Yamaha MT-01 Service Manual Download Page 1

Page: 1 / 864

2005

SERVICE MANUAL

MT-01(T)

5YU1-AE1

Manuals by Motomatrix / www.motomatrix.co.uk

Email: [email protected]

Summary of Contents for MT-01

Page 1: ...2005 SERVICE MANUAL MT 01 T 5YU1 AE1 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 2: ...aha Motor Co Ltd First edition December 2004 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 Email info motomatrix co uk ...

Page 3: ...changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE 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 ALER...

Page 4: ...n smaller print than the section 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 explod...

Page 5: ...iceable with engine 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 with a new one Manuals by Motomatrix www motomatrix co uk Email i...

Page 6: ...NTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 FUEL SYSTEM 6 ELECTRICAL SYSTEM 7 TROUBLESHOOTING 8 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 7: ...GEN INFO 1 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 8: ...INSTRUMENT FUNCTIONS 1 4 IMPORTANT INFORMATION 1 7 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 7 REPLACEMENT PARTS 1 7 GASKETS OIL SEALS AND O RINGS 1 7 LOCK WASHERS PLATES AND COTTER PINS 1 7 BEARINGS AND OIL SEALS 1 8 CIRCLIPS 1 8 CHECKING THE CONNECTIONS 1 9 SPECIAL TOOLS 1 10 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 9: ...Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 10: ...le identification number 1 is stamped on the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the lead holder under the seat This information will be needed to order spare parts 1 1 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 11: ... adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions detected by various sensors The adoption of the FI system has resulted in a highly precise f...

Page 12: ...als that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor air temperature sensor engine temperature sensor speed 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 the engine can be suppli...

Page 13: ... the brightness control For the U K only To switch the speedometer and odometer tripmeter fuel reserve tripmeter displays between kilometers and miles press the SELECT button for at least two seconds Tachometer The electric tachometer allows the rider to mon itor the engine speed and keep it within the ideal power range When the key is turned to ON the tachometer needle will sweep once across the ...

Page 14: ...ifunction display will indicate a two digit er ror code e g 12 13 14 If the multifunction display indicates an error code note the code number and then check the vehicle Refer to FUEL INJECTION SYSTEM on page 7 25 CAUTION EC5YU1010 If the multifunction display indicates an error code the vehicle should be checked as soon as possible in order to avoid engine damage This model is also equipped with ...

Page 15: ...sh the SELECT button to select the LCD Item number 2 is displayed Adjust the LCD brightness level by pushing the RESET button 6 Push the SELECT button to select the ta chometer needle Item number 3 is displayed Adjust the tachometer needle brightness lev el by pushing the RESET button 7 Push the SELECT button and the multi function display will return to the odometer or tripmeter mode 3 Tachometer...

Page 16: ... Keep all parts away 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...

Page 17: ...stalling if appropriate 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 circli...

Page 18: ...se connection Connect 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 9089...

Page 19: ...ada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 9 5 72 7 91 7 92 7 93 7 96 7 97 7 98 7 99 7 100 7 101 7 102 7 103 7 104 7 106 7 107 7 108 Thickness gauge 90890 03079 Narrow gauge set YM 34483 3 4 3 5 5 56 Locknut wrench 90890 04150 3 5 Tappet adju...

Page 20: ... 4 59 Vacuum pressure pump gauge set 90890 06756 4 5 6 9 Fork spring compressor 90890 01441 YM 01441 4 50 4 55 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 50 4 55 Damper rod holder 90890 01504 4 51 4 52 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 53 Tool name Tool No Illustration Reference pages Manuals by Motomatrix www motomatrix co uk Email ...

Page 21: ...nch YU 01268 4 59 Pivot shaft wrench 90890 01485 Frame mount insert wrench YM 01485 5 13 Valve spring compressor 90890 04019 YM 04019 5 35 5 40 Valve guide remover ø6 90890 04064 Valve guide remover 6 0 mm YM 04064 A 5 36 Valve guide installer ø6 90890 04065 Valve guide installer 6 0 mm YM 04065 A 5 36 Tool name Tool No Illustration Reference pages YM A8703 YM A8703 Manuals by Motomatrix www motom...

Page 22: ...90890 04086 YM 91042 5 55 5 58 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 55 5 57 5 68 5 69 5 77 5 79 Yamaha bond No 1215 90890 85505 5 57 5 69 5 78 Rotor puller 90890 01080 Stator rotor puller YM 01080 A 5 68 Pressure gauge 90890 03153 6 9 Tool name Tool No Illustration Reference pages YU 01304 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 23: ...03176 YM 03176 6 9 Digital circuit tester 90890 03174 6 10 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 7 100 Tool name Tool No Illustration Reference pages Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 24: ...SPEC 2 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 25: ...TIGHTENING TORQUE SPECIFICATIONS 2 17 ENGINE TIGHTENING TORQUES 2 18 CHASSIS TIGHTENING TORQUES 2 23 LUBRICATION POINTS AND LUBRICANT TYPES 2 28 ENGINE 2 28 CHASSIS 2 30 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 ENGINE OIL LUBRICATION CHART 2 31 LUBRICATION DIAGRAMS 2 33 CABLE ROUTING 2 41 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 26: ...Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 27: ... 0 in Overall width 790 mm 31 1 in Overall height 1160 mm 45 7 in Seat height 825 mm 32 5 in Wheelbase 1525 mm 60 0 in Ground clearance 143 mm 5 63 in Minimum turning radius 3200 mm 126 0 in Weight With oil and fuel 259 0 kg 571 lb Maximum load 202 kg 445 lb Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 28: ...rade API standard SE or higher grade ACEA standard G4 or G5 Engine oil quantity Total amount 5 00 L 5 29 US qt 4 40 Imp qt Engine 2 2 L 2 33 US qt 1 94 Imp qt Oil tank 2 8 L 2 96 US qt 2 46 Imp qt Without oil filter cartridge replacement 3 70 L 3 91 US qt 3 26 Imp qt With oil filter cartridge replacement 4 10 L 4 33 US qt 3 61 Imp qt Oil filter Oil filter type Cartridge paper Oil pump Oil pump typ...

Page 29: ...cylinder 2 Limit 38 141 mm 1 5016 in cylinder 1 38 143 mm 1 5017 in cylinder 2 Intake B 31 950 32 050 mm 1 2579 1 2618 in Limit 31 850 mm 1 2539 in Exhaust A 38 236 38 336 mm 1 5054 1 5093 in Limit 38 136 mm 1 5014 in Exhaust B 31 950 32 050 mm 1 2579 1 2618 in Limit 31 850 mm 1 2539 in Rocker arm rocker arm shaft Rocker arm inside diameter 18 000 18 018 mm 0 7087 0 7094 in Limit 18 036 mm 0 7101 ...

Page 30: ...8 in Valve seat width C exhaust 0 90 1 10 mm 0 0354 0 0433 in Limit 2 0 mm 0 08 in Valve margin thickness D intake 0 70 1 30 mm 0 0276 0 0512 in Limit 0 4 mm 0 02 in Valve margin thickness D exhaust 0 70 1 30 mm 0 0276 0 0512 in Limit 0 4 mm 0 02 in Valve stem diameter intake 5 975 5 990 mm 0 2352 0 2358 in Limit 5 945 mm 0 2341 in Valve stem diameter exhaust 5 960 5 975 mm 0 2346 0 2352 in Limit ...

Page 31: ...ression spring force intake 63 00 73 00 N 14 16 16 41 lb 6 42 7 44 kgf Installed compression spring force exhaust 63 00 73 00 N 14 16 16 41 lb 6 42 7 44 kgf Spring tilt intake 2 5 1 7 mm 2 5 0 067 in Spring tilt exhaust 2 5 1 7 mm 2 5 0 067 in Winding direction intake Counterclockwise Winding direction exhaust Counterclockwise Outer spring Free length intake 43 25 mm 1 70 in Limit 41 26 mm 1 62 in...

Page 32: ...0 026 0 059 mm 0 0010 0 0023 in Valve push rod Valve push rod 1 length 288 5 mm 11 36 in Valve push rod 2 length 290 5 mm 11 44 in Valve push rod runout 0 3 mm 0 012 in Cylinder Bore 97 000 97 010 mm 3 8189 3 8193 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in Piston Piston to cylinder clearance 0 025 0 050 mm 0 0010 0 0020 in Limit 0 15 mm 0 0059 in Diameter D 96 960 96 9...

Page 33: ...B T 1 20 3 80 mm 0 05 0 15 in End gap installed 0 30 0 45 mm 0 01 0 02 in Limit 0 80 mm 0 0315 in Ring side clearance 0 030 0 070 mm 0 0012 0 0028 in Limit 0 12 mm 0 0047 in Oil ring Dimensions B T 2 50 3 40 mm 0 10 0 13 in End gap installed 0 20 0 70 mm 0 01 0 03 in Connecting rod Oil clearance using plastigauge 0 050 0 074 mm 0 0020 0 0029 in Bearing color code 1 Blue 2 Black 3 Brown 4 Green 5 Y...

Page 34: ...utch plate thickness 1 90 2 10 mm 0 07 0 08 in Plate quantity 9 pcs Warpage limit 0 20 mm 0 0079 in Clutch spring free length 6 88 mm 0 27 in Minimum length 6 38 mm 0 25 in Spring quantity 1 pcs Clutch housing thrust clearance 0 100 0 110 mm 0 0039 0 0043 in Clutch housing radial clearance 0 020 0 066 mm 0 0008 0 0026 in Transmission Transmission type Constant mesh 5 speeds Primary reduction syste...

Page 35: ...NJECTOR Throttle body Type quantity AC40 2 Manufacturer MIKUNI ID mark 5YU1 00 Throttle valve size 100 Throttle position sensor Resistance 4 0 6 0 kΩ blue black Output voltage at idle 0 63 0 73 V Fuel injection sensor Crankshaft position sensor resistance 248 372 Ω gray black Intake pressure sensor output voltage 2 4 V Engine temperature sensor resistance 0 90 1 10 kΩ at 100 C 212 F Idling conditi...

Page 36: ...ubeless Size 120 70 ZR17 M C 58W Manufacturer model METZELER MEZ4J FRONT Europe MICHELIN PILOT ROAD S AUS Wear limit front 1 6 mm 0 06 in Rear tire Type Tubeless Size 190 50 ZR17 M C 73W Manufacturer model METZELER MEZ4 Europe MICHELIN PILOT ROAD AUS 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 250 kPa 36 psi 2 50 kgf cm 2 50 bar ...

Page 37: ...de diameter 30 23 mm 1 19 in Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Brake pedal free play 7 9 19 0 mm 0 31 0 75 in Rear disc brake Disc outside diameter thickness 267 0 6 0 mm 10 51 0 24 in Brake disc thickness limit 5 5 mm 0 22 in Brake disc deflection limit 0 15 mm 0 0059 in Brake pad lining thickness inner 6 5 mm 0 26 in Limit 1 0 mm 0 04 in Bra...

Page 38: ...1 69 in Inner tube bending limit 0 2 mm 0 01 in Optional spring available No Recommended oil Suspension oil 01 Quantity 583 0 cm 19 71 US oz 20 56 Imp oz Level 65 0 mm 2 56 in Spring preload adjusting positions Minimum 0 Standard 2 Maximum 5 Rebound damping adjusting positions With the adjusting screw fully turned in Minimum 17 click s out Standard 15 click s out Maximum 1 click s out Compression ...

Page 39: ...pring length Minimum 155 0 mm 6 10 in Standard 150 0 mm 5 91 in Maximum 145 0 mm 5 71 in Rebound damping adjusting positions With the adjusting knob fully turned in Minimum 20 click s out Standard 12 click s out Maximum 3 click s out Compression damping adjusting positions With the adjusting screw fully turned in Minimum 12 click s out Standard 10 click s out Maximum 1 click s out Swingarm Swingar...

Page 40: ...sistance 8 64 12 96 kΩ Spark plug cap Material Resin Resistance 10 0 kΩ AC magneto Model manufacturer F5YU MORIC Standard output 14 0 V 430 W 5000 r min Stator coil resistance 0 1280 0 1920 Ω Voltage regulator Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer FH010AA SHINDENGEN No load regulated voltage 14 3 15 1 V Rectifier capacity 50 0 A Withstand voltage 40 0 V...

Page 41: ...YU MORIC Power output 0 90 kW Armature coil resistance 0 0081 0 0099 Ω Brush overall length 9 8 mm 0 39 in Limit 5 00 mm 0 20 in Brush spring force 7 36 11 04 N 26 49 39 74 oz 750 1126 gf Commutator diameter 28 5 mm 1 12 in Limit 27 5 mm 1 08 in Mica undercut depth 1 50 mm 0 06 in Starter relay Model manufacturer 2768093 A JIDECO Amperage 180 0 A Coil resistance 4 18 4 62 Ω Horn Horn type Plane Qu...

Page 42: ...ance 162 198 Ω Thermo unit Model manufacturer 5PX DENSO Resistance at 100 C 898 38 1098 02 Ω Fuses Main fuse 50 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 25 0 A Parking lighting fuse 10 0 A ECU fuse 10 0 A Fuel injection system fuse 15 0 A Backup fuse 10 0 A Muffler cover fan fuse 15 0 A Auto decompression fuse 15 0 A Reserve fuse 25 0 A Reserve fuse 15 0 A Reserve fuse ...

Page 43: ...stener assemblies in a 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 m...

Page 44: ... 2 0 m kg 14 ft lb Rear exhaust pipe and catalyst pipe bolt M8 1 20 Nm 2 0 m kg 14 ft lb Catalyst pipe nut M8 1 20 Nm 2 0 m kg 14 ft lb Catalyst pipe and muffler bolt M8 2 20 Nm 2 0 m kg 14 ft lb Front exhaust pipe joint nut M8 2 20 Nm 2 0 m kg 14 ft lb Rear exhaust pipe joint nut M8 2 20 Nm 2 0 m kg 14 ft lb Rear exhaust pipe joint cover bolt M6 3 7 Nm 0 7 m kg 5 1 ft lb EXUP valve pulley cover b...

Page 45: ...nder head nut M10 4 39 Nm 3 9 m kg 28 ft lb Cylinder head stud bolt exhaust pipe M8 4 15 Nm 1 5 m kg 11 ft lb Clutch Crankshaft end cover plug M32 1 10 Nm 1 0 m kg 7 2 ft lb Timing mark accessing screw M16 1 8 Nm 0 8 m kg 5 8 ft lb Clutch cover bolt M6 17 10 Nm 1 0 m kg 7 2 ft lb Crankshaft position sensor lead holder screw M6 7 10 Nm 1 0 m kg 7 2 ft lb Crankshaft position sensor screw M6 2 10 Nm ...

Page 46: ...ear stopper bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Oil pump driven gear stopper bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Generator shaft bolt M8 1 28 Nm 2 8 m kg 20 ft lb Crankcase bolt M8 3 24 Nm 2 4 m kg 17 ft lb Crankcase bolt M6 18 10 Nm 1 0 m kg 7 2 ft lb Engine oil drain bolt crankcase M14 1 43 Nm 4 3 m kg 31 ft lb Engine oil filler plug M20 1 10 Nm 1 0 m kg 7 2 ft lb Oil baffle plate bolt M6 4 10 Nm ...

Page 47: ...m 2 4 m kg 17 ft lb Drive sprocket nut M22 1 95 Nm 9 5 m kg 68 ft lb Stake Fuel injection system surrounding parts Throttle body joint clamp screw M4 2 4 Nm 0 4 m kg 2 9 ft lb Throttle position sensor screw M5 2 5 Nm 0 5 m kg 3 6 ft lb Intake manifold assembly bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Injector joint screw M6 4 5 Nm 0 5 m kg 3 6 ft lb Fuel pipe bolt M12 2 30 Nm 3 0 m kg 22 ft lb ISC idle ...

Page 48: ...QUES 2 22 Oil tank tightening sequence Cylinder head tightening sequence 1 5 7 3 2 6 8 4 10 16 15 13 11 14 12 9 A Front cylinder B Rear cylinder Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 49: ...M12 2 74 Nm 7 4 m kg 53 ft lb Down tube nut rear side M10 2 55 Nm 5 5 m kg 40 ft lb Engine mounting nut front lower side M12 1 94 Nm 9 4 m kg 68 ft lb Engine mounting nut rear lower side M12 1 74 Nm 7 4 m kg 53 ft lb Down tube spacer bolt M18 2 8 Nm 0 8 m kg 5 8 ft lb Engine mounting spacer bolt rear upper side M18 1 8 Nm 0 8 m kg 5 8 ft lb Engine mounting spacer bolt rear lower side M18 1 8 Nm 0 ...

Page 50: ...r duct bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Air duct bracket bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Positive battery lead bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Starter motor lead bolt starter relay side M6 1 7 Nm 0 7 m kg 5 1 ft lb Battery box bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Lead holder and sub frame bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Fuel pump bolt M5 6 4 Nm 0 4 m kg 2 9 ft lb Seat lock bracket bolt M6 1 ...

Page 51: ...aliper M8 2 6 Nm 0 6 m kg 4 3 ft lb Bleed screw front brake master cylinder M8 1 6 Nm 0 6 m kg 4 3 ft lb Front brake hose holder bolt M6 2 6 Nm 0 6 m kg 4 3 ft lb Rear brake Rear brake master cylinder bolt M8 2 23 Nm 2 3 m kg 27 ft lb Locknut rear brake master cylinder M8 1 16 Nm 1 6 m kg 11 ft lb Rear brake hose union bolt M10 2 30 Nm 3 0 m kg 22 ft lb Rear brake hose guide bolt 1 M6 1 7 Nm 0 7 m...

Page 52: ...kg 5 1 ft lb Meter assembly bracket bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Headlight assembly bracket bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Front fork guard bolt M6 4 7 Nm 0 7 m kg 5 1 ft lb Front fender bolt M6 4 6 Nm 0 6 m kg 4 3 ft lb Swingarm and rear shock absorber Swingarm pivot shaft nut M18 1 125 Nm 12 5 m kg 90 ft lb Footrest bracket pinch bolt M8 2 25 Nm 2 5 m kg 18 ft lb Relay arm nut relay arm ...

Page 53: ...ighten the lower ring nut to 23 Nm 2 3 m kg 17 ft lb with a torque wrench Drive chain guard bolt swingarm side M6 2 7 Nm 0 7 m kg 5 1 ft lb Drive chain guide bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Locknut drive chain adjusting bolt M8 2 16 Nm 1 6 m kg 11 ft lb Item Thread size Q ty Tightening torque Remarks Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 54: ... exhaust Valve lifters Rocker arms Rocker arm shafts Oil pump rotors inner and outer and oil pump housing Oil pump driven gear shaft Crankcase stud bolt ends Crankcase bush generator shaft journal Starter clutch idle gear inner surface Starter clutch idle gear shafts Starter clutch roller and starter clutch gears outer surface Crankshaft journal Primary driven gear inner surface Clutch push rods a...

Page 55: ...hift shaft and shift shaft oil seal lip Crankcase mating surface Yamaha bond No 1215 Stator coil lead grommet Yamaha bond No 1215 Crankshaft position sensor lead grommet Yamaha bond No 1215 Lubrication point Lubricant E E LS Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 56: ... metal to metal moving parts Brake pedal shaft pivoting point Passenger footrest pivoting point and ball Sidestand pivoting point and metal to metal moving parts Sidestand switch striker and sidestand switch contact point Sidestand hook and spring Swingarm pivot shaft Bearing spacer and oil seal lips swingarm pivot shaft Bearing spacer and oil seal lips swingarm and relay arm Bearing spacer and oi...

Page 57: ...YSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 9 10 11 7 6 5 1 2 12 14 13 15 16 17 18 19 20 26 23 36 21 31 38 40 39 37 27 30 30 35 35 29 29 34 34 33 33 28 28 32 32 25 24 22 8 3 4 A Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 58: ...l filter cartridge 20 Generator shaft journal left 21 Generator shaft journal right 22 Starter clutch 23 Crankshaft journal camshaft cover side 24 Camshaft journal camshaft cover side 25 Camshaft lobe faces 26 Crankshaft journal right 27 Front cylinder 28 Crank pin 29 Connecting rod 30 Piston 31 Front camshaft 32 Valve lifter 33 Push rod 34 Rocker arm 35 Valve stem end 36 Crankshaft journal left 3...

Page 59: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 EAS20410 LUBRICATION DIAGRAMS 3 5 3 1 B B D D E E A C E E 2 1 B B D D 4 2 A C Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 60: ...RICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Oil delivery pipe 2 Push rod 3 Oil filter cartridge 4 Rocker arm shaft 5 Oil delivery pipe 2 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 61: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 1 4 3 2 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Rocker arm shaft 2 Crankshaft 3 Valve lifter 4 Push rod Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 63: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 3 2 1 1 A A B B B B A A Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Oil pump 2 Oil strainer crankcase 3 Oil pipe 1 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 65: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39 3 4 2 1 A Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 40 1 Main axle 2 Drive axle 3 Oil pump 4 Oil strainer crankcase A To oil filter cartridge Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 67: ...CABLE ROUTING 2 41 EAS20430 CABLE ROUTING A 10 11 12 13 1 2 3 4 5 6 6 6 8 9 14 15 16 17 7 H D E G I J B C F Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 68: ...g sure to fit the grommet on the hose in the guide C Make sure that the brake hose three way joint contacts the tab on the front brake hose joint bracket D Fasten the wire harness stator coil assembly lead rectifier regulator lead and horn lead with the holder Face the fastener of the holder forward E Fasten the horn leads with the holder Face the open ends of the holder upward F There should be n...

Page 69: ...L M M N O P Q R S S T U V W X Y Z AC AB AA AE AF AG AG AH AI AD AK AL AM AN AJ D D C C B B A F E F A E 1 2 3 4 5 6 7 8 9 10 11 12 12 13 13 14 14 15 15 15 15 15 15 16 19 20 20 21 16 17 18 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 70: ...lead and negative battery lead Be sure not to cover the fuel hose Q Route the cylinder 1 left spark plug lead under the frame boss and to the outside of the wire harness and clutch hose R Route the clutch hose to the outside of the wire harness S Fasten the clutch hose and EXUP servo motor lead with the plastic locking ties Face the buckle of the plastic locking tie forward with the end facing out...

Page 71: ... G I H J K L M N Q O P S T U Y AF AB AA AB AC AE AD D D E C A B E D D 1 2 3 3 4 5 6 7 8 9 10 11 12 13 13 14 14 15 16 17 18 19 19 20 21 22 22 23 24 25 26 15 28 27 31 30 W V X R Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 72: ...ve sleeves M Route the cylinder 2 intake air pressure sensor hose to the outside of the wire harness N Route the cylinder 2 intake air pressure sensor lead to the outside of the wire harness headlight lead right handlebar switch lead main switch lead and cylinder 2 left spark plug lead O Fasten the wire harness headlight lead right handlebar switch lead main switch lead and cylinder 2 left spark p...

Page 73: ...U A B C D E D F G H I J A 1 2 3 4 5 6 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23 24 26 27 28 29 R Q M N O P 24 25 S T U V W X AF AA AB AC AD AE Y Z Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 74: ...ng the rear brake fluid reservoir be sure not to pinch the tail brake light lead and muffler cooling fan motor lead between the rear brake fluid reservoir and the rear brake fluid reservoir bracket Route the leads under the damper that is attached to the frame J Fasten the rear turn signal light leads tail brake light lead muffler cooling fan motor lead and license plate light lead with the plasti...

Page 75: ...U A B C D E D F G H I J A 1 2 3 4 5 6 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23 24 26 27 28 29 R Q M N O P 24 25 S T U V W X AF AA AB AC AD AE Y Z Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 76: ... sure not to pinch the seat lock cable when installing the battery box AD Fasten the sub wire harness 1 at the white tape with the plastic locking tie Face the end of the plastic locking tie rearward and then cut off the excess end of the tie AE To cylinder 1 left spark plug AF Fasten the starter motor lead at the white tape with the holder on the cylinder 1 left ignition coil bracket Manuals by M...

Page 77: ...CABLE ROUTING 2 51 A A B D D E F G C 1 2 3 3 4 4 5 6 7 8 9Manuals by Motomatrix www motomatrix co uk Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 78: ...ipe C Connect the end of the fuel hose that has a black connector to the fuel pipe D Face the end of the hose clamp inward angled slightly downward E Install the end of the fuel return hose fuel return pipe to fuel pump with a yellow paint mark onto the fuel return pipe until the hose contacts the yellow paint mark on the pipe F Install the fuel return hose fuel return pipe to fuel pump with its w...

Page 79: ...CABLE ROUTING 2 53 A A A A A B C D D E F A A 1 1 2 2 5 3 6 8 10 10 11 A G H I K J 4 7 9 9 9 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 80: ...their paint marks facing outward E Fasten the fuel tank breather hose at the white paint mark fuel tank overflow hose at the yellow paint mark and fuel return pipe with the holder Fasten the hoses in the order listed with the fuel tank breather hose fastened towards the front of the vehicle F Install the rollover valve hoses with their paint marks facing downward G Face the ends of the hose clamps...

Page 81: ...CABLE ROUTING 2 55 B A B A C C A A B C D E J 1 2 3 4 5 8 6 7 8 9 10 11 12 13 G H I K L M N F 14 15 16 17 10 E 3matrix co uk Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 82: ...dle speed control unit outlet hose with a white paint mark onto the throttle body D Face the ends of the hose clamp to the left angled 45 towards the rear of the vehicle E Face the ends of the hose clamp forward F Install the end of the cylinder 1 intake air pressure sensor hose with a white paint mark onto the throttle body G Face the ends of the hose clamp inward H Face the ends of the hose clam...

Page 83: ...CHK ADJ 3 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 84: ...HAUST SYSTEM 3 17 ADJUSTING THE EXUP CABLES 3 18 CHASSIS 3 20 ADJUSTING THE FRONT DISC BRAKE 3 20 ADJUSTING THE REAR DISC BRAKE 3 20 CHECKING THE BRAKE FLUID LEVEL 3 21 CHECKING THE FRONT BRAKE PADS 3 21 CHECKING THE REAR BRAKE PADS 3 22 CHECKING THE FRONT BRAKE HOSES 3 22 CHECKING THE REAR BRAKE HOSE 3 22 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 22 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 23 ADJUSTIN...

Page 85: ...YSTEM 3 33 CHECKING AND CHARGING THE BATTERY 3 33 CHECKING THE FUSES 3 33 REPLACING THE HEADLIGHT BULBS 3 33 ADJUSTING THE HEADLIGHT BEAM 3 34 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 86: ...es Check valve clearance Adjust 4 Air filter element 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 worn to the limit 8 Brake hoses Check for cracks or dam...

Page 87: ...or damaged 19 Shock absorber as sembly Check operation and shock absorber for oil leakage 20 Rear suspension re lay arm and connect ing arm pivoting points Check operation 21 Fuel injection system Adjust synchronization 22 Engine oil Change Check oil level and vehicle for oil leakage 23 Engine oil filter car tridge Replace 24 Front and rear brake switches Check operation 25 Moving parts and ca ble...

Page 88: ...the adjusting screw 2 side tighten the adjusting screw and bring the valve clearance b within specification Valve clearance adjustment should be made on a cold engine at room temperature When the valve clearance is to be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove Seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 ...

Page 89: ...linder a Turn the crankshaft counterclockwise from the piston 1 TDC by 408 degrees b When piston 2 is at TDC on the compres sion stroke align the TDC mark e on the crankshaft position sensor rotor with the pointer b on the clutch cover c Check the camshaft drive gear mark c posi tion and camshaft driven gear mark d posi tion as shown d Measure the valve clearance with a thickness gauge 8 Adjust Va...

Page 90: ...NOTE For installation reverse the removal procedure Front cylinder head cover Tappet covers Refer to CAMSHAFTS on page 5 16 EAS20570 SYNCHRONIZING THE THROTTLE BODIES NOTE Prior to synchronizing the throttle bodies the valve clearance and the engine idling speed should be properly adjusted and the ignition tim ing should be checked 1 Stand the vehicle on a level surface NOTE Place the vehicle on a...

Page 91: ...hrottle body 1 as standard adjust throttle body 2 using the air screw 1 for throttle body 2 NOTE After each step rev the engine two or three times each time for less than a second and check the synchronization again If the air screw is removed turn the screw 3 4 turn in and be sure to synchronize the throttle body CAUTION EC5YU1027 Do not use the throttle valve adjusting screws to adjust the throt...

Page 92: ...justing nut 3 c Loosen the locknut 4 on the accelerator ca ble d Turn the adjusting nut 5 in direction a or b until the specified throttle cable free play is obtained e Tighten the locknuts 2 4 NOTE If the specified throttle cable free play cannot be obtained on the throttle body side of the cable use the adjusting nut on the handlebar side Handlebar side a Loosen the locknut 1 b Turn the adjustin...

Page 93: ...eplace the spark plug Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 6 Clean Spark plug with a spark plug cleaner or wire brush 7 Measure Spark plug gap a with a wire thickness gauge Out of specification Regap 8 Install Spark plug NOTE Before installing the spark plug clean the spark plug and gasket surface 9 Connect Spark plug cap 10 Install Fuel tank Refer ...

Page 94: ...e following procedure applies to all of the cyl inders NOTE Insufficient compression pressure will result in a loss of performance 1 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 3 2 Start the engine warm it up for several min utes and then turn it off 3 Remove Seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 1...

Page 95: ...r carbon deposits Carbon deposits Eliminate d If the compression pressure is below the min imum specification pour a teaspoonful of en gine oil into the spark plug bore and measure again Refer to the following table 9 Install Spark plug 10 Connect Spark plug cap 11 Connect Decompression solenoid couplers 12 Install Fuel tank Refer to FUEL TANK on page 6 1 Seat Refer to GENERAL CHASSIS on page 4 1 ...

Page 96: ...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 CONSERV ING II b Do not allow foreign materials to enter the crankcase 5 Start the engine warm it up for several min utes and then turn it off 6 Check the engine oil level again NOTE Before checking the engine oil level wait...

Page 97: ...r regulator 9 Check Engine oil drain bolt gaskets Damage Replace 10 Install Engine oil drain bolt crankcase along with the gasket Engine oil drain bolt oil tank along with the gasket 11 Fill Oil tank with the specified amount of the recom mended engine oil Oil filter wrench 90890 01426 YU 38411 1 1 1 1 1 2 2 T R Oil filter cartridge 17 Nm 1 7 m kg 12 ft lb T R Rectifier regulator bolt 7 Nm 0 7 m k...

Page 98: ...1 b Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolts If no engine oil comes out after one minute turn the engine off so that it will not seize c Check the engine oil passages the oil filter cartridge and the oil pump for damage or leakage Refer to OIL PUMP on page 5 81 d Start the engine after solving the problem s and check the engine oil pressure aga...

Page 99: ...ct reading of the clutch fluid level make sure the top of the reservoir is horizontal EAS20910 BLEEDING THE HYDRAULIC CLUTCH SYSTEM WARNING EWA13000 Bleed the hydraulic clutch system whenever the system was disassembled a clutch hose was loosened or removed the clutch fluid level is very low clutch operation is faulty NOTE Be careful not to spill any clutch fluid or allow the clutch fluid reservoi...

Page 100: ...back and away from the air filter case Do not disconnect the fuel hoses 3 Remove Air filter case cover 1 4 Remove Air filter element 1 5 Check Air filter element Damage Replace NOTE Replace the air filter element every 40000 km of operation The air filter needs more frequent service if you are riding in unusually wet or dusty areas 6 Install Air filter case cover CAUTION EC5YU1005 Never operate th...

Page 101: ...ection Connect properly CAUTION ECA14940 Make sure the fuel tank breather hose is rout ed correctly 3 Install Air filter case Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 1 Seat Refer to GENERAL CHASSIS on page 4 1 EAS21050 CHECKING THE CYLINDER HEAD BREATHER HOSES 1 Remove Seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 1 Air filter ...

Page 102: ...r exhaust pipe and rear exhaust pipe joint bolt 8 Rear exhaust pipe bolt 9 Rear exhaust pipe and catalyst pipe bolt 10 Catalyst pipe nut 11 Catalyst pipe and muffler bolts 12 Muffler bolts 13 NOTE When installing the EXUP cables make sure they are parallel and not twisted Upper cable Black metal section 14 Lower cable White metal section 15 1 T R Front exhaust pipe and front exhaust pipe joint bol...

Page 103: ...on 3 Check EXUP cable free play at the EXUP valve pul ley a 4 Adjust EXUP cable free play a Slide back the rubber cover b Loosen both locknuts 1 c Insert a 3 5 mm 0 14 in pin 2 through the projections a in the EXUP valve pulley and into the hole b in the EXUP valve cover d Turn both adjusting nuts 3 in or out until the specification 15 14 1 b c a EXUP cable free play at the EXUP valve pulley a 3 m...

