition coil resistance The following procedure applies to all of the ignition coils Disconnect the ignition coil connectors from the ignition coil...

Page 79: ...the pickup coil OK EAS00748 8 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK Replace the main switch EAS00749 YES NO 9 Engine stop switch Check the engine stop switch for continuity Refer to CHECKING THE SWITCHES Is the engine stop switch OK Replace the right handlebar switch EAS00750 YES NO 10 Neutral switch Check the neutral switch for conti...

Page 80: ...Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM Is the ignition system s wiring properly con nected and without defects Replace the ignitor unit Properly connect or repair the ignition sys tem s wiring NO YES EAS00754 ...

Page 81: ...W B B B B B R R RW L RW L L LW BY Sb SbW RB LY LG LR LB LB YL RW RB Gy2 G B B LB LB Lg LR YB Y L Gy1 LY RB RW B Br Or RL BL W Sb WB YL SbW RB L LB LR LW BY Sb LY LG B B LG B B B W YB L Y BL LY WB RL Sb Br G NS SL1 SL2 SP RPM GND G G Br Br B GL B Y HI BEAM IMOBILIZER RG Br B GW Dg Ch GL W YB Y BW SbW Sb Sb Sb B W W L L B BL B L W BL GW GW BrB BrB B B B G Y LR G B Y LR BLUE 40 4 10 11 39 5 6 7 8 9 1...

Page 82: ...urrent cannot reach the starter motor When at least one of the above conditions have been met however the starting circuit cut off relay is closed and the engine can be started by press ing the starter switch WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED IN 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Starting circuit cut ...

Page 83: ...ry ter minals Recharge or replace the battery Repair or replace the starter motor Pocket tester 90890 03112 1 Main and ignition fuses Check the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in Chapter 3 Are the main and ignition fuses OK Replace the fuse s EAS00738 EASB0031 TROUBLESHOOTING Check 1 Main and ignition fuses 2 Battery 3 Starter motor 4 Starting circuit cut off re...

Page 84: ... between Black and Blue White EAS00739 Replace the relay unit YES NO Replace the starter re lay YES NO 5 Starter relay Disconnect the starter relay from the coupler Connect the pocket tester 1 and bat tery 12V to the starter relay coupler as shown Battery positive terminal Red White 1 Battery negative terminal Blue 2 Tester positive probe Red 3 Tester negative probe Black 4 Does the starter relay ...

Page 85: ... SWITCHES Is the sidestand switch OK Replace the side stand switch EAS00752 YES NO 10 Clutch switch Check the clutch switch for continuity Refer to CHECKING THE SWITCHES Is the clutch switch OK Replace the clutch switch EAS00763 YES NO 11 Start switch Check the start switch for continuity Refer to CHECKING THE SWITCHES Is the start switch OK Replace the right handlebar switch EAS00764 YES NO 12 Wi...

Page 86: ...d 1 2 Starter motor assembly 1 For installation reverse the removal procedure Disassembling the starter motor Disassembly the pats in the order listed 1 Circlip 1 2 Starter motor drive gear 1 3 Starter motor rear cover 1 Refer to Assembling the starter motor 4 Washer set 1 5 Starter motor front cover 1 Refer to Assembling the starter motor STARTER MOTOR ...

Page 87: ...e Q ty Remarks 6 Washer set 1 7 End bracket 1 Refer to Assembling the starter motor 8 Planetary gears 2 9 Armature assembly 1 0 Brush holder brush 1 1 q Starter motor yoke 1 For assembly reverse the disassembly procedure Refer to Assembling the starter motor ...

Page 88: ... fit the commutator NOTE The mica must be undercut to ensure proper operation of the commutator 4 Measure armature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester b If any resistance is out of specification replace the starter motor Min commutator diameter 27 mm Mica undercut 0 7 mm Po...

