Yamaha FJR1300A Service Manual Download

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MIDDLE GEAR

5-63

EAS25710

MIDDLE GEAR

Removing the middle gear

Order

Job/Parts to remove

Q’ty

Remarks

Engine

Refer to “ENGINE REMOVAL” on page 5-1.

Oil pan/Oil pump

Refer to “OIL PUMP” on page 5-58.

Middle gear case cover

Middle gear case cover gasket

Dowel pin

Damper cover

Damper

Middle drive shaft bearing housing

Bearing

Middle driven shaft end cover

Middle driven shaft assembly

Middle driven pinion gear shim

Middle drive pinion gear nut

Lock washer

Middle drive pinion gear

Middle drive shaft assembly

Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys

email: [email protected]

Summary of Contents for FJR1300A

Page 1: ...2006 SERVICE MANUAL FJR1300A V 3P6 28197 E0 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 2: ...st edition January 2006 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 3: ...cations or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice EAS20080 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 I...

Page 4: ...ion title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a disas sembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction chart 6 accompanies the exploded diagram providing the orde...

Page 5: ...gine mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening torque 6 Wear limit clearance 7 Engine speed 8 Electrical data 9 Engine oil 10 Gear oil 11 Molybdenum disulfide oil 12 Wheel bearing grease 13 Lithium soap based grease 14 Molybdenum disulfide grease 15 Apply locking agent LOCTITE 16 Replace the part Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Code...

Page 6: ...Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 7: ...PECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 8: ...Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 9: ...LF DIAGNOSIS FUNCTION 1 20 ABS WARNING LIGHT AND OPERATION 1 22 INSTRUMENT FUNCTIONS 1 24 IMPORTANT INFORMATION 1 30 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 30 REPLACEMENT PARTS 1 30 GASKETS OIL SEALS AND O RINGS 1 30 LOCK WASHERS PLATES AND COTTER PINS 1 30 BEARINGS AND OIL SEALS 1 31 CIRCLIPS 1 31 CHECKING THE CONNECTIONS 1 32 SPECIAL TOOLS 1 33 Manuals by Motomatrix www motomatrix co uk The S...

Page 10: ...cation number 1 is stamped into the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 11: ...e and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions detected by various sensor...

Page 12: ...ition sensor coolant temperature sensor cylinder identification sensor lean angle sensor crankshaft position sensor intake air pressure sensor intake air temperature sensor rear wheel sensor and O2 sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position sensor As a result the volume of fuel that is required by th...

Page 13: ... split at the hydraulic unit to transmit brake fluid pressure to both the rear brake caliper and part of the right front brake caliper in the unified brake system The brake fluid pressure transmitted to the rear brake caliper and part of the right front brake caliper is controlled by the proportioning valve and metering valve respectively The operation of these two valves ensures that the braking ...

Page 14: ...ake caliper in the uni fied brake system is determined mechanically be sure to use the specified brake pads Each set of brake pads should be checked individually and replaced if necessary ET3P61019 OUTLINE OF THE ABS 1 The Yamaha ABS anti lock brake system features an electronic control system which acts on the front and rear brakes independently However one set of pistons in the right front brake...

Page 15: ...though the wheel speed is reduced Brake force The force applied by braking to reduce the wheel speed Wheel lock A condition that occurs when the rotation of one or both of the wheels has stopped but the vehicle continues to travel Side force The force on the tires which supports the vehicle when cornering 4 5 6 7 8 9 10 11 12 13 14 1 2 3 A A 15 16 5 7 1 ABS test coupler 2 ABS warning light 3 ABS E...

Page 16: ...sented by the slip ratio Side force is also closely related to wheel slippage See figure A If the brakes are applied while keeping the proper slip ratio it is possible to obtain the maximum brake force without losing much side force ABS allows full use of the tires capabilities even on slippery road surfaces or less slippery road surfac es See figure B Wheel slip and hydraulic control The ABS ECU ...

Page 17: ... is activated a pulsating action may be felt at the brake lever or brake pedal but this does not indicate a malfunction The higher the side force on a tire the less traction there is available for braking This is true whether the vehicle is equipped with ABS or not Therefore sudden braking while cornering is not recommend ed Excessive side force which ABS cannot prevent could cause the tire to sli...

Page 18: ...response under various vehicle travel conditions The ABS also includes a highly developed self diagnosis function The ABS detects any problem con dition and allows normal braking even if the ABS is not operating properly When this occurs the ABS warning light on the meter assembly comes on The ABS stores the malfunction codes in the memory of the ABS ECU for easy problem identification and trouble...

Page 19: ...nce changes between the top and bottom of the serra tions with the rotation of the wheels inductive electromotive force is generated in the wheel sensors Wheel speed is detected based on the frequency of this alternating voltage 1 8 7 7 6 5 4 2 5 6 7 3 13 14 15 16 12 11 10 9 1 Rear brake master cylinder 2 Hydraulic unit 3 Front brake master cylinder 4 ABS motor 5 Hydraulic pump 6 Buffer chamber 7 ...

Page 20: ...BS operation is normal if the ABS warning light comes on for 2 seconds then goes off Hydraulic unit The hydraulic unit 1 is composed of three hydraulic control valves each with a solenoid valve and flow control valve two buffer chambers two hydraulic pumps and an ABS motor The hydraulic unit adjusts the front and rear wheel brake fluid pressure to control the wheel speed according to signals trans...

Page 21: ... fluid pressure and the spool 3 of the flow control valve is moved toward the solenoid valve 3 When the ABS ECU stops transmitting signals to decrease the brake fluid pressure the solenoid valve 2 closes and the brake fluid is pressurized again Pressurizing the brake fluid again while the ABS is activated limits the flow of the brake fluid with the movement of the flow control valve spool 3 and pr...

Page 22: ...ed by a cover 2 As shown in the block following diagram the ABS ECU receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits 1 Buffer chamber pressurized 2 Buffer chamber depressurized 3 Raised piston 1 2 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 23: ...mory of the ABS ECU e g a drop in battery voltage 7 4 5 6 2 3 1 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1 Battery 2 AC magneto 3 Rectifier regulator 4 Main fuse 5 Main switch 6 ABS fuse 7 ABS motor fuse 8 Front brake light switch 9 Brake light relay 10 Tail brake light 11 Rear brake light switch 12 ABS ECU 13 ABS motor relay 14 Hydraulic unit 15 ABS motor 16 Unified brake syst...

Page 24: ...ECU and the ABS motor oper ates when the ABS starts to reduce the hydraulic pressure of the brake fluid 2 1 3 4 5 6 7 8 A 1 Software operation flow 2 Main switch ON 3 Initialize 4 Self diagnosis when static 5 Self diagnosis when riding 6 Receive signals 7 Control operation 8 Depressurize pressurize A 8 1000th of a second 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle...

Page 25: ...tem 12 14 1 11 10 2 3 4 5 6 7 8 9 13 1 ABS ECU 2 Pump motor monitor 3 Power supply 4 Pump motor relay coil 5 Power supply 6 Front brake solenoid 7 Rear brake solenoid 8 Unified brake system solenoid 9 ABS warning light 10 Battery 11 ABS motor relay 12 Hydraulic unit 13 ABS motor 14 Solenoid valves Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info mot...

Page 26: ...re closed preventing the brake fluid from flowing through the pump As a result the brake master cylinder directly pressurizes the brake caliper during normal braking When the brake lever is released the brake fluid in the brake caliper re turns to the brake master cylinder via port A and port B 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Flow contro...

Page 27: ...C 13 and to the buffer chamber via port D 11 As a result the hydraulic pressure in the brake caliper is reduced The brake fluid stored in the buffer chamber is pumped back to the brake master cylinder by the hy draulic pump linked to the ABS motor 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Flow control valve 7 Port A 8 Spool 9 Port B 10 Orifice 11 ...

Page 28: ...rate regardless of the brake fluid pressure level since the restriction of port A 7 chang es so that a constant pressure difference is maintained between chamber A 20 and chamber B 21 of the flow control valve 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Flow control valve 7 Port A 8 Spool 9 Port B 10 Orifice 11 Port D 12 Solenoid valve 13 Port C 14 ...

Page 29: ...ht comes on while the start switch is being pushed When the engine is being started the ABS warning light comes on while the start switch is being pushed Refer to ELECTRIC STARTING SYSTEM on page 8 9 1 a e d d b c f a ABS warning light b Main switch OFF c Main switch ON d Goes off e Comes on for 2 seconds f ABS self diagnosis b c d e a f i f f h g a ABS warning light b Main switch OFF c Main switc...

Page 30: ...ing light 1 flashes and a malfunction code 2 is indicated on the multi function dis play when the test coupler adapter 3 is connected to the ABS test coupler 4 for troubleshooting the ABS The ABS test coupler can be accessed by removing front cowling right inner panel 1 When the test coupler adapter is connected to the ABS test coupler the ABS warning light starts flashing and the multi function d...

Page 31: ...ds then goes off The ABS operation is normal if the ABS warning light flashes Even if the ABS warning light remains on and does not go off or if it comes on after riding conven tional braking performance of the vehicle is maintained ABS function When hydraulic control is performed by the ABS the brake system alerts the rider that the wheels have a tendency to lock by generating a reaction force pu...

Page 32: ...traight ahead During a turn sudden braking is liable to cause a loss of traction of the tires Even vehicles equipped with ABS cannot be prevented from falling over if braked suddenly The ABS does not work when the main switch is turned to OFF The conventional braking function can be used Wheel lock A condition that occurs when the rotation of one or both of the wheels has stopped but the vehicle c...

Page 33: ...ure to stop the vehicle before making any setting changes to the multi function display The multi function display is equipped with the following an odometer which shows the total distance traveled two tripmeters which show the distance trav eled since they were last set to zero a fuel reserve tripmeter which shows the dis tance traveled on the fuel reserve a clock a fuel meter a coolant temperatu...

Page 34: ...sh the SELECT button and RESET but ton 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 Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The ...

Page 35: ...ure mode and the fuel consumption modes in the following order Air ambient temperature km L or L 100 km instantaneous fuel consumption AV_ _ km L or AV_ _ L 100 km average fuel consumption Air ambient temperature Ambient temperature mode This display shows the ambient temperature from 9 C to 50 C in 1 C increments The tem perature displayed may vary from the ambient temperature NOTE 1 If the ambie...

Page 36: ...ush the RESET button to select the mode again and then push the RESET button for 1 second while the display is flashing NOTE 1 To switch between the two average fuel con sumption displays push the RESET button for 1 second when either display is shown After resetting an average fuel consumption display _ _ will be shown for that display until the vehicle has traveled 1 km CAUTION EC3P61041 If ther...

Page 37: ...esetting the average fuel consumption display _ _ will be shown for that display until the vehicle has traveled 1 km 0 6 mi CAUTION EC3P61041 If there is a malfunction will be dis played Replace the meter assembly Self diagnosis device This model is equipped with a self diagnosis de vice for various electrical circuits If any of those circuits are defective the multi function display will indicate...

Page 38: ...e same key ring Immobilizer system keys may cause signal inter ference which may prevent the engine from starting 2 If the engine starts turn it off and try starting the engine with the standard keys 3 If one or both of the standard keys do not start the engine re register the standard keys If the multi function display indicates any fault codes note the code number and then check the vehicle Refe...

Page 39: ...from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals and O rings All gasket surfac es oil seal lips and O ring...

Page 40: ...te CAUTION ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfac es EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives Manuals by...

Page 41: ...properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector NOTE Make sure all connections are tight 5 Check Continuity with the pocket tester NOTE If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at most part stores Pocket tester 90890 03112 Analog pocket ...

Page 42: ...rting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Test coupler adapter 90890 03149 1 21 4 56 4 58 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 32 4 16 5 39 8 120 8 121 8 143 8 144 8 151 8 152 8 153 8 157 8 159 8 160 8 161 8 162 8 163 8 164 8 165 8 166 8 167 8 168 8 169 Valve lapper 90890 04101 Valve lapping tool YM ...

Page 43: ...3 14 Steering nut wrench 90890 01403 Spanner wrench YU 33975 3 26 4 77 Damper rod holder 90890 01447 YM 01447 4 69 4 70 Slide metal installer 90890 01508 4 71 Fork seal driver 90890 01502 YM A0948 4 71 4 72 Final gear backlash band 90890 01511 4 93 Tool name Tool No Illustration Reference pages Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motoma...

Page 44: ... 100 Pivot shaft wrench 90890 01471 Frame spanner socket YM 01471 5 6 5 7 Pivot shaft wrench adapter 90890 01476 5 6 5 7 Rotor holding tool 90890 01235 Universal magneto rotor holder YU 01235 5 11 5 14 Yamaha bond No 1215 90890 85505 Three Bond No 1215 5 16 5 32 5 35 5 79 6 13 Valve spring compressor 90890 04019 YM 04019 5 22 5 27 Tool name Tool No Illustration Reference pages Manuals by Motomatri...

Page 45: ...taller 5 0 mm YM 04098 5 23 Valve guide reamer ø5 90890 04099 Valve guide reamer 5 0 mm YM 04099 5 23 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 31 5 32 5 35 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 31 Universal clutch holder 90890 04086 YM 91042 5 48 5 51 Tool name Tool No Illustration Reference pages Manuals by Motomatrix www motomatrix co uk The Solution For ...

Page 46: ... retainer wrench YM 04140 5 68 Gear lash measurement tool 90890 01467 YM 01467 5 71 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 83 Piston ring compressor 90890 05158 YM 08037 5 88 Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 5 99 Tool name Tool No Illustration Reference pages 0 40 0 30 0 35 0 25 0 20 0 15 0 10 0 05 0 03 0 50 YU 01304 Manuals by Motomatrix www ...

Page 47: ...33984 6 3 Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A 6 13 Middle driven shaft bearing driver 90890 04058 Bearing driver 40 mm YM 04058 6 13 Pressure gauge 90890 03153 YU 03153 7 7 Tool name Tool No Illustration Reference pages YU 01083 3 YU 24460 01 YU 33984 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix ...

Page 48: ...890 03174 Model 88 Multimeter with tachometer YU A1927 7 8 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 8 162 Tool name Tool No Illustration Reference pages Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 49: ... ENGINE TIGHTENING TORQUES 2 16 CHASSIS TIGHTENING TORQUES 2 20 LUBRICATION POINTS AND LUBRICANT TYPES 2 25 ENGINE 2 25 CHASSIS 2 27 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 ENGINE OIL LUBRICATION CHART 2 29 LUBRICATION DIAGRAMS 2 31 COOLING SYSTEM DIAGRAMS 2 41 CABLE ROUTING 2 45 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 50: ...erall width 750 mm 29 5 in Overall height 1450 mm 57 1 in Seat height 800 mm 31 5 in Wheelbase 1545 mm 60 8 in Ground clearance 130 mm 5 12 in Minimum turning radius 3100 mm 122 0 in Weight With oil and fuel 291 0 kg 642 lb Maximum load 212 kg 467 lb Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 51: ...l filter cartridge replacement 3 80 L 4 02 US qt 3 34 Imp qt With oil filter cartridge replacement 4 00 L 4 23 US qt 3 52 Imp qt Oil pressure hot 30 0 kPa 1000 r min 4 4 psi 1000 r min 0 30 kgf cm 1000 r min Final gear oil Type Shaft drive gear oil Part No 9079E SH001 00 Quantity 0 20 L 0 21 US qt 0 18 Imp qt Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance Less than 0 12 m...

Page 52: ...0 006 in Spark plug s Manufacturer model NGK CR8E Manufacturer model DENSO U24ESR N Spark plug gap 0 7 0 8 mm 0 028 0 031 in Cylinder head Volume 22 74 23 34 cm 1 39 1 42 cu in Warpage limit 0 10 mm 0 0039 in Camshaft Drive system Chain drive right Camshaft cap inside diameter 24 500 24 521 mm 0 9646 0 9654 in Camshaft journal diameter 24 459 24 472 mm 0 9630 0 9635 in Camshaft journal to camshaft...

Page 53: ...h C intake 0 90 1 10 mm 0 0354 0 0433 in Valve seat width C exhaust 0 90 1 10 mm 0 0354 0 0433 in Valve margin thickness D intake 0 80 1 20 mm 0 0315 0 0472 in Valve margin thickness D exhaust 0 50 0 90 mm 0 0197 0 0354 in Valve stem diameter intake 4 975 4 990 mm 0 1959 0 1965 in Valve stem diameter exhaust 4 965 4 980 mm 0 1955 0 1960 in Valve guide inside diameter intake 5 000 5 012 mm 0 1969 0...

Page 54: ...ing rate K2 intake 28 34 N mm 161 82 lb in 2 89 kgf mm Spring rate K1 exhaust 21 85 N mm 124 76 lb in 2 23 kgf mm Spring rate K2 exhaust 28 34 N mm 161 82 lb in 2 89 kgf mm Installed compression spring force intake 136 00 158 00 N 30 57 35 52 lb 13 87 16 11 kgf Installed compression spring force exhaust 136 00 158 00 N 30 57 35 52 lb 13 87 16 11 kgf Spring tilt intake 2 5 1 7 mm 2 5 0 067 in Sprin...

Page 55: ... gap installed 0 35 0 45 mm 0 0138 0 0177 in Limit 0 70 mm 0 0276 in Ring side clearance 0 030 0 070 mm 0 0012 0 0028 in Limit 0 120 mm 0 0047 in 2nd ring Ring type Taper Dimensions B T 1 00 2 90 mm 0 04 0 11 in End gap installed 0 75 0 85 mm 0 0295 0 0335 in Limit 1 20 mm 0 0472 in Ring side clearance 0 020 0 060 mm 0 0008 0 0024 in Limit 0 120 mm 0 0047 in Oil ring Dimensions B T 2 00 2 50 mm 0 ...

Page 56: ...e disc Clutch release method Hydraulic inner push Clutch lever free play 1 9 20 7 mm 0 07 0 81 in Friction plate thickness 2 90 3 10 mm 0 114 0 122 in Wear limit 2 80 mm 0 110 in Plate quantity 9 pcs Clutch plate thickness 1 90 2 10 mm 0 075 0 083 in Plate quantity 8 pcs Warpage limit 0 10 mm 0 0039 in Clutch spring height 6 78 mm 0 27 in Minimum height 6 4 mm 0 25 in Spring quantity 1 pc Transmis...

Page 57: ...9 Ω at 20 C 68 F Cylinder identification sensor output voltage ON More than 4 8 V Cylinder identification sensor output voltage OFF Less than 0 6 V Intake air pressure sensor output voltage 3 75 4 25 V Coolant temperature sensor resistance 290 354 Ω at 80 C 176 F Idling condition Engine idling speed 1000 1100 r min Intake vacuum 33 3 kPa 9 8 inHg 250 mmHg Water temperature 100 0 105 0 C 212 00 221...

Page 58: ...turer model METZELER Roadtec Z6G Manufacturer model BRIDGESTONE BT020F Wear limit front 1 6 mm 0 06 in Rear tire Type Tubeless Size 180 55 ZR17M C 73W Manufacturer model METZELER Roadtec Z6C Manufacturer model BRIDGESTONE BT020R Wear limit rear 1 6 mm 0 06 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 270 kPa 39 psi 2 70 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm...

Page 59: ...0059 in Brake pad lining thickness inner 6 3 mm 0 25 in Limit 0 8 mm 0 03 in Brake pad lining thickness outer 6 3 mm 0 25 in Limit 0 8 mm 0 03 in Master cylinder inside diameter 15 0 mm 0 59 in Caliper cylinder inside diameter 41 30 mm 1 63 in Recommended fluid DOT 4 Clutch Recommended fluid DOT 4 Master cylinder inside diameter 14 0 mm 0 55 in Release cylinder inside diameter 29 6 mm 1 17 in Stee...

Page 60: ...6 2 mm 5 36 in Spring free length 73 9 mm 2 91 in Installed length 67 3 mm 2 65 in Soft Spring rate K1 91 00 N mm 519 60 lb in 9 28 kgf mm Spring rate K2 124 00 N mm 708 04 lb in 12 64 kgf mm Spring stroke K1 0 0 42 0 mm 0 00 1 65 in Spring stroke K2 42 0 60 0 mm 1 65 2 36 in Hard Spring rate K1 124 00 N mm 708 04 lb in 12 64 kgf mm Spring stroke K1 7 0 60 0 mm 0 28 2 36 in Optional spring availab...

Page 61: ...facturer LNX07 DENSO Standard output 14 0 V 590 W 5000 r min Stator coil resistance 0 13 0 19 Ω at 20 C 68 F Voltage regulator Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer FH012AA SHINDENGEN Regulated voltage DC 14 2 14 8 V Rectifier capacity DC 50 0 A Withstand voltage 40 0 V Battery Model GT14B 4 Voltage capacity 12 V 12 0 Ah Manufacturer GS YUASA Ten hour r...

Page 62: ...Commutator diameter 24 5 mm 0 96 in Limit 23 5 mm 0 93 in Mica undercut depth 1 50 mm 0 06 in Starter relay Model manufacturer MS5F 631 JIDECO Amperage 180 0 A Horn Horn type Plane Quantity 2 pcs Model manufacturer HF 12 NIKKO Maximum amperage 3 0 A Coil resistance 1 01 1 11 Ω at 20 C 68 F Performance 108 116 dB 2 m 6 6 ft Turn signal hazard relay Relay type Full transistor Model manufacturer FE24...

Page 63: ...nit Model manufacturer 25978 MITSUBISHI Resistance at 80 C 290 0 390 0 Ω Fuses Main fuse 50 0 A Headlight fuse 25 0 A Signaling system fuse 15 0 A Ignition fuse 10 0 A Radiator fan fuse 15 0 A 2 Auxiliary DC jack fuse 3 0 A Hazard fuse 10 0 A Fuel injection system fuse 15 0 A ABS motor fuse 30 0 A ABS control unit fuse 10 0 A Backup fuse 10 0 A Reserve fuse 30 0 A Reserve fuse 25 0 A Reserve fuse ...

Page 64: ... crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 m...

Page 65: ... 1 6 Nm 0 6 m kg 4 3 ft lb Camshaft sprocket bolt M7 4 24 Nm 2 4 m kg 17 ft lb Water pump assembly bolt M6 3 12 Nm 1 2 m kg 8 7 ft lb Water pump housing cover bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Coolant drain bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Water jacket joint bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Thermostat inlet pipe 1 bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Thermostat housing cover radia tor filler pi...

Page 66: ...lutch cover bolt M6 10 12 Nm 1 2 m kg 8 7 ft lb Middle gear case cover bolt M6 9 12 Nm 1 2 m kg 8 7 ft lb Pickup rotor cover bolt M6 8 12 Nm 1 2 m kg 8 7 ft lb Rear balancer cover bolt M6 4 12 Nm 1 2 m kg 8 7 ft lb Oil baffle plate 1 bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Oil baffle plate 2 bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Timing mark accessing plug M8 1 15 Nm 1 5 m kg 11 ft lb Oil guide plate bolt ...

Page 67: ... spring stopper bolt M8 1 22 Nm 2 2 m kg 16 ft lb Stator coil assembly bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Gear position switch bolt M5 2 4 Nm 0 4 m kg 2 9 ft lb Crankshaft position sensor bolt M5 2 4 Nm 0 4 m kg 2 9 ft lb O2 sensor M18 1 45 Nm 4 5 m kg 32 ft lb Intake air temperature sensor M12 1 18 Nm 1 8 m kg 13 ft lb Cylinder identification sensor bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Coolant temp...