Page 104: ...P valve pulley contacts the stoppers ful ly open and fully closed positions and then check that the notch in the EXUP valve pulley is aligned with the hole in the EXUP valve cover 5 Install EXUP valve pulley cover T R EXUP valve pulley cover bolt 10 Nm 1 0 m kg 7 2 ft lb 3 3 d d c d d c c Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 105: ...pedal position is determined by the in stalled rear brake master cylinder length a 1 Measure Installed rear brake master cylinder length a Incorrect Adjust 2 Adjust Installed rear brake master cylinder length a Loosen the locknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified installed rear brake master cylinder length is obtained WARNING EW5YU1011 After adjusting the instal...

Page 106: ...ated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid 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...

Page 107: ...ge 4 18 EAS21290 CHECKING THE REAR BRAKE HOSE 1 Remove Seat Refer to GENERAL CHASSIS on page 4 1 2 Check Brake hoses 1 Cracks damage wear Replace 3 Check Brake hose guide 2 Loose Tighten the clamp bolt 4 Hold the vehicle upright and apply the brake several times 5 Check Brake hoses Brake fluid leakage Replace the damaged hose Refer to REAR BRAKE on page 4 31 6 Install Seat Refer to GENERAL CHASSIS...

Page 108: ...ficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed Hydraulic brake system a Fill the brake fluid reservoir to the proper level with the recommended brake fluid b Install the brake fluid reservoir diaphragm c Connect a clear plastic hose 1 tightly to the bleed screw 2 NOTE The bleeding ord...

Page 109: ...ift rod length is ob tained c Tighten both locknuts to specification EAS21390 ADJUSTING THE DRIVE CHAIN SLACK CAUTION ECA13550 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its 1 Stand the vehicle on a level surface WARNING ...

Page 110: ... use of a coarse brush can damage these O rings Therefore use only kerosene to clean the drive chain Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O ring chains Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O rings EAS21510 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the v...

Page 111: ... 3 f Install the upper ring nut 2 g Finger tighten the upper ring nut 2 then align the slots of both ring nuts If necessary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 NOTE Make 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 57 EAS21530 CHECKING THE FRONT...

Page 112: ...hicle 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 positions 1 Adjust Spring preload a Turn the adjusting bolt 1 in direction a or b Rebound damping CAUTION ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Rebound damping 1 2 Dir...

Page 113: ... direction a or b Direction a turn in Rebound damping is increased suspension is harder Direction b turn out Rebound damping is decreased suspension is softer Rebound damping adjusting positions Minimum 17 click s out Standard 15 click s out Maximum 1 click s out With the adjusting screw fully turned in Direction a turn in Compression damping is increased suspension is harder Direction b turn out ...

Page 114: ...nstalled spring length Minimum 155 0 mm 6 10 in Standard 150 0 mm 5 91 in Maximum 145 0 mm 5 71 in c Installed spring length T R Locknut rear shock absorber spring preload adjusting nut 42 Nm 4 2 m kg 30 ft lb a b 1 3 2 c Direction a turn in Rebound damping is increased suspension is harder Direction b turn out Rebound damping is decreased suspension is softer Rebound damping adjusting positions M...

Page 115: ...imit re place the tire immediately 2 Check Tire surfaces Damage wear Replace the tire Compression damping adjusting positions Minimum 12 click s out Standard 10 click s out Maximum 1 click s out With the adjusting screw fully turned in 1 a b Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 36 psi 2 50 kgf cm 2 50 bar Rear 290 kPa 42 psi 2 90 kgf cm 2 90 bar...

Page 116: ...combination other than one approved by Yamaha is used on this vehicle WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done NOTE For tires with a direction of rotation mark 1 Install the tire with the mark pointing in the di rection of wheel ...

Page 117: ...evice EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal to metal moving parts of the levers EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal to metal moving parts of the pedal EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point...

Page 118: ...N 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 d Connect Headlight coupler 3 Replace High beam headlight bulb a Remove Headlight bulb cover...

Page 119: ...dlight coupler h Install Headlight bulb cover 4 Install Headlight assembly EAS21810 ADJUSTING THE HEADLIGHT BEAM 1 Adjust Headlight beam vertically a Turn the adjusting screw 1 in direction a or b 2 Adjust Headlight beam horizontally a Turn the adjusting screw 1 in direction a or b T R Headlight assembly bolt 7 Nm 0 7 m kg 5 1 ft lb Direction a Headlight beam is raised Direction b Headlight beam i...

Page 120: ...CHAS 4 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 121: ...ING THE FRONT BRAKE PADS 4 25 REMOVING THE FRONT BRAKE CALIPERS 4 26 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 26 CHECKING THE FRONT BRAKE CALIPERS 4 27 ASSEMBLING THE FRONT BRAKE CALIPERS 4 27 INSTALLING THE FRONT BRAKE CALIPERS 4 27 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 28 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 28 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 29 INSTALLING THE FRONT BRAKE...

Page 122: ...ORBER 4 62 DISPOSING OF A REAR SHOCK ABSORBER 4 62 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 62 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 62 CHECKING THE CONNECTING ARM AND RELAY ARM 4 62 INSTALLING THE CONNECTING ARM AND RELAY ARM 4 63 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 64 SWINGARM 4 65 REMOVING THE SWINGARM 4 67 CHECKING THE SWINGARM 4 67 INSTALLING THE SWINGARM 4 67 CHAIN DRIVE 4...

Page 123: ...y lead 1 Disconnect 4 Positive battery lead 1 Disconnect 5 Main fuse 1 6 Battery band 1 7 Battery 1 8 Battery seat 1 9 Battery box 1 For installation reverse the removal procedure 4 5 7 8 4 3 1 6 9 2 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 10 Nm 1 0 m kg 7 2 ft Ib LT Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 124: ...e harness 3 coupler wire harness side 1 Disconnect 8 Headlight assembly coupler 1 Disconnect 9 Air temperature sensor coupler 1 Disconnect 10 Headlight assembly 1 For installation reverse the removal procedure 8 79 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 9 Nm 0 9 m kg 6 5 ft Ib T R 9 Nm 0 9 m kg 6 5 ft Ib LT LT LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib 6 1 3 5 4 2 10 Manuals by Motoma...

Page 125: ...1 Disconnect 3 Rear right turn signal light coupler 1 Disconnect 4 Rear left turn signal light coupler 1 Disconnect 5 License plate light coupler 1 Disconnect 6 Tail brake light assembly 1 7 Muffler cooling fan motor assembly 1 For installation reverse the removal procedure 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 7 6 1 2 3 4 5 Manuals by Motomatrix www motomatrix co uk Email inf...

Page 126: ...k 1 5 Air filter case joint clamp screw 2 Loosen 6 Air filter case bracket 1 7 ISC idle speed control unit inlet hose 1 Disconnect 8 Intake solenoid vacuum hose air filter case valve to intake solenoid 1 Disconnect 9 Air filter case 1 10 Air filter case valve 1 11 Oil catch tank breather hose 1 12 Oil catch tank 1 For installation reverse the removal procedure 1 2 9 5 5 7 8 6 4 12 11 3 5 T R 9 Nm ...

Page 127: ...Connect the vacuum pressure pump gauge set 1 to the air filter case valve 2 c Check that the air filter case valve operates when vacuum pressure is applied to the valve using the vacuum pressure pump gauge set Faulty Replace the air filter case valve Vacuum pressure pump gauge set 90890 06756 1 2 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 128: ...iper 1 5 Front wheel axle pinch bolt 1 Loosen 6 Front wheel axle 1 7 Front wheel 1 8 Collar 2 9 Dust cover 2 10 Front brake disc 2 For installation reverse the removal procedure T R 23 Nm 2 3 m kg 17 ft Ib T R 72 Nm 7 2 m kg 52 ft lb T R 6 Nm 0 6 m kg 4 3 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib LT LT T R 18 Nm 1 8 m kg 13 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib LS LS 2 6 5 1 3 10 7 10 8 9 9 8 4 T R 35 Nm 3 5 ...

Page 129: ... front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 For assembly reverse the disassembly procedure 2 1 2 1 3 LS LS New New Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 130: ...he 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 Front wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING EWA13460 Do not attempt to straighten a bent wheel ax le 2 Check Tire Front wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 30 and CHEC...

Page 131: ...with the brake disc installed 1 Remove Balancing weight s 2 Find Front wheel 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...

Page 132: ...ONT BRAKE DISCS on page 4 24 EAS22000 INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS The following procedure applies to both of the front brake discs 1 Install Front brake disc NOTE Tighten the brake disc bolts in stages and in a crisscross pattern 2 Check Front brake discs Refer to CHECKING THE FRONT BRAKE DISCS on page 4 24 3 Lubricate Oil seal lips Collars 4 Install Front wheel NOTE Install the t...

Page 133: ...ipers WARNING EWA13500 Make sure the brake hose is routed properly NOTE Make sure that there is enough space between the brake pads before installing the brake cali pers onto the brake discs T R Front wheel axle 72 Nm 7 2 m kg 52 ft lb T R Front wheel axle pinch bolt 23 Nm 2 3 m kg 17 ft lb T R Front brake caliper bolt 35 Nm 3 5 m kg 25 ft lb Manuals by Motomatrix www motomatrix co uk Email info m...

Page 134: ... chain adjusting bolt 2 Loosen 4 Rear wheel axle nut 1 5 Washer 1 6 Rear wheel axle 1 7 Left drive chain puller 1 8 Right drive chain puller 1 9 Rear brake caliper bracket 1 10 Rear wheel 1 For installation reverse the removal procedure T R 150 Nm 15 0 m kg 110 ft lb T R 22 Nm 2 2 m kg 16 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib LT 8 7 6 1 9 10 3 2 5 4 LS Manuals by Motomatrix...

Page 135: ... brake disc side 1 4 Collar wheel sprocket side 1 5 Dust cover 2 6 Oil seal 1 7 Bearing 1 8 Rear wheel drive hub 1 9 Rear wheel drive hub damper 6 For installation reverse the removal procedure LS LS LT New 6 4 2 8 9 5 7 1 5 3 T R 18 Nm 1 8 m kg 13 ft Ib T R 100 Nm 10 0 m kg 72 ft lb 6 6 LT Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 136: ...rder Job Parts to remove Q ty Remarks 1 Collar 1 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Circlip 1 6 Bearing 1 For assembly reverse the disassembly procedure New 2 3 1 5 4 6 LS LS Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 137: ...90 CHECKING THE REAR WHEEL 1 Check Rear wheel axle Rear wheel Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 8 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 30 and CHECKING THE WHEELS on page 3 31 3 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 8 EAS22110 CHECKING THE REAR WHEEL DRIVE HUB 1 Che...

Page 138: ...ke disc and rear wheel drive hub installed 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 9 ET5YU1026 CHECKING THE REAR BRAKE DISC Refer to CHECKING THE REAR BRAKE DISC on page 4 36 EAS22160 INSTALLING THE REAR WHEEL REAR BRAKE DISC 1 Install Rear brake disc NOTE Tighten the brake disc bolts in stages and in a crisscross pattern 2 Check Rear brake di...

Page 139: ... to ADJUSTING THE DRIVE CHAIN SLACK on page 3 24 6 Install Rear brake caliper WARNING EWA13500 Make sure the brake hose is routed properly Drive chain slack 40 0 50 0 mm 1 57 1 97 in T R Rear brake caliper bolt M12 27 Nm 2 7 m kg 19 ft lb Rear brake caliper bolt M8 22 Nm 2 2 m kg 16 ft lb LOCTITE 1 2 a Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 140: ...ont brake calipers 1 Brake hose holder 1 2 Front brake caliper 1 3 Brake pad clip 2 4 Brake pad pin 1 5 Brake pad spring 1 6 Front brake pad 2 For installation reverse the removal procedure T R 6 Nm 0 6 m kg 4 3 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib 1 3 3 4 2 6 5 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 141: ...rake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Right rearview mirror 1 8 Brake fluid reservoir bracket 1 9 Brake lever 1 10 Front brake light switch connector 2 Disconnect 11 Front brake light switch 1 12 Front brake hose union bolt 1 13 Copper washer 2 14 Front brake hose 1 15 Front brake master cylinder holder 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 14 Nm 1 4 m kg...

Page 142: ...he removal procedure Removing the front brake master cylinder Order Job Parts to remove Q ty Remarks T R 10 Nm 1 0 m kg 7 2 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib 7 8 5 4 3 1 2 15 16 13 12 10 14 11 9 6 New Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 143: ...master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Bleed screw 1 3 Brake master cylinder body 1 For assembly reverse the disassembly procedure Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 144: ...Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 1 Front brake hose union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Front brake caliper 1 For installation reverse the removal procedure T R 35 Nm 3 5 m kg 25 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib 1 4 2 3 New Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 145: ...dure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Front brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston seal 8 7 Bleed screw 1 For assembly reverse the disassembly procedure Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 146: ...e Front wheel Refer to FRONT WHEEL on page 4 6 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...

Page 147: ... the brake pads as a set 2 Install Brake pads Brake pad spring NOTE Always install new brake pads and a 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 brake pads and ...

Page 148: ...ose union bolt 1 Copper washers 2 Front brake hose 3 NOTE Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22350 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Remove Brake caliper pistons 1 Brake caliper piston seals 2 WARNING EW5YU1006 Do not loosen the bolts 3 a Blow compressed air into the brake hos...

Page 149: ...d distort Whenever a brake caliper is disassembled replace the brake caliper piston seals EAS22450 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Install Front brake caliper 1 temporarily Copper washers Front brake hose 2 Front brake hose union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer...

Page 150: ...5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 21 7 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 EAS22490 REMOVING THE FR...

Page 151: ...nstall the brake hose at a right angle to the front brake master cylinder as shown in the il lustration While holding the brake hose tighten the union bolt Turn the handlebar to the left and right to make sure the brake hose does not touch other parts e g wire harness cables leads Correct if necessary 3 Fill Brake fluid reservoir with the specified amount of the recom mended brake fluid WARNING EW...

Page 152: ...AULIC BRAKE SYSTEM on page 3 23 5 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 21 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 a Manuals by Motomatrix www motomatrix co uk Email info motomatrix co u...

Page 153: ...Brake pad shim 2 5 Brake pad insulator 2 6 Rear brake pad 2 7 Brake pad spring 2 For installation reverse the removal procedure T R 3 Nm 0 3 m kg 2 2 ft Ib T R 22 Nm 2 2 m kg 16 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib LS LT 3 2 1 7 7 6 5 4 5 4 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 154: ... 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Rear brake hose union bolt 1 8 Copper washer 2 9 Rear brake hose 1 10 Rear brake master cylinder 1 For installation reverse the removal procedure T R 30 Nm 3 0 m kg 22 ft Ib New New T R 23 Nm 2 3 m kg 17 ft Ib T R 7 Nm 0 7 m kg 5...

Page 155: ...ylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake hose joint 1 3 Bush 1 4 Brake master cylinder body 1 For assembly reverse the disassembly procedure Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 156: ... BRAKE SYSTEM on page 3 23 1 Rear brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Rear brake caliper 1 For installation reverse the removal procedure T R 22 Nm 2 2 m kg 16 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib LS LT New 1 2 4 3 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 157: ...sulator 2 5 Rear brake pad 2 6 Brake pad spring 2 7 Brake caliper piston 2 8 Brake caliper piston seal 4 9 Bleed screw 1 For assembly reverse the disassembly procedure LS New New 9 2 1 6 4 3 5 4 3 7 6 8 8 T R 3 Nm 0 3 m kg 2 2 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 158: ... Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 24 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 24 5 Adjust Brake disc deflection Refer to CHECKING THE FRONT ...

Page 159: ...D LEVEL on page 3 21 5 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM 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 Rear brake hose union bolt 1 Copper washers 2 Rear brake hose 3 NOTE Put the end of the brake hose ...

Page 160: ...body Obstruction Blow out with compressed air WARNING EWA13610 Whenever a brake caliper is disassembled replace the brake caliper piston seals 2 Check Brake caliper bracket 1 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 interna...

Page 161: ...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 any s...

Page 162: ...Check Brake hoses Cracks damage wear Replace EAS22730 ASSEMBLING THE REAR 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 EAS22740 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install Copper washers Rear brake hose 1 Rear brake hose union bolt 2 W...

Page 163: ...d may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 4 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 21 5 Check Brake pedal operation Soft or spongy feelin...

Page 164: ... Disconnect 10 Clutch master cylinder holder 1 11 Clutch master cylinder assembly 1 12 Left handlebar switch 1 13 Handlebar grip 1 14 Upper handlebar holder 2 15 Handlebar 1 1 2 4 3 16 LS T R 10 Nm 1 0 m kg 7 2 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 29 Nm 2 9 m kg 21 ft Ib T R 29 Nm 2 9 m kg 21 ft Ib 7 T R 20 Nm 2 0 m kg 14 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib T R 14 Nm 1 4...

Page 165: ... 10 Nm 1 0 m kg 7 2 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 29 Nm 2 9 m kg 21 ft Ib T R 29 Nm 2 9 m kg 21 ft Ib 7 T R 20 Nm 2 0 m kg 14 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib 15 5 5 8 7 6 1 11 12 10 9 14 14 13 16 LS LS 12 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 166: ...o danger of it falling over 2 Install Lower handlebar holders 1 NOTE Temporarily tighten the nuts 2 3 Install Handlebar 1 Upper handlebar holders 2 CAUTION ECA14250 First tighten the bolts on the front side of the handlebar holder and then on the rear side Turn the handlebar all the way to the left and right If there is any contact with the fuel tank adjust the handlebar position NOTE The upper ha...

Page 167: ...r cylinder holder 1 NOTE Align the mating surfaces of the clutch master cylinder holder with the punch mark a on the handlebar First tighten the upper bolt then the lower bolt The clutch master cylinder holder has a punch mark b to distinguish it from the front brake master cylinder holder 8 Install Throttle grip Throttle cables Right handlebar switch 1 Grip end 2 NOTE Align the projection a on th...

Page 168: ...unch mark a on the handlebar First tighten the upper bolt then the lower bolt 10 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 7 T R Front brake 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 1 a Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 169: ...d 2 2 Front fender 1 3 Cap bolt 1 Loosen 4 Upper bracket pinch bolt 1 Loosen 5 Lower bracket pinch bolt 2 Loosen 6 Front fork leg 1 For installation reverse the removal procedure 6 5 1 4 1 2 3 T R 26 Nm 2 6 m kg 19 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 28 Nm 2 8 m kg 20 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 6 Nm 0 6 m kg 4 3 ft Ib Manuals by Motomatrix www motomatrix co...

Page 170: ...ting rod 1 5 Spacer 1 6 Nut 1 7 Upper spring seat 1 8 Fork spring 1 9 Lower spring seat 1 10 Outer tube 1 11 Dust seal 1 12 Oil seal clip 1 13 Oil seal 1 14 Washer 1 15 Damper rod assembly 1 T R 35 Nm 3 5 m kg 25 ft Ib 1 2 3 6 5 7 8 9 4 11 12 13 14 10 15 16 LS New New New T R 20 Nm 2 0 m kg 14 ft Ib T R 25 Nm 2 5 m kg 18 ft Ib New Manuals by Motomatrix www motomatrix co uk Email info motomatrix co...

Page 171: ...sassembling the front fork legs Order Job Parts to remove Q ty Remarks T R 35 Nm 3 5 m kg 25 ft Ib 1 2 3 6 5 7 8 9 4 11 12 13 14 10 15 16 LS New New New T R 20 Nm 2 0 m kg 14 ft Ib T R 25 Nm 2 5 m kg 18 ft Ib New Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 172: ...e collar 1 as shown in the illustra tion by turning the spring preload adjusting bolt 2 counterclockwise until it stops 2 Remove Cap bolt 1 from the damper adjusting rod Spacer 2 Nut 3 a Press down on the spacer with the fork spring compressor 4 b Install the rod holder 5 between the nut 3 and the spacer 2 NOTE Use the side of the rod holder that is marked B c Hold the spring preload adjusting bol...

Page 173: ...llowing procedure applies to both of the front fork legs 1 Check Inner tube Outer tube Bends damage scratches Replace WARNING EWA13650 Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure Spring free length a Out of specification Replace 3 Check Damper rod Damage wear Replace Obstruction Blow out all of the oil passag es with compressed air Damper adjusting ro...

Page 174: ...he following parts Oil seal Dust seal O ring Before assembling the front fork leg make sure all of the components are clean 1 Install Damper rod assembly 1 Inner tube 2 CAUTION ECA14210 Allow the damper rod assembly to slide slowly down the inner tube 2 until it pro trudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate Inner tube s outer surface 3 Tighten Dam...

Page 175: ... that it fits into the outer tube s groove 8 Install Dust seal 1 with the fork seal driver weight 2 9 Install Rod puller 1 Rod puller attachment 2 onto the damper rod 3 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 3 2 1 1 2 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 Rod puller 90890 01437 Universal damping rod bleeding tool set YM A87...

Page 176: ... 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 14 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 15 Install Lower spring seat 1 Fork spring 2 Upper spring seat 3 Nut 4 Spacer 5 Da...

Page 177: ...specifi cation WARNING EWA13670 Always use a new cap bolt O ring CAUTION EC5YU1012 When tightening the spring preload adjust ing bolt 11 into the cap bolt be sure not to break the projections c on the collar 12 NOTE Hold the nut 4 using a proper tool that has a thickness of 3 mm 0 12 in or less n Remove the rod holder and fork spring com pressor 16 Install Cap bolt to the outer tube NOTE Temporari...

Page 178: ...lder 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 3 Adjust Spring preload Rebound damping Compression damping Refer to ADJUSTING THE FRONT FORK LEGS on page 3 27 T R Lower bracket pinch bolt 28 Nm 2 8 m kg 20 ft lb T R Cap bolt 20 Nm 2 0 m kg 14 ft lb T R Upper bracket pinch bolt 26 Nm 2 6 m kg 19 ft lb ...

Page 179: ...ly bracket 1 4 Steering stem nut 1 5 Upper bracket 1 6 Headlight assembly bracket 1 7 Front brake hose joint 1 8 Front brake hose joint bracket 1 9 Lock washer 1 10 Upper ring nut 1 11 Rubber washer 1 12 Lower ring nut 1 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 23 Nm 2 3 m kg 17 ft lb 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 110 Nm 11 0 m kg 80 ft lb LS LS...

Page 180: ...lation reverse the removal procedure Removing the lower bracket Order Job Parts to remove Q ty Remarks T R 7 Nm 0 7 m kg 5 1 ft Ib T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 23 Nm 2 3 m kg 17 ft lb 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 110 Nm 11 0 m kg 80 ft lb LS LS T R 7 Nm 0 7 m kg 5 1 ft Ib 6 8 7 12 18 19 20 21 21 15 16 17 14 9 10 11 5 4 13 3 1 2 Manuals by Motomatrix www motoma...

Page 181: ...races a Remove the bearing races from the steering head pipe with a long rod 1 and hammer b Remove the bearing race from the lower bracket with a floor chisel 2 and hammer 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 a...

Page 182: ... the front brake hose joint bracket 1 contacts the side b of the front brake hose joint 2 4 Install Upper bracket Steering stem nut NOTE Temporarily tighten the steering stem nut 5 Install Front fork legs Refer to FRONT FORK on page 4 47 NOTE Temporarily tighten the upper and lower bracket pinch bolts 6 Tighten Steering stem nut T R Steering stem nut 110 Nm 11 0 m kg 80 ft lb a 1 2 b Manuals by Mo...

Page 183: ...ly 1 5 Collar Spacer Oil seal Bearing 2 1 2 1 6 Self locking nut Bolt Washer 1 1 2 7 Spacer 1 8 Oil seal Bearing 2 1 9 Relay arm 1 10 Spacer Oil seal Bearing 2 8 4 11 Connecting arm 1 12 Collar Spacer 2 1 For installation reverse the removal procedure T R 40 Nm 4 0 m kg 29 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 49 Nm 4 9 m kg 35 ft Ib LS LS LS LS LS LS 5 12 12 4 2 10 6 10 6 10 10 11 7 1 3 8 8 9 3 1...

Page 184: ...m 1 57 in 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 Relay a...

Page 185: ...cing to the right and its arrow mark b facing upward 4 Tighten Rear shock absorber assembly nut rear side Relay arm nut relay arm and connecting arm Recommended lubricant Lithium soap based grease Installed depth a 8 0 mm 0 31 in Installed depth b 4 0 mm 0 16 in Installed depth c 7 0 mm 0 28 in Installed depth d 0 5 1 0 mm 0 02 0 04 in 5 Relay arm 6 Connecting arm 7 Rear shock absorber A Left side...

Page 186: ...t relay arm and swingarm 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 24 T R Relay arm nut relay arm and connecting arm 49 Nm 4 9 m kg 35 ft lb Recommended lubricant Lithium soap based grease T R Rear shock absorber assembly nut front side 49 Nm 4 9 m kg 35 ft lb T R Relay arm nut relay arm and swingarm 40 Nm 4 0 m kg 29 ft lb Drive chain slack 40 0 50 0 mm 1 57 1 ...

Page 187: ...ake hose holder 1 5 Drive chain adjusting bolt Locknut 2 2 6 Footrest bracket pinch bolt 2 Loosen 7 Swingarm pivot shaft nut 1 8 Swingarm pivot shaft 1 9 Collar 2 10 Spacer 1 11 Spacer 1 12 Drive chain 1 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 7 Nm 0 7 m kg 5 1 ft Ib T R 125 Nm 12 5 m kg 90 ft lb LS LS LS LS LT 13 2 8 19 9 9 23 14 11 24 25 24 18 16 2...

Page 188: ...ocedure Removing the swingarm Order Job Parts to remove Q ty Remarks 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 7 Nm 0 7 m kg 5 1 ft Ib T R 125 Nm 12 5 m kg 90 ft lb LS LS LS LS LT 13 2 8 19 9 9 23 14 11 24 25 24 18 16 21 1710 20 7 22 5 5 4 3 6 6 1 12 19 15 New T R 25 Nm 2 5 m kg 18 ft Ib T R 25 Nm 2 5 m kg 18 ft Ib LT LT LT Manuals by Motomatrix www mo...

Page 189: ...inding check the spacers bear ings washers and dust covers 3 Remove Drive chain Refer to REMOVING THE DRIVE CHAIN on page 4 70 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 Spacer Washer Bearings Collars 4 Check O...

Page 190: ... depth of oil seal c 0 5 1 0 mm 0 02 0 04 in Installed depth of oil seal d 0 5 mm 0 02 in Installed depth of bearing e 4 0 mm 0 16 in Installed depth of oil seal f 1 0 mm 0 04 in 5 Swingarm 6 Swingarm pivot shaft 7 Relay arm 8 Bolt A Left side B Right side Drive chain slack 40 0 50 0 mm 1 57 1 97 in 1 1 2 2 5 6 d c a d b A B e f 3 4 7 5 8 A B Manuals by Motomatrix www motomatrix co uk Email info m...

Page 191: ...per washer 2 5 Clutch pipe 1 6 Clutch release cylinder 1 7 Dowel pin 2 8 Drive chain guard drive sprocket side 1 9 Drive sprocket nut 1 10 Washer 1 11 Drive sprocket 1 12 Drive chain 1 For installation reverse the removal procedure 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 95 Nm 9 5 m kg 68 ft Ib New New E LT LT 2 5 3 4 7 8 6 11 10 9 1 T R 26 Nm 2 6 m kg 19 ft Ib T R 24 Nm 2 4 ...

Page 192: ...s 2 Check Drive chain Stiffness Clean and lubricate or replace 3 Clean Drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and remove any remaining dirt c Remove the drive chain from the kerosene and completely dry it CAUTION EC5YU1022 This vehicle has a drive chain with small rubber O rings 1 between the drive chain side plates Never use high pressure water or ...

Page 193: ...KING AND REPLACING THE REAR WHEEL SPROCKET on page 4 15 EAS23480 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4 15 EAS28800 INSTALLING THE DRIVE CHAIN 1 Lubricate Drive chain 2 Install Drive sprocket 1 Washer 2 Drive sprocket nut 3 NOTE While applying the rear brake tighten the drive sprocket nut Install the washer 2 with its OUT mark a facing outward Stake ...

Page 194: ...CHAIN DRIVE 4 72 3 Install Clutch release cylinder Refer to INSTALLING THE CLUTCH RE LEASE CYLINDER on page 5 62 a 1 2 3 New b Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 195: ...ENG 5 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 196: ...ECKING THE OIL DELIVERY PIPE 5 26 INSTALLING THE CAMSHAFTS 5 26 BLEEDING A VALVE LIFTER 5 27 INSTALLING THE VALVE LIFTERS 5 29 INSTALLING THE ROCKER ARMS AND PUSH RODS 5 29 INSTALLING THE CYLINDER HEAD COVERS 5 30 CYLINDER HEADS 5 31 REMOVING THE CYLINDER HEADS 5 32 CHECKING THE CYLINDER HEADS 5 32 CHECKING THE OIL PIPE 5 32 INSTALLING THE CYLINDER HEADS 5 33 VALVES AND VALVE SPRINGS 5 34 REMOVING...

Page 197: ...HE CLUTCH MASTER CYLINDER 5 60 REMOVING THE CLUTCH RELEASE CYLINDER 5 61 CHECKING THE CLUTCH RELEASE CYLINDER 5 61 ASSEMBLING THE CLUTCH RELEASE CYLINDER 5 62 INSTALLING THE CLUTCH RELEASE CYLINDER 5 62 SHIFT SHAFT 5 64 CHECKING THE SHIFT SHAFT 5 65 CHECKING THE STOPPER LEVER 5 65 INSTALLING THE SHIFT SHAFT 5 65 GENERATOR AND STARTER CLUTCH 5 66 REMOVING THE GENERATOR 5 68 CHECKING THE STARTER CLU...

Page 198: ...CHECKING THE CRANKSHAFT AND CONNECTING RODS 5 87 INSTALLING THE CONNECTING RODS 5 90 INSTALLING THE CRANKSHAFT ASSEMBLY 5 91 TRANSMISSION 5 92 CHECKING THE SHIFT FORKS 5 95 CHECKING THE SHIFT DRUM ASSEMBLY 5 95 CHECKING THE TRANSMISSION 5 95 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 96 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 5 96 Manuals by Motomatrix www motomatrix co uk Email info mot...

Page 199: ...Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 200: ...tank breather hose holder 1 7 Oil tank gasket 1 8 Oil strainer cover oil tank 1 9 Oil strainer oil tank 1 For installation reverse the removal procedure T R 13 Nm 1 3 m kg 9 4 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 13 Nm 1 3 m kg 9 4 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 New New New New LS LS LS T R 13 Nm 1 3 m kg 9 4 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib 16 1 2 3 4 7 8 9 5 ...

Page 201: ...RAINER 1 Check Oil strainer oil tank Damage Replace Contaminants Clean with engine oil ET5YU1019 INSTALLING THE OIL TANK 1 Install Oil tank NOTE Tighten the oil tank bolts in the proper tightening sequence as shown T R Oil tank bolt 10 Nm 1 0 m kg 7 2 ft lb 1 5 7 3 2 6 8 4 10 16 15 13 11 14 12 9 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 202: ...sket 2 12 Rear exhaust pipe 1 13 Gasket 2 14 Catalyst pipe 1 For installation reverse the removal procedure LT LT T R 24 Nm 2 4 m kg 17 ft Ib 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 10 Nm 1 0 m kg 7 2 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 20 Nm 2 0 m kg 14 ft Ib R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib LT New Ne...

Page 203: ...alling a muffler end cover plate be sure to insert its hooks a two locations into the holes in the muffler cover and align its tabs b four locations with the grooves in the muf fler cover 2 Install Muffler end covers 1 NOTE When installing a muffler end cover align its pro jections a four locations with the grooves b in the muffler cover and then turn it in the direc tion of the arrow shown in the...

Page 204: ...ER CLUTCH on page 5 66 Drive sprocket Refer to CHAIN DRIVE on page 4 69 Rear shock absorber assembly Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 61 1 Rectifier regulator coupler 1 Disconnect 2 Stator coil assembly coupler 1 Disconnect 3 Rectifier regulator 1 4 Oil filter cartridge 1 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 30 Nm 3 0 m kg 22 ft Ib ...

Page 205: ...or coupler 1 20 Neutral switch coupler 1 Disconnect 21 Neutral switch 1 Removing the EXUP servo motor and rear exhaust pipe joint Order Job Parts to remove Q ty Remarks 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 30 Nm 3 0 m kg 22 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib New New LS LS LS T R 24 Nm 2 4 m ...

Page 206: ... 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 30 Nm 3 0 m kg 22 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib New New LS LS LS T R 24 Nm 2 4 m kg 17 ft Ib LT LS T R 20 Nm 2 0 m kg 14 ft Ib New New T R 17 Nm 1 7 m kg 12 ft Ib 1 2 3 4 6 5 8 7 21 14 13 16 23 22 15 12 10 11 18 19 20 17 24 9 Manuals by Motomatrix www m...