Page 89: ...heck oil seal Damage wear Replace the defective part s EAS00772 Assembling the starter motor 1 Install brush holder 1 NOTE Align the tab a on the brush holder with the slot in the starter motor rear cover 2 Install starter motor yoke 1 end bracket 2 starter motor front cover 3 NOTE Align the projection a on the front cover with the slot b on the end cover and starter motor yoke Min brush length 5 ...

Page 90: ...ELEC ELECTRIC STARTING SYSTEM 82 3 Install starter motor rear cover 1 NOTE Align the match marks a on the rear cover with the match marks b on the front cover ...

Page 91: ... B B B2 B1 BB3 BB4 BB2 BB1 B2 B1 BB3 BB4 BB2 BB1 B R B W W R Gy1 BL Gy Gy B BL W W W W W W W W W W W W OFF ON P BrR BrR BrL RW B B B R R RW L RW L 4 5 6 7 17 1 B 10A BrL BrL R R BLACK B1 B2 10A 43 3 15 21 R 30A R B B B 2 CHARGING SYSTEM CIRCUIT DIAGRAM 1 Pickup coil 2 Rectifier regulator 4 Starter relay 5 Battery 6 Wire minus lead ...

Page 92: ...r min Measure the charging voltage Charging voltage 14 V at 5 000 r min EAS00739 EAS00775 Clean the battery ter minals Recharge or replace the battery Engine tachometer 90890 03113 Pocket tester 90890 03112 1 Main fuse Check the main fuse for continuity Refer to CHECKING THE FUSES in Chapter 3 Is the main fuse OK Replace the fuse EAS00738 EAS00774 TROUBLESHOOTING Check 1 Main fuse 2 Battery 3 Char...

Page 93: ...shown Tester positive probe White 1 Tester negative probe White 2 Tester positive probe White 1 Tester negative probe White 3 Measure the stator coil assembly resistanc es Stator coil resistance 0 36 0 44 at 20 C 68 F Is the stator coil assembly OK EAS00776 5 Wiring Check the wiring connections of the entire charging system Refer to CIRCUIT DIAGRAM Is the charging system s wiring properly conected...

Page 94: ... W OFF ON P BrR BrR BrL RW B B B B B R R RW L RW L L LW BY Sb SbW RB LY LG LR LB LB YL RW RB Gy2 G B B LB LB Lg LR YB Y L Gy1 LY RB RW B Br Or RL BL W Sb WB YL SbW RB L LB LR LW BY Sb LY LG B B LG B B B W YB L Y BL LY WB RL Sb Br G NS SL1 SL2 SP RPM GND G G Br Br B GL B Y HI BEAM IMOBILIZER RG Br B GW Dg Ch GL W YB Y BW SbW Sb Sb Sb B W W L L B BL B L W BL GW GW BrB BrB B B B G Y LR G B Y LR BLUE ...

Page 95: ...nt battery cover Troubleshoot with the following special tool s Any of the following fail to light headlight high beam indicator light license plate light or meter light YES NO 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in Chapter 3 Min open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK EAS00739 Clean the battery ter minals Recharge or r...

Page 96: ...G THE BULBS AND BULB SOCKETS Are the headlight bulb and socket OK Replace the head light bulb socket or both YES NO EAS00788 CHECKING THE LIGHTING SYSTEM 1 The headlight and the high beam indicator light fail to came on Replace the dimmer switch relay YES NO 6 Dimmer switch relay Disconnect the dimmer switch relay from the coupler Connect the pocket tester 1 and bat tery 12V to the dimmer switch r...

Page 97: ...n 2 on the headlight coupler headlight side Measure the voltage 12V of Yellow 4 on the meter assembly coupler Is the voltage within specification 1 Meter light bulb and socket Check the meter light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the meter light bulb and socket OK Replace the meter light bulb socket or both EAS00789 2 A meter light fails to come on Y...

Page 98: ...t OK Replace the license plate light bulb socket or both EASB0034 4 The license plate light fails to come on YES NO The wiring circuit from the main switch to the license plate light coupler is faulty and must be re paired This circuit is OK YES NO 2 Voltage Connect the pocket tester DC 20 V to the license plate light coupler wire harness side as shown Tester positive probe Blue Red 1 Tester negat...