Page 68: ...en tighten them further to reach the specified angle 115 125 NOTE Crankcase bolt Tighten the crankcase bolts to 20 Nm 2 0 m kg 14 ft lb in the proper tightening sequence loosen and retighten the bolts to 20 Nm 2 0 m kg 14 ft lb in the proper tightening sequence and then tighten them further to reach the specified angle 115 125 in the proper tightening sequence Cylinder head tightening sequence Cra...

Page 69: ... 1 24 Nm 2 4 m kg 17 ft lb Pinch bolt rear side M8 2 24 Nm 2 4 m kg 17 ft lb Pivot shaft M28 1 23 Nm 2 3 m kg 17 ft lb Pivot shaft nut M18 1 125 Nm 12 5 m kg 90 ft lb Pivot shaft locknut M28 1 115 Nm 11 5 m kg 85 ft lb Pivot shaft locknut retainer bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Relay arm and frame nut M10 1 40 Nm 4 0 m kg 29 ft lb Connecting arm and relay arm nut M10 1 48 Nm 4 8 m kg 35 ft lb ...

Page 70: ... unit bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Windshield lower inner bracket and windshield drive unit bolt M6 4 7 Nm 0 7 m kg 5 1 ft lb Rearview mirror nut M6 4 7 Nm 0 7 m kg 5 1 ft lb Windshield drive unit bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Windshield drive unit side rail bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Side cover bolt M6 3 7 Nm 0 7 m kg 5 1 ft lb Grab bar bolt M8 5 21 Nm 2 1 m kg 15 ft lb Grab bar...

Page 71: ...brake pad bolt M10 2 17 Nm 1 7 m kg 12 ft lb Rear brake caliper bolt M10 2 27 Nm 2 7 m kg 19 ft lb Rear brake hose rear wheel sen sor lead holder bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Rear brake caliper bleed screw M7 1 6 Nm 0 6 m kg 4 3 ft lb Hydraulic unit nut M8 3 16 Nm 1 6 m kg 11 ft lb Metering valve bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Proportioning valve bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Sidestand...

Page 72: ...t 4 pinch bolt 3 pinch bolt 4 tighten each bolt to 21 Nm 2 1 m kg 15 ft lb without performing temporary tightening Shift arm pinch bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Shift rod locknut M6 2 7 Nm 0 7 m kg 5 1 ft lb Drive shaft dust cover bolt M5 2 4 Nm 0 4 m kg 2 9 ft lb Final gear oil drain bolt M14 1 23 Nm 2 3 m kg 17 ft lb Final gear oil filler bolt M14 1 23 Nm 2 3 m kg 17 ft lb Final drive assem...

Page 73: ...TIGHTENING TORQUES 2 24 1 2 3 4 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 74: ...er and outer and oil pump shaft Oil pump drive sprocket Oil strainer Oil nozzle O ring Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Push rods and ball Transmission gears wheel and pinion Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift pedal bolt Damper drive cam and damper driven cam Middle driven gear Middle drive p...

Page 75: ...5 Crankcase mating surface Yamaha bond No 1215 Three Bond No 1215 Crankshaft position sensor lead grommet Yamaha bond No 1215 Three Bond No 1215 Stator coil assembly lead grommet Yamaha bond No 1215 Three Bond No 1215 Lubrication point Lubricant Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 76: ...r pivot bolt and metal to metal moving parts Silicon grease Clutch lever pivot bolt and metal to metal moving parts Silicon grease Rear shock absorber assembly oil seal Rear shock absorber assembly bearing Rear shock absorber assembly spacer Pivot shaft and pivot shaft thread Pivot shaft bearing Pivot shaft oil seal lip Relay arm bearing Oil seals rear shock absorber relay arm and connecting arm D...

Page 77: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 28 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 78: ...9 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 15 14 13 12 6 5 4 3 2 1 7 8 9 10 11 9 9 9 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 79: ... Oil cooler 6 Main gallery 7 Front balancer shaft 8 Rear balancer shaft 9 Oil nozzle 10 Intake camshaft 11 Exhaust camshaft 12 Main axle 13 Oil pipe 14 Drive axle 15 Middle drive shaft assembly Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 80: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 EAS20410 LUBRICATION DIAGRAMS 5 6 7 1 2 3 4 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 81: ...S 2 32 1 Intake camshaft 2 Cylinder head 3 Exhaust camshaft 4 Oil check bolt 5 Main gallery bolt 6 Crankshaft 7 Oil nozzle Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 82: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 1 3 2 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 83: ...UBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Main axle 2 Drive axle 3 Oil delivery pipe 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 84: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 6 5 4 3 2 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 85: ...T AND DIAGRAMS 2 36 1 Oil check bolt 2 Crankshaft 3 Oil cooler 4 Oil strainer 5 Oil delivery pipe 3 6 Oil pump Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 86: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 1 2 3 4 5 6 7 8 9 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 87: ...il delivery pipe 2 3 Engine oil drain bolt 4 Oil level switch 5 Crankshaft 6 Front balancer 7 Crank pin 8 Oil delivery pipe 3 9 Relief valve assembly Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 88: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39 4 5 3 2 1 9 8 6 7 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 89: ... 2 Oil delivery pipe 2 3 Oil cooler 4 Engine oil drain bolt 5 Oil level switch 6 Oil filter cartridge 7 Oil delivery pipe 3 8 Oil pan 9 Oil pump Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 90: ...S 2 41 EAS20420 COOLING SYSTEM DIAGRAMS A C D B B D A 6 5 15 6 7 8 9 9 10 1 2 3 4 12 11 16 17 18 19 13 14 5 C Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 91: ... 8 Thermostat inlet pipe 2 9 Coolant reservoir hose 10 Radiator inlet hose 11 Thermostat inlet hose 2 12 Thermostat assembly 13 Water jacket joint 14 Oil cooler 15 Oil cooler inlet hose 16 Water pump outlet pipe 17 Water pump breather hose 18 Radiator outlet hose 19 Water jacket joint inlet hose Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motom...

Page 92: ...COOLING SYSTEM DIAGRAMS 2 43 A A 7 1 2 3 4 5 5 7 8 6 8 9 10 11 12 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 93: ...tor 5 Radiator outlet hose 6 Oil cooler outlet hose 7 Water jacket joint inlet hose 8 Water pump outlet pipe 9 Water pump outlet hose 10 Water pump 11 Water jacket joint 12 Water pump breather hose Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 94: ...B A B C D E F G G H H I J K L M 1 1 1 2 2 2 2 3 3 3 4 4 4 5 5 5 6 7 8 9 11 11 12 12 10 11 12 13 14 15 16 17 18 19 20 20 20 21 21 21 1 2 3 M Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 95: ... immobilizer unit lead to the inside of the clutch hose F Temporarily tighten the brake hose joint bolt union bolt and brake hose holder bolt in the proper tightening sequence as shown Then tighten the bolts to the specified torques making sure to tighten the brake hose joint bolt 1 last G To front cowling wire harness H Install the horn L shaped connectors so that the leads are routed outward I F...

Page 96: ... 2 3 3 4 4 5 5 5 5 5 5 6 7 8 9 10 11 12 13 13 14 15 16 17 18 18 18 19 20 21 22 23 24 25 26 27 27 28 29 29 30 31 32 33 34 35 36 37 38 D F G M N P 27 29 29 18 O H Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 97: ...he end of the plastic locking tie rearward Do not cut off the excess end of the plastic locking tie F Route the positive battery lead between the battery stay and the battery box G To front cowling wire harness H Align the rear end of the right radiator fan motor coupler with the tape on the wire harness as shown in the illustration I Fasten the wire harness right horn high leads and right radiato...

Page 98: ...CABLE ROUTING 2 49 A B C D E 1 1 2 3 4 5 6 7 8 9 11 10 12 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 99: ...ake caliper 11 Rear brake light switch 12 Brake hose proportioning valve to rear brake caliper A Route the rear wheel sensor lead to the inside of the swingarm making sure that the lead does not protrude above the swingarm B 45 55 mm 1 77 2 17 in C 10 20 mm 0 39 0 79 in D Route the rear brake light switch lead under the rear wheel sensor lead E Fasten the rear wheel sensor lead to the brake hose p...

Page 100: ...CABLE ROUTING 2 51 A B C 1 2 3 4 6 5 7 8 9 10 11 12 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 101: ...e harness with a plastic locking tie Face the end of the plastic locking tie rearward along the side of the accessory box Do not cut off the excess end of the plastic locking tie B Fasten the wire harness and left radiator fan motor lead with the holder C Fasten the front cowling wire harness to the radiator inlet hose with a plastic locking tie making sure to install the tie on the harness protec...

Page 102: ...A B C D F E H I J K L M N O P Q R S T U V 1 2 6 6 8 14 14 8 9 10 11 12 13 15 16 17 18 19 20 21 22 23 24 25 26 G 6 7 3 5 4 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 103: ...a plastic locking tie making sure that the end of the tie faces upward Do not cut off the excess end of the plastic locking tie G Fasten the sidestand switch lead stator coil lead and oil level switch lead with a plastic locking tie making sure to bundle and fasten the sidestand switch lead so that the coupler is positioned to the front of the tie Face the end of the plastic locking tie outward Do...

Page 104: ... C C B B A A A B C E D F G H I J K 2 2 1 1 4 4 4 5 5 5 6 7 8 9 10 11 12 13 3 3 3 14 15 16 17 16 17 18 19 20 21 22 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 105: ...preload adjusting cable and under the hydraulic unit breather hose D Pass the stator coil lead rectifier regulator lead and hydraulic unit breather hose through the guide on the frame making sure to route the hose to the outside of the leads E Fasten the leads to ABS wire harness and rear brake light switch that branch off from the wire harness with the holder F When installing the ABS ECU be sure...

Page 106: ... D E F G I I J K L M N O P 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 31 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 107: ... in from the end of the protective sleeve of the front wheel sensor lead C Position the plastic locking tie 10 30 mm 0 39 1 18 in from the end of the protective sleeve of the immobilizer unit lead D Route the throttle cables and brake hoses through the right opening in the frame E Install the immobilizer unit coupler holder so that the end with the bolt is facing forward F Install the immobilizer ...

Page 108: ...CABLE ROUTING 2 59 D A B B C E 1 2 3 4 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 109: ...outed on top of the holder B Fasten the tail brake light assembly lead and license plate light lead with the holder C Route the tail brake light assembly lead and license plate light lead between the ribs on the rear fender D Route the intake air temperature sensor lead under the wire harness E Fasten the intake air temperature sensor lead to the air filter case with the holder Manuals by Motomatr...

Page 110: ... ROUTING 2 61 A A A B C D E P F H I J K L M N Q R 1 2 3 4 5 6 9 10 11 13 14 15 16 G 7 8 O 12 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 111: ... the harness J Secure the front cowling wire harness at the location shown in the illustration by inserting the projection on its holder into the hole in the windshield drive unit meter assembly stay K Fasten the leads to windshield drive unit that branch off from the front cowling wire harness to the harness with a plastic locking tie making sure to position the tie 20 mm 0 79 in from the drive u...

Page 112: ... F G G I 1 1 1 1 2 2 2 3 3 3 3 4 4 4 4 4 5 5 5 6 6 6 7 7 7 8 8 8 9 9 8 9 10 10 10 10 12 11 12 17 17 13 13 17 13 14 16 15 16 E H 11 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 113: ...Install the ABS motor relay completely onto the tab on the hydraulic unit bracket B Install the hydraulic unit solenoid coupler completely onto the tab on the hydraulic unit bracket C 87 93 D 5 7 mm 0 20 0 28 in E Install the hydraulic unit breather hose so that the white paint mark on the hose is facing down F Make sure that the brake hose hydraulic unit to proportioning valve contacts the end of...

Page 114: ...CABLE ROUTING 2 65 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 115: ... PRESSURE 3 11 CHECKING THE ENGINE OIL LEVEL 3 12 CHANGING THE ENGINE OIL 3 13 MEASURING THE ENGINE OIL PRESSURE 3 14 ADJUSTING THE CLUTCH LEVER 3 15 CHECKING THE CLUTCH FLUID LEVEL 3 15 BLEEDING THE HYDRAULIC CLUTCH SYSTEM 3 15 CLEANING THE AIR FILTER ELEMENT 3 16 CHECKING THE THROTTLE BODY JOINTS 3 16 CHECKING THE FUEL LINE 3 17 CHECKING THE CRANKCASE BREATHER HOSE 3 17 CHECKING THE EXHAUST SYST...

Page 116: ...HECKING THE FRONT FORK 3 28 ADJUSTING THE FRONT FORK LEGS 3 28 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3 29 ADJUSTING THE SIDE PANELS 3 30 ADJUSTING THE RIDER SEAT HEIGHT 3 31 CHECKING THE TIRES 3 32 CHECKING THE WHEELS 3 34 CHECKING AND LUBRICATING THE CABLES 3 34 LUBRICATING THE LEVERS 3 34 LUBRICATING THE PEDALS 3 34 LUBRICATING THE SIDESTAND 3 35 LUBRICATING THE CENTERSTAND 3 35 LUBRICATING...

Page 117: ...Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 118: ...on Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 4 Air filter element Clean Replace 5 Clutch Check operation fluid level and vehicle for fluid leakage 6 Front brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 7 Rear brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever w...

Page 119: ...el injection Adjust engine idling speed and synchronization 21 Engine oil Change Check oil level and vehicle for oil leakage 22 Engine oil filter car tridge Replace 23 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years 24 Final gear oil Check oil level and vehicle for oil leakage Change 25 Front and rear brake switches Check operation 26 Moving parts and ca ble...

Page 120: ... 3 Remove Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS on page 5 9 4 Remove Hose holder 1 Lead holders 2 Pickup rotor cover 3 5 Measure Valve clearance Out of specification Adjust a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres sion stroke align the TDC mark a on the pickup rotor with the crankcase mating sur face b NOTE TDC on the compress...

Page 121: ...r 1 and valve pad 2 so that they can be in stalled in the correct place b Calculate the difference between the speci fied valve clearance and the measured valve clearance Example Specified valve clearance 0 15 0 22 mm 0 0059 0 0087 in Measured valve clearance 0 25 mm 0 0098 in 0 25 mm 0 0098 in 0 22 mm 0 0087 in 0 03 mm 0 001 in c Check the thickness of the current valve pad NOTE The thickness a o...

Page 122: ...nd camshaft journals First install the exhaust camshaft Turn the crankshaft clockwise several full turns to seat the parts h Measure the valve clearance again i If the valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the specified clearance is obtained 8 Install All removed parts NOTE For installation reverse the removal procedure 9 Adjust Th...

Page 123: ... step rev the engine two or three times each time for less than a second and check the synchronization again If the air screw was removed turn the screw 3 4 turn in and be sure to synchronize the throt tle body CAUTION ECA14900 Do not use the throttle valve adjusting screws to adjust the throttle body synchroni zation NOTE The difference in vacuum pressure between two throttle bodies should not ex...

Page 124: ...ve tripmeter dis plays dIAG appears on the odometer tripmeter fuel reserve tripmeter LCD 3 Press the SELECT button to select the CO adjustment mode Co 1 or the diagnostic mode dIAG 4 After selecting CO simultaneously press the SELECT and RESET buttons for 2 seconds or more to activate the selection 5 Press the SELECT and RESET buttons to select a cylinder number 1 NOTE The selected cylinder number...

Page 125: ...o the spark plug lead of cylinder 1 4 Install Fuel tank Refer to FUEL TANK on page 7 1 5 Check Engine idling speed Out of specification Adjust 6 Adjust Engine idling speed a Turn the engine idle speed adjustment screw 1 in direction a or b until the specified en gine idling speed is obtained 7 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 8 8 Install T ...

Page 126: ...Fuel tank Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS20680 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 T bar Refer to GENERAL CHASSIS on page 4 1 2 Disconnect Spark plug cap 3 Remove Spark plug CAUTION ECA13320 Before removi...

Page 127: ...tand the vehicle on a level surface NOTE Place the vehicle on the centerstand 2 Remove Right side cowling Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 T bar Refer to GENERAL CHASSIS on page 4 1 3 Remove Timing mark accessing plug 1 along with the copper washer 4 Connect Timing light 1 onto the spark plug lead of cylinder 1 Digital tachometer onto the spa...

Page 128: ...ar Refer to GENERAL CHASSIS on page 4 1 4 Disconnect the all spark plug caps 5 Remove Spark plug CAUTION ECA13340 Before removing the spark plugs use com pressed air to blow away any dirt accumulat ed in the spark plug wells to prevent it from falling into the cylinders 6 Install Compression gauge 1 7 Measure Compression pressure Out of specification Refer to steps c and d a Set the main switch to...

Page 129: ...mended engine oil to the proper level CAUTION EC3P61036 Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD a or higher and do not use oils labeled ENERGY CONSERVING II b Do not allow foreign materials to enter the crankcase NOTE Before checking the engine oil level ...

Page 130: ...er wrench 6 Install Engine oil drain bolt along with the gasket 7 Fill Crankcase with the specified amount of the recom mended engine oil 8 Install Engine oil filler cap 9 Start the engine warm it up for several min utes and then turn it off 10 Check Engine for engine oil leaks 11 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 12 12 Check Engine oil pressure a Remove the r...

Page 131: ... increase Therefore be sure to measure the engine oil pressure after warming up the engine 3 Remove Right side cowling Refer to GENERAL CHASSIS on page 4 1 4 Remove Main gallery bolt WARNING EWA12980 The engine muffler and engine oil are ex tremely hot 5 Install Oil pressure gauge set 1 Oil pressure adapter B 2 6 Measure Engine oil pressure at the following conditions Out of specification Adjust 7...

Page 132: ...uld cause vapor lock CAUTION ECA13420 Clutch fluid may damage painted surfaces or plastic parts Therefore always clean up any spilt clutch fluid immediately NOTE In order to ensure a correct reading of the clutch fluid level make sure the top of the reservoir is horizontal EAS20900 BLEEDING THE HYDRAULIC CLUTCH SYSTEM WARNING EWA13000 Bleed the hydraulic clutch system whenever the system was disas...

Page 133: ...lement Apply compressed air to the outer surface of the air filter element 3 Check Air filter element Damage Replace CAUTION EC3P61043 Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect throttle body synchronization leading to poor engin...

Page 134: ...Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS21070 CHECKING THE CRANKCASE BREATHER HOSE 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 T bar Air filter case Refer to GENERAL CHASSIS on page 4 1 2 Check Crankcase breather hose 1 Cracks damage Replace Loose connection Connect properly CAUTION ECA13450 Make sure the crankcase breather hose is r...

Page 135: ...ifreeze concentra tion of the coolant Use only distilled water However if dis tilled water is not available soft water may be used 4 Start the engine warm it up for several min utes and then turn it off 5 Check Coolant level NOTE Before checking the coolant level wait a few minutes until it settles 6 Install Left side panel Refer to GENERAL CHASSIS on page 4 1 EAS21120 CHECKING THE COOLING SYSTEM ...

Page 136: ... which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter clockwise toward the detent to allow any re sidual pressure to escape When the hissing sound has stopped press down on the radi ator cap and turn it counterclockwise to re move 3 Remove Coolant drain bolt water pu...

Page 137: ...is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 12 Install Radiator cap 13 Fill Coolant reservoir with the recommended coolant to the maxi mum level mark a 14 Install Coolant reservoir cap 15 Start the engine warm it up for several min utes and then stop it 16 Check Coolant level ...

Page 138: ...k Brake pedal position distance a from the top of the rider footrest to the top of the brake pedal Out of specification Adjust 2 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained WARNING EWA13070 After adjusting the brake pedal position check that the end of the adjusting bolt c is visible through...

Page 139: ...ction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately NOTE In order to ensure a correct reading of the bra...

Page 140: ...K BRAKE SYSTEM on page 4 50 EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear brake light switch is operated by movement of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking ef fect starts If the switch is not properly adjusted ABS mal function code No 23 may be displayed 1 Check Rear brake light operation timing Incor...

Page 141: ...ster cylinder reservoir or brake fluid reservoir to the proper level with the recommended brake fluid b Install the diaphragm brake master cylinder reservoir or brake fluid reservoir c Connect a clear plastic hose 1 tightly to the bleed screw 2 d Place the other end of the hose into a con tainer e Slowly apply the brake several times f Fully squeeze the brake lever or fully depress the brake pedal...

Page 142: ...tly from the side Incorrect Adjust 2 Adjust Shift pedal position a Loosen both locknuts 1 b Turn the shift rod 2 in direction a or b to obtain the correct shift pedal position NOTE Check that the groove c in the shift pedal is be tween the projections d on the frame c Tighten both locknuts to specification EAS21460 CHECKING THE FINAL GEAR OIL LEVEL 1 Stand the vehicle on a level surface NOTE Place...

Page 143: ...E Place the vehicle on a suitable stand so that the front wheel is elevated 2 Check Steering head Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head 3 Remove Upper bracket Refer to STEERING HEAD on page 4 75 4 Adjust Steering head a Remove the lock washer 1 the upper ring nut 2 and the rubber washer 3 b Tighten the lower ring nut 4 wit...

Page 144: ... sure the lock washer tabs a sit correctly in the ring nut slots b 5 Install Upper bracket Refer to STEERING HEAD on page 4 75 ET3P61034 ADJUSTING THE HANDLEBAR POSITION 1 Check Handlebar position NOTE The handlebar position can be adjusted to one of three positions to suit the rider s preference 2 Adjust Handlebar position a Remove the plates 1 b Remove the handlebar nuts 2 and bolts 3 c Remove t...

Page 145: ...wing procedure applies to both of the front fork legs WARNING EWA13150 Always adjust both front fork legs evenly Uneven adjustment can result in poor han dling and loss of stability Securely support the motorcycle so that there is no danger of it falling over Spring preload CAUTION ECA13570 Grooves are provided to indicate the ad justment position Never go beyond the maximum or mini mum adjustment...

Page 146: ...o beyond the maximum or minimum adjustment positions 2 Current setting Direction a Rebound damping is increased sus pension is harder Direction b Rebound damping is decreased sus pension is softer Rebound damping adjusting posi tions Minimum 17 click s out Standard 12 click s out Maximum 1 click s out With the adjusting knob fully turned in Direction a Compression damping is increased suspension i...

Page 147: ...l a Remove the quick fastener screws 1 b Pull the side panel to the open position and then install the quick fastener screws 1 Direction a Spring preload is increased suspen sion is harder Direction b Spring preload is decreased suspen sion is softer Direction a Rebound damping is increased sus pension is harder Direction b Rebound damping is decreased sus pension is softer Rebound damping adjusti...

Page 148: ...d to the lower position at delivery 2 Remove Passenger seat Rider seat Refer to GENERAL CHASSIS on page 4 1 3 Remove Rider seat height position adjuster 1 NOTE Remove the rider seat height position adjuster by pulling it upward 4 Adjust Rider seat height To change to the high position a Move the rider seat holder cover 1 to the lower position as shown b Install the rider seat height position adjus...

Page 149: ...ark a is aligned with the match mark b c Insert the projection c on the front of the rid er seat into seat holder for low position 3 as shown d Align the low position projection d on the bottom of the rider seat with the L position slot e and then push the rear of the seat down to lock it in place as shown 5 Install Passenger seat Refer to GENERAL CHASSIS on page 4 1 EAS21650 CHECKING THE TIRES Th...