Page 207: ...oupler 1 Disconnect 6 Starter motor connector 1 7 Starter motor lead 1 8 Crankshaft position sensor coupler 1 Disconnect 9 Negative battery lead 1 Disconnect 10 Engine temperature sensor coupler 1 Disconnect 11 Spark plug cap 4 For installation reverse the removal procedure 3 6 11 11 9 5 8 4 1 2 10 7 T R 10 Nm 1 0 m kg 7 2 ft Ib Manuals by Motomatrix www motomatrix co uk Email info motomatrix co u...

Page 208: ...er side 1 9 Engine mounting bolt front upper side 1 10 Engine bracket nut front upper side 4 11 Engine bracket bolt front upper side 4 12 Engine bracket front upper side 2 13 Down tube nut rear side 2 14 Down tube bolt rear side 2 T R 55 Nm 5 5 m kg 40 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib 74 Nm 7 4 m kg 53 ft lb T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7...

Page 209: ... Order Job Parts to remove Q ty Remarks T R 55 Nm 5 5 m kg 40 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib 74 Nm 7 4 m kg 53 ft lb 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 8 Nm 0 8 m kg 5 8 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 94 Nm 9 4 m kg 68 ft Ib T R 94 Nm 9 4 m kg 68 ft Ib E LT LT E 5 17 14 4 3 13 1 6 15 15 2 3 7 16 18 11 12 12 ...

Page 210: ...6 Engine mounting nut rear lower side 1 7 Engine mounting spacer bolt rear lower side 1 Loosen 8 Engine mounting bolt rear lower side 1 9 Engine 1 10 Right side panel bracket 1 11 Cylinder 1 right ignition coil 1 12 Cylinder 1 left ignition coil 1 13 Ignition coil bracket 1 T R 8 Nm 0 8 m kg 5 8 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib E E T R 74 Nm...

Page 211: ...gine Order Job Parts to remove Q ty Remarks T R 8 Nm 0 8 m kg 5 8 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib E E T R 74 Nm 7 4 m kg 53 ft lb 2 1 3 10 14 11 13 12 6 7 4 5 8 9 T R 74 Nm 7 4 m kg 53 ft lb Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 212: ...nut rear side 12 temporarily tighten Engine mounting bolt front lower side 13 NOTE Do not fully tighten the bolts and nuts 5 Tighten Down tube spacer bolt 2 Engine mounting spacer bolt rear lower side 3 Engine mounting spacer bolt rear upper side 1 Down tube nut rear side 12 NOTE Tighten the spacer bolts 1 2 3 to specifi cation with a pivot shaft wrench When tightened the spacer bolts should be fl...

Page 213: ... NOTE Do not fully tighten the bolts and nuts 9 Tighten Engine mounting nut front lower side 21 Engine bracket nuts front upper side 23 Engine mounting nut front upper side 22 Engine bracket bolts left upper side 25 Engine mounting bolts left upper side 26 Engine bracket bolts right upper side 28 Engine mounting bolts right upper side 29 and 30 T R Down tube nut front side 74 Nm 7 4 m kg 53 ft lb ...

Page 214: ...ENGINE REMOVAL 5 15 25 10 11 28 26 12 29 27 14 30 26 24 2 21 19 18 18 19 23 22 20 9 13 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 215: ... 3 Crankshaft end cover 1 4 Decompression solenoid cover 1 5 Camshaft sprocket cover 1 6 Camshaft sprocket cover gasket 1 7 Dowel pin 2 For installation reverse the removal procedure LS T R 18 Nm 1 8 m kg 13 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 8 Nm 0 8 m kg 5 8 ft Ib 4 7 6 5 2 3 1 1 New 6 New New Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk...

Page 216: ...Cylinder head cover bolt 12 l 40 mm 1 57 in 8 Rear cylinder head cover 1 9 Front cylinder head cover 1 10 Cylinder head cover gasket 2 11 Dowel pin 4 For installation reverse the removal procedure T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib New New New New LS LS 7 7 7 7 7 7 7 8 1 1 1 2 2 3 3 4 4 5 5 7 4 6 6 6 6 7 11 6 6 4 6 6 6 6 7 9 10 10 11 11 11 LT T R 10 Nm 1 0 m kg 7 2 ft Ib LT ...

Page 217: ...290 5 mm 11 437 in yellow painting 7 Rear rocker arm base 1 8 Front rocker arm base 1 9 Rocker arm shaft 4 10 Rocker arm 1 2 11 Rocker arm 2 2 12 Locknut 4 13 Adjusting screw 4 For installation reverse the removal procedure E E E E E E E E E E 12 13 10 12 13 11 9 6 5 7 3 4 4 12 13 10 9 12 13 11 9 5 4 3 New New 1 2 8 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 20 Nm 2 0 m kg 14 ft ...

Page 218: ...2 2 O ring 4 3 Seal 2 4 Rear valve lifter case 1 5 Front valve lifter case 1 6 Valve lifter 4 For installation reverse the removal procedure LT LT LT LT E E E E E E E 2 1 3 2 6 6 4 5 2 1 3 2 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib New New New New New New New New New New Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 219: ...inder camshaft end cover 1 9 Oil delivery pipe 1 10 Camshaft cover 1 11 Camshaft cover gasket 1 12 Dowel pin 2 13 Front cylinder camshaft 1 14 Rear cylinder camshaft 1 For installation reverse the removal procedure LT LT LT LT 14 11 13 12 12 10 9 6 3 2 7 4 5 8 1 6 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 30 Nm 3 0 m kg 22 ft Ib T R 52 Nm 5 2 m kg 37 ...

Page 220: ... Remove Valve lifters NOTE Make a note of the position of each valve lifter so that they can be installed in the correct place CAUTION EC5YU1015 Do not lay the removed valve lifter on its side EAS23830 REMOVING THE CAMSHAFTS 1 Loosen Front cylinder camshaft end cover bolts 1 Camshaft drive gear bolt 2 NOTE Place a folded copper washer 3 between the teeth of the camshaft drive gear and camshaft dri...

Page 221: ...860 CHECKING THE CAMSHAFTS 1 Check Cam Blue discoloration pitting scratches Re place the camshaft 2 Measure Cam dimensions a and b Out of specification Replace the camshaft Camshaft lobe dimensions Intake A 38 241 38 341 mm 1 5055 1 5095 in cylinder 1 38 243 38 343 mm 1 5056 1 5096 in cylinder 2 Limit 38 141 mm 1 5016 in cylinder 1 38 143 mm 1 5017 in cylinder 2 Intake B 31 950 32 050 mm 1 2579 1 ...

Page 222: ...ive part s NOTE Calculate the clearance by subtracting the crankcase side camshaft journal diameter crankcase side from the crankcase hole inside diameter 8 Calculate Camshaft to camshaft cover clearance Out of specification Replace the defective part s Camshaft journal diameter crankcase side 24 942 24 965 mm 0 9820 0 9829 in Camshaft journal diameter camshaft cover side 27 967 27 980 mm 1 1011 1...

Page 223: ...f specification Replace 5 Calculate Rocker arm to rocker arm shaft clearance NOTE Calculate the clearance by subtracting the rock er arm shaft outside diameter from the rocker arm inside diameter Above 0 08 mm 0 003 in Replace the de fective part s EAS23900 CHECKING THE ROCKER ARM BASES 1 Check Rocker arm base Cracks damage Replace EAS23910 CHECKING THE PUSH RODS 1 Check Push rod Push rod end Bend...

Page 224: ... lifter case clearance NOTE Calculate the clearance by subtracting the valve lifter case outside diameter Above 0 072 mm 0 0028 in Replace the defective part s EAS23930 CHECKING THE PUSH ROD COVER 1 Check Push rod cover Cranks damage Replace Seal Valve lifter outside diameter intake 22 962 22 974 mm 0 9040 0 9045 in Valve lifter outside diameter exhaust 22 962 22 974 mm 0 9040 0 9045 in Valve lift...

Page 225: ...AFTS 1 Install Camshafts to the camshaft cover NOTE Lubricate molybdenum disulfide oil onto the camshaft journals and lobes Align the punch mark a on the rear cylinder camshaft with the punch mark b on the front cylinder camshaft 2 Install Camshaft cover 1 along with the camshafts Camshaft oil delivery pipe 2 NOTE Tighten the camshaft cover bolts in stages and in a crisscross pattern 3 Install Fro...

Page 226: ...ylinder camshaft end cover bolts 2 NOTE Place a folded copper washer 3 between the teeth of the camshaft drive gear and camshaft driven gear in order to lock them Do not damage the teeth of the camshaft drive and camshaft driven gear After tightening the camshaft drive gear bolt remove the copper washer to clean the teeth of the camshaft drive gear and camshaft driven gear EAS24050 BLEEDING A VALV...

Page 227: ...since the engine is hot g With piston 1 at TDC count the indicated number of gear teeth and place marks 2 through 5 on the camshaft driven gear as shown When these marks align between the centers of the camshaft drive and driven gears the corresponding valve lifter is at its highest point h Rotate the crankshaft until the mark on the camshaft driven gear for the valve lifter to be bled aligns with...

Page 228: ...nstall Rocker arms 1 Rocker arm shafts 2 onto rocker arm base NOTE The thread hole a of the rocker arm shaft must face to the outside 2 Install Rocker arm base with rocker arms Push rods a Put the rocker arm base on the cylinder head b Install the push rods NOTE Be sure to correctly install the push rods be tween the rocker arms and valve lifters as shown The illustration is viewed from the right ...

Page 229: ...97 in Bolt with washer 6 l 50 mm 1 97 in Bolts 7 l 60 mm 2 36 in 2 Install Tappet covers 1 NOTE Install the tappet covers with their UP marks a facing each other A Rear cylinder B Front cylinder 1 Intake side rocker arm 2 Exhaust side rocker arm 3 Intake valve lifter 4 Exhaust valve lifter 5 Push rod 1 l 288 5 mm 11 358 in 6 Push rod 2 l 290 5 mm 11 437 in T R Rocker arm base bolt M6 10 Nm 1 0 m k...

Page 230: ...er heads 4 Copper washer 4 5 Copper washer 2 6 Engine temperature sensor 1 7 Rear cylinder head 1 8 Front cylinder head 1 9 Cylinder head gasket 2 10 Dowel pin 4 For installation reverse the removal procedure E T R 21 Nm 2 1 m kg 15 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 39 Nm 3 9 m kg 28 ft Ib 7 4 4 9 10 3 5 9 10 10 2 8 6 1 E New New New New ...

Page 231: ...d Damage scratches Replace 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge and a thickness gauge across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylinder head as 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...

Page 232: ...er head nuts with engine oil Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages T R Cylinder head nut M12 45 Nm 4 5 m kg 32 ft lb T R Cylinder head nut M10 39 Nm 3 9 m kg 28 ft lb A Front cylinder B Rear cylinder 6 4 2 1 3 5 B Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 233: ...to CYLINDER HEADS on page 5 31 1 Valve cotter 8 2 Upper spring seat 4 3 Outer valve spring 4 4 Inner valve spring 4 5 Intake valve 2 6 Exhaust valve 2 7 Valve stem seal 4 8 Lower spring seat 4 9 Valve guide 4 For installation reverse the removal procedure 5 6 8 3 4 7 2 1 8 3 4 7 2 1 8 3 4 7 2 1 8 3 4 7 2 1 M E M E New New New New 9 9 9 9 M M Manuals by Motomatrix www motomatrix co uk Email info mo...

Page 234: ...lve spring compressor set 1 3 Remove Upper spring seat 1 Outer valve spring 2 Inner valve spring 3 Valve 4 Valve stem seal 5 Lower spring seat 6 NOTE Identify the position of each part very carefully so that it can be reinstalled in its original place EAS24290 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides 1 Measure Valve stem to valve gu...

Page 235: ...nate Carbon deposits from the valve face and valve seat 4 Check Valve face Pitting wear Grind the valve face Valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve 5 Measure Valve margin thickness D a Out of specification Replace the valve Valve guide remover ø6 90890 04064 Valve guide remover 6 0 mm YM 04064 A Valve guide installer ø6 90890 04065 Valve ...

Page 236: ...y 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 valve seat and valve face contacted one another the blueing will have been re moved 4 Lap Valve face Valve seat NOTE After replacing the cylinder head or replacing ...

Page 237: ...t 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 c again If the valve seat width is out of specification reface and lap the valve seat EAS24310 CHECKING THE VALVE SPRINGS The following procedure applies to all of the val...

Page 238: ...n spring force exhaust 63 00 73 00 N 14 16 16 41 lb 6 42 7 44 kgf Installed length intake 29 00 mm 1 14 in Installed length exhaust 29 00 mm 1 14 in Outer spring Installed compression spring force intake 139 00 161 00 N 31 25 36 19 lb 14 17 16 42 kgf Installed compression spring force exhaust 139 00 161 00 N 31 25 36 19 lb 14 17 16 42 kgf Installed length intake 31 00 mm 1 22 in Installed length e...

Page 239: ...ers by compressing the valve springs with the valve spring compressor set 1 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION ECA13800 Hitting the valve tip with excessive force could damage the valve b Smaller pitch Valve spring compressor 90890 04019 YM 04019 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 240: ...HEADS on page 5 31 1 Front cylinder 1 2 Rear cylinder 1 3 Cylinder gasket 2 4 Dowel pin 4 5 Piston pin clip 4 6 Piston pin 2 7 Piston 2 8 Top ring 2 9 2nd ring 2 10 Oil ring 2 For installation reverse the removal procedure 1 3 4 5 7 8 9 10 3 4 6 5 5 7 6 5 8 9 10 2 New New New New New New E E E Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 241: ...on ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS24410 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cyl inders and pistons 1 Check Piston wall Cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure cyli...

Page 242: ...s a set NOTE Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder NOTE Level the piston ring into the cylinder with the piston crown Piston Diameter D 96 960 96 975 mm 3 8173 3 8179 in b 10 mm 0 39 in from the bottom edge of the piston Piston to cylinder clearance Cylinder bore C Piston s...

Page 243: ...TONS AND CYLINDERS The following procedure applies to all of the pis tons and cylinders 1 Install Top ring 1 2nd ring 2 Lower oil ring rail 3 Upper oil ring rail 4 Oil ring expander 5 NOTE Be sure to install the piston rings so that the manufacturer s marks or numbers face up Piston ring Top ring End gap installed 0 30 0 50 mm 0 01 0 02 in Limit 0 70 mm 0 0276 in 2nd ring End gap installed 0 30 0 ...

Page 244: ...einstall each piston into its original cylinder numbering order starting from the left 1 to 2 3 Lubricate Piston Piston rings Cylinder with the recommended lubricant 4 Offset Piston ring end gaps 5 Install Cylinder 1 NOTE While compressing the piston rings with one hand install the cylinder with the other hand Recommended lubricant Engine oil New a Top ring b Upper oil ring rail c Oil ring expande...

Page 245: ...n page 4 1 Oil tank Shift rod Refer to ENGINE REMOVAL on page 5 1 1 Crankshaft position sensor coupler 1 Disconnect 2 Shift arm 1 3 Oil tank bracket 1 4 Clutch cover 1 5 Clutch cover gasket 1 6 Dowel pin 2 For installation reverse the removal procedure T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 10 5 2 3 6 4 5 6 1 New Manuals by Motomatrix www motomatrix co uk Email info motomatrix c...

Page 246: ...rks 1 Oil seal 1 2 Bearing 1 3 Crankshaft position sensor lead holder 3 4 Crankshaft position sensor 1 For installation reverse the removal procedure 2 1 3 3 3 4 LT LT LT LT LT LT LT LS T R 10 Nm 1 0 m kg 7 2 ft Ib New Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 247: ...sher 1 9 Wire circlip 1 10 Clutch plate 1 11 Friction plate 2 1 12 Clutch damper spring 1 13 Clutch damper spring seat 1 14 Clutch boss 1 15 Thrust washer 1 1 16 Bearing 1 17 Clutch housing 1 LS LS New New New E T R 100 Nm 10 0 m kg 72 ft lb LT New T R 125 Nm 12 5 m kg 90 ft lb E E 7 6 18 19 20 24 25 23 22 21 17 16 15 14 13 12 11 10 9 8 1 2 3 4 5 26 27 28 29 6 T R 8 Nm 0 8 m kg 5 8 ft Ib Manuals b...

Page 248: ... drive gear 1 29 Straight key 1 For installation reverse the removal procedure Removing the clutch Order Job Parts to remove Q ty Remarks LS LS New New New E T R 100 Nm 10 0 m kg 72 ft lb LT New T R 125 Nm 12 5 m kg 90 ft lb E E 7 6 18 19 20 24 25 23 22 21 17 16 15 14 13 12 11 10 9 8 1 2 3 4 5 26 27 28 29 6 T R 8 Nm 0 8 m kg 5 8 ft Ib Manuals by Motomatrix www motomatrix co uk Email info motomatri...

Page 249: ...servoir diaphragm 1 5 Clutch fluid reservoir 1 6 Clutch fluid reservoir hose 1 7 Left rearview mirror 1 8 Clutch fluid reservoir bracket 1 9 Clutch lever 1 10 Bushing 1 11 Clutch switch coupler 1 Disconnect 12 Clutch switch 1 13 Clutch hose union bolt 1 14 Copper washer 2 15 Clutch hose 1 T R 13 Nm 1 3 m kg 9 4 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib LS LS New 7 8 1 2 3 4 5 6...

Page 250: ...he removal procedure Removing the clutch master cylinder Order Job Parts to remove Q ty Remarks T R 13 Nm 1 3 m kg 9 4 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib LS LS New 7 8 1 2 3 4 5 6 9 10 11 12 17 15 16 13 14 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 251: ...er cylinder push rod 1 2 Clutch master cylinder kit 1 3 Dust seal 1 4 Circlip 1 5 Clutch fluid reservoir hose joint 1 6 O ring 1 7 Clutch master cylinder body 1 For assembly reverse the disassembly procedure New New LS New 3 4 5 6 7 2 1 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 252: ... SYSTEM on page 3 14 1 Clutch pipe union bolt cap 1 2 Clutch pipe union bolt 1 3 Copper washer 2 4 Clutch pipe 1 5 Clutch release cylinder 1 6 Dowel pin 2 For installation reverse the removal procedure T R 10 Nm 1 0 m kg 7 2 ft Ib T R 26 Nm 2 6 m kg 19 ft Ib New 3 6 2 6 5 4 1 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 253: ...oots 1 2 Clutch release cylinder piston 1 3 Clutch release cylinder spring 1 4 Clutch release cylinder piston seal 1 5 Bleed screw 1 For assembly reverse the disassembly procedure LS LS 1 2 4 3 5 New T R 6 Nm 0 6 m kg 4 3 ft Ib Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 254: ...ear bolt 1 NOTE While holding the generator rotor 2 with the sheave holder 3 loosen the primary drive gear bolt EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replace the friction plates as a set NOTE Measure the frict...

Page 255: ...ing 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 operation EAS...

Page 256: ...xcessive noise during operation Replace the primary drive and primary driven gears as a set EAS24540 INSTALLING THE CRANKSHAFT POSITION SENSOR 1 Apply Sealant onto the crankshaft position sensor lead grommet EAS25230 INSTALLING THE PRIMARY DRIVE GEAR 1 Install Straight key 1 Primary drive gear 2 Crankshaft position sensor rotor 3 Spacer 4 Primary drive gear bolt 5 CAUTION EC5YU1014 The timing mark...

Page 257: ...rfaces with engine oil Install the washer 2 with the OUT mark a facing out While holding the clutch boss with the univer sal clutch holder 4 tighten the clutch boss nut Stake the clutch boss nut 3 at a cutout b in the main axle 4 Lubricate Friction plates Clutch plates with the recommended lubricant 5 Install Friction plates Clutch plates NOTE First install a friction plate and then alternate betw...

Page 258: ... internal clutch com ponents Use only clean or new clutch fluid for clean ing clutch components Clutch fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt fluid immediately Avoid clutch fluid coming into contact with the eyes as it can cause serious injury First aid for clutch fluid entering the eyes Flush with water for 15 minutes and get im mediate medical att...

Page 259: ... sembled replace the piston seals EAS25310 INSTALLING THE CLUTCH MASTER CYLINDER 1 Install Clutch master cylinder 1 Clutch master cylinder holder 2 NOTE Align the end of the clutch master cylinder holder with the punch mark a on the handle bar First tighten the upper bolt then the lower bolt 2 Install Copper washers 1 Clutch hose 2 Clutch hose union bolt 3 CAUTION EC5YU1006 When installing the clu...

Page 260: ...id level make sure the top of the reservoir is horizontal 4 Bleed Clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 14 5 Check Clutch fluid level Below the minimum level mark a Add the recommended clutch fluid to the proper level Refer to CHECKING THE CLUTCH FLUID LEVEL on page 3 14 6 Check Clutch lever operation Soft or spongy feeling Bleed the clutch system Refer to BLEEDING ...

Page 261: ...ecom mended clutch fluid WARNING EWA13370 Use only the designated clutch fluid Other clutch fluids may cause the rubber seals to deteriorate causing leakage and poor clutch performance Refill with the same type of clutch fluid that is already in the system Mixing clutch flu ids may result in a harmful chemical reac tion leading to poor clutch performance When refilling be careful that water does n...

Page 262: ...3 5 Check Clutch lever operation Soft or spongy feeling Bleed the clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 14 a Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 263: ... on page 5 46 1 Shift shaft 1 2 Circlip 2 3 Shift shaft spring 1 4 Shift shaft spring stopper 1 5 Washer 1 6 Stopper lever 1 7 Stopper lever spring 1 For installation reverse the removal procedure LS LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 22 Nm 2 2 m kg 16 ft Ib 1 3 2 7 6 5 4 New Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 264: ...lever bolt 2 Stopper lever spring 3 NOTE Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss 4 Install the stopper lever spring as shown in the illustration Mesh the stopper lever with the shift drum seg ment assembly 2 Install Shift shaft spring 1 Circlips Shift shaft 2 NOTE Lubricate the oil seal lips with lithium soap based grease Hook the end of the shift sh...

Page 265: ...er regulator 1 3 Oil pipe 2 1 From oil pump to generator cover 4 Generator cover 1 5 Generator cover gasket 1 6 Dowel pin 2 7 Stator coil assembly lead holder 1 8 Stator coil assembly 1 For installation reverse the removal procedure LT 9 LT LT T R 7 Nm 0 7 m kg 5 1 ft Ib 8 5 4 6 3 7 2 1 6 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 10 Nm 1 0 m kg 7 2 ...

Page 266: ...aft 2 1 2 Starter clutch idle gear shaft 1 1 3 Starter clutch idle gear 2 1 4 Starter clutch idle gear 1 1 5 Generator rotor 1 6 Woodruff key 1 7 Starter clutch gear 1 For installation reverse the removal procedure E R 80 Nm 8 0 m kg 58 ft Ib T 2 4 3 1 5 7 6 E E Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 267: ... starter clutch gear clock wise A the starter clutch and the starter clutch gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter clutch gear counter clockwise B it should turn freely otherwise the starter clutch is faulty and must be re placed EAS24510 INSTALLING THE GENERATOR 1 Install Woodruff key Generator rotor 1 Washer Generator rotor bolt ...

Page 268: ... the generator rotor 2 with a sheave holder 3 3 Apply Sealant onto the stator coil assembly lead grommet T R Generator rotor bolt 80 Nm 8 0 m kg 58 ft lb Sheave holder 90890 01701 Primary clutch holder YS 01880 A Yamaha bond No 1215 90890 85505 2 3 1 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 269: ...otor Order Job Parts to remove Q ty Remarks Oil tank Refer to ENGINE REMOVAL on page 5 1 1 Starter motor lead 1 Disconnect 2 Starter motor assembly 1 For installation reverse the removal procedure 2 1 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 270: ...irclip 1 7 Starter motor front cover 1 8 Brush 2 9 Brush holder along with the brushes 1 10 Brush seat along with the brushes 1 11 Bearing 1 12 Gasket 2 13 Armature assembly 1 14 Starter motor yoke 1 For assembly reverse the disassembly procedure 8 4 5 7 3 2 1 6 LS New New New New New New 12 11 12 10 9 14 13 New LS Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 271: ...cification Replace the 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 27 5 mm 1 08 in Mica undercut depth 1 50 mm 0 06 in Pocket ...

Page 272: ...the tab b in the starter motor front cover 2 Install Starter motor yoke 1 NOTE Align the tab a on the brush holder with the slot b in the starter motor yoke 3 Install Starter motor yoke 1 Starter motor front cover 2 Starter motor rear cover 3 NOTE Align the match mark a on the starter motor yoke with the match mark b on the starter mo tor rear cover b a 1 1 b a 3 1 2 a b Manuals by Motomatrix www ...

Page 273: ... PISTONS on page 5 41 Shift shaft Refer to SHIFT SHAFT on page 5 64 Generator rotor Refer to GENERATOR AND STARTER CLUTCH on page 5 66 1 Speed sensor 1 2 Oil filter cartridge bracket 1 3 Generator shaft end cover 1 4 Oil delivery pipe 2 1 5 Oil pump driven gear stopper 1 6 Oil pump driven gear 1 7 Left crankcase 1 8 Dowel pin 2 9 Joint pipe 1 Manuals by Motomatrix www motomatrix co uk Email info m...

Page 274: ...E 5 75 10 Right crankcase 1 For installation reverse the removal procedure Separating the crankcase Order Job Parts to remove Q ty Remarks Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 275: ...IL PUMP on page 5 81 Crankshaft Refer to CRANKSHAFT on page 5 86 Transmission Refer to TRANSMISSION on page 5 92 1 Oil baffle plate 1 2 Bearing retainer 1 3 Bearing retainer 1 4 Oil seal 1 5 Bearing 4 For installation reverse the removal procedure Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 276: ...The numbers embossed on the crankcase in dicate the crankcase tightening sequence M8 100 mm bolts 1 2 M8 80 mm bolt 3 M6 105 mm bolt 21 M6 85 mm bolt 9 13 M6 75 mm bolts 14 15 M6 60 mm bolts 4 7 M6 40 mm bolts 8 10 12 16 20 3 Turn Shift drum segment NOTE Turn the shift drum segment 1 to the position shown in the illustration In this position the shift drum segment s teeth will not contact the cran...

Page 277: ...ce Obstruction Wash and blow out with com pressed air EAS25610 CHECKING THE OIL PUMP DRIVE 1 Check Oil pump drive gear Oil pump driven gear Chips pitting roughness wear Replace the defective part s ET5YU1023 INSTALLING THE BEARING RETAINER 1 Install Bearing retainer 1 NOTE Install the bearing retainer 1 with its OUT mark a facing outward Apply locking agent LOCTITE to the threads of the bearing re...

Page 278: ...m bolts 4 7 M6 40 mm bolts 8 10 12 16 20 5 Apply Engine oil onto the crankshaft pins bearings and oil de livery holes 6 Check Crankshaft and transmission operation Rough movement Repair 7 Install Generator shaft bolt 1 NOTE While the holding the generator rotor 2 with the primary sheave holder 3 tighten the generator shaft bolt T R Crankcase bolt M8 24 Nm 2 4 m kg 17 ft lb Crankcase bolt M6 10 Nm ...

Page 279: ...CRANKCASE 5 80 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 280: ...Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 74 1 Oil strainer crankcase 1 2 Oil pump assembly 1 For installation reverse the removal procedure Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 281: ...1 4 Oil pump housing cover 1 1 5 Pin 2 6 Spring 1 7 Collar 1 8 Ball 1 9 Oil pump outer rotor 1 1 10 Oil pump inner rotor 1 1 11 Pin 1 12 Oil pump housing cover 2 1 13 Pin 2 14 Oil pump shaft 1 15 Pin 1 16 Oil pump inner rotor 2 1 17 Oil pump outer rotor 2 1 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 282: ... Oil seal 2 19 Oil pump housing 1 For assembly reverse the disassembly procedure Disassembling the oil pump Order Job Parts to remove Q ty Remarks Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 283: ...ar Replace the defective part s EAS24990 CHECKING THE OIL STRAINER 1 Check Oil strainer crankcase Damage Replace Contaminants Clean with solvent EAS25000 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor Oil pump shaft with the recommended lubricant 2 Install Oil pump housing 1 Oil seal 2 Oil pump outer rotor 2 3 Oil pump inner rotor 2 4 Pin 5 Inner rotor to outer rotor tip clearance 0 1...

Page 284: ...groove in the inner ro tor 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 84 EAS25020 INSTALLING THE OIL PUMP 1 Install Oil pump 1 CAUTION ECA13890 After tightening the bolts make sure the oil pump turns smoothly T R Oil pump housing cover 2 screw 2 Nm 0 2 m kg 1 4 ft lb T R Oil pump housing cover 1 screw 2 Nm 0 2 m kg 1 4 ft lb T R Spring retainer bolt 10 Nm 1 0 m kg 7 2 ft l...

Page 285: ...s Crankcase Separate Refer to CRANKCASE on page 5 74 1 Crankshaft 1 2 Generator shaft 1 3 Connecting rod cap 2 4 Big end lower bearing 2 5 Connecting rod 2 6 Big end upper bearing 2 For installation reverse the removal procedure Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 286: ...of specification Replace the big end bearings The following procedure applies to all of the connecting rods CAUTION ECA13930 Do not interchange the big end bearings and connecting rods To obtain the correct crankshaft pin to big end bearing clear ance and prevent engine damage the big end bearings must be installed in their origi nal positions a Clean the big end bearings crankshaft pins and the i...

Page 287: ... bolts to the spec ified torque g Put a mark 1 on the connecting rod bolts 2 and the connecting rod cap 3 h Tighten the connecting rod bolts further to reach the specified angle 120 150 WARNING EWA12900 When the bolts are tightened more than the specified angle do not loosen the bolt and then retighten it Replace the bolt with a new one and perform the procedure again CAUTION EC5YU1008 Do not use ...

Page 288: ...ter a Out of specification Replace the crank shaft NOTE Measure the diameter of each crankshaft journal at two places 6 Measure Crankshaft journal bearing inside diameter a Out of specification Replace the crank case assembly NOTE Measure the inside diameter of each crankshaft journal bearing at two places P1 P2 a P1 connecting rod P crankshaft 5 2 3 brown Bearing color code 1 Blue 2 Black 3 Brown...

Page 289: ... end bear ings with the notches b in the connecting rods and connecting rod caps Be sure to reinstall each big end bearing in its original place Make sure the projections c on the connect ing rods face towards the left side of the crank shaft Make sure the characters d on both the con necting rod and connecting rod cap are aligned 4 Tighten Connecting rod bolts 1 WARNING EWA12890 Replace the conne...

Page 290: ...o the specified angle Tighten the bolt until it is the specified an gle EAS26210 INSTALLING THE CRANKSHAFT ASSEMBLY 1 Install Crankshaft assembly CAUTION ECA13970 To avoid scratching the crankshaft and to ease the installation procedure lubricate the oil seal lips with lithium soap based grease and each bearing with engine oil NOTE Make sure that the generator shaft drive gear teeth and generator ...

Page 291: ...Remarks Crankcase Separate Refer to CRANKCASE on page 5 74 1 Shift fork guide bar 2 2 Shift drum assembly 1 3 Shift fork L 1 4 Shift fork R 1 5 Shift fork C 1 6 Drive axle assembly 1 7 Main axle assembly 1 8 Spacer 1 For installation reverse the removal procedure Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 292: ...s 1 Circlip 1 2 Washer 1 3 5th pinion gear 1 4 Collar 1 5 Washer 1 6 2nd 3rd pinion gear 1 7 Circlip 1 8 Washer 1 9 4th pinion gear 1 10 Collar 1 11 Main axle 1st pinion gear 1 For assembly reverse the disassembly procedure Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 293: ...lip 1 3 Washer 1 4 2nd wheel gear 1 5 Collar 1 6 Circlip 1 7 Washer 1 8 1st wheel gear 1 9 Collar 1 10 Washer 1 11 4th wheel gear 1 12 Circlip 1 13 Washer 1 14 3rd wheel gear 1 15 Collar 1 16 Drive axle 1 For assembly reverse the disassembly procedure Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 294: ...IFT 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 TRANSMISSION 1 Measure Main axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle 2 Measure Drive axle ...

Page 295: ... circlip sharp edged corner a is positioned opposite side to the toothed washer and gear Install the circlip so that both ends b rest on the sides of a spline c with both axles aligned EAS26320 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 1 Install Shift fork R 1 Shift fork C 2 Shift fork L 3 Shift drum assembly 4 Shift fork guide bars 5 NOTE The embossed marks on the shift forks should face...