Page 99: ...2 BB1 B R B W W R B2 RG GL RW YL B RG B2 B RW GL YL B B2 RG YL GL RW Gy1 BL Gy Gy B BL W W W W W W W W W W W W OFF ON P BrR BrR BrL RW B B B B B R R RW L RW L L LW BY Sb SbW RB LY LG LR LB LB YL RW RB Gy2 G B B LB LB Lg LR YB Y L Gy1 LY RB RW B Br Or RL BL W Sb WB YL SbW RB L LB LR LW BY Sb LY LG B B LG B B B W YB L Y BL LY WB RL Sb Br G NS SL1 SL2 SP RPM GND G G Br Br B GL B Y HI BEAM IMOBILIZER ...

Page 100: ...bar switch u Front brake switch o Signal fuse s Left handlebar switch f Horn g Flasher relay h Multi function display j Neutral switch lead k Neutral switch Front turn signal light L z Front turn signal light R x Rear turn signal light L c Rear turn signal light R Tail brake light Oil level gauge Rear brake switch ...

Page 101: ...ward 5 Storage compartment battery cover Troubleshoot with the following special tool s Any of the following fail to light turn signal light brake light or an indicator light The horn fails to sound YES NO 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in Chapter 3 Min open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK EAS00739 Clean the bat...

Page 102: ...er negative probe Ground Set the main switch to ON Measure the voltage 12 V of Brown at the horn terminal Is the voltage within specification The horn is OK NO YES 3 Horn Disconnect the Black connector at the horn terminal Connect a jumper lead 1 to the horn termi nal and Ground the jumper lead Set the main switch to ON Does the horn sound 5 Wiring Check the entire signaling system s wiring Refer ...

Page 103: ...rake lightbulb socket or both EAS00797 2 A tail brake light fails to come on YES NO 2 Brake light switches Check the brake light switches for continuity Refer to CHECKING THE SWITCHES Is the brake light switch OK Replace the brake light switch YES NO The wiring circuit from the main switch to the tail brake light coupler is faulty and must be repaired This circuit is OK YES NO 3 Voltage Connect th...

Page 104: ...ve probe Brown Green 1 Tester negative probe Ground Set the main switch to ON Measure the voltage 12 V of Brown Green 1 at the flasher relay coupler wire harness side Is the voltage within specification 4 Voltage Connect the pocket tester DC 20 V to the flasher relay coupler wire harness side as shown 1 Turn signal light bulb and socket Check the turn signal light bulb and socket for continuity Re...

Page 105: ...ive probe Ground ELEC SIGNALING SYSTEM Set the main switch to ON Set the turn signal switch to Î or Measure the voltage 12 V of Chocolate 1 or Dark green 2 at the turn signal light con nector wire harness side Is the voltage within specification The wiring circuit from the turn signal switch to the turn signal light connector is faulty and must repaired YES NO 1 Neutral indicator light bulb and so...

Page 106: ...upler is faulty and must be re paired This circuit is OK YES NO The wiring circuit from the main switch to the meter light bulb coupler is faulty and must be repaired This circuit is OK YES NO 3 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler wire harness side as shown Tester positive probe Brown 1 Tester negative probe Sky Blue White 2 Set the main switch to ON Measure the...

Page 107: ...2 G B B LB LB Lg LR YB Y L Gy1 LY RB RW B Br Or RL BL W Sb WB YL SbW RB L LB LR LW BY Sb LY LG B B LG B B B W YB L Y BL LY WB RL Sb Br G NS SL1 SL2 SP RPM GND G G BLUE R 40 R 4 10 5 6 7 8 9 13 14 16 24 25 40 42 45 46 47 17 2 19 18 49 BLUE RB Or Or RB Gy1 Gy2 Gy2 PU VCC TPS S GND HD SS B L Y B PUMP LR L Y B L Y BL B BLACK BLACK B LG B B B B B B B B B B 10A BrL BrL R R BLACK 10A BLACK BW 3 15 21 FUE...