Page 150: ...tall the correct tube Always replace a new tube tire and a new tube as a set To avoid pinching the tube make sure the wheel rim band and tube are centered in the wheel groove Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality re placement Tire air pressure measured on cold tires Loading co...

Page 151: ... LUBRICATING THE CABLES The following procedure applies to all of the in ner and outer cables WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement Re place damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricate NOTE Hold the cable end upright and pour a few drops of ...

Page 152: ...rstand EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle ...

Page 153: ... bulb holder CAUTION ECA13690 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 7 Attach Headlight bulb holder 8 Install Headlight bulb cover 9 Connect H...

Page 154: ...to the left Direction b Headlight beam moves to the right Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left 1 b a b a Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 155: ...4 22 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR 4 22 ASSEMBLING THE REAR WHEEL 4 22 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 23 INSTALLING THE REAR WHEEL REAR BRAKE DISC 4 23 FRONT BRAKE 4 25 INTRODUCTION 4 30 CHECKING THE FRONT BRAKE DISCS 4 30 REPLACING THE FRONT BRAKE PADS 4 31 REMOVING THE FRONT BRAKE CALIPERS 4 32 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 32 CHECKING THE FRONT BRAK...

Page 156: ...C UNIT OPERATION TESTS 4 56 TRIAL RUN 4 59 HANDLEBARS 4 60 REMOVING THE HANDLEBARS 4 62 CHECKING THE HANDLEBARS 4 62 INSTALLING THE HANDLEBARS 4 62 FRONT FORK 4 65 REMOVING THE FRONT FORK LEGS 4 68 DISASSEMBLING THE FRONT FORK LEGS 4 68 CHECKING THE FRONT FORK LEGS 4 69 ASSEMBLING THE FRONT FORK LEGS 4 70 INSTALLING THE FRONT FORK LEGS 4 73 STEERING HEAD 4 75 REMOVING THE LOWER BRACKET 4 77 CHECKI...

Page 157: ... FINAL GEAR BACKLASH 4 93 MEASURING THE RING GEAR TO STOPPER BOLT CLEARANCE 4 94 ADJUSTING THE RING GEAR TO STOPPER BOLT CLEARANCE 4 94 DISASSEMBLING THE FINAL DRIVE ASSEMBLY 4 95 REMOVING AND INSTALLING THE BEARINGS 4 96 ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR 4 96 CHECKING THE DRIVE SHAFT 4 99 INSTALLING THE DRIVE SHAFT AND FINAL DRIVE ASSEMBLY 4 100 Manuals by Motomatrix www motomatr...

Page 158: ...ng 1 6 Center rear cowling 1 7 Left side cover 1 8 Right side cover 1 9 Rider seat height position adjuster 1 For installation reverse the removal proce dure T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 21 Nm 2 1 m kg 15 ft Ib 3 1 4 7 2 5 9 6 8 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co ...

Page 159: ...right inner panel 1 1 9 Headlight beam adjusting knob 2 10 Front cowling right inner panel 2 1 11 Adjusting knob shaft 2 12 Headlight beam adjusting cable 2 Disconnect 13 Front cowling left inner panel 1 1 14 Front cowling left inner panel 2 1 15 Plastic band 2 Disconnect 16 Plastic holder 1 Disconnect T R 32 Nm 3 2 m kg 23 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LT 10 9 4 8 20 1 3 6 7 2 12 11 5 12 ...

Page 160: ...1 For installation reverse the removal proce dure Removing the front cowling assembly Order Job Parts to remove Q ty Remarks T R 32 Nm 3 2 m kg 23 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LT 10 9 4 8 20 1 3 6 7 2 12 11 5 12 16 11 14 13 9 18 19 17 19 15 18 18 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 161: ...olenoid coupler 1 Disconnect 7 Auxiliary DC jack coupler 1 Disconnect 8 Accessory box 1 9 Accessory box solenoid 1 10 Headlight coupler 2 Disconnect 11 Auxiliary light coupler 2 Disconnect 12 Front cowling 1 For assembly reverse the disassembly pro cedure 7 7 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 1 2 3 5 5 6 12 7 8 9 4 10 1...

Page 162: ... remove Q ty Remarks Front cowling Refer to Disassembling the front cowling assembly 1 Headlight assembly 1 For installation reverse the removal proce dure 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 163: ...oupler 1 Disconnect 7 Relay unit 1 8 Turn signal hazard relay coupler 1 Disconnect 9 Turn signal hazard relay 1 10 Headlight relay dimmer coupler 1 Disconnect 11 Headlight relay dimmer 1 12 Lean angle sensor coupler 1 Disconnect 13 Lean angle sensor 1 For installation reverse the removal proce dure T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LS LS T R 10 Nm 1 0 m kg 7 2 ft Ib 3 2 2 1...

Page 164: ...shaft 1 onto the left headlight beam adjusting cable 2 d Place front cowling left inner panel 2 3 be tween the front cowling assembly and the steering stem e Fit the top and side of inner panel 2 into the front cowling assembly to the left of the meter assembly f Fit inner panel 2 under the right side of the ac cessory box NOTE Pull the front cowling assembly outward when fitting the panel under t...

Page 165: ...ign the projection a on the shaft s sleeve with the slot b in the panel and then install the nut d Install the headlight beam adjusting knob 4 e Fit the lower right corner of inner panel 2 into the front cowling assembly making sure to align the bolt hole in the panel with the bolt hole in the cowling f Fit the top and side of inner panel 2 into the front cowling assembly to the right of the meter...

Page 166: ...GENERAL CHASSIS 4 9 b a 1 2 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 167: ...ASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 T bar 1 2 Heat protector 1 For installation reverse the removal proce dure 1 2 T R 37 Nm 3 7 m kg 27 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 168: ...ower fuel tank bracket 1 10 Intake air temperature sensor 1 11 Bypass air unit inlet hose 1 Disconnect 12 Crankcase breather hose 1 Disconnect 13 Air induction system hose air filter case joint assembly to 3 way joint 1 Disconnect 14 Air filter case joint clamp screw 4 Loosen T R 7 Nm 0 7 m kg 5 1 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib New T R 4 Nm 0 4 m kg 2 9 ft Ib 5 6 7 1...

Page 169: ... proce dure Removing the air filter case Order Job Parts to remove Q ty Remarks T R 7 Nm 0 7 m kg 5 1 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib New T R 4 Nm 0 4 m kg 2 9 ft Ib 5 6 7 1 2 4 11 4 8 9 10 14 16 3 4 14 17 18 15 12 17 13 11 14 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 170: ...en 6 Front wheel axle bolt 1 7 Front wheel axle 1 8 Front wheel 1 9 Front wheel sensor housing 1 10 Collar 1 11 Front brake disc 2 For installation reverse the removal proce dure T R 18 Nm 1 8 m kg 13 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 21 Nm 2 1 m kg 15 ft Ib T R 91Nm 9 1 m kg 66 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 6 Nm 0 6 m kg 4 3 ft I...

Page 171: ...el Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 172: ...Clean the outside of the front wheel hub b Remove the oil seals 1 with a flathead screwdriver NOTE To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a gener al bearing puller EAS21920 CHECKING THE FRONT WHEEL 1 Check Wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING EWA13460 Do not attempt to straighten...

Page 173: ...lean 2 Measure Front wheel sensor resistance Out of specification Replace a Connect the pocket tester Ω 1k to the front wheel sensor coupler terminals as shown b Measure the front wheel sensor resistance 3 Check Front wheel sensor rotor 1 Cracks damage Replace the front wheel assembly NOTE The wheel sensor rotor of the vehicle is inserted under pressure by a special process and cannot be replaced ...

Page 174: ...heel s heavy spot NOTE Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps d through f several times un til all the marks come to r...

Page 175: ...SCS on page 4 30 3 Lubricate Oil seal lips 4 Install Collar Front wheel sensor housing Front wheel NOTE Align the slot in the front wheel sensor housing with the projection of the front fork before as sembly 5 Install Front wheel axle Front wheel axle bolt Front wheel axle pinch bolts CAUTION EC3P61022 Before tightening the wheel axle bolt push down hard on the handlebars several times and check i...

Page 176: ...olt to 21 Nm 2 1 m kg 15 ft lb without performing temporary tightening 6 Install Front brake calipers Front wheel sensor NOTE When installing the front wheel sensor check the wheel sensor lead for twists and the sensor electrode for foreign materials CAUTION EC3P61023 Make sure there are no foreign materials in the wheel hub Foreign materials cause damage to the inner sensor rotor and wheel sensor...

Page 177: ...axle nut 1 5 Brake torque rod 1 6 Rear wheel axle 1 7 Rear brake caliper 1 8 Rear wheel 1 9 Rear wheel sensor housing 1 10 Collar 1 11 Rear brake disc 1 For installation reverse the removal proce dure T R 23 Nm 2 3 m kg 17 ft Ib T R 125 Nm 12 5 m kg 90 ft lb T R 30 Nm 3 0 m kg 22 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 1 4 3 5 7 9 11 6 T R 18 Nm 1 8 m kg 13 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib 2 8 10 6 LT ...

Page 178: ... 1 3 Dust seal 1 4 Wheel bearing 1 5 Rear wheel drive hub damper 6 6 Oil seal 1 7 Circlip 1 8 Wheel bearing 1 9 Spacer 1 10 Spacer 1 11 Oil seal 1 12 Bearing 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 179: ...heel Damage wear Replace Refer to CHECKING THE TIRES on page 3 32 and CHECKING THE WHEELS on page 3 34 3 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 15 EAS22200 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR CAUTION EC3P61032 Handle the ABS components with care since they have been accurately adjusted Keep them away from dirt and do not sub j...

Page 180: ...tall Rear wheel sensor housing Rear wheel Rear brake caliper Rear wheel axle Brake torque rod Rear wheel axle nut NOTE Align the slot a of the rear wheel sensor hous ing 1 with the projection b of the rear brake caliper bracket 2 and then assemble them After assembling the rear wheel sensor hous ing and the rear brake caliper bracket make sure that the projection c on the housing is aligned with t...

Page 181: ... sensor lead for twists and the sensor electrode for foreign materials 7 Check Rear wheel sensor installation Check if the wheel sensor housing is installed properly T R Brake torque rod nut 30 Nm 3 0 m kg 22 ft lb Rear wheel axle nut 125 Nm 12 5 m kg 90 ft lb Rear wheel axle pinch bolt 23 Nm 2 3 m kg 17 ft lb T R Rear wheel sensor bolt 30 Nm 3 0 m kg 22 ft lb Manuals by Motomatrix www motomatrix ...

Page 182: ...nt brake caliper 1 3 Brake pad bolt 2 4 Brake pad spring 2 5 Front brake pad 4 For installation reverse the removal proce dure T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib LS LS T R 17 Nm 1 7 m kg 12 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib 1 2 5 4 4 5 3 3 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co...

Page 183: ... er 1 3 Brake master cylinder reservoir diaphragm 1 4 Brake lever 1 5 Front brake light switch connector 2 Disconnect 6 Brake hose union bolt 1 7 Copper washer 2 8 Brake hose front brake master cylinder to hy draulic unit 1 9 Front brake master cylinder holder 1 10 Front brake master cylinder 1 11 Front brake light switch 1 For installation reverse the removal proce dure Manuals by Motomatrix www ...

Page 184: ...remove Q ty Remarks 1 Brake master cylinder push rod 1 2 Dust boot 1 3 Circlip 1 4 Brake master cylinder kit 1 5 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 185: ...hose hydraulic unit to front brake cali pers 1 5 Brake hose union bolt unified brake system 1 Right side only 6 Copper washer 2 Right side only 7 Brake hose metering valve to right front brake caliper 1 Right side only 8 Front brake caliper 1 For installation reverse the removal proce dure T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib 1 2 4 7 5 6 8 3 New New M...

Page 186: ...t brake pad 4 4 Brake caliper piston 4 5 Brake caliper piston seal 8 6 Bleed screw 1 7 Bleed screw 1 Right side only For assembly reverse the disassembly pro cedure T R 17 Nm 1 7 m kg 12 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib New New New New LS 1 2 2 3 4 4 1 6 3 7 5 5 5 5 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motoma...

Page 187: ...to FRONT WHEEL on page 4 13 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflec tion turn the handlebar to the left or right to ensure that the front wheel is stationary c Re...

Page 188: ...n Replace the brake pads as a set 2 Install Brake pads Brake pad spring NOTE Always install new brake pads and a new brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install new br...

Page 189: ...em 1 Remove Brake hose holder 1 Brake hose union bolts 2 Copper washers Brake hose hydraulic unit to front brake cali pers 3 Brake hose metering valve to right front brake caliper 4 NOTE Put the end of the brake hoses into a container and pump out the brake fluid carefully EAS22360 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Remove Brake c...

Page 190: ...with clean or new brake fluid Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals EAS22440 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Install Front brake caliper 1 temporarily Copper washers Brake hose hydraul...

Page 191: ...r the brake master cylinder reser voir and brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 23 6 Check Brake fluid le...

Page 192: ...4 Check Brake hose Cracks damage wear Replace EAS22520 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER WARNING EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents EAS22530 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Brake master cylinder 1 Brake master cylinder holder 2 NOTE ...

Page 193: ...brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir and brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up ...

Page 194: ...ove Q ty Remarks 1 Rear brake caliper bolt 2 2 Rear brake caliper 1 3 Brake pad shim 2 4 Rear brake pad 2 5 Brake pad spring 2 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 195: ...aphragm 1 4 Brake fluid reservoir 1 5 Brake fluid reservoir hose 1 6 Rear brake light switch coupler 1 Disconnect 7 Right footrest assembly 1 8 Rear brake light switch 1 9 Brake hose union bolt 1 10 Copper washer 2 11 Brake hose rear brake master cylinder to hy draulic unit 1 Disconnect 1 2 3 4 5 6 7 9 10 11 8 12 T R 28 Nm 2 8 m kg 20 ft Ib New New T R 28 Nm 2 8 m kg 20 ft Ib T R 30 Nm 3 0 m kg 22...

Page 196: ...ke master cylinder Order Job Parts to remove Q ty Remarks 1 2 3 4 5 6 7 9 10 11 8 12 T R 28 Nm 2 8 m kg 20 ft Ib New New T R 28 Nm 2 8 m kg 20 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 197: ...emove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder push rod 1 4 Brake master cylinder kit 1 5 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 198: ...er washer 2 3 Brake hose proportioning valve to rear brake caliper 1 4 Rear brake caliper bolt 2 Loosen 5 Rear wheel axle pinch bolt 1 Loosen 6 Rear wheel axle nut 1 7 Brake torque rod 1 8 Rear wheel axle 1 9 Rear brake caliper assembly 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co u...

Page 199: ... Brake pad shim 2 3 Rear brake pad 2 4 Brake pad spring 2 5 Rear brake caliper bracket 1 6 Brake caliper piston 1 7 Brake caliper piston seal 2 8 Bleed screw 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 200: ...deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 30 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 30 5 Adjust Brake disc deflection Refer to CHECKING THE FRONT BRAKE DISCS on page ...

Page 201: ...e fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 22 5 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 23 EAS22590 REMOVING THE REAR BRAKE CALIPER NOTE Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolt 1 Copper wash...

Page 202: ...h compressed air WARNING EWA13610 Whenever a brake caliper is disassembled replace the brake caliper piston seals 2 Check Brake caliper bracket Cracks damage Replace EAS22650 ASSEMBLING THE REAR BRAKE CALIPER WARNING EWA13620 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents as they wil...

Page 203: ...1 Brake hose union bolt 2 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 45 CAUTION EC3P61044 When installing the brake hose onto the brake caliper make sure the brake pipe a touches the projection b on the brake cali per 4 Remove Rear brake caliper bolts Rear brake caliper 5 Install Brake pad springs Rear brake pads Brake...

Page 204: ... HYDRAULIC BRAKE SYSTEM ABS on page 3 23 EAS22700 REMOVING THE REAR BRAKE MASTER CYLINDER NOTE Before removing the rear brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Brake hose union bolt 1 Copper washers 2 Brake hose rear brake master cylinder to hy draulic unit 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end...

Page 205: ... that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up...

Page 206: ...JUSTING THE REAR DISC BRAKE on page 3 21 8 Adjust Rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 23 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 207: ...Rear brake caliper 8 Brake hose proportioning valve to rear brake caliper 9 Left front brake caliper 10 Right front brake caliper partially operated together with the rear brake 11 Front wheel sensor 12 Front wheel sensor rotor 13 Brake hose rear brake master cylinder to hydraulic unit 14 Proportioning valve 15 Brake hose hydraulic unit to proportioning valve 16 Brake hose proportioning valve to r...

Page 208: ...on page 3 23 Brake fluid reservoir Refer to REAR BRAKE on page 4 37 1 Tail brake light assembly coupler 1 Disconnect 2 License plate light connector 2 Disconnect 3 Tail brake light assembly 1 4 Seat lock cable assembly 1 5 Rear fender assembly 1 For installation reverse the removal proce dure T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 1 3 2 5 4 Manuals by M...

Page 209: ...oportioning valve 1 9 Brake hose union bolt Copper washer 2 4 10 Brake hose hydraulic unit to metering valve 1 11 Hydraulic unit 1 12 Hydraulic unit solenoid coupler 1 Disconnect 13 ABS motor coupler 1 Disconnect 14 Brake hose union bolt Copper washer 1 2 15 T R 19 Nm 1 9 m kg 13 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T...

Page 210: ...Job Parts to remove Q ty Remarks 15 T R 19 Nm 1 9 m kg 13 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib 17 18 13 16 11 10 9 8 9 9 1 2 1 3 6 3 5 5 4 7 7 9 14 14 New New New New New New New 12 Manuals by Motomatrix www...

Page 211: ...rs Brake fluid may damage the cou plers and cause bad contacts If the union bolts for the hydraulic unit have been removed be sure to tighten them to the specified torque and bleed the brake system 1 Remove Brake hose 1 front brake master cylinder to hydraulic unit Brake hose 2 rear brake master cylinder to hydraulic unit Brake hose 3 hydraulic unit to front brake calipers Brake hose 4 hydraulic u...

Page 212: ... brake hose 1 contacts the stopper a on the metering valve 4 Install Copper washers Brake hose 1 hydraulic unit to metering valve Brake hose 2 hydraulic unit to proportion ing valve Brake hose 3 hydraulic unit to front brake calipers Brake hose 4 rear brake master cylinder to hydraulic unit Brake hose 5 front brake master cylinder to hydraulic unit Brake hose union bolts NOTE Make sure that the br...

Page 213: ...HYDRAULIC UNIT OPERATION TESTS The reaction force pulsating action generated in the brake lever and brake pedal when the ABS is activated can be tested when the vehicle is stopped The hydraulic unit operation can be tested using the following two methods Hydraulic unit operation test 1 this test checks the function of the ABS after the system was disassembled adjusted or serviced Hydraulic unit op...

Page 214: ...leased during the second pulse in the brake pedal third pulse overall by manually applying force to rotate the rear wheel If the rear brake force is released during the second pulse in the brake pedal the second person will be able to rotate the rear wheel for 0 1 second CAUTION EC3P61013 Check that the pulse is felt in the brake le ver once and then in the brake pedal twice If the pulse is felt i...

Page 215: ...or replace the battery NOTE If the battery voltage is lower than 12 8 V charge the battery and then perform hydraulic unit operation test 2 If the battery voltage is lower than 10 V the ABS warning light comes on and the ABS does not operate 5 Connect the test coupler adapter 1 to the ABS test coupler 2 6 Set the engine stop switch 1 to 7 Turn the main switch to ON NOTE After turning the main swit...

Page 216: ...stopped in the brake pedal it is generated in the brake lever 0 5 second later and continues for approxi mately 2 seconds NOTE The reaction force pulsating action consists of two series of quick pulses CAUTION EC3P61018 Check that the pulsating action is felt in the brake lever brake pedal and again in the brake lever in this order If the pulsating action is felt in the brake pedal before it is fe...

Page 217: ...connect 2 Clutch master cylinder holder 1 3 Clutch master cylinder assembly 1 4 Left handlebar 1 5 Lead holder 1 6 Left handlebar switch 1 7 Grip end 1 8 Handlebar grip 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 218: ... holder 1 3 Front brake master cylinder assembly 1 4 Grip end 1 5 Throttle cable housing 2 6 Throttle cable 2 Disconnect 7 Throttle grip 1 8 Right handlebar 1 9 Lead holder 1 10 Right handlebar switch 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 219: ...there is no danger of it falling over 2 Install Handlebar grip Grip end 1 a Apply a thin coat of rubber adhesive onto the end of the left handlebar b Slide the handlebar grip onto the left handle bar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesive has fully dried NOTE There should be 1 3 mm 0 04 0 12 in of clear anc...

Page 220: ...the throttle grip and the grip end 9 Install Front brake master cylinder assembly Front brake master cylinder holder 1 NOTE Install the brake master cylinder holder with the UP mark facing up Align the mating surfaces of the brake master cylinder holder with the punch mark a on the right handlebar First tighten the upper bolt then the lower bolt 10 Install Clutch master cylinder assembly Clutch ma...

Page 221: ...ft handlebar First tighten the upper bolt then the lower bolt 11 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 8 T R Clutch master cylinder holder bolt 10 Nm 1 0 m kg 7 2 ft lb Throttle cable free play 3 0 5 0 mm 0 12 0 20 in Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 222: ...1 Front wheel Refer to FRONT WHEEL on page 4 13 1 Battery holder 1 2 Negative battery lead 1 Disconnect 3 Positive battery lead 1 Disconnect 4 Battery 1 5 Upper bracket pinch bolt 1 Loosen 6 Cap bolt 1 Loosen 7 Lower bracket pinch bolt 2 Loosen 8 Front fork leg 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys e...

Page 223: ...1 2 O ring 1 3 Nut 1 4 Damper adjusting rod 1 5 Spacer 1 6 Washer 1 7 Fork spring 1 8 Dust seal 1 9 Oil seal clip 1 10 Oil seal 1 11 Washer 1 12 Damper rod assembly bolt 1 13 Copper washer 1 14 Damper rod assembly 1 15 Spring 1 16 Oil flow stopper 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 224: ... 2 1 D 51 mm 2 01 in l 15 mm 0 59 in 20 Inner tube bushing 1 21 Outer tube 1 For assembly reverse the disassembly pro cedure Disassembling the front fork legs Order Job Parts to remove Q ty Remarks Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 225: ...t pinch bolts support the front fork leg EAS22980 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Hold the nut 1 and loosen the cap bolt 2 2 Drain Fork oil NOTE Stroke the inner tube several times while drain ing the fork oil 3 Remove Dust seal 1 Oil seal clip 2 with a flat head screwdriver CAUTION ECA14180 Do not scratch the inner tube NOTE Do no...

Page 226: ...leg horizontally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the inner tube from the outer tube by pulling the inner tube forcefully but careful ly CAUTION EC3P61027 Excessive force will damage the bushings Damaged bushings must be replaced Avoid bottoming the inner tube into the out er tube during the above procedure as the oil flow stopper will be damaged EAS23...

Page 227: ...e sure to replace the following parts Inner tube bushing Outer tube bushing 1 Outer tube bushing 2 Oil seal Dust seal Before assembling the front fork leg make sure all of the components are clean 1 Install Inner tube bushing 1 Oil flow stopper 2 Spring Damper rod assembly 3 CAUTION EC3P61028 Allow the damper rod assembly to slide slowly down the inner tube 4 until it pro trudes from the bottom of...