Page 296: ...FUEL 6 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 297: ...TLE BODIES 6 4 CHECKING THE INJECTORS 6 9 CHECKING THE THROTTLE BODIES 6 9 CHECKING THE ROLLOVER VALVES 6 9 CHECKING THE PRESSURE REGULATOR 6 9 CHECKING THE PRESSURE REGULATOR OPERATION 6 9 ADJUSTING THE THROTTLE POSITION SENSOR 6 10 INSTALLING THE FUEL PIPE 6 10 ISC IDLE SPEED CONTROL UNIT 6 11 CHECKING THE ISC IDLE SPEED CONTROL SYSTEM 6 13 Manuals by Motomatrix www motomatrix co uk Email info m...

Page 298: ...Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 299: ...nect 3 Fuel sender coupler 1 Disconnect 4 Fuel tank overflow hose 1 Disconnect 5 Fuel tank breather hose 1 Disconnect 6 Fuel hose 1 Disconnect 7 Fuel return hose 1 Disconnect 8 Fuel tank 1 9 Fuel pump 1 For installation reverse the removal procedure 7 4 3 2 5 6 9 8 1 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib 6 New Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk...

Page 300: ...THE FUEL PUMP 1 Remove Fuel pump CAUTION ECA14720 Do not drop the fuel pump or give 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 2 Check Diaphragms and gaskets Tears fatigue cracks Replace fuel pump assembly EAS26690 CHECKING THE FUEL PUMP OPERATION 1 Check ...

Page 301: ...e is in the correct posi tion otherwise the fuel hose will not be prop erly installed NOTE Install the fuel hose securely onto the fuel pump until a distinct click is heard To install the fuel hose onto the fuel pump slide the fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown 1 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 302: ... 3 Pressure regulator 1 4 Fuel return hose 1 5 Fuel pipe holder 2 6 Fuel return hose fuel return pipe to fuel pump 1 7 Fuel return pipe 1 8 Fuel tank breather hose 1 9 Fuel tank overflow hose 1 10 Fuel tank breather overflow hose holder 1 11 Fuel tank breather overflow hose 1 12 Rollover valve hose 4 13 Rollover valve 1 1 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 9 Nm 0 9 m kg 6 ...

Page 303: ...al procedure Removing the pressure regulator and rollover valves Order Job Parts to remove Q ty Remarks 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 9 Nm 0 9 m kg 6 5 ft Ib 6 7 5 5 10 8 9 13 15 14 12 12 12 12 11 2 4 3 1 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 304: ...ir pressure sensor hose 1 Disconnect 4 Intake solenoid vacuum hose one way valve to throttle body 1 Disconnect 5 Throttle cable 2 Disconnect 6 Throttle body joint clamp screw 2 Loosen 7 Throttle body 1 CAUTION EC5YU1030 The throttle body should not be disassembled 8 Throttle position sensor 1 For installation reverse the removal procedure LS 5 7 8 6 6 3 1 4 2 T R 4 Nm 0 4 m kg 2 9 ft Ib T R 4 Nm 0...

Page 305: ...peed control unit outlet hose 1 4 Cylinder 1 ISC idle speed control unit outlet hose 1 5 Intake manifold assembly 1 6 Cylinder 2 injector coupler 1 Disconnect 7 Cylinder 1 injector coupler 1 Disconnect 8 Gasket 2 For installation reverse the removal procedure 3 4 6 7 8 5 8 1 2 T R 10 Nm 1 0 m kg 7 2 ft Ib New New 2 2 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 306: ...oint 1 1 3 Injector joint 2 1 4 Injector 2 5 Intake manifold 2 For installation reverse the removal procedure 2 4 3 4 1 T R 30 Nm 3 0 m kg 22 ft Ib New New New New New New New New 5 5 T R 5 Nm 0 5 m kg 3 6 ft Ib T R 5 Nm 0 5 m kg 3 6 ft Ib Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 307: ...tion when checking the airflow EAS27000 CHECKING THE PRESSURE REGULATOR 1 Check Pressure regulator Damage Replace EAS27010 CHECKING THE PRESSURE REGULATOR OPERATION 1 Check Pressure regulator operation a Remove the pressure regulator cover Refer to THROTTLE BODIES on page 6 4 b Disconnect the fuel hose 1 from the pres sure regulator 2 c Connect the fuel pressure adapter 3 be tween the fuel hose 1 ...

Page 308: ...c Measure the throttle position sensor voltage d Adjust the throttle position sensor angle so that the voltage is within the specified range e After adjusting the throttle position sensor an gle tighten the throttle position sensor screws 3 ET5YU1016 INSTALLING THE FUEL PIPE 1 Install Fuel pipe 1 NOTE Install the fuel pipe 1 so that it contacts the pro jections a on the injector joints Increase th...

Page 309: ...4 Intake solenoid vacuum hose one way valve to throttle body 1 Disconnect 5 One way valve 1 6 Intake solenoid vacuum hose intake solenoid to one way valve 1 7 Intake solenoid vacuum hose air filter case valve to intake solenoid 1 8 Intake solenoid coupler 1 Disconnect 9 Intake solenoid 1 10 Intake solenoid holder 1 11 Intake solenoid bracket 1 13 12 14 16 15 9 10 2 1 3 11 6 5 4 8 7 T R 7 Nm 0 7 m ...

Page 310: ... 15 ISC idle speed control unit inlet hose 1 16 ISC idle speed control unit 1 For installation reverse the removal procedure Removing the ISC idle speed control unit and intake solenoid Order Job Parts to remove Q ty Remarks 13 12 14 16 15 9 10 2 1 3 11 6 5 4 8 7 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 9 Nm 0 9 m kg 6 5 ft Ib Manuals by Motomatrix www motomatrix co uk Email in...

Page 311: ...roperly Cracks damage Replace 2 Check Surge tank Cracks damage Replace 3 Check One way valve Cracks damage faulty Replace NOTE Check that air flows smoothly only in the direc tion of the arrow shown in the illustration 4 Check Intake solenoid Damage Replace Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 312: ...Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 313: ...ELEC 7 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 314: ... INJECTION SYSTEM 7 25 CIRCUIT DIAGRAM 7 25 ECU SELF DIAGNOSTIC FUNCTION 7 27 SELF DIAGNOSTIC FUNCTION TABLE 7 28 TROUBLESHOOTING METHOD 7 31 DIAGNOSTIC MODE 7 31 TROUBLESHOOTING DETAILS 7 39 FUEL PUMP SYSTEM 7 67 CIRCUIT DIAGRAM 7 67 TROUBLESHOOTING 7 69 MUFFLER COOLING SYSTEM 7 71 CIRCUIT DIAGRAM 7 71 TROUBLESHOOTING 7 73 IMMOBILIZER SYSTEM 7 75 CIRCUIT DIAGRAM 7 75 GENERAL INFORMATION 7 77 PART...

Page 315: ...100 CHECKING THE STATOR COIL 7 101 CHECKING THE RECTIFIER REGULATOR 7 101 CHECKING THE HORN 7 102 CHECKING THE ENGINE TEMPERATURE SENSOR 7 102 CHECKING THE FUEL SENDER 7 103 CHECKING THE SPEED SENSOR 7 103 CHECKING THE THROTTLE POSITION SENSOR 7 104 CHECKING THE FUEL PUMP 7 104 CHECKING THE EXUP SERVO MOTOR 7 105 CHECKING THE DECOMPRESSION SOLENOID 7 105 CHECKING THE INTAKE AIR PRESSURE SENSORS 7 ...

Page 316: ...G L R L R B B GRAY GRAY BLACK BLACK Dg B B L Ch B B Ch B B Ch B Dg Dg BLACK BLACK B B Dg Dg G G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y BLACK B L L Y BLACK L B Sb B Sb Sb R L BLACK BLACK B R B B B R R Br L Br L Br R Br R R R B R B R L L R W B G Y Y G R W R W Y Br Y Br W L Br B L L Y L W Gy R B R Gy W B R B R W R B G B R B L L Lg Dg Ch L B G Y L R G R L B L R W Gy G Gy W Sb Dg Ch Y B ...

Page 317: ...rankshaft position sensor 24 Lean angle cut off switch 29 ECU electronic control unit 32 Spark plug 33 Cylinder 2 right ignition coil 34 Cylinder 2 left ignition coil 35 Cylinder 1 left ignition coil 36 Cylinder 1 right ignition coil 56 Clutch switch 73 Engine stop switch 81 Ignition fuse Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 318: ...als Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 8 Re gap or replace the spark plug s 4 Check the ignition spark gap Refer to CHECKING THE IGNITION SPARK GAP on page 7 100 Ignition system is OK 5 Check the spark plug caps Refer to CHECKING THE SPARK PLUG CAPS on page 7 99 Replace the spark plug cap s 6 Check the ignition coils Refer to CHECKIN...

Page 319: ... switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 7 89 Replace the clutch switch 13 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RELAYS on page 7 96 Replace the relay unit 14 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 7 98 Replace the relay unit 15 Check the lean angle cut off switch Refer to CHECKING THE LEAN ANGL...

Page 320: ...NESS WIRE HARNESS SUB WIRE HARNESS1 SUB WIRE HARNESS2 SUB WIRE HARNESS2 SUB WIRE HARNESS3 W G B Gy B Gy W G BLACK BLACK B Ch B B Dg Ch B B Dg C L L Y Y Br Br D Y Br B B B L L B G Y Br W R B L BB3 BB2 BB1 BB4 B B B B Y Y G G L R L R B B GRAY GRAY BLACK BLACK Dg B B L Ch B B Ch B B Ch B Dg Dg BLACK BLACK B B B Dg Dg G G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y BLACK Y BLACK L B Sb B Sb ...

Page 321: ...3 Relay unit 14 Starting circuit cut off relay 16 Neutral switch 19 Sidestand switch 29 ECU electronic control unit 38 Decompression solenoid 56 Clutch switch 70 Auto decompression fuse 73 Engine stop switch 74 Start switch 81 Ignition fuse Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 322: ...itch circuit is closed and the sidestand is up the sidestand switch circuit is closed The starting circuit cut off relay prevents the starter motor from operating when neither of 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 r...

Page 323: ...itch 4 Ignition fuse 5 Engine stop switch 6 Relay unit starting circuit cut off relay 7 Relay unit diode 8 Clutch switch 9 Sidestand switch 10 Neutral switch 11 Start switch 12 Starter relay 13 Starter motor 14 ECU fuse 15 Auto decompression fuse 16 Decompression solenoid 17 ECU electronic control unit Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 324: ...erminals Recharge or replace the battery 3 Check the starter motor Refer to CHECKING THE STARTER MOTOR on page 5 72 Repair or replace the starter motor 4 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RELAYS on page 7 96 Replace the relay unit 5 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 7 98 Replace the relay unit 6 Check the starter relay...

Page 325: ...switch 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 7 89 Replace the clutch switch 12 Check the start switch Refer to CHECKING THE SWITCHES on page 7 89 Replace the right handlebar switch 13 Check the decompression solenoid Refer to CHECKING THE DECOMPRESSION SOLENOID on page 7 105 Replace the decompression solenoid 14 Check the entire starting system wiring Refer to CIRCUIT D...

Page 326: ...Y G B L Y G L Y Y D B B B L L D Br Br Br B D R R Br Br L Br R Br G R Gy R R R R R R B Br W B B R R R B B R W R W R L L B BB3 BB2 BB1 BB4 B B B B B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y Y BLACK L B Sb B Sb R L L R L Y B R L W1 Sb W Sb R L BLACK BLACK B R B B B R R Br L Br L Br R Br R R R L B B B B Y Br R Br L B2 B L Gy1 B R G R G Y L R W Lg B2 Sb W R L L W1 L Y L G Sb L R B R B Y L R B B2 Lg R W Y L ...

Page 327: ...CHARGING SYSTEM 7 12 1 AC magneto 2 Rectifier regulator 4 Battery 8 Main fuse Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 328: ...on page 7 94 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 7 101 Replace the stator assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTIFIER REGULATOR on page 7 101 Replace the rectifier regulator 5 Check the entire charging system wiring Refer to CIRCUIT DIAGRAM on page 7 11 Properly connect or repair ...

Page 329: ...CHARGING SYSTEM 7 14 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 330: ...RE HARNESS2 SUB WIRE HARNESS3 W G B Gy B Gy W G BLACK BLACK B Ch B B Dg Ch B B Dg C L L Y Y Br Br D Y Br B B B L L B G Y Br W R B L BB3 BB2 BB1 BB4 B B B B Y Y G G L R L R B B GRAY GRAY BLACK BLACK Dg B B L Ch B B Ch B B Ch B Dg Dg BLACK BLACK B B B Dg Dg G G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y Y BLACK L B Sb B Sb R L L R L Y B R L W1 Sb W Sb R L BLACK BLACK B R B B B R R Br L Br...

Page 331: ...tor light 50 Meter light 54 Headlight relay 57 Pass switch 58 Dimmer switch 67 Auxiliary light 68 Headlight high beam 69 Headlight low beam 75 Tail brake light 76 License plate light 80 Headlight fuse 82 Signaling system fuse 83 Parking lighting fuse Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 332: ... headlight signaling system parking lighting and ECU Refer to CHECKING THE FUSES on page 7 93 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 94 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 7 89 Replace the main switch immobilizer unit 5 Check the dimmer switch Refer to CHECKIN...

Page 333: ...OK 8 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 7 15 Properly connect or repair the lighting system wiring This circuit is OK Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 334: ...IRE HARNESS2 SUB WIRE HARNESS3 W G B Gy B Gy W G BLACK BLACK B Ch B B Dg Ch B B Dg C L L Y Y Br Br D Y Br B B B L L B G Y Br W R B L BB3 BB2 BB1 BB4 B B B B Y Y G G L R L R B B GRAY GRAY BLACK BLACK Dg B B L Ch B B Ch B B Ch B Dg Dg BLACK BLACK B B B Dg Dg G G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y Y BLACK L B Sb B Sb R L L R L Y B R L W1 Sb W Sb R L BLACK BLACK B R B B B R R Br L B...

Page 335: ...arning light 48 Left turn signal indicator light 49 Right turn signal indicator light 52 Horn 53 Turn signal hazard relay 59 Hazard switch 60 Turn signal switch 61 Horn switch 62 Front left turn signal light 63 Front right turn signal light 64 Rear right turn signal light 65 Rear left turn signal light 72 Front brake light switch 75 Tail brake light 77 Rear brake light switch 81 Ignition fuse 82 S...

Page 336: ... Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 94 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 89 Replace the main switch immobilizer unit 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 19 Properly connect or repair the signaling system wiring Check the condition ...

Page 337: ...r brake light switch 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 19 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the turn signal light bulbs and sockets Refer to CHECKING THE BULBS AND BULB SOCKETS on page 7 92 Replace the turn signal light bulb socket or both 2 Check the turn signal switch Refer to CHECKING THE SWITCHES on pag...

Page 338: ... CIRCUIT DIAGRAM on page 7 19 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 7 103 Replace the fuel pump assembly 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 19 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the speed sensor Refer to CHEC...

Page 339: ...SIGNALING SYSTEM 7 24 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 340: ...SUB WIRE HARNESS2 SUB WIRE HARNESS3 W G B Gy B Gy W G BLACK BLACK B Ch B B Dg Ch B B Dg C L L Y Y Br Br D Y Br B B B L L B G Y Br W R B L BB3 BB2 BB1 BB4 B B B B Y Y G G L R L R B B GRAY GRAY BLACK BLACK Dg B B L Ch B B Ch B B Ch B Dg Dg BLACK BLACK B B B Dg Dg G G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y Y BLACK L B Sb B Sb R L L R L Y B R L W1 Sb W Sb R L BLACK BLACK B R B B B R R B...

Page 341: ... temperature sensor 27 Air temperature sensor 28 Engine temperature sensor 29 ECU electronic control unit 30 ISC idle speed control unit 31 Intake solenoid 32 Spark plug 33 Cylinder 2 right ignition coil 34 Cylinder 2 left ignition coil 35 Cylinder 1 left ignition coil 36 Cylinder 1 right ignition coil 37 EXUP servo motor 38 Decompression solenoid 39 Injector 1 40 Injector 2 44 Multi function mete...

Page 342: ...been displayed it remains stored in the memory of 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 bulb The engine trouble warning light comes on for 1 4 seconds after the main switch has bee...

Page 343: ...able to drive 12 Crankshaft position sensor No normal signals are received from the crankshaft position sensor Unable Unable 13 Cylinder 1 intake air pressure sensor open or short circuit Cylinder 1 intake air pressure sensor open or short circuit detected Able Able 14 Cylinder 1 intake air pressure sensor hose line Cylinder 1 intake air pressure sensor hose system malfunction clogged or detached ...

Page 344: ...faulty cylin ders 34 Cylinder 2 left ignition coil faulty ignition Malfunction detected in the primary wire of the cylinder 2 left ignition coil Able depending on the number of faulty cylin ders Able depending on the number of faulty cylin ders 35 Cylinder 1 left or right ignition coil faulty ignition Malfunction detected in the primary wire of the cylinder 1 left or right ignition coil Able depen...

Page 345: ...ing fan temperature sensor open or short circuit Muffler cooling fan temperature sensor open or short circuit detected Able Able 63 Muffler cooling fan temperature sensor ambient temperature abnormally high Engine trouble warning light is flashing Abnormally high temperature is detected by muffler cooling fan temperature sensor Able Able Fault code No Item Symptom Able un able to start Able un abl...

Page 346: ...on 1 Check the operation of following sensors and actuators in the Diagnostic mode Refer to Sensor operation table and Actuator oper ation table If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in the sensors and actuators check and repair inner parts of the engine EAS27420 DIAGNOSTIC MODE Setting the diagnostic mode 1 Turn t...

Page 347: ...CT button for 1 second or longer to automatically increase the diagnostic code numbers 8 Verify the operation of the sensor or actuator Sensor operation The data representing the operating conditions of the sensor appears on the odometer trip meter fu el reserve trip meter LCD Actuator operation Set the engine stop switch to to operate the actuator NOTE If the engine stop switch is set to set it t...

Page 348: ...tion in ECU Improperly installed air temperature sensor 05 24 No normal signal is received from the O2 sensor Open or short circuit in wire harness Defective O2 sensor Malfunction in ECU Improperly installed sensor 25 Cylinder 2 intake air pressure sensor open or short circuit detected Open or short circuit in wire harness Defective cylinder 2 intake air pressure sensor Malfunction in ECU 04 26 Cy...

Page 349: ... in the primary wire of the cylinder 2 right ignition coil Open or short circuit in wire harness Malfunction in cylinder 2 right ignition coil Malfunction in ECU Malfunction in a component of ignition cut off circuit system 33 37 Engine speed is high when the engine is idling Open circuit in wire harness Malfunction in throttle body Malfunction in throttle cables ISC valve is stuck fully open due ...

Page 350: ...ng fan temperature sensor open or short circuit detected Open or short circuit in wire harness Defective muffler cooling fan temperature sensor Malfunction in ECU Improperly installed sensor 12 63 Engine trouble warning light is flashing Abnormally high temperature is detected by muffler cooling fan temperature sensor Muffler cover fan fuse or ECU fuse is blown Defective muffler cooling fan temper...

Page 351: ...linder 2 intake air pressure Set the engine stop switch to then operate the throttle while pushing the start switch If the display value changes the performance is OK 05 Air temperature Displays the air temperature Compare the actually measured air temperature with the meter display value 07 Vehicle speed pulse 0 999 Check that the number increases when the rear wheel is rotated The number is cumu...

Page 352: ...ning light comes on twice once when the EXUP valve is closing and once when it is opening 60 EEPROM fault code display No history 00 History exists 01 or 02 Cylinder fault code If both cylinders are defective the display alternates every two seconds 61 Malfunction history code display No history 00 History exists Fault codes 12 63 If more than one code number is detected the display alternates eve...

Page 353: ...s the cylinder 1 left or right ignition coil for five times every second Illuminates the engine trouble warning light Check the spark five times Connect an ignition checker 33 Cylinder 2 right ignition coil Actuates the cylinder 2 right ignition coil for five times every second Illuminates the engine trouble warning light Check the spark five times Connect an ignition checker 36 Injector 1 Actuate...

Page 354: ...heck the operating sound of the muffler cooling fan motor relay five times 52 Headlight relay Actuates the headlight relay for five cycles of five seconds ON 2 seconds OFF 3 seconds Illuminates the engine trouble warning light Check the operating sound of the headlight relay five times 54 ISC valve Actuates and fully closes the ISC valve then opens it to the standby opening position when the engin...

Page 355: ...shaft position sensor Check for looseness or pinching Cranking the engine 2 Connections Crankshaft position sensor coupler Main 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 securely 3 Open or short circuit in wire harness Repair or replace if there is an open or ...

Page 356: ... out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Turning the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between cylinder 1 intake air pressure sensor coupler and ECU coupler black blue black blue pink white pink white blue blue 3 Defective cylinder 1 intake air ...

Page 357: ... at idle 2 Cylinder 1 intake air pressure sensor malfunction at intermediate electrical potential Check and repair the connection Replace it if there is a malfunction 3 Connections Cylinder 1 intake air pressure sensor coupler Main 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 connec...

Page 358: ...dition of the coupler If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire harness and or sub lead Repair or replace if there is an open or short circuit Between throttle position sensor coupler and ECU coupler blue blue yellow yellow back black 4 Throttle position sensor lead wire open circuit output voltage check Check for open circuit and replace ...

Page 359: ...ING THE EXUP SERVO MOTOR on page 7 105 Fault code No 18 Symptom EXUP servo motor is stuck Diagnostic code No 53 EXUP servo motor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections EXUP servo motor coupler Main 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 malf...

Page 360: ... THE SWITCHES on page 7 89 Fault code No 22 Symptom Air temperature sensor open or short circuit detected Diagnostic code No 05 Air temperature sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of air temperature sensor Check for looseness or pinching Turning the main switch to ON 2 Connections Air temperature sensor coupler Main wi...

Page 361: ... 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 securely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between O2 sensor coupler and ECU coupler gray white gray white red blue red blue gray green gray green black blue black blue 4 Ch...

Page 362: ...out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Turning the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between cylinder 2 intake air pressure sensor coupler and ECU coupler black blue black blue pink yellow pink yellow blue blue 3 Defective cylinder 2 intake air...

Page 363: ... at idle 2 Cylinder 2 intake air pressure sensor malfunction at intermediate electrical potential Check and repair the connection Replace it if there is a malfunction 3 Connections Cylinder 2 intake air pressure sensor coupler Main 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 connec...

Page 364: ... coupler Sub wire harness 2 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 securely 3 Open or short circuit in wire harness and or sub lead Repair or replace if there is an open or short circuit Between engine temperature sensor coupler and ECU coupler brown brown black black 4 Def...

Page 365: ... thermistor Execute the diagnostic mode Code No 55 Replace if defective Refer to CHECKING THE DECOMPRESSION SOLENOID on page 7 105 Fault code No 30 Symptom The vehicle has overturned Diagnostic code No 08 Lean angle cut off switch Order Item components and probable cause Check or maintenance job Reinstatement method 1 The vehicle has overturned Raise the vehicle upright Turning the main switch to ...

Page 366: ... Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler securely Starting the engine and operating it at idle 2 Open or short circuit in wire harness and or sub lead Repair or replace if there is an open or short circuit Between cylinder 1 left or right ignition coil connector and ECU coupler main wire harness black red blue red orange ...

Page 367: ... locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler securely Starting the engine and operating it at idle 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between cylinder 2 left ignition coil connector and ECU coupler main wire harness black red blue red gray red gray red 3 Defective cylinder 2 l...

Page 368: ... Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler securely Starting the engine and operating it at idle 2 Open or short circuit in wire harness and or sub lead Repair or replace if there is an open or short circuit Between cylinder 1 left or right ignition coil connector and ECU coupler main wire harness black red blue red orange ...

Page 369: ...ocking condition of the connector and coupler If there is a malfunction repair it and connect the coupler securely Starting the engine and operating it at idle 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between cylinder 2 right ignition coil connector and ECU coupler main wire harness black red blue red gray black gray black 3 Defective cylinder ...

Page 370: ...k fully open due to disconnected ISC unit hose or coupler High engine idle speed is detected with the ISC valve stuck fully open even though signals for the valve to close are continuously being transmitted by the ECU Check that the ISC unit hose is not disconnected Check that the ISC unit coupler is not disconnected The ISC valve is stuck fully open if it does not operate when the main switch is ...

Page 371: ...ler 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 securely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between decompression solenoid coupler and ECU coupler light green light green Between decompression solenoid coupler and auto decompression fuse gray re...

Page 372: ...heck the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Turning the main switch to ON 2 Open or short circuit in lead wire Repair or replace if there is an open or short circuit Between lean angle cut off switch coupler and ECU coupler blue blue yellow green yellow green black blue black blue 3 Defective lean angle cut off switch Execute the d...

Page 373: ...s a malfunction repair it and connect the coupler securely Starting the engine and activating the vehicle speed sensor by operating the vehicle at 20 to 30 km h A 2 Open or short circuit in speed sensor lead Repair or replace if there is an open or short circuit Between speed sensor coupler and ECU coupler blue blue white yellow white yellow black blue black blue A 3 Gear for detecting vehicle spe...

Page 374: ...el pump relay coupler sky blue sky blue Between fuel pump relay coupler and ECU coupler blue yellow blue yellow B 3 Faulty shift drum neutral detection area Replace if defective Refer to TRANSMISSION on page 5 92 B 4 Defective neutral switch Execute the diagnostic mode Code No 21 Replace if defective Refer to CHECKING THE SWITCHES on page 7 89 Fault code No 42 Symptom A No normal signals are recei...

Page 375: ...red blue red red blue red blue Between fuel pump relay coupler and battery terminal red red Between fuel pump relay coupler and engine stop switch coupler black red black red 3 Malfunction or open circuit in fuel pump relay Execute the diagnostic mode Code No 09 Replace if defective If there is no malfunction with the fuel pump relay replace the ECU Fault code No 44 Symptom Error is detected while...

Page 376: ...ion in rectifier regulator Replace if defective Refer to CHARGING SYSTEM on page 7 11 4 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between battery and main switch red red Between main switch and ignition fuse brown blue brown blue Between ignition fuse and ECU red white red white Fault code No 50 Symptom Faulty ECU memory When this malfunction is d...

Page 377: ...n 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 securely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between muffler cooling fan temperature sensor coupler and ECU coupler black blue black blue brown yellow brown ...

Page 378: ...ng fan temperature sensor and its surrounding parts changed due to deformed parts near sensor Muffler cooling fan temperature sensor detected a temperature of 120 C 248 F or higher Check that the parts near the muffler cooling fan temperature sensor are not deformed and that the sensor and its surrounding parts are in their correct positions Repair or replace if necessary Fault code No Er 1 Sympto...

Page 379: ...nction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 3 Symptom Data from the ECU cannot be received correctly Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Main wire harness ECU coupler Main wire harness meter assembly coupler Check the coupler for any pins that may be pul...

Page 380: ...ler 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 securely Turning the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between meter assembly coupler and ECU coupler yellow blue yellow blue 3 Malfunction in meter assembly Replace the meter as...

Page 381: ...FUEL INJECTION SYSTEM 7 66 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 382: ... B B R W R W R L L B Y Br B B B L L B G Y Br W R B L BB3 BB2 BB1 BB4 B B B B G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y Y BLACK L B Sb B Sb R L L R L Y B R L W1 Sb W Sb R L BLACK BLACK B R B B B R R Br L Br L Br R Br R R R B R B R L L R W B G Y Y G R W W Y Y Br Y Br W L Br B L L Y L W Gy W Lg Dg Ch L G R G R L B L R W Gy G Gy W B B W L R L Gy W Gy G B L Br G Br W Br W B G B R B G B R ...

Page 383: ... 4 Battery 5 Fuel injection system fuse 8 Main fuse 10 ECU fuse 15 Fuel pump relay 17 Fuel pump 29 ECU electronic control unit 73 Engine stop switch 81 Ignition fuse Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 384: ...replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 89 Replace the main switch immobilizer unit 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 7 89 Replace the right handlebar switch 5 Check the relay unit fuel pump relay Refer to CHECKING THE RELAYS on page 7 96 Replace the relay unit 6 Check the fuel pump Refer to CHECKING THE FUEL PUMP on ...

Page 385: ...FUEL PUMP SYSTEM 7 70 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 386: ...R R R R R R B Br W B B R R R B B R W R W R L L B Y Br B B B L L B G Y Br W R B L BB3 BB2 BB1 BB4 B B B B G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y Y BLACK L B Sb B Sb R L L R L Y B R L W1 Sb W Sb R L BLACK BLACK B R B B B R R Br L Br L Br R Br R R R B R B R L L R W B G Y Y G R W W Y Y Br Y Br W L Br B L L Y L W Gy W R L Gy G B B W L R L Gy W Gy G B L Br G Br W Br W B G B R G R Y L G ...

Page 387: ...use 9 Muffler cover fan fuse 10 ECU fuse 26 Muffler cooling fan temperature sensor 29 ECU electronic control unit 78 Muffler cooling fan motor 79 Muffler cooling fan motor relay Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 388: ...r cooling fan motor Refer to CHECKING THE MUFFLER COOLING FAN MOTOR on page 7 107 Replace the muffler cooling fan motor 4 Check the muffler cooling fan motor relay Refer to CHECKING THE RELAYS on page 7 96 Replace the muffler cooling fan motor relay 5 Check the muffler cooling fan temperature sensor Refer to CHECKING THE MUFFLER COOLING FAN TEMPERATURE SENSOR on page 7 108 Replace the muffler cool...

Page 389: ...MUFFLER COOLING SYSTEM 7 74 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 390: ... WIRE HARNESS2 SUB WIRE HARNESS3 W G B Gy B Gy W G BLACK BLACK B Ch B B Dg Ch B B Dg C L L Y Y Br Br D Y Br B B B L L B G Y Br W R B L BB3 BB2 BB1 BB4 B B B B Y Y G G L R L R B B GRAY GRAY BLACK BLACK Dg B B L Ch B B Ch B B Ch B Dg Dg BLACK BLACK B B B Dg Dg G G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y Y BLACK L B Sb B Sb R L L R L Y B R L W1 Sb W Sb R L BLACK BLACK B R B B B R R Br L...

Page 391: ... ECU fuse 11 Immobilizer unit 12 Backup fuse odometer clock and immobilizer system 29 ECU electronic control unit 44 Multi function meter 46 Immobilizer system indicator light 81 Ignition fuse Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 392: ...n the standard keys is 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...

Page 393: ...zer system turn the ignition 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 I...

Page 394: ...seconds to activate the 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 registe...

Page 395: ...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 registering key g Remaining standard key h R...

Page 396: ...o CHECKING THE SWITCHES on page 7 89 Replace the main switch immobilizer unit 4 Check the entire immobilizer system wiring Refer to CIRCUIT DIAGRAM on page 7 75 Properly connect or repair the immobilizer system wiring Check the condition of the each immobilizer system circuits Refer to SELF DIAGNOSIS FAULT CODE INDICATION on page 7 81 Fault code Part Symptom Cause Action 51 IMMOBILIZER UNIT Code c...

Page 397: ...e wire harness 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 cable 1 Interference due to radio wave noise 2 Disconnected communication harness 3 Immobilizer unit malfunction 4 ECU failure The ECU or immobilizer unit was replaced with a us...

Page 398: ...IMMOBILIZER SYSTEM 7 83 Example fault code 52 a b a Light on b Light off Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 399: ...IMMOBILIZER SYSTEM 7 84 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 400: ...ELECTRICAL COMPONENTS 7 85 EAS27970 ELECTRICAL COMPONENTS 4 3 5 7 6 8 9 10 12 13 14 15 1 2 11 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 401: ...nit 5 Intake solenoid 6 Cylinder 1 right ignition coil 7 Cylinder 1 left ignition coil 8 Muffler cooling fan temperature sensor 9 Muffler cooling fan motor 10 Speed sensor 11 Rear brake light switch 12 Neutral switch 13 Decompression solenoid 14 Rectifier regulator 15 Horn Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 402: ...ELECTRICAL COMPONENTS 7 87 3 4 6 5 8 7 9 11 12 13 14 15 16 17 18 1 2 10 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 403: ...Fuse box 7 Muffler cooling fan motor relay 8 ECU electronic control unit 9 Headlight relay 10 Relay unit 11 Turn signal hazard relay 12 Fuel injection system fuse 13 Starter relay 14 Lean angle cut off switch 15 Battery 16 EXUP servo motor 17 Crankshaft position sensor 18 Engine temperature sensor Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 404: ...P G Y B Dg Ch B B BLACK R W L W R B B B Y B BLUE BROWN B B BLUE B B B B B 11 12 13 8 5 6 9 10 1 2 7 3 B B R Y Y Y L B G Dg Br W Ch Dg Br W Ch P B Y B B R W R B L W B Y R Br L Br R 4 R Br L Br R ON OFF L W B Y Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 405: ...switch 3 Start switch 4 Main switch 5 Neutral switch 6 Sidestand switch 7 Rear brake light switch 8 Hazard switch 9 Turn signal switch 10 Horn switch 11 Clutch switch 12 Pass switch 13 Dimmer switch Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 406: ...switch back and forth 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 indication by There is contin...