Page 108: ... pump circuit consists of the fuel pump re lay fuel pump engine stop switch and ignitor unit The ignitor unit includes the control unit for the fu el pump 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignitor unit 7 Fuel pump relay 8 Fuel pump ...

Page 109: ...ers 3 Fuel tank lift 4 Storage compartment battery cover Troubleshoot with the following special tool s The fuel pump fails to operate YES NO 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in Chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK EAS00739 Clean the battery ter minals Recharge or replace the battery YES NO 3 Main switch...

Page 110: ...r to CIRCUIT DIAGRAM Is the fuel pump system s wiring properly connected and without defects Replace the ignitor unit Properly connect or repair the fuel pump system s wiring NO YES 5 Starting circuit cutoff relay fuel pump relay Remove the relay unit from the wire harness Connect the pocket tester 1 and bat tery 12 V to the relay unit terminals Battery terminal Red Black terminal 1 Battery termin...

Page 111: ...wipe it up immedi ately with dry rags If gasoline touches the engine when the engine is still hot there is a danger of com bustion Make sure that the engine is com pletely cool before performing the following test 1 Check Fuel pump operation a Fill up the fuel tank b Put the end of the fuel hose into an open con tainer c Connect the battery 12 V to the fuel pump coupler terminals d Operate the eng...

Page 112: ...P BrR BrR BrL RW B B B B B R R RW L RW L L LW BY Sb SbW RB LY LG LR LB LB YL RW RB Gy2 G B B LB LB Lg LR YB Y L Gy1 LY RB RW B Br Or RL BL W Sb WB YL SbW RB L LB LR LW BY Sb LY LG B B LG B B B W YB L Y BL LY WB RL Sb Br G NS SL1 SL2 SP RPM GND G G Br Br B GL B Y HI BEAM IMOBILIZER RG Br B GW Dg Ch GL W YB Y BW SbW Sb Sb Sb B W W L L B BL B L W BL GW GW BrB BrB B B B G Y LR G B Y LR BLUE 40 4 10 11...

Page 113: ...lift 4 Storage compartment battery cover Troubleshoot with the following special tool s The carburetor heater fails to operate YES NO 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in Chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK EAS00739 Clean the battery ter minals Recharge or replace the battery YES NO 3 Main switch Check t...

Page 114: ...ace the thermo switch YES NO Replace the carbure tor heater YES NO 5 Carburetor heater Remove the carburetor heater from the car buretor body Connect the pocket tester to the carburetor heater Tester lead Heater terminal 1 Tester lead Heater body 2 Measure the heater resistance Carburetor heater resistance 12 V 30 W 6 10 at 20 C 68 F Is the carburetor heater OK EASB0041 6 Wiring Check the entire c...

Page 115: ...ilizer system in chapter ELECTRICAL of this manual Spark plug Improper plug gap Worn electrodes Wire between terminals severed Improper heat range Faulty spark plug cap Ignition coil Broken or shorted primary secondary Faulty spark plug lead Broken body Full transistor system Faulty ignitor unit Faulty pickup coil Switch and wiring Faulty main switch Faulty engine stop switch Broken or shorted wir...

Page 116: ...PRINTED IN ITALY YAMAHA MOTOR ITALIA S P A ...

Page 117: ... L Y BL LY WB RL Sb Br G NS SL1 SL2 SP RPM GND G G Br Br B GL B Y HI BEAM IMOBILIZER RG Br B GW Dg Ch GL W YB Y BWSbW Sb Sb Sb B W W L L B BL B L W BL GW GW BrB BrB B B B G Y LR G B Y LR BLUE R 40 R 4 10 11 39 5 6 7 8 9 12 13 14 16 22 23 24 25 26 27 28 29 30 31 32 33 35 36 37 38 40 41 42 45 46 47 17 51 1 2 19 18 20 34 44 49 48 BLUE MAIN HARNESS CARB HEATER HEAD LIGHT MAIN HARNESS RB Or Or RB Gy1 G...

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