Page 228: ...h lithium soap based grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation 7 Install Oil seal clip 1 NOTE Adjust the oil seal clip so that it fits into the outer tube s groove Slide metal installer 90890 01508 Fork seal driver 90890 01502 YM A0948 Fork seal...

Page 229: ...stroke the inner tube 1 up and down 12 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed NOTE Be sure to bleed the front fork leg of any residual air 13 Measure Front fork leg oil level a from the top of the inner tube with the outer tube fully compressed and without the fork spring Out of specification Correct NOTE While filling the ...

Page 230: ...ALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts NOTE Make sure the inner tube is flush with the top of the upper bracket 2 Tighten Lower bracket pinch bolts 1 Cap bolt 2 Upper bracket pinch bolt 3 WARNING EWA13680 Make sure the brake hoses are routed prop erly T R Nut 25 N...

Page 231: ...just Spring preload Rebound damping Compression damping Refer to ADJUSTING THE FRONT FORK LEGS on page 3 28 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 232: ...it coupler cover 2 3 Immobilizer unit coupler 1 Disconnect 4 Main switch coupler 2 Disconnect 5 Lower bracket cover 1 6 Brake hose joint bracket bolt 2 7 Steering stem nut 1 8 Upper bracket 1 9 Handlebar bracket 1 10 Lock washer 1 11 Upper ring nut 1 T R 115 Nm 11 5 m kg 85 ft lb T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 18 Nm 1 8 m kg 13 ft Ib LS LS T R 7 Nm 0 7 m kg 5 1 ft Ib 14 7 8 19 20 18 6 5 9 22 ...

Page 233: ...2 Lower bearing outer race 1 For installation reverse the removal proce dure Removing the lower bracket Order Job Parts to remove Q ty Remarks T R 115 Nm 11 5 m kg 85 ft lb T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 18 Nm 1 8 m kg 13 ft Ib LS LS T R 7 Nm 0 7 m kg 5 1 ft Ib 14 7 8 19 20 18 6 5 9 22 21 3 1 2 2 17 16 15 13 12 11 10 4 4 LS LT Manuals by Motomatrix www motomatrix co uk The Solution For Lost M...

Page 234: ... pipe 1 with a long rod 2 and hammer b Remove the bearing race from the lower bracket 3 with a floor chisel 4 and ham mer c Install new bearing races CAUTION ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged NOTE Always replace the bearings and bearing races as a set 4 Check Upper bracket Lower bracket along with the steering stem Bends cracks damage Re...

Page 235: ...arily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 65 NOTE Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut T R Steering stem nut 115 Nm 11 5 m kg 85 ft lb Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 236: ...nut 3 4 Rear shock absorber assembly lower nut Wash er Bolt 1 1 1 5 Connecting arm nut Washer Bolt 2 2 2 6 Connecting arm 2 7 Rear shock absorber assembly upper nut Bolt Spacer 1 1 1 8 Rear shock absorber assembly 1 9 Centerstand 1 10 Relay arm nut Bolt Spacer 1 1 1 New New New New T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib 5 T R 64 Nm 6 4 m kg 46 ft Ib T R...

Page 237: ...er Job Parts to remove Q ty Remarks New New New New T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib 5 T R 64 Nm 6 4 m kg 46 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib 7 7 10 3 10 1 2 LS LS 8 13 15 12 17 15 15 15 5 6 1616 1514 17 11 5 5 6 15 4 4 9 LS T R 55 Nm 5 5 m kg 40 ft Ib Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email in...

Page 238: ... from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23230 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Remove Rear shock absor...

Page 239: ...LING THE RELAY ARM 1 Lubricate Spacer Bearings 2 Install Bearing 1 2 to the relay arm 3 Install Relay arm NOTE Make sure that the embossed mark 5JW on the relay arm faces to the left EAS23310 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Install Rear shock absorber assembly NOTE Make sure that the warning label on the rear shock absorber assembly faces to the right When installing the rear shock a...

Page 240: ...ft end cover 1 3 Pivot shaft locknut retainer 1 4 Pivot shaft nut 1 5 Pivot shaft locknut 1 6 Pivot shaft 1 7 Swingarm 1 8 Spacer 1 9 Oil seal 2 10 Bearing 2 11 Collar 1 12 Oil seal 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 125 Nm 12 5 m kg 90 ft lb T R 115 Nm 11 5 m kg 85 ft lb New LS LS LS New LS New 3 5 6 1 4 2 LS 1 17...

Page 241: ...move Q ty Remarks T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 125 Nm 12 5 m kg 90 ft lb T R 115 Nm 11 5 m kg 85 ft lb New LS LS LS New LS New 3 5 6 1 4 2 LS 1 17 16 15 12 11 10 8 9 18 14 13 9 10 7 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 242: ...r ings washers and dust covers EAS23360 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash Pivot shaft Spacers Washer Bearings Collar 4 Check Spacers Washer Collar Oil seals Damage wear Replace Bearings Damage pitting Replace EAS23390 INST...

Page 243: ...A Left side B Right side T R Pivot shaft 23 Nm 2 3 m kg 17 ft lb T R Pivot shaft locknut 115 Nm 11 5 m kg 85 ft lb T R Pivot shaft nut 125 Nm 12 5 m kg 90 ft lb 1 3 a A 3 2 b 2 A B b 4 4 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 244: ...emarks Final gear oil Drain Refer to CHANGING THE ENGINE OIL on page 3 13 Rear wheel Refer to REAR WHEEL on page 4 20 1 Final drive assembly 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 245: ...trest assembly 1 3 Sidestand switch coupler 1 Disconnect 4 Sidestand 1 5 Drive shaft dust cover 1 6 Universal joint dust cover 1 7 Universal joint 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 246: ...using 1 6 Dust cover 1 7 Oil seal 1 8 Stopper bolt 1 Left hand threads 9 Stopper bolt shim s 10 Ring gear shim s 11 Ring gear 1 12 Bearing 1 13 Thrust washer 1 14 Coupling gear nut 1 15 Coupling gear 1 16 Bearing retainer 1 Left hand threads 17 Oil seal 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 247: ...1 Final drive pinion gear bearing 1 22 Ring gear bearing 1 23 Oil seal 1 24 Collar 1 25 Final gear case 1 For assembly reverse the disassembly pro cedure Disassembling the final drive assembly Order Job Parts to remove Q ty Remarks Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 248: ...if broken gear teeth are suspected This condition could result in the shaft drive assembly locking up causing a loss of control and possible injury to the rider Troubleshooting chart When causes A or B shown in the table at the beginning of the TROUBLESHOOTING section ex ist check the following points YES NO Symptom Possible cause 1 A pronounced hesitation or jerky movement during acceleration dec...

Page 249: ...tion of a rust preventive coating or excessive seal lubrication Always clean the vehicle and recheck the area where the leak is thought to originate from EAS23580 MEASURING THE FINAL GEAR BACKLASH 1 Secure the final drive assembly in a vise 2 Remove Final gear oil drain bolt 3 Drain Final gear oil from the final drive assembly 4 Measure Final gear backlash Out of specification Adjust 2 Place the v...

Page 250: ...d and dial gauge i Repeat steps d to h three more times for a total of four measurements j If any of the readings are over specification adjust the final gear backlash EAS23590 ADJUSTING THE FINAL GEAR BACKLASH 1 Remove Ring gear bearing housing bolts 1 Ring gear bearing housing nuts 2 NOTE Working in a crisscross pattern loosen each bolt and nut 1 4 of a turn After all of the bolts and nuts are f...

Page 251: ... the ring gear EAS23610 ADJUSTING THE RING GEAR TO STOPPER BOLT CLEARANCE 1 Remove Ring gear 1 Stopper bolt 2 Stopper bolt shim s 3 Ring gear bearing housing 4 2 Select Stopper bolt shim s 3 Install Ring gear bearing housing 1 Stopper bolt shim s 2 Stopper bolt 3 Ring gear 4 CAUTION ECA14320 The stopper bolt has left hand threads To tighten the stopper bolt turn it counter clockwise Thinner shim F...

Page 252: ...emove Bearing retainer with the bearing retainer wrench 1 CAUTION ECA14330 The bearing retainer has left hand threads To loosen the bearing retainer turn it clock wise 4 Remove Final drive pinion gear WARNING EWA13800 Always use new bearings CAUTION ECA14340 The final drive pinion gear should only be re moved if ring gear replacement is necessary NOTE Lightly tap on the end of the final drive pini...

Page 253: ...atches the diameter of the races c Install the inner race onto the final drive pin ion gear 5 Install Collar 1 Oil seal 2 Bearing 3 with an appropriate press tool 4 and press NOTE The bearing can be reused but Yamaha recom mends installing a new one EAS23640 ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR NOTE Aligning the final drive pinion gear and ring gear is necessary when any of the follo...

Page 254: ...nd off the 1 to 0 Thus you should use a 0 50 mm final drive pinion gear shim c To find ring gear shim thickness B use the following formula Where c a numeral on the final gear case to be di vided by 100 and added to 45 d a numeral usually on the outside of the ring gear bearing housing to be divided by 100 and added to 3 e a numeral positive or negative on the in side of the ring gear to be divide...

Page 255: ...bearing retainer wrench 1 CAUTION ECA14350 The bearing retainer has left hand threads To tighten the bearing retainer turn it coun terclockwise 3 Install Coupling gear 1 Coupling gear nut with the coupling gear middle shaft tool 2 Ring gear bearing thickness 13 00 mm 0 51 in B 45 51 100 3 35 100 35 40 5 100 13 45 0 51 3 0 35 35 40 0 05 13 45 51 3 35 35 40 0 05 13 48 86 35 45 13 48 86 48 45 0 41 Ri...

Page 256: ... e Measure the width of the flattened Plasti gauge 1 f If the ring gear to thrust washer clearance is within specification install the ring gear bear ing housing along with the ring gear g If the ring gear to thrust washer clearance is out of specification select the correct thrust washer as follows h Select the suitable thrust washer from the fol lowing chart i Repeat the measurement steps until ...

Page 257: ...ified torques in the proper tightening sequence as shown 8 Install Shift arm 1 NOTE Align the punch mark a in the shift shaft with the slot in the shift arm 9 Install Rear wheel Refer to REAR WHEEL on page 4 20 10 Fill Final gear case Refer to CHECKING THE FINAL GEAR OIL LEVEL on page 3 25 11 Check Shift pedal position Refer to ADJUSTING THE SHIFT PEDAL on page 3 25 Recommended lubricant Molybdenu...

Page 258: ...SHAFT DRIVE 4 101 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 259: ...E VALVES 5 22 CHECKING THE VALVES AND VALVE GUIDES 5 22 CHECKING THE VALVE SEATS 5 24 CHECKING THE VALVE SPRINGS 5 25 CHECKING THE VALVE LIFTERS 5 26 INSTALLING THE VALVES 5 26 GENERATOR AND STARTER CLUTCH 5 28 REMOVING THE GENERATOR 5 31 REMOVING THE STARTER CLUTCH 5 31 CHECKING THE STARTER CLUTCH 5 31 INSTALLING THE STARTER CLUTCH 5 32 INSTALLING THE GENERATOR 5 32 PICKUP ROTOR 5 34 REMOVING THE...

Page 260: ...R 5 57 INSTALLING THE SHIFT SHAFT 5 57 OIL PUMP 5 58 CHECKING THE OIL PUMP 5 61 CHECKING THE RELIEF VALVE 5 61 CHECKING THE OIL DELIVERY PIPES 5 61 CHECKING THE OIL STRAINER 5 62 ASSEMBLING THE OIL PUMP 5 62 INSTALLING THE OIL PAN 5 62 MIDDLE GEAR 5 63 REMOVING THE MIDDLE DRIVE SHAFT ASSEMBLY 5 67 DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 5 67 DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 5 6...

Page 261: ...STALLING THE CONNECTING RODS AND PISTONS 5 87 CRANKSHAFT 5 90 REMOVING THE CRANKSHAFT JOURNAL BEARINGS 5 91 CHECKING THE OIL NOZZLES 5 91 CHECKING THE CRANKSHAFT 5 91 INSTALLING THE CRANKSHAFT 5 92 TRANSMISSION 5 94 REMOVING THE TRANSMISSION 5 99 CHECKING THE SHIFT FORKS 5 99 CHECKING THE SHIFT DRUM ASSEMBLY 5 99 CHECKING THE TRANSMISSION 5 99 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 100 INSTALLI...

Page 262: ...tor Refer to RADIATOR on page 6 1 1 O2 sensor coupler 1 Disconnect 2 O2 sensor 1 3 Left muffler 1 4 Right muffler 1 5 Exhaust pipe assembly 1 6 Gasket 4 For installation reverse the removal proce dure T R 20 Nm 2 0 m kg 14 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib 5 6 2 8 3 1 4 New T R 25 Nm 2 5 m kg 18 ft Ib Manuals by M...

Page 263: ... on page 6 6 Engine oil Oil filter cartridge Drain Refer to CHANGING THE ENGINE OIL on page 3 13 Oil cooler Refer to OIL COOLER on page 6 4 Water pump Refer to WATER PUMP on page 6 10 Starter motor Refer to ELECTRIC STARTER on page 5 37 Left footrest assembly Sidestand Refer to SHAFT DRIVE on page 4 87 1 Clutch release cylinder 1 2 Dowel pin 2 3 Crankcase breather hose 1 4 Stator coil coupler 1 Di...

Page 264: ... Disconnect 8 Ground lead 1 Disconnect 9 Spark plug cap 4 For installation reverse the removal proce dure Disconnecting the leads and hoses Order Job Parts to remove Q ty Remarks 9 2 2 1 3 5 6 7 4 8 T R 10 Nm 1 0 m kg 7 2 ft Ib Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 265: ...side 1 13 Engine mounting bolt left front lower side 1 14 Engine mounting bolt left front upper side 1 15 Engine mounting nut rear upper side 1 T R 32 Nm 3 2 m kg 23 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 49 Nm 4 9 m kg 35 ft Ib T R 49 Nm 4 9 m kg 35 ft Ib T R ...

Page 266: ...m kg 11 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 49 Nm 4 9 m kg 35 ft Ib T R 49 Nm 4 9 m kg 35 ft Ib T R 49 Nm 4 9 m kg 35 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib E E 9 9 15 11 1 11 12 17 10 6 7 16 5 5 18 2 3 4 7 6 13 19 14 20 8 Manuals by M...

Page 267: ...lts rear side 11 Engine brackets top 12 Engine bracket bolts top 13 NOTE Lubricate the engine mounting bolt rear lower side threads with engine oil Do not fully tighten the bolts 3 Tighten Engine mounting bolt left front upper side 5 4 Tighten Engine mounting bolt rear lower side 4 5 Tighten Spacer bolt 1 NOTE Tighten the spacer bolt 1 to specification with a pivot shaft wrench When tightened the ...

Page 268: ...and frame surface 12 Tighten Engine mounting bolts top 15 Engine bracket bolts top 13 13 Install Engine bracket left rear side 1 Engine bracket bolt left rear side 2 Engine mounting bolts left rear side 3 Pivot shaft wrench 90890 01471 Frame spanner socket YM 01471 Pivot shaft wrench adapter 90890 01476 T R Engine mounting nut rear upper side 45 Nm 4 5 m kg 32 ft lb T R Engine mounting bolt left f...

Page 269: ...he punch mark a on the brake pedal with the punch mark b on the brake pedal pivot shaft T R Engine bracket bolt left rear side 32 Nm 3 2 m kg 23 ft lb T R Engine mounting bolt left rear side 16 Nm 1 6 m kg 11 ft lb T R Brake pedal pinch bolt 8 Nm 0 8 m kg 5 8 ft lb 3 2 1 a b 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 270: ...EM on page 7 9 1 Spark plug 4 2 Cylinder identification sensor 1 3 Cylinder head cover 1 4 Cylinder head cover gasket 1 5 Dowel pin 4 6 Timing chain guide upper side 1 For installation reverse the removal proce dure 1 New New 4 5 5 5 2 8 LT LS 6 3 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email i...

Page 271: ...g chain tensioner gasket 1 3 Intake camshaft cap 4 4 Exhaust camshaft cap 4 5 Intake camshaft 1 6 Exhaust camshaft 1 7 Intake camshaft sprocket 1 8 Exhaust camshaft sprocket 1 9 Timing chain guide exhaust side 1 10 Pin 1 11 Timing chain guide intake side 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email in...

Page 272: ...et clockwise 4 Remove Timing chain tensioner Timing chain tensioner gasket 5 Remove Camshaft caps Dowel pins CAUTION ECA13720 To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a criss cross pattern working from the outside in 6 Remove Intake camshaft 1 Exhaust camshaft 2 NOTE To prevent the timing chain from falling into the crankcase ...

Page 273: ...shaft caps b Position a strip of Plastigauge 1 onto the camshaft journal as shown c Install the dowel pins and camshaft caps Camshaft lobe dimensions Intake A 33 050 33 150 mm 1 3012 1 3051 in Limit 32 050 mm 1 2618 in Intake B 24 997 25 097 mm 0 9841 0 9881 in Limit 23 997 mm 0 9448 in Exhaust A 33 050 33 150 mm 1 3012 1 3051 in Limit 32 950 mm 1 2972 in Exhaust B 24 997 25 097 mm 0 9841 0 9881 i...

Page 274: ...take side Timing chain guide upper side Damage wear Replace the defective part s EAS23970 CHECKING THE TIMING CHAIN TENSIONER 1 Check Timing chain tensioner Cracks damage rough movement Re place a Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand NOTE While pressing the timing chain tensioner rod wind it clockwise with a thin screwdriver 1 until it stops ...

Page 275: ...ON ECA13740 Do not turn the crankshaft when installing the camshaft s to avoid damage or improper valve timing a Install the timing chain onto both camshaft sprockets and then install the camshafts NOTE Make sure the holes a on each camshaft fac es up When installing the timing chain start with the exhaust camshaft and be sure to keep the tim ing chain as tight as possible on the exhaust side Make...

Page 276: ... crankcase mating surface a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres sion stroke align the T mark a on the pick up rotor with the crankcase mating surface b 6 Install Timing chain tensioner Timing chain tensioner gasket a While lightly pressing the timing chain ten sioner rod by hand turn the tensioner rod ful ly clockwise with a thin screwdriver 1 b With the timing c...

Page 277: ...cation Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 3 10 Install Cylinder head cover gasket Cylinder head cover NOTE Apply Three Bond 1514 1 onto the mating surfaces of the cylinder head cover and cylin der head cover gasket Apply Yamaha bond No 1215 2 onto the mat ing surfaces of the cylinder head cover gasket and cylinder head Tighten the cylinder head cover bolts in stages and in a ...

Page 278: ...CAMSHAFTS 5 17 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 279: ... 1 Cylinder head 1 2 Cylinder head gasket 1 3 Dowel pin 2 For installation reverse the removal proce dure T R 12 Nm 1 2 m kg 8 7 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 1st 25 Nm 2 5 m kg 18 ft lb 2nd 25 Nm 2 5 m kg 18 ft lb Final Specified angle 175 185 New New 3 3 2 New 1 10 E Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 280: ... follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern NOTE To ensure an even surface rotate the cylinder head several times EAS24240 INSTALLING THE CYLINDER HEAD 1 Install Cylinder head NOTE Pass the timing chain through the timing chain cavity 2 Tighten Cylinder head bolts M10 1 10 Cylinder head bolts M6 11 12 WARNI...

Page 281: ...Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angle NOTE On a hexagonal bolt note that the angle from one corner to another is 60 f Tighten the cylinder head bolts M6 in proper tightening sequence as shown T R Cylinder head bolt M10 2nd 25 Nm 2 5 m kg 18 ft lb T R Cylinder head bolt M10 Final Specified angle 175 185 T R Cylinder...

Page 282: ...ter 16 2 Valve pad 16 3 Valve cotter 32 4 Upper spring seat 16 5 Intake valve spring 8 6 Exhaust valve spring 8 7 Intake valve 8 8 Exhaust valve 8 9 Valve stem seal 16 10 Lower spring seat 16 11 Intake valve guide 8 12 Exhaust valve guide 8 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co...

Page 283: ...ports b Check that the valves properly seal NOTE There should be no leakage at the valve seat 1 3 Remove Valve cotters NOTE Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 4 Remove Upper spring seat 1 Valve spring 2 Valve 3 Valve stem seal 4 Lower spring seat 5 NOTE Identify the position of each part very care...

Page 284: ...proper valve stem to valve guide clearance NOTE After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clear ance exhaust 0 020 0 047 mm 0 0008 0 0019 in Limit 0 105 mm 0 0041 in Valve g...

Page 285: ...face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width C a Out of specification Replace the cylinder head a Apply Mechanic s blueing dye Dykem b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width NOTE Where the va...

Page 286: ...ng compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b onto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear impres sion j Measure the valve seat width ...

Page 287: ...h an oil stone 2 Lubricate Valve stem 1 Valve stem seal 2 with the recommended lubricant 3 Lubricate Valve stem end with the recommended lubricant Installed compression spring force intake 136 00 158 00 N 30 57 35 52 lb 13 87 16 11 kgf Installed compression spring force exhaust 136 00 158 00 N 30 57 35 52 lb 13 87 16 11 kgf Installed length intake 33 00 mm 1 30 in Installed length exhaust 33 00 mm...

Page 288: ...m lightly tap the valve tip with a soft face hammer CAUTION ECA13800 Hitting the valve tip with excessive force could damage the valve 7 Lubricate Valve lifter with the recommended lubricant 8 Install Valve pad Valve lifter NOTE The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in its original position b Smaller pitch New Valve spr...

Page 289: ...GENERAL CHASSIS on page 4 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 13 1 Stator coil coupler 1 Disconnect 2 Generator cover 1 3 Generator cover gasket 1 4 Dowel pin 2 5 Starter clutch idle gear shaft 1 6 Starter clutch idle gear 1 7 Generator rotor 1 8 Woodruff key 1 9 Starter clutch gear 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys e...

Page 290: ... 1 For installation reverse the removal proce dure Removing the generator rotor and starter clutch Order Job Parts to remove Q ty Remarks Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 291: ...ly Order Job Parts to remove Q ty Remarks 1 Stator coil assembly lead holder 1 2 Stator coil assembly 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 292: ...Replace 2 Check Starter clutch idle gear Starter clutch gear Burrs chips roughness wear Replace the defective part s 3 Check Starter clutch gear s contacting surfaces Damage pitting wear Replace the starter clutch gear 4 Check Starter clutch operation a Install the starter clutch gear onto the starter clutch and hold the starter clutch b When turning the starter clutch gear clock wise A the starte...

Page 293: ...threads and washer mating surfaces with engine oil 2 Tighten Generator rotor bolt 1 NOTE While holding the generator rotor 2 with the sheave holder 3 tighten the generator rotor bolt 3 Apply Sealant onto the stator coil assembly lead grommet 4 Install Generator cover gasket Generator cover T R Starter clutch bolt 32 Nm 3 2 m kg 23 ft lb LOCTITE Sheave holder 90890 01701 Primary clutch holder YS 01...