Page 407: ...ng procedure applies to all of the bulbs 1 Remove Bulb WARNING EW5YU1009 Since headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down CAUTION EC5YU1020 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 b...

Page 408: ...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 circuit WARNING EWA13310 Nev...

Page 409: ...alance 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 batteries The MF battery should be charged as ex plained in the charging method illustra tions If the battery is overcharged the electrolyte level will drop considerably Therefore take special care whe...

Page 410: ...nutes after charging has been completed Therefore wait 30 min utes after charging is completed before measuring the open circuit voltage Charging method using a variable current voltage 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 NOTE Set the ch...

Page 411: ...als CAUTION ECA13630 First connect the positive battery lead 1 and then the negative battery lead 2 8 Check Battery terminals Dirt Clean with a wire brush Loose connection Connect properly 9 Lubricate Battery terminals 10 Install Seat Refer to GENERAL CHASSIS on page 4 1 EAS28040 CHECKING THE RELAYS Check each switch for continuity with the pocket tester If the continuity reading is incorrect re p...

Page 412: ...1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal Sb W L G L Y Sb B Y L W R L L R R B R L 1 3 2 4 Sb W L G L Y Sb B Y L W R L L R R B R L 1 3 2 4 R Y G L R Y Y B 1 2 3 4 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Po...

Page 413: ...tive tester probe brown white 1 Negative tester probe ground Pocket tester 90890 03112 Analog pocket tester YU 03112 C 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 blue yellow 3 No continuity Positive tester probe ...

Page 414: ...il resistance Out of specification Replace a Disconnect the ignition coil connectors from the ignition coil terminals b Connect the pocket tester Ω 1 to the igni tion coil as shown c Measure the primary coil resistance 2 Check Secondary coil resistance Out of specification Replace a Disconnect the spark plug cap from the igni tion coil b Connect the pocket tester Ω 1k to the ig nition coil as show...

Page 415: ...CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace the crank shaft position sensor a Connect the pocket tester Ω 100 to the crankshaft position sensor coupler as shown b Measure the crankshaft position sensor re sistance EAS28130 CHECKING THE LEAN ANGLE CUT OFF SWITCH 1 Remove L...

Page 416: ...il coupler as shown b Measure the stator coil resistance EAS28170 CHECKING THE RECTIFIER REGULATOR 1 Check Charging voltage Out of specification Replace the rectifi er regulator Lean angle cut off switch output voltage Less than 65 0 4 1 4 V More than 65 3 7 4 4 V Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe yellow green 1 Negative tester probe black blue 2 Stato...

Page 417: ... the horn sound is obtained EAS28210 CHECKING THE ENGINE TEMPERATURE SENSOR 1 Remove Engine temperature sensor from the front cylinder head WARNING EWA14140 Handle the engine temperature sensor with special care Never subject the engine temperature sen sor to strong shocks If the engine temper ature sensor is dropped replace it 2 Check Engine temperature sensor resistance Out of specification Repl...

Page 418: ...on Replace the fuel pump assembly a Connect the pocket tester Ω 1k to the fuel sender terminal as shown b Measure the fuel sender resistance EAS28240 CHECKING THE SPEED SENSOR 1 Check Speed sensor output voltage Out of specification Replace a Connect the pocket tester DC 20 V to the speed sensor coupler wire harness side as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C T R Engine...

Page 419: ...ITION SENSOR on page 6 10 EAS28350 CHECKING THE FUEL PUMP WARNING EWA13850 Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire Be extremely careful and note the following points Stop the engine before refueling Do not smoke and keep away from open flames sparks or any other source of fire If you do accidentally spill gasoline wipe it up imm...

Page 420: ...23 To prevent damaging the EXUP servo motor perform this test within a few seconds of connecting the battery EAS28400 CHECKING THE DECOMPRESSION SOLENOID 1 Check Decompression solenoid thermistor resis tance Out of specification Replace NOTE The resistance value for the thermistor changes when the temperature changes therefore mea sure the decompression solenoid thermistor resistance at the specif...

Page 421: ...re 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 b Turn the main switch to ON c Measure the intake air pressure sensor out put voltage Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe green 1 Negative tester probe green 2 Decompression solenoid resistance 0 96 1 44 Ω at 20 C ...

Page 422: ...T5YU1008 CHECKING THE INTAKE SOLENOID 1 Check Intake solenoid resistance Out of specification Replace a Disconnect the intake solenoid coupler from the intake solenoid b Connect the pocket tester Ω 10 to the in take solenoid terminal as shown c Measure the intake solenoid resistance ET5YU1005 CHECKING THE MUFFLER COOLING FAN MOTOR 1 Check Muffler cooling fan motor Faulty rough movement Replace a D...

Page 423: ...k to the muf fler cooling fan temperature sensor terminal as shown b Immerse the muffler cooling fan temperature sensor 3 in a container filled with water 4 NOTE Make sure that the muffler cooling fan tempera ture sensor terminals do not get wet c Place a thermometer 5 in the water d Slowly heat the water then let it cool down to the specified temperature e Measure the muffler cooling fan temperat...

Page 424: ...TRBL SHTG 8 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 425: ... AND HIGH SPEED PERFORMANCE 8 2 FAULTY GEAR SHIFTING 8 2 SHIFT PEDAL DOES NOT MOVE 8 2 JUMPS OUT OF GEAR 8 2 FAULTY CLUTCH 8 2 OVERHEATING 8 3 POOR BRAKING PERFORMANCE 8 3 FAULTY FRONT FORK LEGS 8 3 UNSTABLE HANDLING 8 3 FAULTY LIGHTING OR SIGNALING SYSTEM 8 3 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 426: ...Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 427: ...el pump relay 3 Throttle body ies Deteriorated or contaminated fuel 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...

Page 428: ...mission 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 drum groove Transmission Worn gear dog EAS28570 FAULTY CLUTCH Clutch slips 1 Clutch Improperly assembled clutch Improperly assembled clu...

Page 429: ...ed outer tube Damaged fork spring Worn or damaged outer tube bushing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS28670 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handlebar 2 Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tightened ring nut Bent steering stem Damaged ball bearing or bearing race...

Page 430: ...urn signal does not come on Faulty turn signal switch Faulty turn signal hazard relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signal flashes slowly Faulty turn signal hazard relay Faulty main switch Faulty turn signal switch Incorrect turn signal bulb Turn signal remains lit Fault...

Page 431: ...ator light 48 Left turn signal indicator light 49 Right turn signal indicator light 50 Meter light 51 O2 sensor 52 Horn 53 Turn signal hazard relay 54 Headlight relay 55 Left handlebar switch 56 Clutch switch 57 Pass switch 58 Dimmer switch 59 Hazard switch 60 Turn signal switch 61 Horn switch 62 Front left turn signal light 63 Front right turn signal light 64 Rear right turn signal light 65 Rear ...

Page 432: ...k White P Y Pink Yellow R B Red Black R G Red Green R L Red Blue R W Red White R Y Red Yellow Sb W Sky blue White W B White Black W G White Green W R White Red W Y White Yellow Y B Yellow Black Y G Yellow Green Y L Yellow Blue Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 433: ...Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 434: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 435: ...r Y L B L Y B L Y B Br L L B Br L Br L Br L R B G Y R W Br R Br G R Gy R R R B R R R B Br W B B R R R B B R W R W R L L B O O B R O O B R A WIRE HARNESS WIRE HARNESS WIRE HARNESS WIRE HARNESS SUB WIRE HARNESS1 SUB WIRE HARNESS2 SUB WIRE HARNESS2 SUB WIRE HARNESS3 W G B Gy B Gy W G BLACK BLACK B Ch B B Dg Ch B B Dg C L L Y Y Br Br D Y Br B B B L L B G Y Br W R B L BB3 BB2 BB1 BB4 B B B B Y Y G G L ...

Page 436: ...2007 SERVICE MANUAL MT01 W 5YU 28197 E2 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 437: ...ha Motor Co Ltd First edition September 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 Email info motomatrix co uk ...

Page 438: ...changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE 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 ALER...

Page 439: ...n smaller print than the section 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 explod...

Page 440: ...iceable with engine 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 with a new one Manuals by Motomatrix www motomatrix co uk Email i...

Page 441: ...Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 442: ...NTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 FUEL SYSTEM 6 ELECTRICAL SYSTEM 7 TROUBLESHOOTING 8 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 443: ...Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 444: ...INSTRUMENT FUNCTIONS 1 4 IMPORTANT INFORMATION 1 7 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 7 REPLACEMENT PARTS 1 7 GASKETS OIL SEALS AND O RINGS 1 7 LOCK WASHERS PLATES AND COTTER PINS 1 7 BEARINGS AND OIL SEALS 1 8 CIRCLIPS 1 8 CHECKING THE CONNECTIONS 1 9 SPECIAL TOOLS 1 10 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 445: ...le identification number 1 is stamped on the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the lead holder under the seat This information will be needed to order spare parts 1 1 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 446: ... adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions detected by various sensors The adoption of the FI system has resulted in a highly precise f...

Page 447: ...als that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor air temperature sensor engine temperature sensor speed 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 the engine can be suppli...

Page 448: ...g the brightness control For the U K only To switch the speedometer and odometer tripmeter fuel reserve tripmeter displays between kilometers and miles press the SELECT button for at least two seconds Tachometer The electric tachometer allows the rider to mon itor the engine speed and keep it within the ideal power range When the key is turned to ON the tachometer needle will sweep once across the...

Page 449: ...ome on and then the multi function display will indicate a two digit er ror code e g 12 13 14 If the multi function display indicates an error code note the code number and then check the vehicle Refer to FUEL INJECTION SYSTEM on page 7 25 CAUTION EC5YU1010 If the multi function display indicates an er ror code the vehicle should be checked as soon as possible in order to avoid engine damage This ...

Page 450: ...he SELECT button to select the LCD Item number 2 is displayed Adjust the LCD brightness level by pushing the RESET button 6 Push the SELECT button to select the ta chometer needle Item number 3 is displayed Adjust the tachometer needle brightness lev el by pushing the RESET button 7 Push the SELECT button and the multi function display will return to the odometer or tripmeter mode 1 Tachometer pan...

Page 451: ... Keep all parts away 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...

Page 452: ...stalling if appropriate 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 circli...

Page 453: ...se connection Connect 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 9089...

Page 454: ...akes NOTE For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 9 5 73 7 91 7 92 7 93 7 96 7 98 7 99 7 100 7 101 7 102 7 103 7 104 7 106 7 107 7 108 Thickness gauge 90890 03079 Narrow gauge set YM 34483 3 4 3 5 5 57 Locknut wrench 90890...

Page 455: ...nut wrench 90890 01403 Spanner wrench YU 33975 3 26 4 58 Vacuum pressure pump gauge set 90890 06756 Mityvac brake bleeding tool YS 42423 4 5 6 9 Fork spring compressor 90890 01441 YM 01441 4 49 4 54 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 49 4 54 Damper rod holder 90890 01504 YM 01504 4 50 4 51 Tool name Tool No Illustration Reference pages Manuals by Motomatrix www motoma...

Page 456: ...hment M10 90890 01436 Universal damping rod bleeding tool set YM A8703 4 53 4 54 Ring nut wrench 90890 01268 Spanner wrench YU 01268 4 58 Pivot shaft wrench 90890 01485 Frame mount insert wrench YM 01485 5 13 Valve spring compressor 90890 04019 YM 04019 5 35 5 40 Tool name Tool No Illustration Reference pages YM A8703 YM A8703 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 457: ...mer ø6 90890 04066 Valve guide reamer 6 0 mm YM 04066 5 37 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 43 Universal clutch holder 90890 04086 YM 91042 5 56 5 59 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 56 5 58 5 69 5 70 5 78 5 80 Tool name Tool No Illustration Reference pages YU 01304 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 458: ...e gauge 90890 03153 YU 03153 6 9 Fuel pressure adapter 90890 03176 YM 03176 6 9 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 6 10 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 7 100 Tool name Tool No Illustration Reference pages Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 459: ...SPECIAL TOOLS 1 15 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 460: ...TIGHTENING TORQUE SPECIFICATIONS 2 16 ENGINE TIGHTENING TORQUES 2 17 CHASSIS TIGHTENING TORQUES 2 22 LUBRICATION POINTS AND LUBRICANT TYPES 2 27 ENGINE 2 27 CHASSIS 2 29 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 ENGINE OIL LUBRICATION CHART 2 31 LUBRICATION DIAGRAMS 2 33 CABLE ROUTING 2 41 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 461: ...gth 2185 mm 86 0 in Overall width 800 mm 31 5 in Overall height 1105 mm 43 5 in Seat height 825 mm 32 5 in Wheelbase 1525 mm 60 0 in Ground clearance 145 mm 5 71 in Minimum turning radius 3200 mm 126 0 in Weight With oil and fuel 262 0 kg 578 lb Maximum load 199 kg 439 lb Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 462: ...ntity Total amount 5 00 L 5 29 US qt 4 40 Imp qt Engine 2 2 L 2 33 US qt 1 94 Imp qt Oil tank 2 8 L 2 96 US qt 2 46 Imp qt Without oil filter cartridge replacement 3 70 L 3 91 US qt 3 26 Imp qt With oil filter cartridge replacement 4 10 L 4 33 US qt 3 61 Imp qt Oil filter Oil filter type Cartridge paper Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance Less than 0 12 mm 0 00...

Page 463: ...5 1 5095 in cylinder 1 38 243 38 343 mm 1 5056 1 5096 in cylinder 2 Limit 38 141 mm 1 5016 in cylinder 1 38 143 mm 1 5017 in cylinder 2 Intake B 31 950 32 050 mm 1 2579 1 2618 in Limit 31 850 mm 1 2539 in Exhaust A 38 236 38 336 mm 1 5054 1 5093 in Limit 38 136 mm 1 5014 in Exhaust B 31 950 32 050 mm 1 2579 1 2618 in Limit 31 850 mm 1 2539 in Rocker arm rocker arm shaft Rocker arm inside diameter ...

Page 464: ...in Valve margin thickness D exhaust 0 70 1 30 mm 0 0276 0 0512 in Limit 0 4 mm 0 02 in Valve stem diameter intake 5 975 5 990 mm 0 2352 0 2358 in Limit 5 945 mm 0 2341 in Valve stem diameter exhaust 5 960 5 975 mm 0 2346 0 2352 in Limit 5 930 mm 0 2335 in Valve guide inside diameter intake 6 000 6 012 mm 0 2362 0 2367 in Limit 6 050 mm 0 2382 in Valve guide inside diameter exhaust 6 000 6 012 mm 0...

Page 465: ...1 7 mm 2 5 0 067 in Winding direction intake Counterclockwise Winding direction exhaust Counterclockwise Outer spring Free length intake 43 25 mm 1 70 in Limit 41 26 mm 1 62 in Free length exhaust 43 25 mm 1 70 in Limit 41 26 mm 1 62 in Installed length intake 31 00 mm 1 22 in Installed length exhaust 31 00 mm 1 22 in Spring rate K1 intake 12 20 N mm 69 66 lb in 1 24 kgf mm Spring rate K2 intake 1...

Page 466: ...ut of round limit 0 050 mm 0 0020 in Piston Piston to cylinder clearance 0 025 0 050 mm 0 0010 0 0020 in Limit 0 15 mm 0 0059 in Diameter D 96 960 96 975 mm 3 8173 3 8179 in Height H 10 0 mm 0 39 in Offset 1 00 mm 0 0394 in Piston pin bore inside diameter 22 004 22 015 mm 0 8663 0 8667 in Limit 22 045 mm 0 8679 in Piston pin outside diameter 21 991 22 000 mm 0 8658 0 8661 in Limit 21 971 mm 0 8650...

Page 467: ... 228 5 244 in Runout limit C 0 040 mm 0 0016 in Big end side clearance D 0 320 0 474 mm 0 0126 0 0187 in Big end radial clearance E 0 037 0 074 mm 0 0015 0 0029 in Limit 0 09 mm 0 0035 in Journal oil clearance using plastigauge 0 030 0 062 mm 0 0012 0 0024 in Limit 0 09 mm 0 0035 in Clutch Clutch type Wet multiple disc Clutch release method Hydraulic inner push Operation Left hand operation Fricti...

Page 468: ...it 0 08 mm 0 0032 in Shifting mechanism Shift mechanism type Guide bar Shift fork guide bar bending limit 0 025 mm 0 0010 in Shift fork thickness 6 26 6 39 mm 0 2465 0 2516 in Air filter Air filter element Oil coated paper element Fuel pump Pump type Electrical Model manufacturer 5YU DENSO Maximum consumption amperage 4 6 A Output pressure 392 0 kPa 56 8 psi 3 92 kgf cm Fuel injector Model quantit...

Page 469: ... kΩ at 100 C 212 F Idling condition Engine idling speed 850 950 r min Intake vacuum 26 6 kPa 7 9 inHg 200 mmHg Oil temperature 80 0 90 0 C 176 00 194 00 F Throttle cable free play 3 0 5 0 mm 0 12 0 20 in Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 470: ...beless Size 120 70 ZR17 M C 58W Manufacturer model METZELER ROADTEC Z6 E FRONT MICHELIN PILOT ROAD S Wear limit front 1 6 mm 0 06 in Rear tire Type Tubeless Size 190 50 ZR17 M C 73W Manufacturer model METZELER ROADTEC Z6 E MICHELIN PILOT ROAD 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 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 p...

Page 471: ... outer 6 5 mm 0 26 in Limit 1 0 mm 0 04 in Master cylinder inside diameter 14 0 mm 0 55 in Caliper cylinder inside diameter 27 00 mm 2 1 06 in 2 Recommended fluid DOT 4 Steering Steering bearing type Angular bearing Lock to lock angle left 33 0 Lock to lock angle right 33 0 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 120 0 mm 4 72 in Fo...

Page 472: ... 00 1 97 in Optional spring available No Enclosed gas air pressure STD 1200 kPa 170 7 psi 12 0 kgf cm Spring preload adjusting positions Installed spring length Minimum 155 0 mm 6 10 in Standard 150 0 mm 5 91 in Maximum 145 0 mm 5 71 in Rebound damping adjusting positions With the adjusting knob fully turned in Minimum 20 click s out Standard 12 click s out Maximum 3 click s out Compression dampin...

Page 473: ...IC Standard output 14 0 V 430 W 5000 r min Stator coil resistance 0 128 0 192 Ω Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer FH010AA SHINDENGEN No load regulated voltage 14 3 15 1 V Rectifier capacity 50 0 A Withstand voltage 40 0 V Battery Model GT14B 4 Voltage capacity 12 V 12 0 Ah Manufacturer GS YUASA Ten hour rate amperage 1 20 A Headlight Bulb type Halog...

Page 474: ...2 in Limit 27 5 mm 1 08 in Mica undercut depth 1 50 mm 0 06 in Starter relay Model manufacturer 2768093 A JIDECO Amperage 180 0 A Coil resistance 4 18 4 62 Ω Horn Horn type Plane Quantity 1 pc 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 Turn signal hazard relay Relay type Full transistor Model manufacturer FE218BM DENSO ...

Page 475: ...se 15 0 A Signaling system fuse 10 0 A Ignition fuse 25 0 A Parking lighting fuse 10 0 A ECU fuse 10 0 A Fuel injection system fuse 15 0 A Backup fuse 10 0 A Muffler cover fan fuse 15 0 A Auto decompression fuse 15 0 A Reserve fuse 25 0 A Reserve fuse 15 0 A Reserve fuse 10 0 A Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 476: ...stener assemblies in a 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 m...

Page 477: ...aust pipe and catalyst pipe bolt M8 1 20 Nm 2 0 m kg 14 ft lb Catalyst pipe nut M8 1 20 Nm 2 0 m kg 14 ft lb Catalyst pipe and muffler bolt M8 2 20 Nm 2 0 m kg 14 ft lb Front exhaust pipe joint nut M8 2 20 Nm 2 0 m kg 14 ft lb Rear exhaust pipe joint nut M8 2 20 Nm 2 0 m kg 14 ft lb Rear exhaust pipe joint cover bolt M6 3 7 Nm 0 7 m kg 5 1 ft lb EXUP valve pulley cover bolt M6 3 10 Nm 1 0 m kg 7 2...

Page 478: ...ead stud bolt exhaust pipe M8 4 15 Nm 1 5 m kg 11 ft lb Clutch Crankshaft end cover plug M32 1 10 Nm 1 0 m kg 7 2 ft lb Timing mark accessing screw M16 1 8 Nm 0 8 m kg 5 8 ft lb Clutch cover bolt M6 17 10 Nm 1 0 m kg 7 2 ft lb Crankshaft position sensor lead holder screw M6 7 10 Nm 1 0 m kg 7 2 ft lb Crankshaft position sensor screw M6 2 10 Nm 1 0 m kg 7 2 ft lb Clutch spring plate retainer bolt M...

Page 479: ...en gear stopper bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Generator shaft bolt M8 1 28 Nm 2 8 m kg 20 ft lb Crankcase bolt M8 3 24 Nm 2 4 m kg 17 ft lb Crankcase bolt M6 18 10 Nm 1 0 m kg 7 2 ft lb Engine oil drain bolt crankcase M14 1 43 Nm 4 3 m kg 31 ft lb Engine oil filler plug M20 1 10 Nm 1 0 m kg 7 2 ft lb Oil baffle plate bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Main axle bearing retainer bolt M6 2 10 N...

Page 480: ...ut M22 1 95 Nm 9 5 m kg 68 ft lb Stake Fuel injection system sur rounding parts Throttle body joint clamp screw M4 2 4 Nm 0 4 m kg 2 9 ft lb Throttle position sensor screw M5 2 5 Nm 0 5 m kg 3 6 ft lb Intake manifold assembly bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Injector joint screw M6 4 5 Nm 0 5 m kg 3 6 ft lb Fuel pipe bolt M12 2 30 Nm 3 0 m kg 22 ft lb ISC idle speed control unit bolt M6 2 10 Nm ...

Page 481: ...QUES 2 21 Oil tank tightening sequence Cylinder head tightening sequence 1 5 7 3 2 6 8 4 10 16 15 13 11 14 12 9 A Front cylinder B Rear cylinder Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 482: ...M12 2 74 Nm 7 4 m kg 53 ft lb Down tube nut rear side M10 2 55 Nm 5 5 m kg 40 ft lb Engine mounting nut front lower side M12 1 94 Nm 9 4 m kg 68 ft lb Engine mounting nut rear lower side M12 1 74 Nm 7 4 m kg 53 ft lb Down tube spacer bolt M18 2 8 Nm 0 8 m kg 5 8 ft lb Engine mounting spacer bolt rear upper side M18 1 8 Nm 0 8 m kg 5 8 ft lb Engine mounting spacer bolt rear lower side M18 1 8 Nm 0 ...

Page 483: ... 0 m kg 7 2 ft lb Air duct bracket bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Positive battery lead bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Starter motor lead bolt starter relay side M6 1 7 Nm 0 7 m kg 5 1 ft lb Battery box bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Lead holder and sub frame bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Fuel pump bolt M5 6 4 Nm 0 4 m kg 2 9 ft lb Seat lock bracket bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb ...

Page 484: ...r M8 2 6 Nm 0 6 m kg 4 3 ft lb Rear brake Rear brake master cylinder bolt M8 2 23 Nm 2 3 m kg 27 ft lb Locknut rear brake master cylin der M8 1 16 Nm 1 6 m kg 11 ft lb Rear brake hose union bolt M10 2 30 Nm 3 0 m kg 22 ft lb Rear brake hose guide bolt 1 M6 1 7 Nm 0 7 m kg 5 1 ft lb Rear brake hose guide bolt 2 M6 2 10 Nm 1 0 m kg 7 2 ft lb Rear brake pad pin M10 1 17 Nm 1 7 m kg 12 ft lb Rear brak...

Page 485: ...Nm 0 7 m kg 5 1 ft lb Front fork guard bolt M6 4 7 Nm 0 7 m kg 5 1 ft lb Front fender bolt M6 4 6 Nm 0 6 m kg 4 3 ft lb Swingarm and rear shock ab sorber Swingarm pivot shaft nut M18 1 125 Nm 12 5 m kg 90 ft lb Footrest bracket pinch bolt M8 2 25 Nm 2 5 m kg 18 ft lb Relay arm nut relay arm and swingarm M10 1 40 Nm 4 0 m kg 29 ft lb Relay arm nut relay arm and connecting arm M12 1 49 Nm 4 9 m kg 3...

Page 486: ...g nut to approximately 52 Nm 5 2 m kg 37 ft lb with a torque wrench then loosen the lower ring nut completely 2 Retighten the lower ring nut to 23 Nm 2 3 m kg 17 ft lb with a torque wrench Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 487: ...fts Oil pump rotors inner and outer and oil pump housing Oil pump driven gear shaft Crankcase stud bolt ends Crankcase bush generator shaft journal Starter clutch idle gear inner surface Starter clutch idle gear shafts Starter clutch roller and starter clutch gears outer surface Crankshaft journal Primary driven gear inner surface Clutch push rods and ball Clutch boss nut and washer Transmission g...

Page 488: ...a bond No 1215 Three Bond No 1215 Stator coil lead grommet Yamaha bond No 1215 Three Bond No 1215 Crankshaft position sensor lead grommet Yamaha bond No 1215 Three Bond No 1215 Lubrication point Lubricant Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 489: ... metal to metal moving parts Brake pedal shaft pivoting point Passenger footrest pivoting point and ball Sidestand pivoting point and metal to metal moving parts Sidestand switch striker and sidestand switch contact point Sidestand hook and spring Swingarm pivot shaft Bearing spacer and oil seal lips swingarm pivot shaft Bearing spacer and oil seal lips swingarm and relay arm Bearing spacer and oi...

Page 490: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 30 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 491: ...YSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 9 10 11 7 6 5 1 2 12 14 13 15 16 17 18 19 20 26 23 36 21 31 38 40 39 37 27 30 30 35 35 29 29 34 34 33 33 28 28 32 32 25 24 22 8 3 4 A Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 492: ...l filter cartridge 20 Generator shaft journal left 21 Generator shaft journal right 22 Starter clutch 23 Crankshaft journal camshaft cover side 24 Camshaft journal camshaft cover side 25 Camshaft lobe faces 26 Crankshaft journal right 27 Front cylinder 28 Crank pin 29 Connecting rod 30 Piston 31 Front camshaft 32 Valve lifter 33 Push rod 34 Rocker arm 35 Valve stem end 36 Crankshaft journal left 3...

Page 493: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 EAS20410 LUBRICATION DIAGRAMS 3 5 3 1 B B D D E E A C E E 2 1 B B D D 4 2 A C Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 494: ...RICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Oil delivery pipe 2 Push rod 3 Oil filter cartridge 4 Rocker arm shaft 5 Oil delivery pipe 2 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 495: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 1 4 3 2 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 496: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Rocker arm shaft 2 Crankshaft 3 Valve lifter 4 Push rod Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 497: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 3 2 1 1 A A B B B B A A Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 498: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Oil pump 2 Oil strainer crankcase 3 Oil pipe 1 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 499: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39 3 4 2 1 A Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 500: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 40 1 Main axle 2 Drive axle 3 Oil pump 4 Oil strainer crankcase A To oil filter cartridge Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 501: ...CABLE ROUTING 2 41 EAS20430 CABLE ROUTING A 10 11 12 13 1 2 3 4 5 6 6 6 8 9 14 15 16 17 H D E G I J B C F 7 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 502: ... fit the grommet on the hose in the guide C Make sure that the brake hose three way joint contacts the tab on the front brake hose joint bracket D Fasten the wire harness stator coil assembly lead rectifier regulator lead and horn lead with the holder Face the fastener of the holder forward E Fasten the horn leads with the holder Face the open ends of the holder upward F There should be no slack i...

Page 503: ... M N O P Q R S S T U V W X Y Z AC AB AA AE AF AG AG AH AI AD AK AM AN AO AJ D D C C B B A F E F A E 1 2 3 4 5 6 7 8 9 10 11 12 12 13 13 14 14 15 15 15 15 15 15 16 19 20 20 21 16 17 18 AL Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 504: ...eet should hang down over the wire harness clutch hose cylinder 1 left spark plug lead EXUP servo motor lead and negative battery lead Be sure not to cover the fuel hose Q Route the cylinder 1 left spark plug lead under the frame boss and to the outside of the wire harness and clutch hose R Route the clutch hose to the outside of the wire harness S Fasten the clutch hose and EXUP servo motor lead ...

Page 505: ...H J K L O P S Q R U V W AH AD AD AC AD AE AG AF D D E C A B E D D 1 2 3 3 4 5 6 7 8 9 10 11 12 12 13 13 14 15 16 17 18 18 19 20 21 21 22 23 24 25 14 27 26 30 29 Y X Z T AA AB N M Manuls byt Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 506: ... outward M 70 110 mm 2 76 4 33 in N Fasten the cylinder 2 left spark plug lead and cylinder 2 intake air pressure sensor hose O Route the cylinder 2 intake air pressure sensor hose to the outside of the wire harness P Route the cylinder 2 intake air pressure sensor lead to the outside of the wire harness headlight lead right handlebar switch lead main switch lead and cylinder 2 left spark plug lea...

Page 507: ...A B C D E D F G H I J A 1 2 3 4 5 6 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23 24 26 27 28 29 R Q M N O P 24 25 T U V W X AG AB AC AD AE Y S Z AA AF Manuls by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 508: ... brake fluid reservoir be sure not to pinch the tail brake light lead and muffler cooling fan motor lead between the rear brake fluid reservoir and the rear brake fluid reservoir bracket Route the leads under the damper that is attached to the frame J Fasten the rear turn signal light leads tail brake light lead coupler muffler cooling fan motor lead coupler and license plate light lead with the p...

Page 509: ...A B C D E D F G H I J A 1 2 3 4 5 6 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23 24 26 27 28 29 R Q M N O P 24 25 T U V W X AG AB AC AD AE Y S Z AA AF Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 510: ... under the battery box making sure that they are routed between the bolt holes in the battery box AD Route the seat lock cable under the wire harness to the left of the battery box Be sure not to pinch the seat lock cable when installing the battery box AE Fasten the sub wire harness 1 at the white tape with the plastic locking tie Face the end of the plastic locking tie rearward and then cut off ...

Page 511: ...CABLE ROUTING 2 51 A A B D D E F G C 1 2 3 3 4 4 5 6 7 8 9 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 512: ...ipe C Connect the end of the fuel hose that has a black connector to the fuel pipe D Install the end of the fuel return hose fuel return pipe to fuel pump with a yellow paint mark onto the fuel return pipe until the hose contacts the yellow paint mark on the pipe E Face the end of the hose clamp inward angled slightly downward F Install the fuel return hose fuel return pipe to fuel pump with its w...

Page 513: ...CABLE ROUTING 2 53 A A A A A B C D D E F A A 1 1 2 2 5 3 6 8 10 10 11 A G H I K J 4 7 9 9 9 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 514: ...their paint marks facing outward E Fasten the fuel tank breather hose at the white paint mark fuel tank overflow hose at the yellow paint mark and fuel return pipe with the holder Fasten the hoses in the order listed with the fuel tank breather hose fastened towards the front of the vehicle F Install the rollover valve hoses with their paint marks facing downward G Face the ends of the hose clamps...

Page 515: ...CABLE ROUTING 2 55 B A B A C C A A B C D E J 1 2 3 4 5 8 6 7 8 9 10 11 12 13 G H I K L M F 14 15 16 17 10 3 H E Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 516: ... of the cylinder 1 ISC idle speed control unit outlet hose with a blue paint mark onto the throttle body D Face the ends of the hose clamp to the left angled 45 towards the rear of the vehicle E Face the ends of the hose clamp forward F Install the end of the cylinder 1 intake air pressure sensor hose with a white paint mark onto the throttle body G Face the ends of the hose clamp to the right ang...

Page 517: ...CABLE ROUTING 2 57 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 518: ...HAUST SYSTEM 3 17 ADJUSTING THE EXUP CABLES 3 18 CHASSIS 3 20 ADJUSTING THE FRONT DISC BRAKE 3 20 ADJUSTING THE REAR DISC BRAKE 3 20 CHECKING THE BRAKE FLUID LEVEL 3 21 CHECKING THE FRONT BRAKE PADS 3 22 CHECKING THE REAR BRAKE PADS 3 22 CHECKING THE FRONT BRAKE HOSES 3 22 CHECKING THE REAR BRAKE HOSE 3 22 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 23 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 23 ADJUSTIN...