Page 294: ...D STARTER CLUTCH 5 33 NOTE Tighten the generator cover bolts in stages and in a crisscross pattern Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 295: ... 28 1 Pickup rotor cover 1 2 Pickup rotor cover gasket 1 3 Dowel pin 2 4 Crankshaft position sensor coupler 1 Disconnect 5 Crankshaft position sensor 1 6 Pickup rotor 1 For installation reverse the removal proce dure LT New New 2 1 6 3 3 5 4 LT 6 LS T R 4 Nm 0 4 m kg 2 9 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 15 Nm 1 5 m kg 11 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib Manuals by Motomatrix www motomatrix ...

Page 296: ...with the projection b in the pickup rotor 2 Tighten Pickup rotor bolt 1 NOTE While holding the generator rotor 2 with the sheave holder 3 tighten the pickup rotor bolt 3 Apply Sealant onto the crankshaft position sensor lead grommet Sheave holder 90890 01701 Primary clutch holder YS 01880 A 1 2 3 T R Pickup rotor bolt 45 Nm 4 5 m kg 32 ft lb Sheave holder 90890 01701 Primary clutch holder YS 01880...

Page 297: ...rotor cover NOTE Tighten the pickup rotor cover bolts in stages and in a crisscross pattern T R Pickup rotor cover bolt 12 Nm 1 2 m kg 8 7 ft lb New Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 298: ...remove Q ty Remarks Throttle bodies Refer to THROTTLE BODIES on page 7 4 1 Starter motor lead 1 Disconnect 2 Starter motor assembly 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 299: ... Brush seat along with brushes 1 5 Washer 1 6 Lock washer 1 7 Oil seal 1 8 Bearing 1 9 Starter motor rear cover 1 10 Collar 1 11 O ring 2 12 Starter motor yoke 1 13 Armature assembly 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 300: ...he starter motor a Measure the armature assembly resistances with the pocket tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Limit 23 5 mm 0 93 in Mica undercut depth 1 50 mm 0 06 in Pocket tester 90890 03112 A...

Page 301: ...lign the slot a on the brush seat with the tab b in the starter motor front cover 2 Install Starter motor yoke 1 Starter motor front cover 2 Starter motor rear cover 3 NOTE Align the match marks a on the starter motor yoke with the match marks b on the starter mo tor front and rear covers Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix c...

Page 302: ... THE ENGINE OIL on page 3 13 1 Clutch cover 1 2 Clutch cover gasket 1 3 Dowel pin 2 4 Damper cover 1 5 Damper 1 For installation reverse the removal proce dure LT 3 4 5 2 1 10 5 3 New T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 303: ... 1 1 Inside diameter 124 mm 4 88 in 10 Clutch plate 8 11 Friction plate 2 7 Inside diameter 124 mm 4 88 in 12 Friction plate 3 1 Inside diameter 135 mm 5 31 in 13 Clutch damper spring 1 14 Clutch damper spring seat 1 15 Lock washer 1 16 Clutch boss 1 19 18 17 16 14 15 12 1110 9 8 7 6 5 4 3 2 1 13 6 New New LT T R 90 Nm 9 0 m kg 65 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib E 9 ...

Page 304: ... the clutch Order Job Parts to remove Q ty Remarks 19 18 17 16 14 15 12 1110 9 8 7 6 5 4 3 2 1 13 6 New New LT T R 90 Nm 9 0 m kg 65 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib E 9 12 11 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 305: ...agm holder 1 3 Clutch master cylinder reservoir diaphragm 1 4 Clutch lever 1 5 Clutch master cylinder push rod pin 1 6 Clutch switch coupler 1 Disconnect 7 Clutch hose union bolt 1 8 Copper washer 2 9 Clutch hose 1 Disconnect 10 Clutch switch 1 11 Clutch master cylinder holder 1 12 Clutch master cylinder 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk T...

Page 306: ...Remarks 1 Clutch master cylinder push rod 1 2 Dust boot 1 3 Circlip 1 4 Washer 1 5 Clutch master cylinder kit 1 6 Clutch master cylinder body 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 307: ...THE HYDRAULIC CLUTCH SYSTEM on page 3 15 1 Clutch hose union bolt 1 2 Copper washer 2 3 Clutch hose 1 Disconnect 4 Clutch release cylinder 1 5 Dowel pin 2 6 Plate 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 308: ... 2 Clutch release cylinder spring 1 3 Clutch release cylinder piston seal 1 4 Bleed screw 1 5 Clutch release cylinder body 1 For assembly reverse the disassembly pro cedure 5 2 3 1 4 New T R 6 Nm 0 6 m kg 4 3 ft Ib Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 309: ...ng and primary driven gear and then rotate the inner primary driven gear until both primary drive gears are aligned The teeth of both primary driven gears must be aligned for installation Insert two 5 mm bolts 2 into the spacer and then remove the spacer by pulling on the bolts EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check Friction pla...

Page 310: ...mage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE Pitting on the clutch housing dogs will cause er ratic clutch operation 2 Check Bearing Damage wear Replace the bearing and clutch housing EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss NOTE Pitting on the clutch boss splines will cause er ratic clutch oper...

Page 311: ...50 INSTALLING THE CLUTCH 1 Install Clutch housing 1 NOTE Make sure that the projections a in the clutch housing align with the slots b in the oil pump drive sprocket Make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly Insert a cross headed screwdriver into one of the holes of the clutch housing and primary driven gear and then rotate the inner primary driven ge...

Page 312: ...en a clutch plate and a friction plate 8 Install Clutch spring bolts NOTE Tighten the clutch spring bolts in stages and in a crisscross pattern 9 Install Rear balancer weight Refer to BALANCERS on page 5 103 10 Install Clutch cover NOTE Tighten the clutch cover bolts in the proper tight ening sequence as shown EAS25280 DISASSEMBLING THE CLUTCH MASTER CYLINDER CAUTION ECA13840 Clutch components rar...

Page 313: ...lutch master cylinder body Obstruction Blow out with compressed air 2 Check Clutch master cylinder Clutch master cylinder kit Rust scratches wear Replace the clutch master cylinder and clutch master cylinder kit as a set 3 Check Clutch master cylinder reservoir Cracks damage Replace Clutch master cylinder reservoir diaphragm Damage wear Replace 4 Check Clutch hose Cracks damage wear Replace EAS253...

Page 314: ...t in a harmful chemical reac tion leading to poor clutch performance When refilling be careful that water does not enter the clutch fluid reservoir Water will significantly lower the boiling point of the clutch fluid and could cause vapor lock CAUTION ECA13420 Clutch fluid may damage painted surfaces or plastic parts Therefore always clean up any spilt clutch fluid immediately NOTE In order to ens...

Page 315: ...ver use solvents on internal clutch com ponents as they will cause the piston seal to swell and distort Whenever a clutch release cylinder is dis assembled replace the piston seal EAS25350 INSTALLING THE CLUTCH RELEASE CYLINDER 1 Check Copper washers 1 Clutch hose 2 Clutch hose union bolt 3 WARNING EW3P61017 Proper clutch hose routing is essential to in sure safe vehicle operation Refer to CABLE R...

Page 316: ...Clutch fluid may damage painted surfaces or plastic parts Therefore always clean up any spilt clutch fluid immediately NOTE In order to ensure a correct reading of the clutch fluid level make sure that the top of the reservoir is horizontal 3 Bleed Clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 15 4 Check Clutch fluid level Below the minimum level mark a Add the recommended ...

Page 317: ...41 1 Oil baffle plate 1 1 2 Shift arm 1 3 Circlip 1 4 Shift shaft 1 5 Shift shaft spring 1 6 Spacer 1 7 Stopper lever spring 1 8 Stopper lever 1 9 Circlip 1 10 Collar 1 11 Shift shaft spring stopper 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 318: ...ver 1 Stopper lever spring 2 NOTE Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss 3 Mesh the stopper lever with the shift drum seg ment assembly 2 Install Shift shaft 1 NOTE Hook the end of the shift shaft spring onto the shift shaft spring stopper 2 3 Install Shift arm 1 NOTE Align the punch mark a in the shift shaft with the slot in the shift arm 1 2 3 2 1...

Page 319: ...bly Refer to ENGINE REMOVAL on page 5 1 Sidestand Refer to SHAFT DRIVE on page 4 87 Water pump Refer to WATER PUMP on page 6 10 1 Oil level switch coupler 1 Disconnect 2 Oil level switch 1 3 Oil pan 1 4 Oil pan gasket 1 5 Dowel pin 2 6 Oil delivery pipe 2 1 7 Oil delivery pipe 3 1 8 Oil strainer 1 9 Dowel pin 2 10 Oil pump 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcyc...

Page 320: ...y 1 For installation reverse the removal proce dure Removing the oil pan and oil pump Order Job Parts to remove Q ty Remarks Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 321: ...g cover 1 2 Pin 2 3 Oil pump inner rotor 1 4 Oil pump outer rotor 1 5 Pin 1 6 Washer 1 7 Oil pump driven sprocket 1 8 Oil pump housing 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 322: ...THE RELIEF VALVE 1 Check Relief valve body 1 Relief valve 2 Spring 3 O ring 4 Damage wear Replace the defective part s EAS24980 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance Less than 0 12 mm 0 0047 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump housing cle...

Page 323: ...sher 2 Pin 3 Oil pump inner rotor 4 Oil pump outer rotor NOTE When installing the inner rotor align the pin 3 in the oil pump shaft with the groove a in the in ner rotor 4 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 61 EAS25050 INSTALLING THE OIL PAN 1 Install Oil pan gasket Oil pan NOTE Tighten the oil pan bolts in stages and in a criss cross pattern Recommended lubricant ...

Page 324: ...e cover gasket 1 3 Dowel pin 2 4 Damper cover 1 5 Damper 1 6 Middle drive shaft bearing housing 1 7 Bearing 1 8 Middle driven shaft end cover 1 9 Middle driven shaft assembly 1 10 Middle driven pinion gear shim 11 Middle drive pinion gear nut 1 12 Lock washer 1 13 Middle drive pinion gear 1 14 Middle drive shaft assembly 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle...

Page 325: ...earing 1 19 Middle drive pinion gear shim 20 Bearing 1 For installation reverse the removal proce dure Removing the middle gear Order Job Parts to remove Q ty Remarks Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 326: ...ty Remarks 1 Spring retainer 2 2 Spring seat 1 3 Damper spring 1 4 Damper driven cam 1 5 Damper drive cam 1 6 Middle drive shaft 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 327: ...iddle driven pinion gear nut 1 3 Middle driven shaft 1 4 Middle driven pinion gear 1 5 Bearing retainer 1 6 Bearing 1 7 Middle driven shaft bearing housing 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 328: ...DRIVE SHAFT ASSEMBLY 1 Remove Spring retainers 1 NOTE While compressing the spring with the damper spring compressor 2 remove the spring retain ers EAS25770 DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1 Remove Middle driven pinion gear nut a Straighten the thread on the middle driven pinion gear nut b Loosen the middle driven pinion gear nut NOTE Secure the middle driven shaft in a vise making ...

Page 329: ...dle driven pinion gear Galling pitting wear Replace 2 Check Bearings Damage pitting Replace EAS25800 ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1 Install Spring retainers 1 NOTE While compressing the spring with the damper spring compressor 2 install the spring retain ers EAS25820 ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1 Tighten Bearing retainer a Temporarily install the middle driven shaft b...

Page 330: ...Bearing retainer 1 a Attach the bearing retainer wrench 2 b Tighten the bearing retainer to specification c Lock the threads with a drift punch 2 Install Lock washer 1 Middle drive pinion gear nut 2 T R Bearing retainer 110 Nm 11 0 m kg 80 ft lb T R Middle driven pinion gear nut 110 Nm 11 0 m kg 80 ft lb LOCTITE 1 New Bearing retainer wrench 90890 04137 Middle drive shaft bearing retain er wrench ...

Page 331: ...en the middle driven shaft bearing housing bolts 2 Tighten Middle driven shaft bearing housing bolts NOTE Before tightening the bolts 1 Adjust the middle gear backlash Refer to ADJUSTING THE MIDDLE GEAR BACKLASH on page 5 71 2 Check that the middle gears turns smoothly ET3P61025 INSTALLING THE MIDDLE GEAR CASE COVER 1 Install Middle gear case cover Middle gear case cover bolts NOTE Apply locking a...

Page 332: ...he bolts are overtightened loosen them until the crankcase to middle driven shaft bearing housing clearance is within specification as stated below Then repeat all of the previous steps NOTE Tighten the middle driven shaft bearing hous ing bolts carefully one thread turn at a time only Push in the middle driven shaft bearing housing and then tighten the bolts to specifica tion After tightening the...

Page 333: ...E MIDDLE GEAR NOTE Aligning the middle gear is necessary when any of the following parts are replaced Crankcase Middle drive shaft Middle driven shaft bearing housing 1 Select Middle drive pinion gear shim s 1 Middle driven pinion gear shim s 2 NOTE Select the middle driven gear shim s 2 by cal culating the middle drive gear shim thickness and then measuring the middle gear backlash a Position the...

Page 334: ...o be divided by 100 and added to 87 Example If the middle driven pinion gear is marked 03 d is 33 97 i e 34 00 0 03 33 97 e is 54 49 If the lower crankcase is marked 95 f is 87 95 i e 87 00 0 95 87 95 B 33 97 54 49 87 95 0 51 Round off to the hundredths digit and select the appropriate shim s NOTE In the above example the calculated number is 0 51 The chart instructs you to round off the 1 to 0 Th...

Page 335: ...CLUTCH on page 5 41 1 Timing chain 1 2 Oil pump drive chain guide 1 3 Oil pump drive chain 1 4 Oil pump drive sprocket 1 5 Spacer 1 6 Collar 1 7 Spring washer 1 8 Gear position switch 1 T R 24 Nm 2 4 m kg 17 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 1st 20 Nm 2 0 m kg 14 ft lb 2nd 20 Nm 2 0 m kg 14 ft lb Final Specified angle 115 125 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm...

Page 336: ...m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 1st 20 Nm 2 0 m kg 14 ft lb 2nd 20 Nm 2 0 m kg 14 ft lb Final Specified angle 115 125 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT New LS T R 4 Nm 0 4 m kg 2 9 ft Ib E E E E E E E E LT LT 8 10 10 7 6 5 4 1 2 3 10 9 4 10 10 2 2 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix ...

Page 337: ...ing 1 6 Oil seal 1 7 Bearing 1 8 Upper crankcase 1 9 Bearing 1 10 Oil filter cartridge bolt 1 11 Upper crankcase damper 1 12 Crankcase plug 1 10 LS LS 2 LT LT LT LT 4 8 3 LT 5 7 6 12 1 9 13 T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 70 Nm 7 0 m kg 50 ft lb New New New New LS LS New E E T R 12 ...

Page 338: ... 5 7 6 12 1 9 13 T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 70 Nm 7 0 m kg 50 ft lb New New New New LS LS New E E T R 12 Nm 1 2 m kg 8 7 ft Ib 11 E T R 20 Nm 2 0 m kg 14 ft Ib 3 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 339: ...ating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air EAS25600 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes 1 Check Oil delivery pipe Damage Replace Obstruction Wash and blow out with com pressed air ET3P61026 CHECKING THE BEARINGS AND OIL SEAL 1 Check Bearings Clean and lubricate th...

Page 340: ...gears shift correctly when the shift drum assembly is turned by hand 6 Install Crankcase bolts NOTE Lubricate the bolts 1 10 thread and wash ers with engine oil Lubricate the bolts 11 31 thread part and mating surface with engine oil Apply locking agent LOCTITE to the threads of the bolt 16 Finger tighten the crankcase bolts M9 115 mm bolts 1 10 M8 65 mm bolt 11 M8 50 mm bolt 12 M6 80 mm bolts 23 ...

Page 341: ...the speci fied angle do not loosen the bolt and then re tighten it Instead replace the bolt with a new one and perform the procedure again CAUTION EC3P61033 Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angle NOTE On a hexagonal bolt note that the angle from one corner to another is 60 8 Tighten Crankcase bolts 11 31 T R Crankca...

Page 342: ...e bolt 11 12 24 Nm 2 4 m kg 17 ft lb Crankcase bolt 13 14 12 Nm 1 2 m kg 8 7 ft lb Crankcase bolt 15 31 10 Nm 1 0 m kg 7 2 ft lb 13 21 18 15 16 17 20 19 22 14 24 29 30 23 25 31 28 26 27 11 12 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 343: ...efer to CRANKCASE on page 5 74 1 Connecting rod cap 4 2 Big end lower bearing 4 3 Piston pin clip 8 4 Piston pin 4 5 Piston 4 6 Connecting rod 4 7 Big end upper bearing 4 8 Top ring 4 9 2nd ring 4 10 Oil ring 4 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 344: ...emoving the piston pin deburr the pis ton pin clip s groove and the piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 5 4 Remove Top ring 2nd ring Oil ring NOTE When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS24410 CHECKING THE CYLINDE...

Page 345: ...gs as a set NOTE Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings Bore 79 000 79 010 mm 3 1102 3 1106 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in C maximum of D1 D6 T maximum of D1 or D2 maximum of D5 or D6 R maximum of D1 D3 or D5 minimum of D2 D4 or D6 Piston Diameter D 78 965 78 980 mm 3 1089 ...

Page 346: ... b Out of specification Replace the piston 4 Calculate Piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set a 5 mm 0 20 in Piston ring Top ring End gap installed 0 35 0 45 mm 0 0138 0 0177 in Limit 0 70 mm 0 0276 in 2nd ring End gap installed 0 75 0 85 mm 0 0295 0 0335 in Limit 1 20 mm 0 0472 in Oil ring End gap installed 0 20 0 60 mm 0 0079 0 023...

Page 347: ...ce of Plastigauge 1 on the crank shaft pin d Assemble the connecting rod halves NOTE Do not move the connecting rod or crankshaft until the clearance measurement has been completed Lubricate the bolt threads and nut seats with molybdenum disulfide grease Make sure the Y mark c on the connecting rod faces towards the left side of the crank shaft Make sure the characters d on both the con necting ro...

Page 348: ...ing expander 4 Lower oil ring rail 5 NOTE Be sure to install the piston rings so that the manufacturer s marks face up 2 Install Piston 1 onto the respective connecting rod 2 Piston pin 3 Piston pin clips 4 NOTE Apply engine oil onto the piston pin Make sure that the Y mark a on the connect ing rod is facing to the left when the punch mark b on the piston is pointing up Refer to the illustration W...

Page 349: ...ches in the connecting rods and connecting rod caps Be sure to reinstall each big end bearing in its original place While compressing the piston rings with piston ring compressor 2 install the connecting rod assembly 1 into the cylinder with the other hand Make sure the Y marks a on the connecting rods face towards the left side of the crank shaft Make sure the characters b on both the con necting...

Page 350: ...NING EWA13400 If the connecting rod nut is tightened more than the specified angle do not loosen the nut and then retighten it Instead replace the connecting rod bolt and nut with a new one and perform the procedure again CAUTION ECA13950 Do not use a torque wrench to tighten the connecting rod nut to the specified angle NOTE On a hexagonal nut note that the angle from one corner to another is 60 ...

Page 351: ...BALANCERS on page 5 103 Connecting rod caps Refer to CONNECTING RODS AND PIS TONS on page 5 82 1 Crankshaft 1 2 Crankshaft journal upper bearing 5 3 Crankshaft journal lower bearing 5 4 Oil nozzle 4 For installation reverse the removal proce dure 3 1 2 2 E E New 4 LS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 352: ...eplace the crank shaft journal bearings CAUTION ECA13920 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crank shaft journal bearings must be installed in their original positions a Clean the crankshaft journal bearings crank shaft journals and bearing portions of the crankcase b Plac...

Page 353: ...Select Crankshaft journal bearings J1 J5 NOTE The numbers A stamped into the lower crank case and the numbers B stamped into the crankshaft web are used to determine the re placement crankshaft journal bearing sizes J1 J5 refer to the bearings shown in the lower crankcase and crankshaft web illustration If J1 J5 are the same use the same size for all of the bearings For example if the lower crankc...

Page 354: ...rankshaft jour nal bearings 1 with the notches b in the crankcases Be sure to install each crankshaft journal bear ing in its original place Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 355: ...topper lever Refer to SHIFT SHAFT on page 5 56 1 Drive axle assembly 1 2 Bearing 1 3 Washer 1 4 Bearing 1 5 Shift drum retainer 1 6 Long shift fork guide bar 1 7 Shift fork L 1 8 Shift fork R 1 9 Short shift fork guide bar 1 10 Spring 4 11 Shift drum assembly 1 12 Shift fork C 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 356: ...lation reverse the removal proce dure Removing the transmission shift drum assembly and shift forks Order Job Parts to remove Q ty Remarks Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 357: ...oothed spacer 1 6 Toothed washer 2 7 Circlip 2 8 3rd pinion gear 1 9 4th pinion gear 1 10 Collar 1 11 Main axle 1st pinion gear 1 12 Bearing 1 13 Main axle bearing housing 1 For assembly reverse the disassembly pro cedure 13 12 11 10 9 New New New New 7 8 7 6 5 4 3 2 1 6 E M M M M Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 358: ... Circlip 2 8 Toothed washer 2 9 3rd wheel gear 1 10 Toothed spacer 1 11 Toothed lock washer 1 12 Toothed lock washer retainer 1 13 4th wheel gear 1 14 Washer 1 15 1st wheel gear 1 16 Bearing 1 17 Washer 1 1 18 17 16 15 14 8 7 12 11 10 2 3 4 6 7 8 9 13 E M M M M M M 5 New New Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 359: ...pro cedure Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks 1 18 17 16 15 14 8 7 12 11 10 2 3 4 6 7 8 9 13 E M M M M M M 5 New New Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 360: ...ork movement along the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as a set EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum groove Damage scratches wear Replace the shift drum assembly Shift drum segment 1 Damage wear Replace the shift drum as sembly Shift drum bearing 2 Damage pitting Replace the shift drum as sembly EAS26300 CHECKING THE TRAN...

Page 361: ...ed washer 1 Circlip 2 NOTE Be sure the circlip sharp edged corner a is positioned opposite side to the toothed washer and gear For main axle Install the circlip so that both ends b rest on the sides of a spline c with both axles aligned 2 Install Toothed lock washer retainer 1 Toothed lock washer 2 NOTE With the toothed lock washer retainer 1 in the groove a in the axle align the projection on the...

Page 362: ... Install Shift fork C Shift drum assembly Springs Short shift fork guide bar Shift fork R Shift fork L Long shift fork guide bar NOTE The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence R C L 3 Install Washer 1 NOTE Install the washer with its chamfered side facing towards the drive axle assembly as shown in the illustration 4 Ins...

Page 363: ... Make sure the bearing circlip 2 is inserted into the groove in the upper crankcase 5 Check Transmission Rough movement Repair NOTE Oil each gear shaft and bearing thoroughly 1 2 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 364: ...fer to CRANKCASE on page 5 74 1 Front balancer lever 1 2 Front balancer shaft 1 3 Washer 2 4 Bearing 2 5 Front balancer gear 1 6 Damper 4 7 Front balancer weight 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 365: ... Clutch cover Refer to CLUTCH on page 5 41 1 Rear balancer cover 1 2 Rear balancer cover gasket 1 3 Rear balancer lever 1 4 Rear balancer shaft 1 5 Washer 2 6 Bearing 2 7 Rear balancer gear 1 8 Damper 4 9 Rear balancer weight 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 366: ... tions as shown in the illustration Align the punch mark b in the balancer weight with the mark c in the balancer gear 2 Align T mark on the pickup rotor with the crankcase mating surface a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres sion stroke align the T mark a on the pick up rotor with the crankcase mating surface b 3 Install Front balancer shaft a Align the punch ma...