Page 519: ...YSTEM 3 33 CHECKING AND CHARGING THE BATTERY 3 33 CHECKING THE FUSES 3 33 REPLACING THE HEADLIGHT BULBS 3 33 ADJUSTING THE HEADLIGHT BEAM 3 34 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 520: ...Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 521: ...es Check valve clearance Adjust 4 Air filter element 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 worn to the limit 8 Brake hoses Check for cracks or dam...

Page 522: ...or damaged 19 Shock absorber as sembly Check operation and shock absorber for oil leakage 20 Rear suspension re lay arm and connect ing arm pivoting points Check operation 21 Fuel injection system Adjust synchronization 22 Engine oil Change Check oil level and vehicle for oil leakage 23 Engine oil filter car tridge Replace 24 Front and rear brake switches Check operation 25 Moving parts and ca ble...

Page 523: ...the adjusting screw 2 side tighten the adjusting screw and bring the valve clearance b within specification Valve clearance adjustment should be made on a cold engine at room temperature When the valve clearance is to be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove Seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 ...

Page 524: ...haft counterclockwise from the piston 1 TDC by 408 degrees b When piston 2 is at TDC on the compres sion stroke align the TDC mark e on the crankshaft position sensor rotor with the pointer b on the clutch cover c Check the camshaft drive gear mark c posi tion and camshaft driven gear mark d posi tion as shown d Measure the valve clearance with a thickness gauge 8 Adjust Valve clearance a Loosen t...

Page 525: ...head cover Tappet covers Refer to CAMSHAFTS on page 5 16 EAS20570 SYNCHRONIZING THE THROTTLE BODIES NOTE Prior to synchronizing the throttle bodies the valve clearance and the engine idling speed should be properly adjusted and the ignition tim ing should be checked 1 Stand the vehicle on a level surface NOTE Place the vehicle on a suitable stand 2 Remove Seat Refer to GENERAL CHASSIS on page 4 1 ...

Page 526: ... adjust throttle body 2 using the air screw 1 for throttle body 2 NOTE After each step rev the engine two or three times each time for less than a second and check the synchronization again If the air screw is removed turn the screw 3 4 turn in and be sure to synchronize the throttle body CAUTION EC5YU1027 Do not use the throttle valve adjusting screws to adjust the throttle body synchroni zation ...

Page 527: ... 3 c Loosen the locknut 4 on the accelerator ca ble d Turn the adjusting nut 5 in direction a or b until the specified throttle cable free play is obtained e Tighten the locknuts 2 4 NOTE If the specified throttle cable free play cannot be obtained on the throttle body side of the cable use the adjusting nut on the handlebar side Handlebar side a Loosen the locknut 1 b Turn the adjusting nut 2 in ...

Page 528: ...park plug Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 6 Clean Spark plug with a spark plug cleaner or wire brush 7 Measure Spark plug gap a with a wire thickness gauge Out of specification Regap 8 Install Spark plug NOTE Before installing the spark plug clean the spark plug and gasket surface 9 Connect Spark plug cap 10 Install Fuel tank Refer to FUEL TANK...

Page 529: ...e following procedure applies to all of the cyl inders NOTE Insufficient compression pressure will result in a loss of performance 1 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 3 2 Start the engine warm it up for several min utes and then turn it off 3 Remove Seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 1...

Page 530: ...ification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the min imum specification pour a teaspoonful of en gine oil into the spark plug bore and measure again Refer to the following table 9 Install Spark plug 10 Connect Spark plug cap Compression gauge 90890 03081 Engine compression tester YU 33223 Exte...

Page 531: ...TION EC5YU1003 Since engine oil also lubricates the clutch 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 CONSERV ING II b Do not allow foreign materials to enter the crankcase 5 Start the engine warm it up for several min utes and then turn it off 6 Check ...

Page 532: ...groove of the oil filter cartridge d Tighten the new oil filter cartridge to specifi cation with an oil filter wrench e Install the rectifier regulator 9 Check Engine oil drain bolt gaskets Damage Replace 10 Install Engine oil drain bolt crankcase along with the gasket Engine oil drain bolt oil tank along with the gasket Oil filter wrench 90890 01426 YU 38411 1 1 1 T R Oil filter cartridge 17 Nm 1...

Page 533: ...e oil gallery bolts 1 b Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolts If no engine oil comes out after one minute turn the engine off so that it will not seize c Check the engine oil passages the oil filter cartridge and the oil pump for damage or leakage Refer to OIL PUMP on page 5 82 d Start the engine after solving the problem s and check the eng...

Page 534: ...tch 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 ensure a correct reading of the clutch fluid level make sure the top of the reservoir is horizontal 4 Install Clutch master cylinder reservoir diaphragm Clutch master cylinder reservoir diaphragm holder Clutch ...

Page 535: ...il all of the air bub bles have disappeared from the clutch fluid in the plastic hose j Tighten the bleed screw to specification k Add the recommended clutch fluid to the proper level Refer to CHECKING THE CLUTCH FLUID LEVEL on page 3 14 WARNING EWA13010 After bleeding the hydraulic clutch system check the clutch operation EAS20960 REPLACING THE AIR FILTER ELEMENT 1 Remove Seat Refer to GENERAL CH...

Page 536: ... to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 1 Seat Refer to GENERAL CHASSIS on page 4 1 EAS21030 CHECKING THE FUEL LINE 1 Remove Seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 2 Check Fuel hoses 1 Breather hose 2 Vacuum hose Cracks damage Replace Loose connection Connect properly CAU...

Page 537: ...damage Replace Gaskets 5 Exhaust gas leaks Replace 3 Check Tightening torques Front exhaust pipe and front exhaust pipe joint bolts 6 Front exhaust pipe and rear exhaust pipe bolt 7 Rear exhaust pipe and rear exhaust pipe joint bolt 8 Rear exhaust pipe bolt 9 Rear exhaust pipe and catalyst pipe bolt 10 Catalyst pipe nut 11 Catalyst pipe and muffler bolts 12 Muffler bolts 13 2 1 1 T R Front exhaust...

Page 538: ...stem operation a Turn the main switch to ON b Check that the EXUP valve operates proper ly NOTE Check that the projections a on the EXUP valve pulley contact the stopper b fully open position and the stopper c fully closed posi tion 3 Check EXUP cable free play at the EXUP valve pul ley a 10 4 4 5 3 5 1 5 2 5 5 5 9 12 11 7 6 12 13 13 8 15 14 EXUP cable free play at the EXUP valve pulley a 3 mm 0 1...

Page 539: ...ber cover to its original position f Remove the pin g Turn the main switch to ON check that the EXUP valve pulley contacts the stoppers ful ly open and fully closed positions and then check that the notch in the EXUP valve pulley is aligned with the hole in the EXUP valve cover 5 Install EXUP valve pulley cover Turn in c Free play is increased Turn out d Free play is decreased 1 1 2 a b 3 3 d d c ...

Page 540: ... THE REAR DISC BRAKE NOTE The brake pedal position is determined by the in stalled rear brake master cylinder length a 1 Measure Installed rear brake master cylinder length a Incorrect Adjust 2 Adjust Installed rear brake master cylinder length a Loosen the locknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified installed rear brake master cylinder length is obtained WARNING ...

Page 541: ...rk a Add the recommended brake fluid to the proper level WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be c...

Page 542: ...lowing procedure applies to all of the brake hoses and brake hose holders 1 Check Brake hoses 1 Cracks damage wear Replace 2 Check Brake hose holders Loose Tighten the clamp bolt 3 Hold the vehicle upright and apply the brake several times 4 Check Brake hoses Brake fluid leakage Replace the damaged hoses Refer to FRONT BRAKE on page 4 18 EAS21290 CHECKING THE REAR BRAKE HOSE 1 Remove Seat Refer to...

Page 543: ...ed disconnected or replaced the brake fluid level is very low brake operation is faulty NOTE Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow When bleeding the hydraulic brake system make sure there is always enough brake fluid before applying the brake Ignoring this pre caution could allow air to enter the hydraulic brake sy...

Page 544: ... BRAKE FLUID LEVEL on page 3 21 WARNING EWA13110 After bleeding the hydraulic brake system check the brake operation 3 Install Seat Refer to GENERAL CHASSIS on page 4 1 EAS21380 ADJUSTING THE SHIFT PEDAL NOTE The shift pedal position is determined by the in stalled shift rod length a 1 Measure Installed shift rod length a Incorrect Adjust 2 Adjust Installed shift rod length a Loosen both locknuts ...

Page 545: ...e end of the drive chain guide 3 Adjust Drive chain slack a Loosen the wheel axle nut 1 b Loosen both locknuts 2 c Turn both adjusting bolts 3 in direction a or b until the specified drive chain slack is ob tained NOTE To maintain the proper wheel alignment adjust both sides evenly Push the rear wheel forward to make sure there is no clearance between the swingarm end plates and the ends of the sw...

Page 546: ...e 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 56 4 Adjust Steering head a Remove the lock washer 1 the upper ring nut 2 and the rubber washer 3 b Loosen the lower ring nut 4 and then tight en it to the specified torque with a st...

Page 547: ...pply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK on page 4 46 EAS21580 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING EW5YU1008 Always adjust both front fork legs evenly Uneven adjustment can result in poor han ...

Page 548: ...Direction a turn in Rebound damping is increased sus pension is harder Direction b turn out Rebound damping is decreased sus pension is softer Rebound damping adjusting posi tions Minimum 17 click s out Standard 15 click s out Maximum 1 click s out With the adjusting screw fully turned in Direction a turn in Compression damping is increased suspension is harder Direction b turn out Compression dam...

Page 549: ...mping CAUTION ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Rebound damping a Turn the adjusting knob 1 in direction a or b Direction a Spring preload is increased suspen sion is harder Direction b Spring preload is decreased suspen sion is softer Spring preload adjusting posi tions Installed spring length Minimum 155 0 mm 6 10 in Standard 150 0 mm 5 91 in Maximum 1...

Page 550: ...al weight including cargo rider passenger and ac cessories and the anticipated riding speed Operation of an overloaded vehicle could cause tire damage an accident or an injury NEVER OVERLOAD THE VEHICLE Rebound damping adjusting posi tions Minimum 20 click s out Standard 12 click s out Maximum 3 click s out With the adjusting knob fully turned in Direction a turn in Compression damping is increase...

Page 551: ...r Co Ltd for this model The front and rear tires should always be by the same manufacturer and of the same design No guarantee con cerning handling characteristics can be giv en if a tire combination other than one approved by Yamaha is used on this vehicle Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm L...

Page 552: ...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 lubricant into the cable sheath or use a suit able lubricating device EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal to metal moving parts of the levers EAS21710 LUBRICATING THE PEDAL Lubricate the p...

Page 553: ...b with the head light 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 d Connect Headlight coupler 3 Replace High beam head...

Page 554: ... Headlight bulb holder g Connect Headlight coupler h Install Headlight bulb cover 4 Install Headlight assembly EAS21810 ADJUSTING THE HEADLIGHT BEAM 1 Adjust Headlight beam vertically a Turn the adjusting screw 1 in direction a or b 2 Adjust Headlight beam horizontally a Turn the adjusting screw 1 in direction a or b T R Headlight assembly bolt 7 Nm 0 7 m kg 5 1 ft lb Direction a Headlight beam is...

Page 555: ...ELECTRICAL SYSTEM 3 35 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 556: ...T 4 15 ASSEMBLING THE REAR WHEEL 4 16 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 16 CHECKING THE REAR BRAKE DISC 4 16 INSTALLING THE REAR WHEEL REAR BRAKE DISC 4 16 FRONT BRAKE 4 18 INTRODUCTION 4 23 CHECKING THE FRONT BRAKE DISCS 4 23 REPLACING THE FRONT BRAKE PADS 4 24 REMOVING THE FRONT BRAKE CALIPERS 4 25 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 25 CHECKING THE FRONT BRAKE CALIPERS 4 26 ASSEMBL...

Page 557: ...G THE FRONT FORK LEGS 4 49 DISASSEMBLING THE FRONT FORK LEGS 4 49 CHECKING THE FRONT FORK LEGS 4 50 ASSEMBLING THE FRONT FORK LEGS 4 51 INSTALLING THE FRONT FORK LEGS 4 55 STEERING HEAD 4 56 REMOVING THE LOWER BRACKET 4 58 CHECKING THE STEERING HEAD 4 58 INSTALLING THE STEERING HEAD 4 58 REAR SHOCK ABSORBER ASSEMBLY 4 60 HANDLING THE REAR SHOCK ABSORBER 4 61 DISPOSING OF A REAR SHOCK ABSORBER 4 61...

Page 558: ...69 CHECKING THE DRIVE CHAIN 4 69 CHECKING THE DRIVE SPROCKET 4 70 CHECKING THE REAR WHEEL SPROCKET 4 70 CHECKING THE REAR WHEEL DRIVE HUB 4 70 INSTALLING THE DRIVE CHAIN 4 70 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 559: ... lead 1 Disconnect 4 Positive battery lead 1 Disconnect 5 Main fuse 1 6 Battery band 1 7 Battery 1 8 Battery seat 1 9 Battery box 1 For installation reverse the removal proce dure 4 5 7 8 4 3 1 6 9 2 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 10 Nm 1 0 m kg 7 2 ft Ib LT Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 560: ...e harness 3 coupler wire harness side 1 Disconnect 8 Headlight assembly coupler 1 Disconnect 9 Air temperature sensor coupler 1 Disconnect 10 Headlight assembly 1 For installation reverse the removal proce dure 8 79 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 9 Nm 0 9 m kg 6 5 ft Ib T R 9 Nm 0 9 m kg 6 5 ft Ib LT LT LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib 6 1 3 5 4 2 10 Manuals by Motom...

Page 561: ... Disconnect 3 Rear right turn signal light coupler 1 Disconnect 4 Rear left turn signal light coupler 1 Disconnect 5 License plate light coupler 1 Disconnect 6 Tail brake light assembly 1 7 Muffler cooling fan motor 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 LT 7 6 1 2 3 4 5 Manuals by Motomatrix www motomatrix co uk Email inf...

Page 562: ...k 1 5 Air filter case joint clamp screw 2 Loosen 6 Air filter case bracket 1 7 ISC idle speed control unit inlet hose 1 Disconnect 8 Intake solenoid vacuum hose air filter case valve to intake solenoid 1 Disconnect 9 Air filter case 1 10 Air filter case valve 1 11 Oil catch tank breather hose 1 12 Oil catch tank 1 For installation reverse the removal proce dure 1 2 9 5 5 7 8 6 4 12 11 3 5 T R 9 Nm...

Page 563: ... pressure pump gauge set 1 to the air filter case valve 2 c Check that the air filter case valve operates when vacuum pressure is applied to the valve using the vacuum pressure pump gauge set Faulty Replace the air filter case valve Vacuum pressure pump gauge set 90890 06756 Mityvac brake bleeding tool YS 42423 1 2 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 564: ...nt wheel 1 6 Collar 2 7 Dust cover 2 8 Front brake disc 2 For installation reverse the removal proce dure T R 23 Nm 2 3 m kg 17 ft Ib T R 72 Nm 7 2 m kg 52 ft lb LT LT T R 18 Nm 1 8 m kg 13 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib 1 4 3 1 2 8 5 8 6 7 7 6 2 T R 35 Nm 3 5 m kg 25 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib 6 6 T R 6 Nm 0 6 m kg 4 3 ft Ib Manuals by Motomatrix www motomatr...

Page 565: ...front wheel 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 2 1 2 1 3 LS LS New New Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 566: ...he 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 Front wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING EWA13460 Do not attempt to straighten a bent wheel ax le 2 Check Tire Front wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 30 and CHEC...

Page 567: ...with the brake disc installed 1 Remove Balancing weight s 2 Find Front wheel 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...

Page 568: ...HECKING THE FRONT BRAKE DISCS on page 4 23 EAS22000 INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS The following procedure applies to both of the front brake discs 1 Install Front brake disc NOTE Tighten the brake disc bolts in stages and in a crisscross pattern 2 Check Front brake discs Refer to CHECKING THE FRONT BRAKE DISCS on page 4 23 3 Lubricate Oil seal lips Collars 4 Install Front wheel NOTE...

Page 569: ...ont brake calipers WARNING EWA13500 Make sure the brake hose is routed properly NOTE Make sure that there is enough space between the brake pads before installing the brake cali pers onto the brake discs T R Front wheel axle 72 Nm 7 2 m kg 52 ft lb T R Front wheel axle pinch bolt 23 Nm 2 3 m kg 17 ft lb T R Front brake caliper bolt 35 Nm 3 5 m kg 25 ft lb Manuals by Motomatrix www motomatrix co uk...

Page 570: ... chain adjusting bolt 2 Loosen 4 Rear wheel axle nut 1 5 Washer 1 6 Rear wheel axle 1 7 Left drive chain puller 1 8 Right drive chain puller 1 9 Rear brake caliper bracket 1 10 Rear wheel 1 For installation reverse the removal proce dure T R 150 Nm 15 0 m kg 110 ft lb T R 22 Nm 2 2 m kg 16 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib LT 8 7 6 1 9 10 3 2 5 4 LS Manuals by Motomatri...

Page 571: ...brake disc side 1 4 Collar wheel sprocket side 1 5 Dust cover 2 6 Oil seal 1 7 Bearing 1 8 Rear wheel drive hub 1 9 Rear wheel drive hub damper 6 For installation reverse the removal proce dure LS LS LT New 6 4 2 8 9 5 7 1 5 3 T R 18 Nm 1 8 m kg 13 ft Ib T R 100 Nm 10 0 m kg 72 ft lb 6 6 LT Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 572: ...der Job Parts to remove Q ty Remarks 1 Collar 1 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Circlip 1 6 Bearing 1 For assembly reverse the disassembly pro cedure New 2 3 1 5 4 6 LS LS Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 573: ...90 CHECKING THE REAR WHEEL 1 Check Rear wheel axle Rear wheel Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 8 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 30 and CHECKING THE WHEELS on page 3 32 3 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 8 EAS22110 CHECKING THE REAR WHEEL DRIVE HUB 1 Che...

Page 574: ...ke disc and rear wheel drive hub installed 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 9 ET5YU1026 CHECKING THE REAR BRAKE DISC Refer to CHECKING THE REAR BRAKE DISC on page 4 35 EAS22160 INSTALLING THE REAR WHEEL REAR BRAKE DISC 1 Install Rear brake disc NOTE Tighten the brake disc bolts in stages and in a crisscross pattern 2 Check Rear brake di...

Page 575: ... to ADJUSTING THE DRIVE CHAIN SLACK on page 3 25 6 Install Rear brake caliper WARNING EWA13500 Make sure the brake hose is routed properly Drive chain slack 40 0 50 0 mm 1 57 1 97 in T R Rear brake caliper bolt M12 27 Nm 2 7 m kg 19 ft lb Rear brake caliper bolt M8 22 Nm 2 2 m kg 16 ft lb LOCTITE 1 2 a Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 576: ...h of the front brake calipers 1 Brake hose holder 1 2 Front brake caliper 1 3 Brake pad clip 4 4 Brake pad pin 2 5 Brake pad spring 2 6 Front brake pad 4 For installation reverse the removal proce dure 1 2 3 4 3 4 5 6 6 T R 6 Nm 0 6 m kg 4 3 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 577: ...Brake master cylinder reservoir diaphragm 1 5 Brake lever 1 6 Front brake light switch connector 2 Disconnect 7 Front brake light switch 1 8 Front brake hose union bolt 1 9 Copper washer 2 10 Front brake hose 1 11 Front brake master cylinder holder 1 12 Front brake master cylinder 1 For installation reverse the removal proce dure 4 5 12 11 10 3 2 8 9 6 7 1 New T R 10 Nm 1 0 m kg 7 2 ft Ib T R 13 N...

Page 578: ...aster cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure 1 2 1 New New LS Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 579: ... Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 1 Front brake hose union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Front brake caliper 1 For installation reverse the removal proce dure New 3 1 2 4 T R 30 Nm 3 0 m kg 22 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 580: ...brake calipers 1 Brake pad clip 4 2 Brake pad pin 2 3 Brake pad spring 2 4 Front brake pad 4 5 Brake caliper piston 6 6 Brake caliper piston seal 12 7 Bleed screw 1 For assembly reverse the disassembly pro cedure 2 5 2 3 1 4 4 1 3 7 5 5 6 6 6 6 New New New New T R 6 Nm 0 6 m kg 4 3 ft Ib 6 New 6 New Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 581: ...e Front wheel Refer to FRONT WHEEL on page 4 6 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...

Page 582: ... brake pads as a set 2 Install Brake pads Brake pad springs NOTE Always install new brake pads and brake pad springs 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 brake pads and new ...

Page 583: ...e union bolt 2 Copper washers 3 Front brake hose 4 NOTE Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22350 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Remove Brake caliper pistons 1 Brake caliper piston seals 2 WARNING EW5YU1006 Do not loosen the bolts a Blow compressed air into the brake hose jo...

Page 584: ... to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals EAS22450 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Install Front brake caliper 1 temporarily Copper washers Front brake hose 2 Front brake hose union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle ope...

Page 585: ...e fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 21 7 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 EAS2...

Page 586: ...2 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 41 NOTE Install the brake hose at 40 50 angle a to the front brake master cylinder as shown in the il lustration While holding the brake hose tighten the union bolt Turn the handlebar to the left and right to make sure the brake hose does not touch other parts e g wire harne...

Page 587: ...n up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 5 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 21 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTE...

Page 588: ...rake pad shim 2 5 Brake pad insulator 2 6 Rear brake pad 2 7 Brake pad spring 2 For installation reverse the removal proce dure T R 3 Nm 0 3 m kg 2 2 ft Ib T R 22 Nm 2 2 m kg 16 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib LS LT 3 2 1 7 7 6 5 4 5 4 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 589: ...1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Rear brake hose union bolt 1 8 Copper washer 2 9 Rear brake hose 1 10 Rear brake master cylinder 1 For installation reverse the removal proce dure T R 30 Nm 3 0 m kg 22 ft Ib New New T R 23 Nm 2 3 m kg 17 ft Ib T R 7 Nm 0 7 m kg 5...

Page 590: ...linder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake hose joint 1 3 Bush 1 4 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 591: ...BRAKE SYSTEM on page 3 23 1 Rear brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Rear brake caliper 1 For installation reverse the removal proce dure T R 22 Nm 2 2 m kg 16 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib LS LT New 1 2 4 3 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 592: ...sulator 2 5 Rear brake pad 2 6 Brake pad spring 2 7 Brake caliper piston 2 8 Brake caliper piston seal 4 9 Bleed screw 1 For assembly reverse the disassembly pro cedure LS New New 9 2 1 6 4 3 5 4 3 7 6 8 8 T R 3 Nm 0 3 m kg 2 2 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 593: ...Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 23 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 23 5 Adjust Brake disc deflection Refer to CHECKING THE FRONT B...

Page 594: ...D LEVEL on page 3 21 5 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM 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 Rear brake hose union bolt 1 Copper washers 2 Rear brake hose 3 NOTE Put the end of the brake hose ...

Page 595: ...body Obstruction Blow out with compressed air WARNING EWA13610 Whenever a brake caliper is disassembled replace the brake caliper piston seals 2 Check Brake caliper bracket 1 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 interna...

Page 596: ...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 any s...

Page 597: ...Check Brake hoses Cracks damage wear Replace EAS22730 ASSEMBLING THE REAR 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 EAS22740 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install Copper washers Rear brake hose 1 Rear brake hose union bolt 2 W...

Page 598: ...d may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 4 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 21 5 Check Brake pedal operation Soft or spongy feelin...

Page 599: ...ler 1 Disconnect 11 Clutch master cylinder holder 1 12 Clutch master cylinder assembly 1 13 Spacer 1 14 Left handlebar switch 1 15 Handlebar grip 1 16 Upper handlebar holder 2 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 29 Nm 2 9 m kg 21 ft Ib T R 29 Nm 2 9 m kg 21 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 14 Nm 1 4 m kg 10 ft I...

Page 600: ... 0 m kg 7 2 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 29 Nm 2 9 m kg 21 ft Ib T R 29 Nm 2 9 m kg 21 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib 8 9 7 1 1 12 LS LS 6 11 14 13 18 18 14 15 8 10 16 16 17 5 3 6 2 4 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 601: ...o danger of it falling over 2 Install Lower handlebar holders 1 NOTE Temporarily tighten the nuts 2 3 Install Handlebar 1 Upper handlebar holders 2 CAUTION ECA14250 First tighten the bolts on the front side of the handlebar holder and then on the rear side Turn the handlebar all the way to the left and right If there is any contact with the fuel tank adjust the handlebar position NOTE The upper ha...

Page 602: ...2 NOTE Face the slit in the spacer forward downward or in any direction in between The clutch master cylinder holder should be in stalled with the punch mark a forward Align the mating surfaces of the clutch master cylinder holder with the punch mark b on the handlebar First tighten the front bolt then the rear bolt 8 Install Throttle grip Throttle cables Right handlebar switch 1 Grip end 2 NOTE A...

Page 603: ...the brake master cylinder hold er with the punch mark b on the handlebar First tighten the front bolt then the rear bolt 10 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 7 T R Front brake master cylinder hold er 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 a b 1 Manuals by Motomatrix www motomatrix co uk Email info moto...

Page 604: ... 2 2 Front fender 1 3 Cap bolt 1 Loosen 4 Upper bracket pinch bolt 1 Loosen 5 Lower bracket pinch bolt 2 Loosen 6 Front fork leg 1 For installation reverse the removal proce dure 6 5 1 4 1 2 3 T R 26 Nm 2 6 m kg 19 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 28 Nm 2 8 m kg 20 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 6 Nm 0 6 m kg 4 3 ft Ib Manuals by Motomatrix www motomatrix co...

Page 605: ...ting rod 1 5 Spacer 1 6 Nut 1 7 Upper spring seat 1 8 Fork spring 1 9 Lower spring seat 1 10 Outer tube 1 11 Dust seal 1 12 Oil seal clip 1 13 Oil seal 1 14 Washer 1 15 Damper rod assembly 1 T R 35 Nm 3 5 m kg 25 ft Ib 1 2 3 6 5 7 8 9 4 11 12 13 14 10 15 16 LS New New New T R 20 Nm 2 0 m kg 14 ft Ib T R 25 Nm 2 5 m kg 18 ft Ib New Manuals by Motomatrix www motomatrix co uk Email info motomatrix co...

Page 606: ...sassembling the front fork legs Order Job Parts to remove Q ty Remarks T R 35 Nm 3 5 m kg 25 ft Ib 1 2 3 6 5 7 8 9 4 11 12 13 14 10 15 16 LS New New New T R 20 Nm 2 0 m kg 14 ft Ib T R 25 Nm 2 5 m kg 18 ft Ib New Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 607: ...o both of the front fork legs 1 Position the collar 1 as shown in the illustra tion by turning the spring preload adjusting bolt 2 counterclockwise until it stops 2 Remove Cap bolt 1 from the damper adjusting rod Spacer 2 Nut 3 a Press down on the spacer with the fork spring compressor 4 b Install the rod holder 5 between the nut 3 and the spacer 2 NOTE Use the side of the rod holder that is marke...

Page 608: ... rod holder 1 5 Remove Oil seal clip 1 with a flat head screwdriver EAS23010 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check Inner tube Outer tube Bends damage scratches Replace WARNING EWA13650 Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure Spring free length a Out of specification Replace Damper rod h...

Page 609: ...the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability NOTE When assembling the front fork leg be sure to replace the following parts Oil seal Dust seal O ring Before assembling the front fork leg make sure all of the components are clean 1 Install Damper rod assembly 1 Inner tube 2 CAUTION ECA14210 Allow the damper rod assembly to s...

Page 610: ...eg with a plastic bag to protect the oil seal during installation 5 Install Outer tube to the inner tube 6 Install Washer Oil seal 1 with the fork seal driver 2 7 Install Oil seal clip 1 NOTE Adjust the oil seal clip so that it fits into the outer tube s groove 8 Install Dust seal 1 with the fork seal driver weight 2 1 New New New 4 3 2 1 Fork seal driver 90890 01442 Adjustable fork seal driver 36...

Page 611: ... be cause the fork oil may spurt out 13 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 14 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 15 Install Lower sprin...

Page 612: ... holder that is marked B i Remove the rod puller and rod puller attach ment j Install the nut 4 all the way onto the damper rod assembly k Install the damper adjusting rod l Install the washer and cap bolt and then fin ger tighten the cap bolt m Hold the nut and tighten the spring preload adjusting bolt 11 into the cap bolt to specifi cation 4 7 8 5 6 3 2 1 Rod puller 90890 01437 Universal damping...

Page 613: ... the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts NOTE Make sure the outer tube is flush with the top of the handlebar holder 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 3 Adjust Spring preload Rebound damping Compression damping Refer to ADJUSTING...

Page 614: ...racket 1 4 Steering stem nut 1 5 Upper bracket 1 6 Headlight assembly bracket 1 7 Front brake hose joint 1 8 Front brake hose joint bracket 1 9 Lock washer 1 10 Upper ring nut 1 11 Rubber washer 1 12 Lower ring nut 1 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 23 Nm 2 3 m kg 17 ft lb T R 7 Nm 0 7 m kg 5 1 ft Ib T R 110 Nm 11 0 m kg 80 ft lb LS LS FWD T R 9 Nm 0 9 m kg 6 5 ft Ib...

Page 615: ...on reverse the removal proce dure Removing the lower bracket Order Job Parts to remove Q ty Remarks T R 7 Nm 0 7 m kg 5 1 ft Ib T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 23 Nm 2 3 m kg 17 ft lb T R 7 Nm 0 7 m kg 5 1 ft Ib T R 110 Nm 11 0 m kg 80 ft lb LS LS FWD T R 9 Nm 0 9 m kg 6 5 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib LT 6 8 7 12 18 19 20 21 21 15 16 17 14 9 10 11 5 4 13 3 1 2 Manuals by Motomatrix www mo...

Page 616: ...eplace Bearings Bearing races a Remove the bearing races from the steering head pipe with a long rod 1 and hammer b Remove the bearing race from the lower bracket with a floor chisel 2 and hammer 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...

Page 617: ...int bracket 1 contacts the side b of the front brake hose joint 2 4 Install Upper bracket Steering stem nut NOTE Temporarily tighten the steering stem nut 5 Install Front fork legs Refer to FRONT FORK on page 4 46 NOTE Temporarily tighten the upper and lower bracket pinch bolts 6 Tighten Steering stem nut Recommended lubricant Lithium soap based grease a 1 2 b T R Steering stem nut 110 Nm 11 0 m k...

Page 618: ...ly 1 5 Collar Spacer Oil seal Bearing 2 1 2 1 6 Self locking nut Bolt Washer 1 1 2 7 Spacer 1 8 Oil seal Bearing 2 1 9 Relay arm 1 10 Spacer Oil seal Bearing 2 8 4 11 Connecting arm 1 12 Collar Spacer 2 1 For installation reverse the removal proce dure T R 40 Nm 4 0 m kg 29 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 49 Nm 4 9 m kg 35 ft Ib LS LS LS LS LS LS 5 12 12 4 2 10 6 10 6 10 10 11 7 1 3 8 8 9 3 ...

Page 619: ...m 1 57 in 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 Relay a...

Page 620: ...m with its R mark a facing to the right and its arrow mark b facing upward 4 Tighten Rear shock absorber assembly nut rear side Recommended lubricant Lithium soap based grease Installed depth a 8 0 mm 0 31 in Installed depth b 4 0 mm 0 16 in Installed depth c 7 0 mm 0 28 in Installed depth d 0 5 1 0 mm 0 02 0 04 in 5 Relay arm 6 Connecting arm 7 Rear shock absorber A Left side B Right side T R Rea...

Page 621: ...ont side Relay arm nut relay arm and swingarm 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 25 T R Relay arm nut relay arm and con necting arm 49 Nm 4 9 m kg 35 ft lb Recommended lubricant Lithium soap based grease T R Rear shock absorber assembly nut front side 49 Nm 4 9 m kg 35 ft lb T R Relay arm nut relay arm and swingarm 40 Nm 4 0 m kg 29 ft lb Drive chain slac...

Page 622: ...chain adjusting bolt Locknut 2 2 6 Footrest bracket pinch bolt 2 Loosen 7 Swingarm pivot shaft nut 1 8 Swingarm pivot shaft 1 9 Collar 2 10 Spacer 1 11 Spacer 1 12 Drive chain 1 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 7 Nm 0 7 m kg 5 1 ft Ib T R 125 Nm 12 5 m kg 90 ft lb LS LS LS LS LT T R 9 Nm 0 9 m kg 6 5 ft Ib LT LT T R 9 Nm 0 9 m kg 6 5 ft Ib 13 ...