Page 367: ... lash by turning the balancer shaft NOTE With each adjustment turn the balancer shaft one scale ET3P61033 INSTALLING THE REAR BALANCER 1 Install Rear balancer gear 1 Dampers 2 Rear balancer weight 3 Bearings Washers NOTE Install the dampers onto the balancer gear so that the middle section a of each damper is positioned to the outside of the gear projec tions as shown in the illustration Align the...

Page 368: ...h the punch mark b in the upper crankcase b Align the balancer gear punch mark c with the primary driven gear point d as shown NOTE Make sure that the rear balancer gear teeth and the primary driven gear teeth mesh cor rectly Make sure that the balancer gear punch mark c is aligned with the projection e on the up per crankcase Make sure that the slot f is facing in the direc tion indicated in the ...

Page 369: ...t 2 NOTE Make sure that the balancer shaft does not ro tate 7 Start the engine and check that there is no abnormal noise coming from the balancer gear If noise is abnormal adjust the gear lash by turning the balancer shaft NOTE With each adjustment turn the balancer shaft one scale T R Rear balancer shaft 0 4 Nm 0 04 m kg 0 29 ft lb f e c 2 1 1 T R Rear balancer lever bolt 14 Nm 1 4 m kg 10 ft lb ...

Page 370: ...BALANCERS 5 109 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 371: ...COOLER 6 5 THERMOSTAT 6 6 CHECKING THE THERMOSTAT 6 8 INSTALLING THE THERMOSTAT ASSEMBLY 6 8 WATER PUMP 6 10 DISASSEMBLING THE WATER PUMP 6 12 CHECKING THE WATER PUMP 6 12 ASSEMBLING THE WATER PUMP 6 12 INSTALLING THE WATER PUMP 6 13 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 372: ... unit hose 2 1 8 Oil cooler outlet hose 1 9 Left horn low 1 10 Coolant reservoir bracket 1 11 Water pump breather hose 1 12 Radiator outlet hose 1 13 Right horn high 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib LT LT LT T R 7 Nm 0 7 m kg 5 1 f...

Page 373: ...al proce dure Removing the radiator Order Job Parts to remove Q ty Remarks T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib LT LT LT T R 7 Nm 0 7 m kg 5 1 ft Ib 1 2 4 5 6 7 8 3 9 10 11 13 14 15 21 16 17 18 19 20 12 Manuals by Motomatrix www motomatr...

Page 374: ...r fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 37 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 2 Check Cooling system Leaks Repair or replace any faulty part 3 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refe...

Page 375: ...Refer to RADIATOR on page 6 1 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 1 1 Water pump outlet hose 1 2 Water pump outlet pipe 1 3 Water jacket joint inlet hose 1 4 Water jacket joint 1 5 Oil cooler inlet hose 1 6 Oil cooler outlet hose 1 7 Oil cooler 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Key...

Page 376: ... ring is positioned properly 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 13 4 Check Cooling system Leaks Repair or replace any faulty part 5 Measure Radiator cap opening pressure Below the specified pressure Replace...

Page 377: ... hose 2 1 5 Thermostat cover radiator filler pipe 1 6 Thermostat housing 1 7 Thermostat 1 8 Thermostat inlet pipe 2 1 9 Thermostat inlet hose 1 1 10 Plunger control unit hose 1 1 11 Coolant temperature sensor coupler 1 Disconnect 12 Coolant temperature sensor 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib New 1 10 13 12 11 2 7 5 ...

Page 378: ...at assembly Order Job Parts to remove Q ty Remarks T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib New 1 10 13 12 11 2 7 5 3 4 6 8 9 3 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 379: ...ler pipe Plunger control unit hose 1 Cracks damage wear Replace EAS26490 INSTALLING THE THERMOSTAT ASSEMBLY 1 Install Copper washer Coolant temperature sensor CAUTION EC3P61019 Use extreme care when handling the coolant temperature sensor Replace any part that was dropped or subjected to a strong im pact 2 Install Thermostat 1 Thermostat housing 2 NOTE Install the thermostat with its breather hole...

Page 380: ...r cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 381: ... oil Right side cowling Refer to GENERAL CHASSIS on page 4 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 19 1 Water pump breather hose 1 Disconnect 2 Radiator outlet hose 1 Disconnect 3 Water pump outlet hose 1 Disconnect 4 Water pump assembly 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email inf...

Page 382: ... O ring 1 3 Circlip 1 4 Impeller shaft 1 5 Rubber damper holder 1 6 Rubber damper 1 7 Water pump seal 1 8 Oil seal 1 9 Bearing 2 10 Water pump housing 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 383: ... Check Bearing Rough movement Replace EAS26560 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 into the water pump housing NOTE Before installing the oil seal apply tap water or coolant onto its outer surface Install the oil seal with a socket that matches its outside diameter 2 Install Water pump seal 1 CAUTION ECA14080 Never lubricate the water pump seal surface with oil or grease NOTE Install th...

Page 384: ... ring 1 Water pump assembly 2 NOTE Align the slit a on the impeller shaft with the projection b on the oil pump driven sprocket Lubricate the O ring with a thin coat of lithium soap base grease Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A Middle driven shaft bearing driv er 90890 04058 Bearing driver 40 mm YM 04058 Yamaha bond No 1215 90890 85505 Three Bond No 1215 A ...

Page 385: ... page 3 19 3 Check Cooling system Leaks Repair or replace any faulty part 4 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 386: ...WATER PUMP 6 15 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 387: ...4 CHECKING THE INJECTORS 7 7 CHECKING THE THROTTLE BODIES 7 7 CHECKING THE FUEL PRESSURE 7 7 ADJUSTING THE THROTTLE POSITION SENSOR 7 7 AIR INDUCTION SYSTEM 7 9 CHECKING THE PRESSURE REGULATOR 7 13 CHECKING THE AIR INDUCTION SYSTEM 7 13 INSTALLING THE AIR INDUCTION SYSTEM 7 13 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 388: ...coupler 1 Disconnect 4 Fuel tank breather hose 1 5 Fuel tank overflow hose 1 6 Fuel hose holder 1 7 Fuel hose 1 8 Fuel tank 1 9 Fuel pump 1 For installation reverse the removal proce dure T R 16 Nm 1 6 m kg 11 ft Ib New T R 4 Nm 0 4 m kg 2 9 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 1 5 4 3 7 6 8 9 2 6 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motom...

Page 389: ... it a strong shock Do not touch the base section of the fuel sender EAS26670 CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Obstruction Clean Cracks damage Replace fuel pump as sembly EAS26700 INSTALLING THE FUEL PUMP 1 Install Fuel pump NOTE Do not damage the installation surfaces of the fuel tank when installing the fuel pump Always use a new fuel pump gasket Install the fuel pump as shown i...

Page 390: ...and that the fuel hose holder is in the correct position other wise the fuel hose will not be properly in stalled NOTE Install the fuel hose connector securely onto the fuel tank until a distinct click is heard and then make sure that it does not come loose After installing the fuel hose holder 1 make sure that the sections a b and c of the holder are installed securely 1 1 a b c Manuals by Motoma...

Page 391: ... 2 Cylinder identification sensor coupler 1 Disconnect 3 Sub wire harness coupler 1 Disconnect 4 Engine idle speed adjusting screw 1 Disconnect 5 Throttle body joint clamp screw 8 Loosen 6 Throttle bodies 1 7 Throttle cable accelerator cable 1 Disconnect 8 Throttle cable decelerator cable 1 Disconnect 9 Plunger control unit hose 1 1 Disconnect T R 3 Nm 0 3 m kg 2 2 ft Ib T R 3 Nm 0 3 m kg 2 2 ft I...

Page 392: ...rse the removal proce dure Removing the throttle bodies Order Job Parts to remove Q ty Remarks T R 3 Nm 0 3 m kg 2 2 ft Ib T R 3 Nm 0 3 m kg 2 2 ft Ib 5 5 5 5 11 11 11 5 5 5 5 11 9 10 1 2 4 8 7 6 3 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 393: ...pler 1 Disconnect 7 Sub wire harness 1 8 Negative pressure hose 7 9 Bypass air unit inlet hose 1 10 Bypass air unit 1 11 Bypass air unit outlet hose 4 12 Intake air pressure sensor 1 13 Fuel rail 1 14 Injector 4 15 Throttle position sensor 1 For installation reverse the removal proce dure 12 3 4 5 6 1 7 2 8 8 8 8 9 8 8 8 14 15 11 11 11 13 14 14 14 10 New New T R 4 Nm 0 4 m kg 2 9 ft Ib T R 3 5 Nm ...

Page 394: ...he fuel pressure adapter 3 be tween the fuel hose 1 and fuel rail 2 d Connect the pressure gauge 4 to fuel pres sure adapter 3 e Start the engine f Measure the fuel pressure Faulty Replace the fuel pump EAS27030 ADJUSTING THE THROTTLE POSITION SENSOR NOTE Before adjusting the throttle position sensor the engine idling speed should be properly adjusted 1 Check Throttle position sensor Refer to CHEC...

Page 395: ...sting the throttle position sensor an gle tighten the throttle position sensor screws 3 to specification Digital circuit tester 90890 03174 Model 88 Multimeter with ta chometer YU A1927 Output voltage at idle 0 63 0 73 V T R Throttle position sensor screw 3 5 Nm 0 35 m kg 2 53 ft lb 3 2 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix c...

Page 396: ... INDUCTION SYSTEM 7 9 EAS27040 AIR INDUCTION SYSTEM 1 2 3 4 5 1 1 1 1 2 2 5 2 3 3 4 7 8 6 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 397: ... joint 4 Air induction system hose 3 way joint to air cut off valve 5 Air cut off valve 6 Air induction system hose 3 way joint to hose plug 7 Air induction system hose air filter case joint assembly to 3 way joint 8 Air filter case joint asssembly Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 398: ...oint assembly to 3 way joint 1 3 Air induction system hose 3 way joint to hose plug 1 4 Air induction system hose 3 way joint to air cut off valve 1 5 Air induction system hose 3 way joint to reed valve cover 4 6 Air induction system hose air cut off valve to 3 way joint 2 7 Air cut off valve 1 For installation reverse the removal proce dure 5 5 5 5 6 3 6 4 2 1 7 Manuals by Motomatrix www motomatr...

Page 399: ...ve cover cylinder 1 1 2 Reed valve cover cylinders 2 3 1 3 Reed valve cover cylinder 4 1 4 Reed valve assembly 4 5 Reed valve plate 4 For installation reverse the removal proce dure LT LT LT LT 1 4 5 2 3 4 4 4 5 5 5 T R 14 Nm 1 4 m kg 10 ft Ib Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 400: ...ses to cut off the flow when the vehicle is be ing driven However if the coolant temperature is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value 1 Check Hoses Loose connections Connect properly Cracks damage Replace Pipes Cracks damage Replace 2 Check Reed valve Reed valve sto...

Page 401: ...GRAM 2 2 8 23 TROUBLESHOOTING 8 25 SIGNALING SYSTEM 8 27 CIRCUIT DIAGRAM 1 2 8 27 CIRCUIT DIAGRAM 2 2 8 29 TROUBLESHOOTING 8 31 COOLING SYSTEM 8 37 CIRCUIT DIAGRAM 8 37 TROUBLESHOOTING 8 39 FUEL INJECTION SYSTEM 8 41 CIRCUIT DIAGRAM 1 2 8 41 CIRCUIT DIAGRAM 2 2 8 43 ECU SELF DIAGNOSTIC FUNCTION 8 45 SELF DIAGNOSTIC FUNCTION TABLE 8 46 TROUBLESHOOTING METHOD 8 48 DIAGNOSTIC MODE 8 49 TROUBLESHOOTIN...

Page 402: ...IC PROCESS FOR TROUBLESHOOTING 8 123 A CHECKING THE ABS WARNING LIGHT 8 124 B 1 THE ABS WARNING LIGHT DOES NOT COME ON 8 124 B 2 THE ABS WARNING LIGHT REMAINS ON 8 124 B 3 THE ABS WARNING LIGHT FLASHES 8 124 B 4 MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS PAST MALFUNCTION 8 124 B 5 MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS PRESENT MALFUNCTION 8 125 C 1 ONLY THE ABS WARNING LIGHT FAILS TO COME ON...

Page 403: ...8 163 CHECKING THE STARTER MOTOR OPERATION 8 163 CHECKING THE STATOR COIL 8 164 CHECKING THE RECTIFIER REGULATOR 8 164 CHECKING THE HORNS 8 165 CHECKING THE OIL LEVEL SWITCH 8 165 CHECKING THE FUEL SENDER 8 166 CHECKING THE RADIATOR FAN MOTORS 8 166 CHECKING THE COOLANT TEMPERATURE SENSOR 8 167 CHECKING THE THROTTLE POSITION SENSOR 8 167 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 8 168 CHECKING TH...

Page 404: ... B Y Sb G Y R B B G R Lg Sb Br R R W G O C C B C A A A A A A A C C C C C A A A A A D B B B A SUB WIRE HARNESS B D W B Gy Gy W B2 B1 B1 BB Lg W B B Lg W W B W R Y G L R Y Y W B L Y Ch Dg B W L G Ch Dg B L B L R B Y G Ch Dg Ch B W L G Dg B L B G L R B R B G L O B GRAY R L B L Br W BLACK GREEN B L G W L B GRAY R L G B GRAY R L R B GRAY R L Gy B L Gy B B L W B BLACK W L Y B L L Y B L BLACK P W B L L B...

Page 405: ...1 Coupler 3 wire harness front cowling wire harness 32 Sidestand switch 33 Cylinders 1 4 ignition coil 34 Spark plug 35 Cylinders 2 3 ignition coil 41 ECU engine control unit 42 Crankshaft position sensor 52 Coupler 5 wire harness front cowling wire harness 57 Ignition fuse Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 406: ... L B P Sb B Y Ch Y R Y Dg B Lg Br G L B P Sb W B Y B R Ch G L R W Br Br B L R R Y R B L W Br R G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G B B BLACK R B Br L BLACK B B GRAY Br Br L GRAY Lg R B L R Br G Br Br L Br L R B Br R Br B B B L R G L L R Y Y G G B B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Y Lg Sb W Dg Br G L B Ch B Dg Br G Ch W L B Y L W L W R B R L R Sb...

Page 407: ...ire harness wire harness 31 Coupler 3 front cowling wire harness wire harness 52 Coupler 5 front cowling wire harness wire harness 69 Engine stop switch 79 Relay unit 95 Lean angle sensor Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 408: ...llowing con ditions The transmission is in gear the neutral circuit of the gear position switch is open and the sidestand is up the sidestand switch circuit is closed The transmission is in neutral the neutral circuit of the gear position switch is closed and the side stand is down the sidestand switch circuit is open 10 11 9 1 4 5 7 2 6 3 8 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 En...

Page 409: ...the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 9 Re gap or replace the spark plug s 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 162 Ignition system is OK 5 Check the spark plug caps Refer to CHECKING THE SPARK PLUG CAPS on page 8 161 Replace the spark plug cap s 6 Check the ignition coils Refer to CHECKING THE IGNI TION COILS ...

Page 410: ...stand switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the sidestand switch 12 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 160 Replace the relay unit 13 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 163 Replace the lean angle sensor 14 Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 1 and CIRC...

Page 411: ...IGNITION SYSTEM 8 8 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 412: ... B B A B D W B B2 B1 B1 BB Lg W B B Lg W W B W R Y G L R Y Y W B L Y Ch Dg B W L G Ch Dg B L B L R B Y G Ch Dg Ch B W L G Dg B L B G L R B R B G L O B GRAY R L B L Br W BLACK GREEN B L G W L B GRAY R L G B GRAY R L R B GRAY R L Gy B L Gy B B L W B BLACK W L Y B L L Y B L BLACK P W B L L BLACK B B B B W W W W B L BLACK B BLACK L B BLACK B BLACK L WIRE HARNESS B WIRE HARNESS C WIRE HARNESS D WIRE HA...

Page 413: ... switch 17 Coupler 2 wire harness front cowling wire harness 31 Coupler 3 wire harness front cowling wire harness 32 Sidestand switch 52 Coupler 5 wire harness front cowling wire harness 57 Ignition fuse Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 414: ...R Ch G L R W Br Br B L R R Y R B L W Br R G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G B B BLACK R B Br L BLACK B B GRAY Br Br L GRAY Lg R B L R Br G Br Br L Br L R B Br R Br B B B L R G L L R Y Y G G B B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Y Lg Sb W L B Dg Br G Ch W L B Y L W L W R B R L R Sb W L Y Sb B R L G Y G L W L Y L G W R G Sb Sb W Ch Dg Y B Y P Y W ...

Page 415: ...cowling wire harness wire harness 52 Coupler 5 front cowling wire harness wire harness 69 Engine stop switch 70 Start switch 73 Clutch switch 79 Relay unit 80 Starting circuit cut off relay Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 416: ... these condi tions has been met In this instance the starting circuit cut off relay stays open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be started by pushing the start switch 13 1 12 4 5 7 7 a b 9 7 10 8 6 2 3 11 a WHEN THE TRANSMISSION IS IN NEUTRAL b WHEN THE SIDESTAND IS UP AN...

Page 417: ...peration Refer to CHECKING THE START ER MOTOR OPERATION on page 8 163 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 39 Repair or replace the starter motor 5 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RE LAYS on page 8 157 Replace the relay unit 6 C...

Page 418: ...sidestand switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the clutch switch 13 Check the start switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the right handlebar switch 14 Check the entire starting system wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 9 and CIRCUIT DIA GRAM ...

Page 419: ...ELECTRIC STARTING SYSTEM 8 16 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 420: ...P R Br L B R R R Br L B Br R Br R W W W GRAY B R BLACK R R L W R L R W G W B R L B DARK GREEN A A A A A A A B2 B1 B1 BB Lg W B B Lg W R Y G L R Y Y W G L R B R B G L B L Br W BLACK GREEN B L G W W L Y B L L Y B L BLACK P W B L L BLACK B B B B W W W W B L BLACK B BLACK L B BLACK B BLACK L BLUE BLUE B G B W R G R W G B Y L B W BB B Y L Lg R W R G B2 Sb B Y B R Y W L W P Ch B G B R Dg B L B L W B BLA...

Page 421: ...CHARGING SYSTEM 8 18 2 Rectifier regulator 3 AC magneto 7 Main fuse 8 Battery Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 422: ... Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 164 Replace the stator coil 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 164 Replace the rectifier regulator 5 Check the entire charging system wiring Refer to CIRCUIT DIAGRAM on page 8 17 Properly connect or repair the charging sy...

Page 423: ...CHARGING SYSTEM 8 20 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 424: ...W C C B C A A A A A A A C C C C C A A A A A D B B B A B D W B B2 B1 B1 BB Lg W B B Lg W W B W R Y G L R Y Y W B L Y Ch Dg B W L G Ch Dg B L B L R B Y G Ch Dg Ch B W L G Dg B L B G L R B R B G L O B GRAY R L B L Br W BLACK GREEN B L G W L B GRAY R L G B GRAY R L R B GRAY R L Gy B L Gy B B L W B BLACK W L Y B L L Y B L BLACK P W B L L BLACK B B B B W W W W B L BLACK B BLACK L B BLACK B BLACK L WIRE ...

Page 425: ...re harness front cowling wire harness 41 ECU engine control unit 52 Coupler 5 wire harness front cowling wire harness 53 Headlight relay on off 54 Hazard lighting fuse 56 Headlight fuse 57 Ignition fuse Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 426: ...B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg Br G L B P Sb W B Y B R Ch G L R W Br Br B L R R Y R B L W Br R G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G B B BLACK R B Br L BLACK B B GRAY Br Br L GRAY Lg R B L R Br G Br Br L Br L R B Br R Br B B B L R G L L R Y Y G G B B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Y Lg Sb W L B Dg Br G Ch W L B Y L W L W R B R L R Sb...

Page 427: ...ront cowling wire harness wire harness 74 Pass switch 75 Dimmer switch 90 Meter light 91 High beam indicator light 99 Headlight relay dimmer 101 Auxiliary light 102 Headlight Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 428: ... to CHECKING THE FUS ES on page 8 153 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 154 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the main switch immobilizer unit 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the left handleba...

Page 429: ...adlight relay dimmer 9 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 21 and CIRCUIT DIA GRAM 2 2 on page 8 23 Properly connect or repair the lighting sys tem wiring Replace the ECU Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 430: ...B1 B1 BB Lg W B B Lg W W B W R Y G L R Y Y W BROWN B L Y Ch Dg B W L G Ch Dg B L B L R B Y G Ch Dg Ch B W L G Dg B L B G L R B R B G L O B GRAY R L B L Br W BLACK GREEN B L G W L B GRAY R L G B GRAY R L R B GRAY R L Gy B L Gy B BLACK W L Y B L L Y B L BLACK P W B L L BLACK B B B B W W W W B L BLACK B BLACK L B BLACK B BLACK L WIRE HARNESS B WIRE HARNESS C WIRE HARNESS D WIRE HARNESS B Y G G Y Br B...

Page 431: ...witch 25 Brake light relay 28 Tail brake light 29 Rear left turn signal light 30 Rear right turn signal light 31 Coupler 3 wire harness front cowling wire harness 41 ECU engine control unit 49 Coupler 4 wire harness front cowling wire harness 50 Oil level switch 52 Coupler 5 wire harness front cowling wire harness 54 Hazard lighting fuse 55 Signaling system fuse 57 Ignition fuse Manuals by Motomat...

Page 432: ...W L G B R Sb B Y Sb W Sb B Lg Br R R Br R G Sb Lg B Sb W Br R B B R B R R B B B B L Y G L L Y B Y BLACK Y R Y Dg B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg Br G L B P Sb W B Y B R Ch G L R W Br Br B L R R Y R B L W Br R G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G B B BLACK R B Br L BLACK B B GRAY Br Br L GRAY Lg R B L R Br G Br Br L Br L R B Br R Br B B B L R G L L R ...

Page 433: ...65 Turn signal hazard relay 68 Front brake light switch 71 Hazard switch 77 Turn signal switch 78 Horn switch 79 Relay unit 84 Neutral indicator light 87 Multi function meter 88 Oil level warning light 92 Right turn signal indicator light 93 Left turn signal indicator light 96 Horn 97 Front left turn signal light 98 Front right turn signal light 105 Windshield drive unit Manuals by Motomatrix www ...

Page 434: ...ce the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 154 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the main switch immobilizer unit 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 27 and CIRCUIT DIA GRAM 2 2 on page 8 29 Properly connect...

Page 435: ... the tail brake light bulb socket or both 2 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the front brake light switch 3 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the rear brake light switch 4 Check the brake light relay Refer to CHECKING THE RE LAYS on page 8 157 Replace the brake light relay 5 Check the entire...

Page 436: ... page 8 149 Replace the left handlebar switch 4 Check the turn signal hazard relay Refer to CHECKING THE TURN SIGNAL HAZARD RELAY on page 8 160 Replace the turn signal hazard relay 5 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 27 and CIRCUIT DIA GRAM 2 2 on page 8 29 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the gear posit...

Page 437: ...re signaling system wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 27 and CIRCUIT DIA GRAM 2 2 on page 8 29 Properly connect or repair the signaling system wiring Replace the meter assembly 1 Check the oil level switch Refer to CHECKING THE OIL LEVEL SWITCH on page 8 165 Replace the oil level switch 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 27 and CIRCUIT DIA...