Page 623: ...arm Order Job Parts to remove Q ty Remarks 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 7 Nm 0 7 m kg 5 1 ft Ib T R 125 Nm 12 5 m kg 90 ft lb LS LS LS LS LT T R 9 Nm 0 9 m kg 6 5 ft Ib LT LT T R 9 Nm 0 9 m kg 6 5 ft Ib 13 2 8 19 9 9 23 14 11 24 25 24 18 16 21 1710 20 7 22 5 5 4 3 6 6 1 12 19 15 New T R 25 Nm 2 5 m kg 18 ft Ib T R 25 Nm 2 5 m kg 18 ft Ib M...

Page 624: ...e is binding check the spacers bear ings washers and dust covers 3 Remove Drive chain Refer to REMOVING THE DRIVE CHAIN on page 4 69 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 Spacer Washer Bearings Collars 4 C...

Page 625: ...talled depth of oil seal c 0 5 1 0 mm 0 02 0 04 in Installed depth of oil seal d 0 5 mm 0 02 in Installed depth of bearing e 4 0 mm 0 16 in Installed depth of oil seal f 1 0 mm 0 04 in 5 Swingarm 6 Swingarm pivot shaft 7 Relay arm 8 Bolt A Left side B Right side Drive chain slack 40 0 50 0 mm 1 57 1 97 in 1 1 2 2 5 6 d c a d b A B e f 3 4 7 5 8 A B Manuals by Motomatrix www motomatrix co uk Email ...

Page 626: ...per washer 2 5 Clutch pipe 1 6 Clutch release cylinder 1 7 Dowel pin 2 8 Drive chain guard drive sprocket side 1 9 Drive sprocket nut 1 10 Washer 1 11 Drive sprocket 1 12 Drive chain 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 T R 95 Nm 9 5 m kg 68 ft Ib New New E LT LT 2 5 3 4 7 8 6 11 10 9 1 T R 26 Nm 2 6 m kg 19 ft Ib T R 24 Nm 2 4...

Page 627: ...s 2 Check Drive chain Stiffness Clean and lubricate or replace 3 Clean Drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and remove any remaining dirt c Remove the drive chain from the kerosene and completely dry it CAUTION EC5YU1022 This vehicle has a drive chain with small rubber O rings 1 between the drive chain side plates Never use high pressure water or ...

Page 628: ...KING AND REPLACING THE REAR WHEEL SPROCKET on page 4 15 EAS23480 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4 15 EAS28800 INSTALLING THE DRIVE CHAIN 1 Lubricate Drive chain 2 Install Drive sprocket 1 Washer 2 Drive sprocket nut 3 NOTE While applying the rear brake tighten the drive sprocket nut Install the washer 2 with its OUT mark a facing outward Stake ...

Page 629: ...CHAIN DRIVE 4 71 3 Install Clutch release cylinder Refer to INSTALLING THE CLUTCH RE LEASE CYLINDER on page 5 63 a 1 2 3 New b Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 630: ...ECKING THE OIL DELIVERY PIPE 5 26 INSTALLING THE CAMSHAFTS 5 26 BLEEDING A VALVE LIFTER 5 27 INSTALLING THE VALVE LIFTERS 5 29 INSTALLING THE ROCKER ARMS AND PUSH RODS 5 29 INSTALLING THE CYLINDER HEAD COVERS 5 30 CYLINDER HEADS 5 31 REMOVING THE CYLINDER HEADS 5 32 CHECKING THE CYLINDER HEADS 5 32 CHECKING THE OIL PIPE 5 32 INSTALLING THE CYLINDER HEADS 5 33 VALVES AND VALVE SPRINGS 5 34 REMOVING...

Page 631: ...HE CLUTCH MASTER CYLINDER 5 61 REMOVING THE CLUTCH RELEASE CYLINDER 5 62 CHECKING THE CLUTCH RELEASE CYLINDER 5 62 ASSEMBLING THE CLUTCH RELEASE CYLINDER 5 63 INSTALLING THE CLUTCH RELEASE CYLINDER 5 63 SHIFT SHAFT 5 65 CHECKING THE SHIFT SHAFT 5 66 CHECKING THE STOPPER LEVER 5 66 INSTALLING THE SHIFT SHAFT 5 66 GENERATOR AND STARTER CLUTCH 5 67 REMOVING THE GENERATOR 5 69 CHECKING THE STARTER CLU...

Page 632: ...CHECKING THE CRANKSHAFT AND CONNECTING RODS 5 88 INSTALLING THE CONNECTING RODS 5 91 INSTALLING THE CRANKSHAFT ASSEMBLY 5 92 TRANSMISSION 5 93 CHECKING THE SHIFT FORKS 5 96 CHECKING THE SHIFT DRUM ASSEMBLY 5 96 CHECKING THE TRANSMISSION 5 96 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 97 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 5 97 Manuals by Motomatrix www motomatrix co uk Email info mot...

Page 633: ...ank breather hose holder 1 7 Oil tank gasket 1 8 Oil strainer cover oil tank 1 9 Oil strainer oil tank 1 For installation reverse the removal proce dure T R 13 Nm 1 3 m kg 9 4 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 13 Nm 1 3 m kg 9 4 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 New New New New LS LS LS T R 13 Nm 1 3 m kg 9 4 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib 16 1 2 3 4 7 8 9 5 ...

Page 634: ...RAINER 1 Check Oil strainer oil tank Damage Replace Contaminants Clean with engine oil ET5YU1019 INSTALLING THE OIL TANK 1 Install Oil tank NOTE Tighten the oil tank bolts in the proper tightening sequence as shown T R Oil tank bolt 10 Nm 1 0 m kg 7 2 ft lb 1 5 7 3 2 6 8 4 10 16 15 13 11 14 12 9 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 635: ...ket 2 12 Rear exhaust pipe 1 13 Gasket 2 14 Catalyst pipe 1 For installation reverse the removal proce dure LT T R 24 Nm 2 4 m kg 17 ft Ib 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 10 Nm 1 0 m kg 7 2 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 20 Nm 2 0 m kg 14 ft Ib R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib LT T R 6 Nm 0 6 m kg 4 3 ft Ib New New N...

Page 636: ...alling a muffler end cover plate be sure to insert its hooks a two locations into the holes in the muffler cover and align its tabs b four locations with the grooves in the muf fler cover 2 Install Muffler end covers 1 NOTE When installing a muffler end cover align its pro jections a four locations with the grooves b in the muffler cover and then turn it in the direc tion of the arrow shown in the...

Page 637: ...ge 5 67 Drive sprocket Refer to CHAIN DRIVE on page 4 68 Rear shock absorber assembly Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 60 1 Rectifier regulator coupler 1 Disconnect 2 Stator coil assembly coupler 1 Disconnect 3 Rectifier regulator 1 4 Oil filter cartridge 1 5 Horn connector 2 Disconnect 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 30 Nm 3 ...

Page 638: ...oupler 1 Disconnect 21 Neutral switch 1 22 Rear exhaust pipe joint cover 1 Removing the EXUP servo motor and rear exhaust pipe joint Order Job Parts to remove Q ty Remarks 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 30 Nm 3 0 m kg 22 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib New New LS LS LS T R 24 Nm 2 4...

Page 639: ...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 30 Nm 3 0 m kg 22 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib New New LS LS LS T R 24 Nm 2 4 m kg 17 ft Ib LT LS T R 20 Nm 2 0 m kg 14 ft Ib New New T R 17 Nm 1 7 m kg 12 ft Ib 1 2 3 4 6 5 8 7 21 14 13 16 23 22 15 12 10 11 18 19 20 17 24 9 Manuals by Motomatrix www motomatrix co uk E...

Page 640: ...oupler 1 Disconnect 6 Starter motor connector 1 7 Starter motor lead 1 8 Crankshaft position sensor coupler 1 Disconnect 9 Negative battery lead 1 Disconnect 10 Engine temperature sensor coupler 1 Disconnect 11 Spark plug cap 4 For installation reverse the removal proce dure 3 6 11 11 9 5 8 4 1 2 10 7 T R 10 Nm 1 0 m kg 7 2 ft Ib Manuals by Motomatrix www motomatrix co uk Email info motomatrix co ...

Page 641: ...pper side 1 9 Engine mounting bolt front upper side 1 10 Engine bracket nut front upper side 4 11 Engine bracket bolt front upper side 4 12 Engine bracket front upper side 2 13 Down tube nut rear side 2 14 Down tube bolt rear side 2 T R 55 Nm 5 5 m kg 40 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib 74 Nm 7 4 m kg 53 ft lb T R 7 Nm 0 7 m kg 5 1 ft Ib T R...

Page 642: ...be Order Job Parts to remove Q ty Remarks T R 55 Nm 5 5 m kg 40 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib 74 Nm 7 4 m kg 53 ft lb 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 8 Nm 0 8 m kg 5 8 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 94 Nm 9 4 m kg 68 ft Ib T R 94 Nm 9 4 m kg 68 ft Ib E LT E 5 17 14 4 3 13 1 6 15 15 2 3 7 16 18 11 12 12 1...

Page 643: ...6 Engine mounting nut rear lower side 1 7 Engine mounting spacer bolt rear lower side 1 Loosen 8 Engine mounting bolt rear lower side 1 9 Engine 1 10 Right side panel bracket 1 11 Cylinder 1 right ignition coil 1 12 Cylinder 1 left ignition coil 1 13 Ignition coil bracket 1 T R 8 Nm 0 8 m kg 5 8 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib E E T R 74 Nm...

Page 644: ...ngine Order Job Parts to remove Q ty Remarks T R 8 Nm 0 8 m kg 5 8 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib E E T R 74 Nm 7 4 m kg 53 ft lb 2 1 3 10 14 11 13 12 6 7 4 5 8 9 T R 74 Nm 7 4 m kg 53 ft lb Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 645: ...nut rear side 12 temporarily tighten Engine mounting bolt front lower side 13 NOTE Do not fully tighten the bolts and nuts 5 Tighten Down tube spacer bolt 2 Engine mounting spacer bolt rear lower side 3 Engine mounting spacer bolt rear upper side 1 Down tube nut rear side 12 NOTE Tighten the spacer bolts 1 2 3 to specifi cation with a pivot shaft wrench When tightened the spacer bolts should be fl...

Page 646: ...NOTE Do not fully tighten the bolts and nuts 9 Tighten Engine mounting nut front lower side 21 Engine mounting nut front upper side 22 Engine bracket nuts front upper side 23 Engine bracket bolts left upper side 25 Engine mounting bolts left upper side 26 Engine bracket bolts right upper side 28 Engine mounting bolts right upper side 29 and 30 T R Down tube nut front side 74 Nm 7 4 m kg 53 ft lb E...

Page 647: ...ENGINE REMOVAL 5 15 25 10 11 28 26 12 29 27 14 30 26 24 2 21 19 18 18 19 23 22 20 9 13 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 648: ... 3 Crankshaft end cover 1 4 Decompression solenoid cover 1 5 Camshaft sprocket cover 1 6 Camshaft sprocket cover gasket 1 7 Dowel pin 2 For installation reverse the removal proce dure LS T R 18 Nm 1 8 m kg 13 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 8 Nm 0 8 m kg 5 8 ft Ib 4 7 6 5 2 3 1 1 New 6 New New Manuals by Motomatrix www motomatrix co uk Email info motomatrix co u...

Page 649: ... Cylinder head cover bolt 12 l 40 mm 1 57 in 8 Rear cylinder head cover 1 9 Front cylinder head cover 1 10 Cylinder head cover gasket 2 11 Dowel pin 4 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 New New New New LS LS 7 7 7 7 7 7 7 8 1 1 1 2 2 3 3 4 4 5 5 7 4 6 6 6 6 7 11 6 6 4 6 6 6 6 7 9 10 10 11 11 11 LT T R 10 Nm 1 0 m kg 7 2 ft Ib L...

Page 650: ...90 5 mm 11 437 in yellow painting 7 Rear rocker arm base 1 8 Front rocker arm base 1 9 Rocker arm shaft 4 10 Rocker arm 1 2 11 Rocker arm 2 2 12 Locknut 4 13 Adjusting screw 4 For installation reverse the removal proce dure E E E E E E E E E E 12 13 10 12 13 11 9 6 5 7 3 4 4 12 13 10 9 12 13 11 9 5 4 3 New New 1 2 8 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 20 Nm 2 0 m kg 14 ft ...

Page 651: ...r 2 2 O ring 4 3 Seal 2 4 Rear valve lifter case 1 5 Front valve lifter case 1 6 Valve lifter 4 For installation reverse the removal proce dure LT LT E E E E E E E 2 1 3 2 6 6 4 5 2 1 3 2 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib New New New New New New New New New New Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 652: ...ylinder camshaft end cover 1 9 Oil delivery pipe 1 10 Camshaft cover 1 11 Camshaft cover gasket 1 12 Dowel pin 2 13 Front cylinder camshaft 1 14 Rear cylinder camshaft 1 For installation reverse the removal proce dure LT LT 14 11 13 12 12 10 9 6 3 2 7 4 5 8 1 6 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 30 Nm 3 0 m kg 22 ft Ib T R 52 Nm 5 2 m kg 37 ft ...

Page 653: ... Remove Valve lifters NOTE Make a note of the position of each valve lifter so that they can be installed in the correct place CAUTION EC5YU1015 Do not lay the removed valve lifter on its side EAS23830 REMOVING THE CAMSHAFTS 1 Loosen Front cylinder camshaft end cover bolts 1 Camshaft drive gear bolt 2 NOTE Place a folded copper washer 3 between the teeth of the camshaft drive gear and camshaft dri...

Page 654: ...860 CHECKING THE CAMSHAFTS 1 Check Cam Blue discoloration pitting scratches Re place the camshaft 2 Measure Cam dimensions a and b Out of specification Replace the camshaft Camshaft lobe dimensions Intake A 38 241 38 341 mm 1 5055 1 5095 in cylinder 1 38 243 38 343 mm 1 5056 1 5096 in cylinder 2 Limit 38 141 mm 1 5016 in cylinder 1 38 143 mm 1 5017 in cylinder 2 Intake B 31 950 32 050 mm 1 2579 1 ...

Page 655: ...learance Out of specification Replace the defective part s NOTE Calculate the clearance by subtracting the crankcase side camshaft journal diameter crankcase side from the crankcase hole inside diameter Camshaft journal diameter crankcase side 24 942 24 965 mm 0 9820 0 9829 in Camshaft journal diameter cam shaft cover side 27 967 27 980 mm 1 1011 1 1016 in Crankcase hole inside diameter 25 000 25 ...

Page 656: ...Measure Rocker arm shaft outside diameter a Out of specification Replace 5 Calculate Rocker arm to rocker arm shaft clearance NOTE Calculate the clearance by subtracting the rock er arm shaft outside diameter from the rocker arm inside diameter Above 0 08 mm 0 003 in Replace the de fective part s EAS23900 CHECKING THE ROCKER ARM BASES 1 Check Rocker arm base Cracks damage Replace EAS23910 CHECKING...

Page 657: ...ifter case clearance NOTE Calculate the clearance by subtracting the valve lifter case outside diameter Above 0 072 mm 0 0028 in Replace the defective part s EAS23930 CHECKING THE PUSH ROD COVER 1 Check Push rod cover Cranks damage Replace Seal Valve lifter outside diameter in take 22 962 22 974 mm 0 9040 0 9045 in Valve lifter outside diameter ex haust 22 962 22 974 mm 0 9040 0 9045 in Valve lift...

Page 658: ...rings Damage wear Replace EAS24030 INSTALLING THE CAMSHAFTS 1 Install Camshafts to the camshaft cover NOTE Lubricate molybdenum disulfide oil onto the camshaft journals and lobes Align the punch mark a on the rear cylinder camshaft with the punch mark b on the front cylinder camshaft 2 Install Camshaft cover 1 along with the camshafts Camshaft oil delivery pipe 2 NOTE Tighten the camshaft cover bo...

Page 659: ...eeth of the camshaft drive gear and camshaft driven gear 6 Tighten Camshaft drive gear bolt 1 Front cylinder camshaft end cover bolts 2 NOTE Place a folded copper washer 3 between the teeth of the camshaft drive gear and camshaft driven gear in order to lock them Do not damage the teeth of the camshaft drive and camshaft driven gear After tightening the camshaft drive gear bolt remove the copper w...

Page 660: ...plugs are removed WARNING EWA12880 Be careful since the engine is hot g With piston 1 at TDC count the indicated number of gear teeth and place marks 2 through 5 on the camshaft driven gear as shown When these marks align between the centers of the camshaft drive and driven gears the corresponding valve lifter is at its highest point h Rotate the crankshaft until the mark on the camshaft driven ge...

Page 661: ...nstall Rocker arms 1 Rocker arm shafts 2 onto rocker arm base NOTE The thread hole a of the rocker arm shaft must face to the outside 2 Install Rocker arm base with rocker arms Push rods a Put the rocker arm base on the cylinder head b Install the push rods NOTE Be sure to correctly install the push rods be tween the rocker arms and valve lifters as shown The illustration is viewed from the right ...

Page 662: ...97 in Bolt with washer 6 l 50 mm 1 97 in Bolts 7 l 60 mm 2 36 in 2 Install Tappet covers 1 NOTE Install the tappet covers with their UP marks a facing each other A Rear cylinder B Front cylinder 1 Intake side rocker arm 2 Exhaust side rocker arm 3 Intake valve lifter 4 Exhaust valve lifter 5 Push rod 1 l 288 5 mm 11 358 in 6 Push rod 2 l 290 5 mm 11 437 in T R Rocker arm base bolt M6 10 Nm 1 0 m k...

Page 663: ...r heads 4 Copper washer 4 5 Copper washer 2 6 Engine temperature sensor 1 7 Rear cylinder head 1 8 Front cylinder head 1 9 Cylinder head gasket 2 10 Dowel pin 4 For installation reverse the removal proce dure E T R 21 Nm 2 1 m kg 15 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 39 Nm 3 9 m kg 28 ft Ib 7 4 4 9 10 3 5 9 10 10 2 8 6 1 E New New New New ...

Page 664: ...d Damage scratches Replace 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge and a thickness gauge across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylinder head as 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...

Page 665: ...er head nuts with engine oil Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages T R Cylinder head nut M12 45 Nm 4 5 m kg 32 ft lb T R Cylinder head nut M10 39 Nm 3 9 m kg 28 ft lb A Front cylinder B Rear cylinder 6 4 2 1 3 5 B Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 666: ...to CYLINDER HEADS on page 5 31 1 Valve cotter 8 2 Upper spring seat 4 3 Outer valve spring 4 4 Inner valve spring 4 5 Intake valve 2 6 Exhaust valve 2 7 Valve stem seal 4 8 Lower spring seat 4 9 Valve guide 4 For installation reverse the removal proce dure 5 6 8 3 4 7 2 1 8 3 4 7 2 1 8 3 4 7 2 1 8 3 4 7 2 1 M E M E New New New New 9 9 9 9 M M Manuals by Motomatrix www motomatrix co uk Email info m...

Page 667: ...t 1 2 Remove Valve cotters NOTE Remove the valve cotters by compressing the valve springs with the valve spring compressor set 1 3 Remove Upper spring seat 1 Outer valve spring 2 Inner valve spring 3 Valve 4 Valve stem seal 5 Lower spring seat 6 NOTE Identify the position of each part very carefully so that it can be reinstalled in its original place EAS24290 CHECKING THE VALVES AND VALVE GUIDES T...

Page 668: ... and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance NOTE After replacing the valve guide reface the valve seat 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 0 025 0 052 mm 0 0010 0 ...

Page 669: ...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 Valve guide remover ø6 90890 04064 Valve guide remover 6 0 mm YM 04064 A Valve guide installer ø6 90890 04065 Valve guide installer 6 0 mm YM 04065 A Valve guide reamer ø6 90890 04066 V...

Page 670: ...valve seat are evenly polished then clean off all of the lapping compound NOTE For the best lapping results lightly tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping 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 Mech...

Page 671: ...42 7 44 kgf Installed compression spring force exhaust 63 00 73 00 N 14 16 16 41 lb 6 42 7 44 kgf Installed length intake 29 00 mm 1 14 in Installed length exhaust 29 00 mm 1 14 in Outer spring Installed compression spring force intake 139 00 161 00 N 31 25 36 19 lb 14 17 16 42 kgf Installed compression spring force exhaust 139 00 161 00 N 31 25 36 19 lb 14 17 16 42 kgf Installed length intake 31 ...

Page 672: ...g seat 2 Valve stem seal 3 Valve 4 Inner valve spring 5 Outer valve spring 6 Upper spring seat 7 into the cylinder head NOTE Install the valve springs with the larger pitch a facing up 4 Install Valve cotters NOTE Install the valve cotters by compressing the valve springs with the valve spring compressor set 1 Recommended lubricant Molybdenum disulfide oil b Smaller pitch Valve spring compressor 9...

Page 673: ... the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION ECA13800 Hitting the valve tip with excessive force could damage the valve Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 674: ...HEADS on page 5 31 1 Front cylinder 1 2 Rear cylinder 1 3 Cylinder gasket 2 4 Dowel pin 4 5 Piston pin clip 4 6 Piston pin 2 7 Piston 2 8 Top ring 2 9 2nd ring 2 10 Oil ring 2 For installation reverse the removal proce dure 1 3 4 5 7 8 9 10 3 4 6 5 5 7 6 5 8 9 10 2 New New New New New New E E E Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 675: ...on ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS24410 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cyl inders and pistons 1 Check Piston wall Cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure cyli...

Page 676: ... a set NOTE Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder NOTE Level the piston ring into the cylinder with the piston crown Piston Diameter D 96 960 96 975 mm 3 8173 3 8179 in b 10 mm 0 39 in from the bottom edge of the piston Piston to cylinder clearance Cylinder bore C Piston sk...

Page 677: ...ion Replace the piston pin and piston as a set EAS24460 INSTALLING THE PISTONS AND CYLINDERS The following procedure applies to all of the pis tons and cylinders 1 Install Top ring 1 2nd ring 2 Piston ring Top ring End gap installed 0 30 0 50 mm 0 0118 0 0197 in Limit 0 70 mm 0 0276 in 2nd ring End gap installed 0 30 0 45 mm 0 0118 0 0177 in Limit 0 80 mm 0 0315 in Oil ring End gap installed 0 20 ...

Page 678: ... opening with a clean rag to prevent the clip from falling into the crankcase Reinstall each piston into its original cylinder numbering order starting from the left 1 to 2 3 Lubricate Piston Piston rings Cylinder with the recommended lubricant 4 Offset Piston ring end gaps 5 Install Cylinder 1 NOTE While compressing the piston rings with one hand install the cylinder with the other hand Recommend...

Page 679: ...n page 4 1 Oil tank Shift rod Refer to ENGINE REMOVAL on page 5 1 1 Crankshaft position sensor coupler 1 Disconnect 2 Shift arm 1 3 Oil tank bracket 1 4 Clutch cover 1 5 Clutch cover gasket 1 6 Dowel pin 2 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 10 5 2 3 6 4 5 6 1 New Manuals by Motomatrix www motomatrix co uk Email info motomatrix ...

Page 680: ...marks 1 Oil seal 1 2 Bearing 1 3 Crankshaft position sensor lead holder 3 4 Crankshaft position sensor 1 For installation reverse the removal proce dure 2 1 3 3 3 4 LT LT LT LT LT LS T R 10 Nm 1 0 m kg 7 2 ft Ib New Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 681: ...sher 1 9 Wire circlip 1 10 Clutch plate 1 11 Friction plate 2 1 12 Clutch damper spring 1 13 Clutch damper spring seat 1 14 Clutch boss 1 15 Thrust washer 1 1 16 Bearing 1 17 Clutch housing 1 LS LS New New New E T R 100 Nm 10 0 m kg 72 ft lb LT New T R 125 Nm 12 5 m kg 90 ft lb E E 7 6 18 19 20 24 25 23 22 21 17 16 15 14 13 12 11 10 9 8 1 2 3 4 5 26 27 28 29 6 T R 8 Nm 0 8 m kg 5 8 ft Ib Manuals b...

Page 682: ... drive gear 1 29 Straight key 1 For installation reverse the removal proce dure Removing the clutch Order Job Parts to remove Q ty Remarks LS LS New New New E T R 100 Nm 10 0 m kg 72 ft lb LT New T R 125 Nm 12 5 m kg 90 ft lb E E 7 6 18 19 20 24 25 23 22 21 17 16 15 14 13 12 11 10 9 8 1 2 3 4 5 26 27 28 29 6 T R 8 Nm 0 8 m kg 5 8 ft Ib Manuals by Motomatrix www motomatrix co uk Email info motomatr...

Page 683: ...nder reservoir diaphragm holder 1 4 Clutch master cylinder reservoir diaphragm 1 5 Clutch lever 1 6 Bushing 1 7 Clutch switch coupler 1 Disconnect 8 Clutch switch 1 9 Clutch hose union bolt 1 10 Copper washer 2 11 Clutch hose 1 12 Clutch master cylinder holder 1 T R 30 Nm 3 0 m kg 22 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib 10 9 11 8 6 7 12 1 5 13 2 3 4 New Manuals by Motomat...

Page 684: ... the removal proce dure Removing the clutch master cylinder Order Job Parts to remove Q ty Remarks T R 30 Nm 3 0 m kg 22 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib 10 9 11 8 6 7 12 1 5 13 2 3 4 New Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 685: ...nder Order Job Parts to remove Q ty Remarks 1 Clutch master cylinder push rod 1 2 Clutch master cylinder kit 1 3 Clutch master cylinder body 1 For assembly reverse the disassembly pro cedure 3 2 1 New Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 686: ...SYSTEM on page 3 14 1 Clutch pipe union bolt cap 1 2 Clutch pipe union bolt 1 3 Copper washer 2 4 Clutch pipe 1 5 Clutch release cylinder 1 6 Dowel pin 2 For installation reverse the removal proce dure T R 10 Nm 1 0 m kg 7 2 ft Ib T R 26 Nm 2 6 m kg 19 ft Ib New 3 6 2 6 5 4 1 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 687: ...ots 1 2 Clutch release cylinder piston 1 3 Clutch release cylinder spring 1 4 Clutch release cylinder piston seal 1 5 Bleed screw 1 For assembly reverse the disassembly pro cedure LS LS 1 2 4 3 5 New T R 6 Nm 0 6 m kg 4 3 ft Ib Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 688: ...ar bolt 1 NOTE While holding the generator rotor 2 with the sheave holder 3 loosen the primary drive gear bolt EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replace the friction plates as a set NOTE Measure the fricti...

Page 689: ...ng 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 operation EAS2...

Page 690: ...oise during operation Replace the primary drive and primary driven gears as a set EAS24540 INSTALLING THE CRANKSHAFT POSITION SENSOR 1 Apply Sealant onto the crankshaft position sensor lead grommet EAS25230 INSTALLING THE PRIMARY DRIVE GEAR 1 Install Straight key 1 Primary drive gear 2 Crankshaft position sensor rotor 3 Spacer 4 Primary drive gear bolt 5 CAUTION EC5YU1014 The timing marks on the c...

Page 691: ...rfaces with engine oil Install the washer 2 with the OUT mark a facing out While holding the clutch boss with the univer sal clutch holder 4 tighten the clutch boss nut Stake the clutch boss nut 3 at a cutout b in the main axle 4 Lubricate Friction plates Clutch plates with the recommended lubricant 5 Install Friction plates Clutch plates NOTE First install a friction plate and then alternate betw...

Page 692: ... internal clutch com ponents Use only clean or new clutch fluid for clean ing clutch components Clutch fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt fluid immediately Avoid clutch fluid coming into contact with the eyes as it can cause serious injury First aid for clutch fluid entering the eyes Flush with water for 15 minutes and get im mediate medical att...

Page 693: ...master cylinder 1 Clutch master cylinder holder 2 NOTE The clutch master cylinder holder should be in stalled with the punch mark a forward Align the end of the clutch master cylinder holder with the punch mark b on the handle bar First tighten the front bolt then the rear bolt 2 Install Copper washers 1 Clutch hose 2 Clutch hose union bolt 3 WARNING EWA5YU8001 Proper clutch hose routing is essent...

Page 694: ...d level make sure the top of the reservoir is horizontal 4 Bleed Clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 14 5 Check Clutch fluid level Below the minimum level mark a Add the recommended clutch fluid to the proper level Refer to CHECKING THE CLUTCH FLUID LEVEL on page 3 14 6 Check Clutch lever operation Soft or spongy feeling Bleed the clutch system Refer to BLEEDING T...

Page 695: ...the recom mended clutch fluid WARNING EWA13370 Use only the designated clutch fluid Other clutch fluids may cause the rubber seals to deteriorate causing leakage and poor clutch performance Refill with the same type of clutch fluid that is already in the system Mixing clutch flu ids may result in a harmful chemical reac tion leading to poor clutch performance When refilling be careful that water d...

Page 696: ...eck Clutch lever operation Soft or spongy feeling Bleed the clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 14 LOWER UPPER a Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 697: ... on page 5 47 1 Shift shaft 1 2 Circlip 2 3 Shift shaft spring 1 4 Shift shaft spring stopper 1 5 Washer 1 6 Stopper lever 1 7 Stopper lever spring 1 For installation reverse the removal proce dure LS LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 22 Nm 2 2 m kg 16 ft Ib 1 3 2 7 6 5 4 New Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 698: ...lever bolt 2 Stopper lever spring 3 NOTE Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss 4 Install the stopper lever spring as shown in the illustration Mesh the stopper lever with the shift drum seg ment assembly 2 Install Shift shaft spring 1 Circlips Shift shaft 2 NOTE Lubricate the oil seal lips with lithium soap based grease Hook the end of the shift sh...

Page 699: ...ier regulator 1 3 Oil pipe 2 1 From oil pump to generator cover 4 Generator cover 1 5 Generator cover gasket 1 6 Dowel pin 2 7 Stator coil assembly lead holder 1 8 Stator coil assembly 1 For installation reverse the removal proce dure LT 9 LT T R 7 Nm 0 7 m kg 5 1 ft Ib 8 5 4 6 3 7 2 1 6 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 10 Nm 1 0 m kg 7 2 f...

Page 700: ...ft 2 1 2 Starter clutch idle gear shaft 1 1 3 Starter clutch idle gear 2 1 4 Starter clutch idle gear 1 1 5 Generator rotor 1 6 Woodruff key 1 7 Starter clutch gear 1 For installation reverse the removal proce dure E R 80 Nm 8 0 m kg 58 ft Ib T 2 4 3 1 5 7 6 E E Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 701: ... starter clutch gear clock wise A the starter clutch and the starter clutch gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter clutch gear counter clockwise B it should turn freely otherwise the starter clutch is faulty and must be re placed EAS24510 INSTALLING THE GENERATOR 1 Install Woodruff key Generator rotor 1 Washer Generator rotor bolt ...

Page 702: ...rator rotor 2 with a sheave holder 3 3 Apply Sealant onto the stator coil assembly lead grommet T R Generator rotor bolt 80 Nm 8 0 m kg 58 ft lb Sheave holder 90890 01701 Primary clutch holder YS 01880 A Yamaha bond No 1215 90890 85505 Three Bond No 1215 2 3 1 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 703: ...otor Order Job Parts to remove Q ty Remarks Oil tank Refer to ENGINE REMOVAL on page 5 1 1 Starter motor lead 1 Disconnect 2 Starter motor assembly 1 For installation reverse the removal proce dure 2 1 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 704: ...rclip 1 7 Starter motor front cover 1 8 Brush 2 9 Brush holder along with the brushes 1 10 Brush seat along with the brushes 1 11 Bearing 1 12 Gasket 2 13 Armature assembly 1 14 Starter motor yoke 1 For assembly reverse the disassembly pro cedure 8 4 5 7 3 2 1 6 LS New New New New New New 12 11 12 10 9 14 13 New LS Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 705: ...cification Replace the 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 27 5 mm 1 08 in Mica undercut depth 1 50 mm 0 06 in Pocket ...

Page 706: ...the tab b in the starter motor front cover 2 Install Starter motor yoke 1 NOTE Align the tab a on the brush holder with the slot b in the starter motor yoke 3 Install Starter motor yoke 1 Starter motor front cover 2 Starter motor rear cover 3 NOTE Align the match mark a on the starter motor yoke with the match mark b on the starter mo tor rear cover b a 1 1 b a 3 1 2 a b Manuals by Motomatrix www ...

Page 707: ... PISTONS on page 5 42 Shift shaft Refer to SHIFT SHAFT on page 5 65 Generator rotor Refer to GENERATOR AND STARTER CLUTCH on page 5 67 1 Speed sensor 1 2 Oil filter cartridge bracket 1 3 Generator shaft end cover 1 4 Oil delivery pipe 2 1 5 Oil pump driven gear stopper 1 6 Oil pump driven gear 1 7 Left crankcase 1 8 Dowel pin 2 9 Joint pipe 1 Manuals by Motomatrix www motomatrix co uk Email info m...