Page 438: ... wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 27 and CIRCUIT DIA GRAM 2 2 on page 8 29 Properly connect or repair the signaling system wiring Replace the meter assembly 1 Check the rear wheel sensor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 22 Replace the rear wheel sensor 2 Check the entire speed sensor wir ing Refer to NOTE Properly connect or repair the speed sen...

Page 439: ...SIGNALING SYSTEM 8 36 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 440: ... W B B Lg W W B W R Y G L R Y Y W B L Y Ch Dg B W L G Ch Dg B L B L R B Y G Ch Dg Ch B W L G Dg B L B G L R B R B G L O B GRAY R L B L Br W BLACK GREEN B L G W L B GRAY R L G B GRAY R L R B GRAY R L Gy B L Gy B BLACK W L Y B L L Y B L BLACK P W B L L BLACK B B B B W W W W B L BLACK B BLACK L B BLACK B BLACK L WIRE HARNESS B WIRE HARNESS C WIRE HARNESS D WIRE HARNESS B Y G G Y Br Br B BLACK Gy Gy B...

Page 441: ...emperature sensor 57 Ignition fuse 60 Radiator fan motor relay 61 Left radiator fan motor fuse 62 Left radiator fan motor 63 Right radiator fan motor fuse 64 Right radiator fan motor Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 442: ...h Refer to CHECKING THE SWITCHES on page 8 149 Replace the main switch immobilizer unit 4 Check the radiator fan motors Refer to CHECKING THE RADIA TOR FAN MOTORS on page 8 166 Replace the radiator fan motor s 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 157 Replace the radiator fan motor relay 6 Check the coolant temperature sen sor Refer to CHECKING THE COOL ANT T...

Page 443: ...COOLING SYSTEM 8 40 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 444: ...B B B A B D W B Gy W B2 B1 B1 BB Lg W B B Lg W W B Gy W R Y G L R Y Y W B L Y Ch Dg B W L G Ch Dg B L B L R B Y G Ch Dg Ch B W L G Dg B L B G L R B R B G L O B GRAY R L B L Br W BLACK GREEN B L G W L B GRAY R L G B GRAY R L R B GRAY R L Gy B L Gy B W L Y B L L Y B L BLACK P W B L L BLACK B B B B W W W W B L BLACK B BLACK L B BLACK B BLACK L WIRE HARNESS B WIRE HARNESS C WIRE HARNESS D WIRE HARNESS...

Page 445: ...Injector 3 38 Injector 2 39 Injector 1 40 Air induction system solenoid 41 ECU engine control unit 42 Crankshaft position sensor 43 Intake air temperature sensor 44 Coolant temperature sensor 45 O2 sensor 46 Cylinder identification sensor 47 Throttle position sensor 48 Intake air pressure sensor 52 Coupler 5 wire harness front cowling wire harness 53 Headlight relay on off 56 Headlight fuse 57 Ign...

Page 446: ...Y Ch Y R Y Dg B Lg Br G L B P Sb W B Y B R Ch G L R W Br Br B L R R Y R B L W Br R G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G B B BLACK R B Br L BLACK B B GRAY Br Br L GRAY Lg R B L R Br G Br Br L Br L R B Br R Br B B B L R G L L R Y Y G G B B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Y Lg Sb W L B Dg Br G Ch W L B Y L W L W R B R L R Sb W L Y Sb B R L G Y G L W...

Page 447: ...harness 52 Coupler 5 front cowling wire harness wire harness 69 Engine stop switch 74 Pass switch 75 Dimmer switch 79 Relay unit 81 Fuel pump relay 87 Multi function meter 89 Engine trouble warning light 95 Lean angle sensor 99 Headlight relay dimmer 102 Headlight Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 448: ...the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation The warning light flashes when any one of the conditions listed below is present and the start switch is pushed Checking the engine trouble warning light The engine trouble warning light comes on for 1 4 seconds after the main switch has been turned to ON and it comes on while the start switch i...

Page 449: ...drive 11 Cylinder identification sensor No normal signals are received from the cylinder identification sensor Unable Unable 12 Crankshaft position sensor No normal signals are received from the crankshaft position sen sor Unable Unable 13 Intake air pressure sensor open or short circuit Intake air pressure sensor open or short circuit detected Able Able 14 Intake air pressure sensor hose line Int...

Page 450: ... ders 34 Cylinders 2 3 igni tion coil faulty ignition Malfunction detected in the prima ry wire of the cylinders 2 3 igni tion coil Able depending on the number of faulty cylin ders Able depending on the number of faulty cylin ders 41 Lean angle sensor open or short circuit Lean angle sensor open or short circuit detected Unable Unable 42 Rear wheel sensor No normal signals are received from the r...

Page 451: ...tected in the ECU the fault code number might not appear on the meter Unable Unable Fault code No Item Symptom Able un able to start Able un able to drive Er 1 ECU internal malfunc tion output signal error No signals are received from the ECU Unable Unable Er 2 ECU internal malfunc tion output signal error No signals are received from the ECU within the specified duration Unable Unable Er 3 ECU in...

Page 452: ...ometer tripmeter fuel reserve tripmeter displays dIAG appears on the odometer tripmeter fuel reserve tripmeter LCD 4 Press the SELECT button to select the CO adjustment mode Co or the diagnostic mode dIAG 5 After selecting dIAG simultaneously press the SELECT and RESET buttons for 2 seconds or more to activate the diagnostic mode The diagnostic code number d 01 appears on the clock LCD 6 Select th...

Page 453: ...n or short circuit in wire harness Defective crankshaft position sensor Malfunction in pickup rotor Malfunction in ECU Improperly installed crankshaft position sensor 13 Intake air pressure sensor open or short circuit detect ed Open or short circuit in sub wire harness Open or short circuit in wire harness Defective intake air pressure sensor Malfunction in ECU 03 14 Intake air pressure sensor ho...

Page 454: ...or The vehicle has overturned Defective lean angle sensor Malfunction in ECU Improperly installed lean angle sensor 08 31 The amount of air fuel ratio feedback compensation is maintained continuously in the vicinity of the upper lim it lean air fuel ratio Open or short circuit in sub wire harness Open or short circuit in front cowling wire harness Open or short circuit in wire harness Fuel pressur...

Page 455: ...Malfunction in the engine side of the gear position switch Malfunction in ECU Malfunction in ABS ECU 07 21 43 The ECU is unable to moni tor the battery voltage an open or short circuit in the line to the ECU Open or short circuit in front cowling wire harness Open or short circuit in wire harness Malfunction in ECU 09 44 An error is detected while reading or writing on EE PROM CO adjustment val ue...

Page 456: ... Check with throttle fully closed Fully opened position 97 100 Check with throttle fully open 03 Pressure difference atmospheric pressure and intake air pressure Displays the intake air pres sure Set the engine stop switch to and then push the start switch If the dis play value changes the performance is OK 05 Intake air temperature Displays the intake air tem perature Compare the actually mea sur...

Page 457: ...ear OFF 60 EEPROM fault code dis play No history 00 History exists 01 04 Cylinder fault code If more than one cylinder is defective the display alter nates every two seconds to show all the detected cylin der numbers When all cyl inder numbers are shown the display repeats the same process 61 Malfunction history code display No history 00 History exists Fault codes 11 50 If more than one code numb...

Page 458: ...rk five times Connect an ignition checker 31 Cylinders 2 3 ignition coil Actuates the cylinders 2 3 ignition coil five times at one second intervals Illuminates the engine trou ble warning light Check the spark five times Connect an ignition checker 36 Injector 1 Actuates the injector 1 five times at one second inter vals Illuminates the engine trou ble warning light Check the operating sound of t...

Page 459: ...ble warning light is OFF when the relay is ON and the engine trouble warning light is ON when the relay is OFF Check the operating sound of the fuel pump relay five times 51 Radiator fan motor relay Actuates the radiator fan mo tor relay for five cycles of five seconds ON 2 seconds OFF 3 seconds Illuminates the engine trou ble warning light and rotates the radiator fan motors Check the operating s...

Page 460: ...en gine and oper ating it at idle 2 Connections Cylinder identification sensor cou pler Wire harness ECU coupler Sub wire harness coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness and or sub wire harness Repair or replace if there is a...

Page 461: ...upler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between the crankshaft position sensor coupler and ECU cou pler gray gray black blue black blue 4 Defective crankshaft position sens...

Page 462: ...c mode Code No 03 Replace if defective Refer to CHECKING THE IN TAKE AIR PRESSURE SEN SOR on page 8 168 Fault code No 14 Symptom Intake air pressure sensor hose system malfunction clogged or detached hose Diagnostic code No 03 Intake air pressure sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Intake air pressure sensor hose Check the intake air pres...

Page 463: ...he coupler se curely 3 Open or short circuit in wire harness and or sub wire harness Repair or replace if there is an open or short circuit Between throttle position sen sor coupler and ECU coupler black blue black blue yellow yellow blue blue 4 Throttle position sensor lead wire open circuit output voltage check Check for open circuit and re place the throttle position sen sor black blue yellow O...

Page 464: ...any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Throttle position sensor lead wire open circuit output voltage check Check for open circuit and re place the throttle position sen sor black blue yellow Open circuit item Output voltage Ground wire open circuit 5 V Output wire open circuit 0 V Power sup...

Page 465: ...pler If there is a malfunction repair it and connect the coupler se curely If the transmis sion is in gear retracting the sidestand If the transmis sion is in neu tral reconnecting the wiring 2 Open or short circuit in wire harness and or front cowling wire harness Repair or replace if there is an open or short circuit Between ECU and black red lead 3 Defective sidestand switch Replace if defectiv...

Page 466: ...ck the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between coolant temperature sensor coupler and ECU cou pler black blue black blue green white green white 4 Defective coolant temperature sen...

Page 467: ...eck the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between intake air temperature sensor coupler and ECU cou pler black blue black blue brown white brown white 4 Defective intake air temperat...

Page 468: ...rness coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness sub wire harness and or front cowling wire harness Repair or replace if there is an open or short circuit Between O2 sensor coupler and ECU coupler black blue black blue gray whit...

Page 469: ...rst turned OFF 2 Installed condition of lean angle sen sor Check the installed direction and condition of the sensor 3 Connections Lean angle sensor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 4 Defective lean angle sensor Execute the diagnosti...

Page 470: ...ely Starting the en gine warming it up until the coolant temper ature is 60 C or more and then running it between 2000 3000 r min un til the engine trouble warn ing light turns off 2 Open or short circuit in wire harness sub wire harness and or front cowling wire harness Repair or replace if there is an open or short circuit Between O2 sensor coupler and ECU coupler black blue black blue gray whit...

Page 471: ...throttle position sen sor Execute the diagnostic mode Code No 01 Replace if defective Check the fuel system discon nection etc Repair or replace if there is a malfunction Check the intake system im proper sealing etc Repair or replace if there is a malfunction Fault code No 31 Symptom The amount of air fuel ratio feedback compensation is maintained continuously in the vicinity of the upper limit l...

Page 472: ...rming it up until the coolant temper ature is 60 C or more and then running it between 2000 3000 r min un til the engine trouble warn ing light turns off 2 Open or short circuit in wire harness sub wire harness and or front cowling wire harness Repair or replace if there is an open or short circuit Between O2 sensor coupler and ECU coupler black blue black blue gray white gray white Between O2 sen...

Page 473: ...gnostic mode Code No 01 Replace if defective Checking the fuel system clog ging etc Repair or replace if there is a malfunction Fault code No 32 Symptom The amount of air fuel ratio feedback compensation is maintained continuously in the vicinity of the lower limit rich air fuel ratio Diagnostic code No 01 Throttle position sensor Order Item components and probable cause Check or maintenance job R...

Page 474: ...n repair it and connect the coupler se curely Starting the en gine and oper ating it at idle 2 Open or short circuit in wire harness and or front cowling wire harness Repair or replace if there is an open or short circuit Between cylinders 1 4 igni tion coil connector and ECU coupler orange orange Between cylinders 1 4 igni tion coil connector and right handlebar switch coupler red black red black...

Page 475: ...repair it and connect the coupler se curely Starting the en gine and oper ating it at idle 2 Open or short circuit in wire harness and or front cowling wire harness Repair or replace if there is an open or short circuit Between cylinders 2 3 igni tion coil connector and ECU coupler gray red gray red Between cylinders 2 3 igni tion coil connector and right handlebar switch coupler red blue red blac...

Page 476: ... of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to ON 2 Open or short circuit in wire harness and or front cowling wire harness Repair or replace if there is an open or short circuit Between lean angle sensor coupler and ECU coupler black blue black blue yellow green yellow green blue blue 3 Defective lean angle sensor Execute the diagn...

Page 477: ...air it and connect the coupler se curely Starting the en gine and input ting the vehicle speed signals by operating the vehicle at a 20 to 30 km h A 2 Open or short circuit in wire harness and or ABS wire harness Repair or replace if there is an open or short circuit Between rear wheel sensor coupler and ABS ECU coupler white white black black Between ABS ECU coupler and ECU coupler white yellow w...

Page 478: ...y blue sky blue Between relay unit coupler and ECU coupler black yellow black yellow B 3 Faulty shift drum neutral detection ar ea Replace if defective Refer to TRANSMISSION on page 5 94 B 4 Defective gear position switch neutral circuit Execute the diagnostic mode Code No 21 Replace if defective Refer to CHECKING THE SWITCHES on page 8 149 Fault code No 42 Symptom A No normal signals are received...

Page 479: ...nect the coupler se curely Starting the en gine and oper ating it at idle 2 Open or short circuit in the wire har ness and or sub wire harness Repair or replace if there is an open or short circuit Between relay unit coupler and ECU coupler blue yellow blue yellow red blue red blue Between relay unit coupler and main switch coupler red brown blue Between relay unit coupler and engine stop switch c...

Page 480: ...o 60 to check the faulty cylinder number If multiple cylinders are defec tive the numbers of the faulty cylinders are displayed alternately at 2 second inter vals 2 Execute the CO adjustment mode and set the exhaust gas volume of the faulty cyl inder to 0 Refer to ADJUSTING THE EXHAUST GAS VOLUME on page 3 7 Replace ECU if it does not re cover from the malfunction Turning the main switch to ON Rea...

Page 481: ...if defective Refer to CHARGING SYS TEM on page 8 17 4 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between battery and main switch coupler red red Between main switch coupler and ignition fuse brown blue brown blue Between ignition fuse and ECU coupler red white red white Fault code No 50 Symptom Faulty ECU memory When this malfunction is detected in...

Page 482: ...mbly 4 Malfunction in ECU Replace the ECU Fault code No Er 2 Symptom No signals are received from the ECU within the specified duration Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Meter assembly coupler Wire harness ECU coupler Front cowling wire harness coupler Check the coupler for any pins that may be pulled out Check t...

Page 483: ...e meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 4 Symptom Non registered data has been received from the meter Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Meter assembly coupler Wire harness ECU coupler Front cowling wire harness coupler Check the coupler for any pins that may be pulled out Check the...

Page 484: ... Lg Sb W Sb Lg G R B W Y W Ch B G B R Dg B L G W B R L B DARK GREEN L Y B R R L R G G Y Sb R B B Y Br W Y G W L L W B W Br B G Y B R G R L B R L Y B Y Sb G Y R B B G R Lg Sb Br R R W G O W W W B Br B W L Br W B B B W G R G Y W Y Lg R B B W G W L W Y R L Y G Sb B2 L W R W C C B C A A A A A A A C C C C C A A A A A D B B B B D W B Gy W B2 B1 B1 BB Lg W B B Lg W W B Gy W R L R B R W W B R Br B R W G Y...

Page 485: ...ttery 15 Fuel pump 17 Coupler 2 wire harness front cowling wire harness 41 ECU engine control unit 52 Coupler 5 wire harness front cowling wire harness 57 Ignition fuse Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 486: ... B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg Br G L B P Sb W B Y B R Ch G L R W Br Br B L R R Y R B L W Br R G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G B B BLACK R B Br L BLACK B B GRAY Br Br L GRAY Lg R B L R Br G Br Br L Br L R B Br R Br B B B L R G L L R Y Y G G B B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Y Lg Sb W L B Dg Br G Ch W L B Y L W L W R B R L R S...

Page 487: ... wire harness wire harness 52 Coupler 5 front cowling wire harness wire harness 69 Engine stop switch 79 Relay unit 81 Fuel pump relay Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 488: ...r to CHECKING THE SWITCHES on page 8 149 Replace the main switch immobilizer unit 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the right handlebar switch 5 Check the relay unit fuel pump re lay Refer to CHECKING THE RE LAYS on page 8 157 Replace the relay unit 6 Check the fuel pump Refer to CHECKING THE FUEL PUMP BODY on page 7 2 Replace the fuel pump assembl...

Page 489: ...FUEL PUMP SYSTEM 8 86 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 490: ...A A A A D B B B A B D W B Gy W B2 B1 B1 BB Lg W B B Lg W W B Gy W R Y G L R Y Y W B L Y Ch Dg B W L G Ch Dg B L B L R B Y G Ch Dg Ch B W L G Dg B L B G L R B R B G L O B GRAY R L B L Br W BLACK GREEN B L G W L B GRAY R L G B GRAY R L R B GRAY R L Gy B L Gy B W L Y B L L Y B L BLACK P W B L L BLACK B B B B W W W W B L BLACK B BLACK L B BLACK B BLACK L WIRE HARNESS B WIRE HARNESS C WIRE HARNESS D WI...

Page 491: ...nd windshield drive system 7 Main fuse 8 Battery 17 Coupler 2 wire harness front cowling wire harness 52 Coupler 5 wire harness front cowling wire harness 55 Signaling system fuse Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 492: ... B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg Br G L B P Sb W B Y B R Ch G L R W Br Br B L R R Y R B L W Br R G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G B B BLACK R B Br L BLACK B B GRAY Br Br L GRAY Lg R B L R Br G Br Br L Br L R B Br R Br B B B L R G L L R Y Y G G B B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Y Lg Sb W L B Dg Br G Ch W L B Y L W L W R B R L R S...

Page 493: ...ing wire harness wire harness 52 Coupler 5 front cowling wire harness wire harness 76 Windshield position switch 105 Windshield drive unit Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 494: ... battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the main switch immobilizer unit 4 Check the windshield position switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the left handlebar switch 5 Check the entire windshield drive system wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 87 and CIRCUIT DIA GRAM 2 2 on p...

Page 495: ...WINDSHIELD DRIVE SYSTEM 8 92 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 496: ...UE R Br L B B G R R R Br L B B W Br R Br R W W W GRAY B R BLACK R R L W R L R W R G R W G B Y L B W BB B Y L Lg R W R G B2 B2 B1 B1 BB Lg W B B Lg W R Br B R W G Y R Y G L R Y Y W G L R B R B G L B B L Gy W R L BLACK B L W B BLACK W L Y B L L W B B L L Y B L BLACK P W B L L BLACK B B B B BB2 BB1 BB4 BB3 W W W W R Br R W G L L W R Y R B L R Br B G L R W Br Br B L R R Y R B L W Br R B L BLACK B BLAC...

Page 497: ...1 Main switch 7 Main fuse 8 Battery 52 Coupler 5 wire harness front cowling wire harness 55 Signaling system fuse Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 498: ... B B B R B B R B R R B B B B B B B Ch B B Dg B Br Y BLACK G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G B B BLACK R B Br L BLACK B B GRAY Br Br L GRAY Lg R B L R Br G Br Br L Br L R B Br R Br B B B L R G L L R Y Y G G B B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Y Lg Sb W Dg Ch B B Dg Br G L B Ch B Dg Br G Ch W L B Y L W L W R B R L R Sb W L Y Sb B R L G Y G L W L...

Page 499: ... BOX SYSTEM 8 96 52 Coupler 5 front cowling wire harness wire harness 82 Accessory box solenoid Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 500: ...echarge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 149 Replace the main switch immobilizer unit 4 Check the accessory box solenoid Refer to CHECKING THE ACCES SORY BOX SOLENOID on page 8 169 Replace the accessory box solenoid 5 Check the entire accessory box system wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 87 and CIRCUIT DIA GRAM 2 2 on page 8 89 Pr...

Page 501: ...ACCESSORY BOX SYSTEM 8 98 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 502: ... R L W R L R W R G R W G B Y L B W BB Sb B Y B R Y W L W P B Y L Lg R W R G B2 W Y B G R Lg Sb W Sb Lg G R B W Y W Ch B G B R Dg B L G W B R L B DARK GREEN L Y B R R L R G G Y Sb R B B Y Br W Y G W L L W B W Br B G Y B R G R L B R L Y B Y Sb G Y R B B G R Lg Sb Br R R W G O W W W B Br B W L Br W B B B W G R G Y W Y Lg R B B W G W L W Y R L Y G Sb B2 L W R W C C B C A A A A A A A C C C C C A A A A ...

Page 503: ...pler 1 wire harness front cowling wire harness 17 Coupler 2 wire harness front cowling wire harness 31 Coupler 3 wire harness front cowling wire harness 41 ECU engine control unit 52 Coupler 5 wire harness front cowling wire harness 57 Ignition fuse Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 504: ...L G B R Sb B Y Sb W Sb B Lg Br R R Br B L Y G L L Y B Y BLACK Y R Y Dg B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg Br G L B P Sb W B Y B R Ch R W L W Dg R B B Br Br W Ch G Y L R Br G B B BLACK R B Br L BLACK B B GRAY Br Br L GRAY Lg R B L R Br G Br Br L Br L R B Br R Br B B B L R G L L R Y Y G G B B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Y Lg Sb W L B Dg Br G Ch W L B Y L W L W R B R L R ...

Page 505: ...ire harness wire harness 31 Coupler 3 front cowling wire harness wire harness 52 Coupler 5 front cowling wire harness wire harness 86 Immobilizer system indicator light 87 Multi function meter Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 506: ...s impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made or all keys are lost the entire immobilizer system must be replaced Therefore it is highly rec ommended to use either standard key for driving and to keep the code re registering key in a safe place Do not submerse the keys in water Do not expose the ke...

Page 507: ...nition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours After that time the indicator light will stop flashing but the immobilizer system is still enabled Parts to be replaced Key registration re quirement Main switch immo bilizer unit Standard key ECU Accesso ry lock and key Main switch Immobiliz er unit Stand...

Page 508: ...e key registration mode NOTE The existing standard key code is erased from the memory when the key registration mode is activated When the key registration mode is activated the immobilizer system indicator light flashes rapidly 4 While the indicator light is flashing turn the main switch to OFF remove the key and within 5 sec onds insert the second standard key to be registered into the main swit...

Page 509: ...tch ON b Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g First standard key h Second standard key i Registration mode A Registration of the second standard key is complete B Immobilizer system indicator light stops flashing when the registration of the second standard key is complete a Main switch ON b Main switch OFF c LED on d LED off e Less than 5 0 s f Code re ...

Page 510: ...switch immobilizer unit 4 Check the entire immobilizer sys tem wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 99 and CIRCUIT DIA GRAM 2 2 on page 8 101 Properly connect or repair the immobilizer system wiring Check the condition each of the im mobilizer system circuits Refer to SELF DIAGNOSIS FAULT CODE INDICATION on page 8 107 Fault code Part Symptom Cause Action 51 IMMOBILIZER UNIT Code cannot be...

Page 511: ...ss and connector 2 Replace the main switch im mobilizer unit 3 Replace the ECU 54 IMMOBILIZER UNIT Codes transmitted between the ECU and the immobilizer unit do not match Noise interference or disconnected lead ca ble 1 Interference due to radio wave noise 2 Disconnected com munication harness 3 Immobilizer unit mal function 4 ECU failure The ECU or immobi lizer unit was re placed with a used unit...

Page 512: ...IMMOBILIZER SYSTEM 8 109 a Light on b Light off Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 513: ...IMMOBILIZER SYSTEM 8 110 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 514: ... BLACK R R L W R L R W R G R W G B Y L B W BB Sb B Y B R Y W L W P B Y L Lg R W R G B2 W Y B G R Lg Sb W Sb Lg G R B W Y W Ch B G B R Dg B L G W B R L B DARK GREEN L Y B R R L R G G Y Sb R B B Y Br W Y G W L L W B W Br B G Y B R G R L B R L Y B Y Sb G Y R B B G R Lg Sb Br R R W G O W W W B Br B W L Br W B B B W G R G Y W Y Lg R B B W G W L W Y R L Y G Sb B2 L W R W C C B C A A A A A A A C C C C C ...

Page 515: ...ectronic control unit 20 Front wheel sensor 21 Rear wheel sensor 22 ABS motor relay 23 Hydraulic unit 24 Rear brake light switch 25 Brake light relay 28 Tail brake light 31 Coupler 3 wire harness front cowling wire harness 41 ECU engine control unit 52 Coupler 5 wire harness front cowling wire harness 55 Signaling system fuse 57 Ignition fuse Manuals by Motomatrix www motomatrix co uk The Solution...

Page 516: ...K B B B B R B B R B R R B B B B B B B Ch B B Dg B Br Y BLACK G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G B B BLACK R B Br L BLACK B B GRAY Br Br L GRAY Lg R B L R Br G Br Br L Br L R B Br R Br B B B L R G L L R Y Y G G B B B Br B B L R W R W R B W L B Br G Y B Y B R R Y Y Lg Sb W Dg Ch B B Dg Br G L B Ch B Dg Br G Ch W L B Y L W L W R B R L R Sb W L Y Sb B R L G Y G L ...

Page 517: ...cowling wire harness wire harness 52 Coupler 5 front cowling wire harness wire harness 68 Front brake light switch 69 Engine stop switch 70 Start switch 79 Relay unit 80 Starting circuit cut off relay 85 ABS warning light 87 Multi function meter Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 518: ...onic control unit 7 Hydraulic unit HU 8 Rear wheel sensor 9 Rear wheel sensor rotor 10 Rear brake caliper 11 Left front brake caliper 12 Right front brake caliper partially operated together with the rear brake 13 Front wheel sensor 14 Front wheel sensor rotor 15 Proportioning valve 16 Metering valve Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info ...

Page 519: ...ABS ANTI LOCK BRAKE SYSTEM 8 116 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 520: ...W R R W G G W B W R B R B B W R L B W R L W Y B G R Lg Sb W Sb Lg G R B W Y W Br W Y G W L L W B W Br B G Y B L W W L Y G Br W B Br B B W G Y L Y L Y W B Y G W W L Y G L W P B R G B G R B Y Y W Y L L L W Y G W L G W P G R G B B R L Y B R R L R G G Y Sb R B B Y R G R L B R L Y B Y Sb G Y R B R Br R W G L L W R Y R B L R Br B G L R W Br Br B L R R Y R B L W Br R B W L G Ch Dg B L B Ch B W L G Dg B L...

Page 521: ...t solenoid coupler 5 ABS motor coupler 6 Rear wheel sensor coupler 7 ABS ECU coupler 8 Wire harness ABS wire harness coupler 9 Front wheel sensor coupler 10 Wire harness front cowling wire harness coupler Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 522: ...ENERAL CHASSIS on page 4 1 Storage compartment Refer to GENERAL CHASSIS on page 4 1 1 ABS ECU cover 1 2 ABS ECU coupler 2 Disconnect 3 ABS ECU 1 4 ABS motor relay coupler 1 Disconnect 5 ABS motor relay 1 For installation reverse the removal proce dure 4 5 3 2 2 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 523: ...on Replace the hydraulic unit NOTE Measure the resistance of the front brake rear brake and unified brake system solenoid valves a Connect the pocket tester Ω 1 to the sole noid valve terminals as shown b Measure the solenoid valve resistance 2 Check Solenoid valve insulation Continuity Replace the hydraulic unit a Connect the pocket tester Ω 1k to the so lenoid terminal and negative battery termi...

Page 524: ...d on components related to the ABS be sure to perform a final check before delivering the vehicle to the customer Refer to D 3 FINAL CHECK on page 8 144 ABS operation when the ABS warning light comes on 1 The ABS warning light remains on ABS operates as a normal brake system A malfunction was detected using the ABS self diagnosis function 2 The ABS warning light comes on and then goes off when sta...

Page 525: ... them to shocks or pulling on them with too much force since the ABS components are precisely adjusted The ABS ECU hydraulic unit wheel sensors and ABS motor relay are united assemblies and cannot be disassembled The malfunction history is stored in the memory of the ABS ECU Delete the malfunction codes when the service is finished This is because the past malfunction codes will be displayed again...

Page 526: ...Only the ABS warn ing light does not come on C 3 The ABS warning light does not come on when pushing the start switch Check the test coupler adapter B 1 The ABS warning light does not come on B 3 The ABS warning light flashes B 2 The ABS warning light remains on B 5 Present malfunction B 4 Past malfunction A Check the ABS warning light C 2 All indicator lights do not come on C 4 The ABS warning li...

Page 527: ...nly the ABS warning light fails to come on when the main switch is turned to ON C 1 2 The ABS warning light and all other indicator lights fail to come on C 2 3 The ABS warning light fails to come on while the start switch is being pushed C 3 ET3P61062 B 2 THE ABS WARNING LIGHT REMAINS ON 1 A present malfunction is detected B 5 2 The ABS warning light remains on C 6 ET3P61063 B 3 THE ABS WARNING L...

Page 528: ...es and then start the check again The test coupler adapter must be connected to the ABS test coupler to display the malfunction codes If the adapter is not connected the ABS warning light will come on or flash but no malfunction codes will be displayed EAS27870 B 5 MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS PRESENT MALFUNCTION Remove front cowling right inner panel 1 to access the ABS test couple...

Page 529: ...al black 5 T C terminal sky blue 6 T F terminal light green 7 ABS warning light terminal green red 8 Test coupler adapter 9 Light green lead 10 Black lead 11 White red lead A This example is the pattern for malfunction code 12 B This example is the pattern for malfunction code 21 C Time seconds Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motoma...

Page 530: ...ECKING AND CHARGING THE BATTERY on page 8 154 If the battery is defective clean the battery terminals and recharge it or replace the battery 3 Main fuse Check the main fuse for continuity Refer to CHECKING THE FUSES on page 8 153 If the main fuse is blown replace the fuse 4 Wiring Check the entire multi function meter wiring Refer to CIRCUIT DIAGRAM 1 2 on page 8 111 and CIRCUIT DIAGRAM 2 2 on pag...

Page 531: ...shes every 0 5 second if a malfunction code for a past malfunction is not stored in the memory of the ABS ECU The ABS warning light flashes quicker if a malfunction code is displayed on the multi function display If no malfunction code is displayed make sure that the custom er understands the possible conditions that may cause the ABS warning light to come on or flash even if the system is normal ...

Page 532: ...BS ECU couplers ABS wire harness front cowling wire harness and wire harness 6 Check the connection of the ABS wire harness to the ABS ECU Check that the ABS wire harness is securely connected to the ABS ECU Refer to ABS COUPLER LOCATION CHART on page 8 117 7 The ABS ECU ABS wire harness front cowling wire harness or wire harness couplers are discon nected Connect the couplers if they are disconne...

Page 533: ...ar wheel sensor signal is not re ceived properly Installation of the rear wheel sensor Rear wheel sensor lead and coupler ABS wire harness rear wheel sensor circuit Rear wheel sensor rotor Malfunction code 12 See page 8 133 13 26 14 27 Incorrect signal from the front 13 26 or rear 14 27 wheel sensor is detect ed 13 14 26 27 Installation of the wheel sensors Wheel sensor housings Wheel sensor rotor...

Page 534: ...Wire harness and ABS wire harness front wheel sensor circuit Malfunction code 25 See page 8 137 41 Front wheel will not recover from the locking tendency even though the sig nal is continuously transmitted from the ABS ECU to release the hydraulic pressure when the battery voltage is normal 41 Brake dragging Hydraulic unit operation tests Front wheel brake lines Malfunction code 41 See page 8 137 ...

Page 535: ...function code 35 See page 8 141 51 Front wheel will not recover from the locking tendency even though the sig nal is continuously transmitted from the ABS ECU to release the hydraulic pressure when the battery voltage is low Brake dragging Hydraulic unit operation tests Front wheel brake line Battery voltage Malfunction code 51 See page 8 142 52 Rear wheel will not recover from the locking tendenc...

Page 536: ...RONT WHEEL FRONT BRAKE DISCS on page 4 18 Front wheel sensor rotor is defective Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 16 and INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS on page 4 18 c Front wheel sensor circuit is short circuited Front wheel sensor or lead is short circuited Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 16 and INSTAL...

Page 537: ...eel and 14 27 rear wheel Incorrect signal from the front 13 26 or rear 14 27 wheel sensor is detected 1 The wheel sensors or sensor rotors are not properly installed a Installation of the front or rear wheel sensor Check that the wheel sensor is properly installed in the housing Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 16 INSTALLING THE FRONT WHEEL FRONT BRAKE DISC...

Page 538: ...RAKE DISC on page 4 23 Front or rear wheel sensor circuit is broken Refer to CIRCUIT DIAGRAM 1 2 on page 8 111 and CIRCUIT DIAGRAM 2 2 on page 8 113 ABS wire harness is disconnected from the ABS ECU coupler terminal Refer to MAINTENANCE OF THE ABS ECU on page 8 120 NOTE Check that both the front and rear wheel sensor couplers are connected securely If the vehicle is ridden after malfunction code 1...

Page 539: ... on page 3 23 5 Wire harness ABS wire harness and front cowling wire harness Check the front and rear brake light switch monitor circuits Check the green yellow lead for continuity between 1 and 2 of the front brake light switch monitor circuit Check the brown black lead for continuity between 3 and 4 of the rear brake light switch monitor circuit R W W G W L W Y R W R W W W W B Br B W L Br W B B ...

Page 540: ...THE FRONT WHEEL FRONT BRAKE DISCS on page 4 18 Check if there is looseness between the housing and the wheel Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 16 and INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS on page 4 18 3 Front wheel sensor circuit is short circuited Front wheel sensor or lead is short circuited Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ...

Page 541: ...rake hose inlet and outlet connections are incorrect on the hydraulic unit the brake lever will be pulled to its full stroke position without responding and then it will be pushed back slowly without pulsating when the final check on page D 3 FINAL CHECK on page 8 144 is performed If the front and rear brake hose connections are reversed on the hydraulic unit the pulsating action in the brake leve...

Page 542: ... kinks and deterioration particularly between the hydraulic unit and the rear brake caliper WARNING EW3P61005 Only use genuine Yamaha parts Using other brake pipes hoses and union bolts may close the brake hose lines Check that the connections of the brake hose lines from the brake master cylinder to the hydraulic unit and from the hydraulic unit to the proportioning valve are correct WARNING EW3P...

Page 543: ... 8 111 and CIRCUIT DIAGRAM 2 2 on page 8 113 4 ABS ECU If the malfunction is not corrected after checking items 1 to 3 replace the ABS ECU Malfunction code 32 ABS ECU circuit is broken or short circuited 1 ABS ECU circuit positive battery terminal to red white terminal of the ABS ECU coupler Turn the main switch to OFF and disconnect the ABS ECU coupler and battery leads Check for continuity betwe...

Page 544: ...BS motor for continuity Refer to MAINTENANCE OF THE HYDRAULIC UNIT on page 8 120 2 ABS wire harness Disconnect the ABS motor coupler and then check for continuity between the black white terminal of the ABS motor coupler of ABS wire harness and the negative battery terminal Disconnect the ABS ECU couplers and then check for continuity between the red black terminal of the ABS ECU coupler and the r...

Page 545: ...22830 D 1 DELETING THE MALFUNCTION CODES 1 Connect the test coupler adapter 1 to the ABS test coupler 2 Refer to B 5 MAL FUNCTION CHECK BY THE ABS SELF DI AGNOSIS PRESENT MALFUNCTION on page 8 125 2 Turn the main switch to ON Previously recorded malfunction codes will be displayed in the multi function display 3 Set the engine stop switch 1 to CAUTION EC3P61014 If the start switch is pushed withou...

Page 546: ... D 2 DELETE FUNCTION TEST 1 Place the vehicle on the centerstand 2 Turn the main switch to OFF 3 Connect the test coupler adapter to the ABS test coupler 4 Turn the main switch to ON 5 Check ABS ECU voltage Lower than 12 8 V Charge or replace the battery a Connect the pocket tester DC 20 V to the ABS ECU couplers b Measure the ABS ECU voltage 6 Check ABS ECU to start switch lead continuity No cont...

Page 547: ...TALLING THE REAR WHEEL REAR BRAKE DISC on page 4 23 3 Perform hydraulic unit operation test 1 or 2 Refer to HYDRAULIC UNIT OPERATION TESTS on page 4 56 4 Delete the malfunction codes Refer to D 1 DELETING THE MALFUNCTION CODES on page 8 142 5 Perform a trial run Refer to TRIAL RUN on page 4 59 Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe white blue 1 ABS ECU Nega...

Page 548: ...AL COMPONENTS 8 145 EAS27970 ELECTRICAL COMPONENTS 1 18 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 549: ... box 2 8 Fuse box 1 9 Right radiator fan motor 10 Left radiator fan motor 11 Gear position switch 12 Sidestand switch 13 Oil level switch 14 Rear brake light switch 15 Left horn low 16 Right horn high 17 Ignition coil 18 Main fuse Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 550: ...ELECTRICAL COMPONENTS 8 147 1 17 16 18 19 3 2 4 5 6 7 8 9 10 11 12 13 14 15 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 551: ...rol unit 8 ABS ECU 9 Cylinder identification sensor 10 O2 sensor 11 Crankshaft position sensor 12 Accessory box solenoid 13 Headlight relay dimmer 14 Radiator fan motor relay 15 Headlight relay on off 16 Brake light relay 17 Turn signal hazard relay 18 Relay unit 19 Lean angle sensor Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 552: ...Br W L B Ch Dg B Y Y R Y L Y Lg B Sb UP DOWN 13 DgBr W Ch 14 B P 10 12 R Y Y R Y L B 11 B Br W Ch Dg R B R W G Y L W Br 8 L W B R W R B 9 Ch Dg Br W 7 B Y L Y BLACK 6 BLUE B B 5 L B Ch B R Dg B G 4 G Y Br Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 553: ...on switch 5 Sidestand switch 6 Clutch switch 7 Hazard switch 8 Start switch 9 Engine stop switch 10 Horn switch 11 Dimmer switch 12 Pass switch 13 Windshield position switch 14 Turn signal switch Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 554: ... between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch position is indicated by There is continuity between red brown...

Page 555: ... of the bulbs 1 Remove Bulb WARNING EW3P61001 Since headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down CAUTION EC3P61002 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of a headlight bulb to keep it free from oi...

Page 556: ... Fuse a Connect the pocket tester to the fuse and check the 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 the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical c...

Page 557: ...f water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion CAUTION EC3P61004 This is a sealed battery Never remove the sealing caps because the balance between cells will not be maintained and battery per formance will deteriorate Charging time charging amperage and charging voltage for an MF battery are dif ferent from those of conventional batter...

Page 558: ... the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the battery ...

Page 559: ...charger a Measure the open circuit voltage prior to charging NOTE Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery NOTE If the current is lower than the standard charging current written on the battery this type of bat...

Page 560: ... cut off relay Relay unit fuel pump relay Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 R B L W R W R L 1 2 4 3 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester ...

Page 561: ...esult Continuity between 1 and 2 No continuity between 1 and 3 R Y G L R Y Y W 1 2 3 4 G L Y L B B 1 3 2 G 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester probe Result No continuity between 3 and 4 Continuity between 3 and 5 1 Positive tester probe 2 Negative tester probe Result Continuity between 1 and 2 G L Y L B B 1 2 3 5...

Page 562: ... No continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 ABS motor relay resistance 50 150 Ω Y G G Y Br 1 2 4 3 Br B R Br B R W G Y 1 2 3 4 Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe red white 1 Negative tester probe white black 2 Pocket tester 90890 ...

Page 563: ...own b Turn the main switch to ON c Measure the turn signal hazard relay output voltage EAS28050 CHECKING THE RELAY UNIT DIODE 1 Check Relay unit diode Out of specification Replace NOTE The pocket tester and the analog pocket tester readings are shown in the following table Turn signal hazard relay input voltage DC 12 V Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe...

Page 564: ...nition coil terminals b Connect the pocket tester Ω 1 to the igni tion coil as shown Continuity Positive tester probe sky blue 1 Negative tester probe black yellow 2 No continuity Positive tester probe black yellow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe black red 3 No continuity Positive tester probe black red 3 Negative tester probe sk...

Page 565: ...rn the main switch to ON and engine stop switch to d Measure the ignition spark gap a e Crank the engine by pushing the start switch and gradually increase the spark gap un til a misfire occurs EAS28120 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe red bla...

Page 566: ...rform the electric starting system troubleshooting starting with step 4 Refer to TROUBLESHOOTING on page 8 14 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 WARNING EWA13810 A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make s...

Page 567: ...ocket tester DC 20 V to the rectifier regulator coupler as shown c Start the engine and let it run at approximate ly 5000 r min d Measure the charging voltage Stator coil resistance 0 13 0 19 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe white 1 Negative tester probe white 2 Positive tester probe white 1 Negative tester probe white 3 Positive tester...

Page 568: ... Check Oil level switch continuity Out of specification Replace a Connect the pocket tester Ω 1 to the oil level switch terminal as shown Coil resistance 1 01 1 11 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe horn terminal 1 Negative tester probe horn terminal 2 1 2 Oil level switch resistance Minimum level position No continuity Maximum level posi...

Page 569: ...G THE RADIATOR FAN MOTORS The following procedure applies to both of the radiator fan motors 1 Check Radiator fan motor Faulty rough movement Replace a Disconnect the radiator fan motor coupler from the wire harness b Connect the battery DC 12 V as shown c Measure the radiator fan motor movement Fuel sender Sender unit resistance full 19 0 21 0 Ω Sender unit resistance empty 139 0 141 0 Ω Pocket t...

Page 570: ... Coolant temperature sensor EAS28300 CHECKING THE THROTTLE POSITION SENSOR 1 Remove Throttle position sensor from the throttle body 2 Check Throttle position sensor maximum resistance Out of specification Replace the throttle position sensor a Connect the pocket tester Ω 1k to the throttle position sensor terminals as shown b Measure the throttle position sensor maxi mum resistance 3 Install Throt...

Page 571: ...haft twice and check that the output voltage rises to approx imately 4 8 V once EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSOR 1 Check Intake air pressure sensor output voltage Out of specification Replace a Connect the pocket tester DC 20 V to the in take air pressure sensor coupler as shown Solenoid resistance 19 25 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Posit...

Page 572: ...t get wet c Place a thermometer 3 in the water d Slowly heat the water then let it cool down to the specified temperature e Measure the intake air temperature sensor resistance ET3P61017 CHECKING THE ACCESSORY BOX SOLENOID 1 Check Accessory box solenoid resistance Out of specification Replace a Disconnect the accessory box solenoid cou pler from the wire harness b Connect the pocket tester Ω 10 to...

Page 573: ...ELECTRICAL COMPONENTS 8 170 c Measure the accessory box solenoid resis tance B Br 1 2 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 574: ...ELECTRICAL COMPONENTS 8 171 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 575: ...2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 3 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 576: ...l Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Faulty spark plug cap 4 Ignition coil s Cracked or broken ignition coil body Broken or shorted primary or seconda...

Page 577: ... Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift d...

Page 578: ...tays open EAS28620 POOR BRAKING PERFORMANCE Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper kit Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS28660 FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or damaged o...

Page 579: ... circuit Faulty main switch Headlight bulb life expired Tail brake light does not come on Wrong tail brake light bulb Too many electrical accessories Incorrect connection Burnt out tail brake light bulb Tail brake light bulb burnt out Wrong tail brake light bulb Faulty battery Incorrectly adjusted rear brake light switch Tail brake light bulb life expired Turn signal does not come on Faulty turn s...

Page 580: ...4 Right radiator fan motor 65 Turn signal hazard relay 66 Auxiliary DC jack 67 Right handlebar switch 68 Front brake light switch 69 Engine stop switch 70 Start switch 71 Hazard switch 72 Left handlebar switch 73 Clutch switch 74 Pass switch 75 Dimmer switch 76 Windshield position switch 77 Turn signal switch 78 Horn switch 79 Relay unit 80 Starting circuit cut off relay 81 Fuel pump relay 82 Acce...

Page 581: ...Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 582: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 583: ... L B W R L B B W Br R Br R W W W GRAY B R BLACK R R L W R L R W R G R W G B Y L B W BB Sb B Y B R Y W L W P B Y L Lg R W R G B2 W Y B G R Lg Sb W Sb Lg G R B W Y W Ch B G B R Dg B L G W B R L B DARK GREEN L Y B R R L R G G Y Sb R B B Y Br W Y G W L L W B W Br B G Y B R G R L B R L Y B Y Sb G Y R B B G R Lg Sb Br R R W G O W W W B Br B W L Br W B B B W G R G Y W Y Lg R B B W G W L W Y R L Y G Sb B2...

Page 584: ... Y Dg B Lg L Y Br W L B P Sb B Y Ch Y R Y Dg B Lg Br G L B P Sb W B Y B R Ch G L R W Br Br B L R R Y R B L W Br R Br B B BLACK B B B B R B B R B R R B B B B B B B Ch B B Dg B Br Y BLACK G Y Dg W L R W Ch Br Br G B R B R W L W Dg R B B Br Br W Ch G Y L R Br G BLACK R B Br L BLACK B B B B GRAY Br Br L GRAY Lg R B L R Br G Br Br L Br L R B Br R Br B B B L R G L L R Y Y G G B B B Br B B L R W R W R B ...

Page 585: ...K GREEN GRAY GRAY GRAY BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK WIRE HARNESS B WIRE HARNESS C WIRE HARNESS D WIRE HARNESS B BLACK GRAY GRAY BLACK GRAY GRAY BROWN BROWN ABS WIRE HARNESS ABS WIRE HARNESS ABS WIRE HARNESS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 28 29 30 31 32 33 34 34 34 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 ...

Page 586: ...ettrico del cupolino FJR1300A V 2006 DIAGRAMA ELÉCTRICO 2 2 Mazo decables delcarenado delantero BLACK BLACK UP DOWN BLACK BLACK BLACK BLACK BLACK GRAY GRAY GRAY GRAY GRAY GRAY 49 31 14 17 52 65 66 67 68 69 71 72 73 74 75 76 77 78 79 70 81 82 83 84 85 86 87 88 89 80 91 92 93 94 95 96 96 97 98 99 90 101 101 102 102 103 104 105 100 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Moto...

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