Page 708: ...E 5 76 10 Right crankcase 1 For installation reverse the removal proce dure Separating the crankcase Order Job Parts to remove Q ty Remarks Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 709: ...L PUMP on page 5 82 Crankshaft Refer to CRANKSHAFT on page 5 87 Transmission Refer to TRANSMISSION on page 5 93 1 Oil baffle plate 1 2 Bearing retainer 1 3 Bearing retainer 1 4 Oil seal 1 5 Bearing 4 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 710: ... tightening sequence M8 100 mm bolts 1 2 M8 80 mm bolt 3 M6 105 mm bolt 21 M6 85 mm bolt 9 13 M6 75 mm bolts 14 15 M6 60 mm bolts 4 7 M6 40 mm bolts 8 10 12 16 20 3 Turn Shift drum segment NOTE Turn the shift drum segment 1 to the position shown in the illustration In this position the shift drum segment s teeth will not contact the crank case during crankcase separation 4 Remove Left crankcase CA...

Page 711: ... THE OIL PUMP DRIVE 1 Check Oil pump drive gear Oil pump driven gear Chips pitting roughness wear Replace the defective part s ET5YU1023 INSTALLING THE BEARING RETAINER 1 Install Bearing retainer 1 NOTE Install the bearing retainer 1 with its OUT mark a facing outward Apply locking agent LOCTITE to the threads of the bearing retainer bolt EAS25690 ASSEMBLING THE CRANKCASE 1 Apply Sealant onto the ...

Page 712: ...m bolts 4 7 M6 40 mm bolts 8 10 12 16 20 5 Apply Engine oil onto the crankshaft pins bearings and oil de livery holes 6 Check Crankshaft and transmission operation Rough movement Repair 7 Install Generator shaft bolt 1 NOTE While the holding the generator rotor 2 with the primary sheave holder 3 tighten the generator shaft bolt T R Crankcase bolt M8 24 Nm 2 4 m kg 17 ft lb Crankcase bolt M6 10 Nm ...

Page 713: ...CRANKCASE 5 81 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 714: ...rder Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 75 1 Oil strainer crankcase 1 2 Oil pump assembly 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 715: ...1 4 Oil pump housing cover 1 1 5 Pin 2 6 Spring 1 7 Collar 1 8 Ball 1 9 Oil pump outer rotor 1 1 10 Oil pump inner rotor 1 1 11 Pin 1 12 Oil pump housing cover 2 1 13 Pin 2 14 Oil pump shaft 1 15 Pin 1 16 Oil pump inner rotor 2 1 17 Oil pump outer rotor 2 1 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 716: ... Oil seal 2 19 Oil pump housing 1 For assembly reverse the disassembly pro cedure Disassembling the oil pump Order Job Parts to remove Q ty Remarks Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 717: ...r Replace the defective part s EAS24990 CHECKING THE OIL STRAINER 1 Check Oil strainer crankcase Damage Replace Contaminants Clean with solvent EAS25000 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor Oil pump shaft with the recommended lubricant 2 Install Oil pump housing 1 Oil seal 2 Oil pump outer rotor 2 3 Oil pump inner rotor 2 4 Pin 5 Inner rotor to outer rotor tip clearance Less...

Page 718: ...groove in the inner ro tor 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 85 EAS25020 INSTALLING THE OIL PUMP 1 Install Oil pump 1 CAUTION ECA13890 After tightening the bolts make sure the oil pump turns smoothly T R Oil pump housing cover 2 screw 2 Nm 0 2 m kg 1 4 ft lb T R Oil pump housing cover 1 screw 2 Nm 0 2 m kg 1 4 ft lb T R Spring retainer bolt 10 Nm 1 0 m kg 7 2 ft l...

Page 719: ... Crankcase Separate Refer to CRANKCASE on page 5 75 1 Crankshaft 1 2 Generator shaft 1 3 Connecting rod cap 2 4 Big end lower bearing 2 5 Connecting rod 2 6 Big end upper bearing 2 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 720: ...of specification Replace the big end bearings The following procedure applies to all of the connecting rods CAUTION ECA13930 Do not interchange the big end bearings and connecting rods To obtain the correct crankshaft pin to big end bearing clear ance and prevent engine damage the big end bearings must be installed in their origi nal positions a Clean the big end bearings crankshaft pins and the i...

Page 721: ... bolts to the spec ified torque g Put a mark 1 on the connecting rod bolts 2 and the connecting rod cap 3 h Tighten the connecting rod bolts further to reach the specified angle 120 150 WARNING EWA12900 When the bolts are tightened more than the specified angle do not loosen the bolt and then retighten it Replace the bolt with a new one and perform the procedure again CAUTION EC5YU1008 Do not use ...

Page 722: ...ter a Out of specification Replace the crank shaft NOTE Measure the diameter of each crankshaft journal at two places 6 Measure Crankshaft journal bearing inside diameter a Out of specification Replace the crank case assembly NOTE Measure the inside diameter of each crankshaft journal bearing at two places P1 P2 a P1 connecting rod P crankshaft 5 2 3 brown Bearing color code 1 Blue 2 Black 3 Brown...

Page 723: ...aps onto the crankshaft pins NOTE Align the projections a on the big end bear ings with the notches b in the connecting rods and connecting rod caps Be sure to reinstall each big end bearing in its original place Make sure the projections c on the connect ing rods face towards the left side of the crank shaft Make sure the characters d on both the con necting rod and connecting rod cap are aligned...

Page 724: ...n CAUTION EC5YU1008 Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is the specified an gle EAS26210 INSTALLING THE CRANKSHAFT ASSEMBLY 1 Install Crankshaft assembly CAUTION ECA13970 To avoid scratching the crankshaft and to ease the installation procedure lubricate the oil seal lips with lithium soap based grease and each bearing with engine oil NOT...

Page 725: ...Remarks Crankcase Separate Refer to CRANKCASE on page 5 75 1 Shift fork guide bar 2 2 Shift drum assembly 1 3 Shift fork L 1 4 Shift fork R 1 5 Shift fork C 1 6 Drive axle assembly 1 7 Main axle assembly 1 8 Spacer 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 726: ... 1 Circlip 1 2 Washer 1 3 5th pinion gear 1 4 Collar 1 5 Washer 1 6 2nd 3rd pinion gear 1 7 Circlip 1 8 Washer 1 9 4th pinion gear 1 10 Collar 1 11 Main axle 1st pinion gear 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 727: ...ip 1 3 Washer 1 4 2nd wheel gear 1 5 Collar 1 6 Circlip 1 7 Washer 1 8 1st wheel gear 1 9 Collar 1 10 Washer 1 11 4th wheel gear 1 12 Circlip 1 13 Washer 1 14 3rd wheel gear 1 15 Collar 1 16 Drive axle 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 728: ...IFT 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 TRANSMISSION 1 Measure Main axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle 2 Measure Drive axle ...

Page 729: ... circlip sharp edged corner a is positioned opposite side to the toothed washer and gear Install the circlip so that both ends b rest on the sides of a spline c with both axles aligned EAS26320 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 1 Install Shift fork R 1 Shift fork C 2 Shift fork L 3 Shift drum assembly 4 Shift fork guide bars 5 NOTE The embossed marks on the shift forks should face...

Page 730: ...TLE BODIES 6 4 CHECKING THE INJECTORS 6 9 CHECKING THE THROTTLE BODIES 6 9 CHECKING THE ROLLOVER VALVES 6 9 CHECKING THE PRESSURE REGULATOR 6 9 CHECKING THE PRESSURE REGULATOR OPERATION 6 9 ADJUSTING THE THROTTLE POSITION SENSOR 6 10 INSTALLING THE FUEL PIPE 6 10 ISC IDLE SPEED CONTROL UNIT 6 11 CHECKING THE ISC IDLE SPEED CONTROL SYSTEM 6 13 Manuals by Motomatrix www motomatrix co uk Email info m...

Page 731: ...nect 3 Fuel sender coupler 1 Disconnect 4 Fuel tank overflow hose 1 Disconnect 5 Fuel tank breather hose 1 Disconnect 6 Fuel hose 1 Disconnect 7 Fuel return hose 1 Disconnect 8 Fuel tank 1 9 Fuel pump 1 For installation reverse the removal proce dure 7 4 3 2 5 6 9 8 1 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib 6 New Manuals by Motomatrix www motomatrix co uk Email info motomatrix co u...

Page 732: ...THE FUEL PUMP 1 Remove Fuel pump CAUTION ECA14720 Do not drop the fuel pump or give 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 2 Check Diaphragms and gaskets Tears fatigue cracks Replace fuel pump assembly EAS26690 CHECKING THE FUEL PUMP OPERATION 1 Check ...

Page 733: ...e is in the correct posi tion otherwise the fuel hose will not be prop erly installed NOTE Install the fuel hose securely onto the fuel pump until a distinct click is heard To install the fuel hose onto the fuel pump slide the fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown 1 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 734: ... 3 Pressure regulator 1 4 Fuel return hose 1 5 Fuel pipe holder 2 6 Fuel return hose fuel return pipe to fuel pump 1 7 Fuel return pipe 1 8 Fuel tank breather hose 1 9 Fuel tank overflow hose 1 10 Fuel tank breather overflow hose holder 1 11 Fuel tank breather overflow hose 1 12 Rollover valve hose 4 13 Rollover valve 1 1 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 9 Nm 0 9 m kg 6 ...

Page 735: ...al proce dure Removing the pressure regulator and rollover valves Order Job Parts to remove Q ty Remarks 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 9 Nm 0 9 m kg 6 5 ft Ib 6 7 5 5 10 8 9 13 15 14 12 12 12 12 11 2 4 3 1 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 736: ...r pressure sensor hose 1 Disconnect 4 Intake solenoid vacuum hose one way valve to throttle body 1 Disconnect 5 Throttle cable 2 Disconnect 6 Throttle body joint clamp screw 2 Loosen 7 Throttle body 1 CAUTION EC5YU1030 The throttle body should not be disas sembled 8 Throttle position sensor 1 For installation reverse the removal proce dure LS 5 7 8 6 6 3 1 4 2 T R 4 Nm 0 4 m kg 2 9 ft Ib T R 4 Nm ...

Page 737: ...peed control unit outlet hose 1 4 Cylinder 1 ISC idle speed control unit outlet hose 1 5 Intake manifold assembly 1 6 Cylinder 2 injector coupler 1 Disconnect 7 Cylinder 1 injector coupler 1 Disconnect 8 Gasket 2 For installation reverse the removal proce dure 3 4 6 7 8 5 8 1 2 T R 10 Nm 1 0 m kg 7 2 ft Ib New New 2 2 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 738: ...int 1 1 3 Injector joint 2 1 4 Injector 2 5 Intake manifold 2 For installation reverse the removal proce dure 2 4 3 4 1 T R 30 Nm 3 0 m kg 22 ft Ib New New New New New New New New 5 5 T R 5 Nm 0 5 m kg 3 6 ft Ib T R 5 Nm 0 5 m kg 3 6 ft Ib Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 739: ...on when checking the airflow EAS27000 CHECKING THE PRESSURE REGULATOR 1 Check Pressure regulator Damage Replace EAS27010 CHECKING THE PRESSURE REGULATOR OPERATION 1 Check Pressure regulator operation a Remove the pressure regulator cover Refer to THROTTLE BODIES on page 6 4 b Disconnect the fuel hose 1 from the pres sure regulator 2 c Connect the fuel pressure adapter 3 be tween the fuel hose 1 an...

Page 740: ...voltage d Adjust the throttle position sensor angle so that the voltage is within the specified range e After adjusting the throttle position sensor an gle tighten the throttle position sensor screws 3 ET5YU1016 INSTALLING THE FUEL PIPE 1 Install Fuel pipe 1 NOTE Install the fuel pipe 1 so that it contacts the pro jections a on the injector joints Fuel pressure 392 kPa 3 92 kg cm 55 7 psi Increase...

Page 741: ...4 Intake solenoid vacuum hose one way valve to throttle body 1 Disconnect 5 One way valve 1 6 Intake solenoid vacuum hose intake solenoid to one way valve 1 7 Intake solenoid vacuum hose air filter case valve to intake solenoid 1 8 Intake solenoid coupler 1 Disconnect 9 Intake solenoid 1 10 Intake solenoid holder 1 11 Intake solenoid bracket 1 13 12 14 16 15 9 10 2 1 3 11 6 5 4 8 7 T R 7 Nm 0 7 m ...

Page 742: ... 15 ISC idle speed control unit inlet hose 1 16 ISC idle speed control unit 1 For installation reverse the removal proce dure Removing the ISC idle speed control unit and intake solenoid Order Job Parts to remove Q ty Remarks 13 12 14 16 15 9 10 2 1 3 11 6 5 4 8 7 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 9 Nm 0 9 m kg 6 5 ft Ib Manuals by Motomatrix www motomatrix co uk Email i...

Page 743: ...roperly Cracks damage Replace 2 Check Surge tank Cracks damage Replace 3 Check One way valve Cracks damage faulty Replace NOTE Check that air flows smoothly only in the direc tion of the arrow shown in the illustration 4 Check Intake solenoid Damage Replace Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 744: ... INJECTION SYSTEM 7 25 CIRCUIT DIAGRAM 7 25 ECU SELF DIAGNOSTIC FUNCTION 7 27 SELF DIAGNOSTIC FUNCTION TABLE 7 28 TROUBLESHOOTING METHOD 7 31 DIAGNOSTIC MODE 7 31 TROUBLESHOOTING DETAILS 7 39 FUEL PUMP SYSTEM 7 67 CIRCUIT DIAGRAM 7 67 TROUBLESHOOTING 7 69 MUFFLER COOLING SYSTEM 7 71 CIRCUIT DIAGRAM 7 71 TROUBLESHOOTING 7 73 IMMOBILIZER SYSTEM 7 75 CIRCUIT DIAGRAM 7 75 GENERAL INFORMATION 7 77 PART...

Page 745: ...101 CHECKING THE STATOR COIL 7 101 CHECKING THE RECTIFIER REGULATOR 7 102 CHECKING THE HORN 7 102 CHECKING THE ENGINE TEMPERATURE SENSOR 7 103 CHECKING THE FUEL SENDER 7 103 CHECKING THE SPEED SENSOR 7 104 CHECKING THE THROTTLE POSITION SENSOR 7 104 CHECKING THE FUEL PUMP 7 105 CHECKING THE EXUP SERVO MOTOR 7 105 CHECKING THE DECOMPRESSION SOLENOID 7 106 CHECKING THE INTAKE AIR PRESSURE SENSORS 7 ...

Page 746: ...Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 747: ...G L R L R B B GRAY GRAY BLACK BLACK Dg B B L Ch B B Ch B B Ch B Dg Dg BLACK BLACK B B Dg Dg G G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y BLACK B L L Y BLACK L B Sb B Sb Sb R L BLACK BLACK B R B B B R R Br L Br L Br R Br R R R B R B R L L R W B G Y Y G R W R W Y Br Y Br W L Br B L L Y L W Gy R B R Gy W B R B R W R B G B R B L L Lg Dg Ch L B G Y L R G R L B L R W Gy G Gy W Sb Dg Ch Y B ...

Page 748: ...rankshaft position sensor 24 Lean angle cut off switch 29 ECU electronic control unit 32 Spark plug 33 Cylinder 2 right ignition coil 34 Cylinder 2 left ignition coil 35 Cylinder 1 left ignition coil 36 Cylinder 1 right ignition coil 56 Clutch switch 73 Engine stop switch 81 Ignition fuse Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 749: ...s Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 8 Re gap or replace the spark plug s 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 7 100 Ignition system is OK 5 Check the spark plug caps Refer to CHECKING THE SPARK PLUG CAPS on page 7 99 Replace the spark plug cap s 6 Check the ignition coils Refer to CHECKING...

Page 750: ...switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 7 89 Replace the clutch switch 13 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RE LAYS on page 7 96 Replace the relay unit 14 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 7 98 Replace the relay unit 15 Check the lean angle cut off switch Refer to CHECKING THE LEAN ANGL...

Page 751: ...NESS WIRE HARNESS SUB WIRE HARNESS1 SUB WIRE HARNESS2 SUB WIRE HARNESS2 SUB WIRE HARNESS3 W G B Gy B Gy W G BLACK BLACK B Ch B B Dg Ch B B Dg C L L Y Y Br Br D Y Br B B B L L B G Y Br W R B L BB3 BB2 BB1 BB4 B B B B Y Y G G L R L R B B GRAY GRAY BLACK BLACK Dg B B L Ch B B Ch B B Ch B Dg Dg BLACK BLACK B B B Dg Dg G G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y BLACK Y BLACK L B Sb B Sb ...

Page 752: ...3 Relay unit 14 Starting circuit cut off relay 16 Neutral switch 19 Sidestand switch 29 ECU electronic control unit 38 Decompression solenoid 56 Clutch switch 70 Auto decompression fuse 73 Engine stop switch 74 Start switch 81 Ignition fuse Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 753: ...itch circuit is closed and the sidestand is up the sidestand switch circuit is closed The starting circuit cut off relay prevents the starter motor from operating when neither of 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 r...

Page 754: ...itch 4 Ignition fuse 5 Engine stop switch 6 Relay unit starting circuit cut off relay 7 Relay unit diode 8 Clutch switch 9 Sidestand switch 10 Neutral switch 11 Start switch 12 Starter relay 13 Starter motor 14 ECU fuse 15 Auto decompression fuse 16 Decompression solenoid 17 ECU electronic control unit Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 755: ...rminals Recharge or replace the battery 3 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 73 Repair or replace the starter motor 4 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RE LAYS on page 7 96 Replace the relay unit 5 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 7 98 Replace the relay unit 6 Check the starter rela...

Page 756: ...witch 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 7 89 Replace the clutch switch 12 Check the start switch Refer to CHECKING THE SWITCHES on page 7 89 Replace the right handlebar switch 13 Check the decompression sole noid Refer to CHECKING THE DE COMPRESSION SOLENOID on page 7 106 Replace the decompression solenoid 14 Check the entire starting system wiring Refer to CIRCUIT ...

Page 757: ...Y G B L Y G L Y Y D B B B L L D Br Br Br B D R R Br Br L Br R Br G R Gy R R R R R R B Br W B B R R R B B R W R W R L L B BB3 BB2 BB1 BB4 B B B B B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y Y BLACK L B Sb B Sb R L L R L Y B R L W1 Sb W Sb R L BLACK BLACK B R B B B R R Br L Br L Br R Br R R R L B B B B Y Br R Br L B2 B L Gy1 B R G R G Y L R W Lg B2 Sb W R L L W1 L Y L G Sb L R B R B Y L R B B2 Lg R W Y L ...

Page 758: ...CHARGING SYSTEM 7 12 1 AC magneto 2 Rectifier regulator 4 Battery 8 Main fuse Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 759: ...on page 7 94 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 7 101 Replace the stator assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 7 102 Replace the rectifier regulator 5 Check the entire charging system wiring Refer to CIRCUIT DIAGRAM on page 7 11 Properly connect or repair...

Page 760: ...CHARGING SYSTEM 7 14 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 761: ...RE HARNESS2 SUB WIRE HARNESS3 W G B Gy B Gy W G BLACK BLACK B Ch B B Dg Ch B B Dg C L L Y Y Br Br D Y Br B B B L L B G Y Br W R B L BB3 BB2 BB1 BB4 B B B B Y Y G G L R L R B B GRAY GRAY BLACK BLACK Dg B B L Ch B B Ch B B Ch B Dg Dg BLACK BLACK B B B Dg Dg G G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y Y BLACK L B Sb B Sb R L L R L Y B R L W1 Sb W Sb R L BLACK BLACK B R B B B R R Br L Br...

Page 762: ...tor light 50 Meter light 54 Headlight relay 57 Pass switch 58 Dimmer switch 67 Auxiliary light 68 Headlight high beam 69 Headlight low beam 75 Tail brake light 76 License plate light 80 Headlight fuse 82 Signaling system fuse 83 Parking lighting fuse Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 763: ...headlight signaling system parking lighting and ECU Refer to CHECKING THE FUS ES on page 7 93 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 94 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 7 89 Replace the main switch immobilizer unit 5 Check the dimmer switch Refer to CHECKIN...

Page 764: ...K 8 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 7 15 Properly connect or repair the lighting sys tem wiring This circuit is OK Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 765: ...IRE HARNESS2 SUB WIRE HARNESS3 W G B Gy B Gy W G BLACK BLACK B Ch B B Dg Ch B B Dg C L L Y Y Br Br D Y Br B B B L L B G Y Br W R B L BB3 BB2 BB1 BB4 B B B B Y Y G G L R L R B B GRAY GRAY BLACK BLACK Dg B B L Ch B B Ch B B Ch B Dg Dg BLACK BLACK B B B Dg Dg G G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y Y BLACK L B Sb B Sb R L L R L Y B R L W1 Sb W Sb R L BLACK BLACK B R B B B R R Br L B...

Page 766: ...arning light 48 Left turn signal indicator light 49 Right turn signal indicator light 52 Horn 53 Turn signal hazard relay 59 Hazard switch 60 Turn signal switch 61 Horn switch 62 Front left turn signal light 63 Front right turn signal light 64 Rear right turn signal light 65 Rear left turn signal light 72 Front brake light switch 75 Tail brake light 77 Rear brake light switch 81 Ignition fuse 82 S...

Page 767: ... Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 94 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 89 Replace the main switch immobilizer unit 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 19 Properly connect or repair the signaling system wiring Check the condition ...

Page 768: ...r brake light switch 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 19 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the turn signal light bulbs and sockets Refer to CHECKING THE BULBS AND BULB SOCKETS on page 7 92 Replace the turn signal light bulb socket or both 2 Check the turn signal switch Refer to CHECKING THE SWITCHES on pag...

Page 769: ... CIRCUIT DIAGRAM on page 7 19 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 7 103 Replace the fuel pump assembly 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 19 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the speed sensor Refer to CHEC...

Page 770: ...SIGNALING SYSTEM 7 24 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 771: ...SUB WIRE HARNESS2 SUB WIRE HARNESS3 W G B Gy B Gy W G BLACK BLACK B Ch B B Dg Ch B B Dg C L L Y Y Br Br D Y Br B B B L L B G Y Br W R B L BB3 BB2 BB1 BB4 B B B B Y Y G G L R L R B B GRAY GRAY BLACK BLACK Dg B B L Ch B B Ch B B Ch B Dg Dg BLACK BLACK B B B Dg Dg G G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y Y BLACK L B Sb B Sb R L L R L Y B R L W1 Sb W Sb R L BLACK BLACK B R B B B R R B...

Page 772: ... temperature sensor 27 Air temperature sensor 28 Engine temperature sensor 29 ECU electronic control unit 30 ISC idle speed control unit 31 Intake solenoid 32 Spark plug 33 Cylinder 2 right ignition coil 34 Cylinder 2 left ignition coil 35 Cylinder 1 left ignition coil 36 Cylinder 1 right ignition coil 37 EXUP servo motor 38 Decompression solenoid 39 Injector 1 40 Injector 2 44 Multi function mete...

Page 773: ...en displayed it remains stored in the memory of 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 bulb The engine trouble warning light comes on for 1 4 seconds after the main switch has been ...

Page 774: ...e to drive 12 Crankshaft position sensor No normal signals are received from the crankshaft position sen sor Unable Unable 13 Cylinder 1 intake air pressure sensor open or short circuit Cylinder 1 intake air pressure sensor open or short circuit de tected Able Able 14 Cylinder 1 intake air pressure sensor hose line Cylinder 1 intake air pressure sensor hose system malfunction clogged or detached h...

Page 775: ...ulty cylin ders 34 Cylinder 2 left igni tion coil faulty ignition Malfunction detected in the prima ry wire of the cylinder 2 left igni tion coil Able depending on the number of faulty cylin ders Able depending on the number of faulty cylin ders 35 Cylinder 1 left or right ignition coil faulty ignition Malfunction detected in the prima ry wire of the cylinder 1 left or right ignition coil Able dep...

Page 776: ... fan temperature sensor open or short circuit Muffler cooling fan temperature sensor open or short circuit de tected Able Able 63 Muffler cooling fan temperature sensor ambient temperature abnormally high Engine trouble warning light is flashing Abnormally high temper ature is detected by muffler cool ing fan temperature sensor Able Able Fault code No Item Symptom Able un able to start Able un abl...

Page 777: ... 1 Check the operation of following sensors and actuators in the Diagnostic mode Refer to Sensor operation table and Actuator oper ation table If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in the sensors and actuators check and repair inner parts of the engine EAS27420 DIAGNOSTIC MODE Setting the diagnostic mode 1 Turn the...

Page 778: ...T button for 1 second or longer to automatically increase the diagnostic code numbers 8 Verify the operation of the sensor or actuator Sensor operation The data representing the operating conditions of the sensor appears on the odometer trip meter fu el reserve trip meter LCD Actuator operation Set the engine stop switch to to operate the actuator NOTE If the engine stop switch is set to set it to...

Page 779: ...ion in ECU Improperly installed air temperature sensor 05 24 No normal signal is re ceived from the O2 sensor Open or short circuit in wire harness Defective O2 sensor Malfunction in ECU Improperly installed sensor 25 Cylinder 2 intake air pres sure sensor open or short circuit detected Open or short circuit in wire harness Defective cylinder 2 intake air pressure sensor Malfunction in ECU 04 26 C...

Page 780: ...on in ECU Malfunction in a component of ignition cut off circuit system 33 37 Engine speed is high when the engine is idling Open circuit in wire harness Malfunction in throttle body Malfunction in throttle cables ISC valve is stuck fully open due to discon nected ISC unit hose or coupler High en gine idle speed is detected with the ISC valve stuck fully open even though signals for the valve to c...

Page 781: ...ng light is flashing Abnormal ly high temperature is de tected by muffler cooling fan temperature sensor Muffler cover fan fuse or ECU fuse is blown Defective muffler cooling fan temperature sensor or muffler cooling fan motor relay Positions of muffler cooling fan temperature sensor and its surrounding parts changed due to deformed parts near sensor Muffler cooling fan temperature sensor de tecte...

Page 782: ... Displays the air temperature Compare the actually mea sured air temperature with the meter display value 07 Vehicle speed pulse 0 999 Check that the number in creases when the rear wheel is rotated The num ber is cumulative and does not reset each time the wheel is stopped 08 Lean angle cut off switch Remove the lean angle cut off switch and incline it more than 65 degrees Upright 0 4 1 4 Overtur...

Page 783: ...ry code display No history 00 History exists Fault codes 12 63 If more than one code number is detected the dis play alternates every two seconds to show all the de tected code numbers When all code numbers are shown the display repeats the same process 62 Malfunction history code erasure No history 0 History exists Up to 28 fault codes To erase the history set the engine stop switch to 63 Stoppin...

Page 784: ...e 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 the injector 1 five times 37 Injector 2 Actuates the injector 2 five times at one second inter vals Illuminates the en...

Page 785: ...fler cooling fan motor relay five times 52 Headlight relay Actuates the headlight relay for five cycles of five sec onds ON 2 seconds OFF 3 seconds Illuminates the engine trou ble warning light Check the operating sound of the headlight relay five times 54 ISC valve Actuates and fully closes the ISC valve then opens it to the standby opening position when the engine is started This operation takes...

Page 786: ...Main 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 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 ...

Page 787: ...ut Check the locking condition 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 Repair or replace if there is an open or short circuit Between cylinder 1 intake air pressure sensor coupler and ECU coupler black blue black blue pink white pink white blue blue 3 Defective cylinder 1 intake air p...

Page 788: ... idle 2 Cylinder 1 intake air pressure sensor malfunction at intermediate electrical potential Check and repair the connec tion Replace it if there is a malfunc tion 3 Connections Cylinder 1 intake air pressure sen sor coupler Main 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 connec...

Page 789: ...tion 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 lead Repair or replace if there is an open or short circuit Between throttle position sen sor coupler and ECU coupler blue blue yellow yellow back black 4 Throttle position sensor lead wire open circuit output voltage check Check for open circuit and re place...

Page 790: ...NG THE EXUP SERVO MOTOR on page 7 105 Fault code No 18 Symptom EXUP servo motor is stuck Diagnostic code No 53 EXUP servo motor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections EXUP servo motor coupler Main 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 malfu...

Page 791: ...G THE SWITCHES on page 7 89 Fault code No 22 Symptom Air temperature sensor open or short circuit detected Diagnostic code No 05 Air temperature sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of air temperature sensor Check for looseness or pinching Turning the main switch to ON 2 Connections Air temperature sensor coupler Main w...

Page 792: ...U 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 Repair or replace if there is an open or short circuit Between O2 sensor coupler and ECU coupler gray white gray white red blue red blue gray green gray green black blue black blue 4 ...

Page 793: ...t Check the locking condition 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 Repair or replace if there is an open or short circuit Between cylinder 2 intake air pressure sensor coupler and ECU coupler black blue black blue pink yellow pink yellow blue blue 3 Defective cylinder 2 intake air ...

Page 794: ... idle 2 Cylinder 2 intake air pressure sensor malfunction at intermediate electrical potential Check and repair the connec tion Replace it if there is a malfunc tion 3 Connections Cylinder 2 intake air pressure sen sor coupler Main 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 connec...

Page 795: ...oupler Sub wire harness 2 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 lead Repair or replace if there is an open or short circuit Between engine temperature sensor coupler and ECU cou pler brown brown black black 4 Def...

Page 796: ...d thermistor Execute the diagnostic mode Code No 55 Replace if defective Refer to CHECKING THE DE COMPRESSION SOLENOID on page 7 106 Fault code No 30 Symptom The vehicle has overturned Diagnostic code No 08 Lean angle cut off switch Order Item components and probable cause Check or maintenance job Reinstatement method 1 The vehicle has overturned Raise the vehicle upright Turning the main switch t...

Page 797: ...heck the locking condition of the connector and coupler If there is a malfunction 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 sub lead Repair or replace if there is an open or short circuit Between cylinder 1 left or right ignition coil connector and ECU coupler main wire harness black red blue red orange...

Page 798: ...ocking condition of the connector and coupler If there is a malfunction 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 Repair or replace if there is an open or short circuit Between cylinder 2 left ignition coil connector and ECU cou pler main wire harness black red blue red gray red gray red 3 Defective cylinder 2...

Page 799: ...heck the locking condition of the connector and coupler If there is a malfunction 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 sub lead Repair or replace if there is an open or short circuit Between cylinder 1 left or right ignition coil connector and ECU coupler main wire harness black red blue red orange...

Page 800: ...cking condition of the connector and coupler If there is a malfunction 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 Repair or replace if there is an open or short circuit Between cylinder 2 right igni tion coil connector and ECU coupler main wire harness black red blue red gray black gray black 3 Defective cylind...

Page 801: ...fully open due to disconnected ISC unit hose or cou pler High engine idle speed is de tected with the ISC valve stuck fully open even though signals for the valve to close are continuously being trans mitted by the ECU Check that the ISC unit hose is not disconnected Check that the ISC unit coupler is not disconnected The ISC valve is stuck fully open if it does not operate when the main switch is...

Page 802: ...r 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 decompression sole noid coupler and ECU coupler light green light green Between decompression sole noid coupler and auto decom pression fuse gray ...

Page 803: ...eck the locking condition 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 lead wire Repair or replace if there is an open or short circuit Between lean angle cut off switch coupler and ECU cou pler blue blue yellow green yellow green black blue black blue 3 Defective lean angle cut off switch Execute the ...

Page 804: ... malfunction repair it and connect the coupler se curely Starting the en gine and acti vating the vehicle speed sensor by oper ating the vehi cle at 20 to 30 km h A 2 Open or short circuit in speed sensor lead Repair or replace if there is an open or short circuit Between speed sensor coupler and ECU coupler blue blue white yellow white yellow black blue black blue A 3 Gear for detecting vehicle s...

Page 805: ...uel pump relay coupler sky blue sky blue Between fuel pump relay cou pler and ECU coupler blue yellow blue yellow B 3 Faulty shift drum neutral detection ar ea Replace if defective Refer to TRANSMISSION on page 5 93 B 4 Defective neutral switch Execute the diagnostic mode Code No 21 Replace if defective Refer to CHECKING THE SWITCHES on page 7 89 Fault code No 42 Symptom A No normal signals are re...

Page 806: ... red blue red red blue red blue Between fuel pump relay cou pler and battery terminal red red Between fuel pump relay cou pler and engine stop switch coupler black red black red 3 Malfunction or open circuit in fuel pump relay Execute the diagnostic mode Code No 09 Replace if defective If there is no malfunction with the fuel pump relay replace the ECU Fault code No 44 Symptom Error is detected wh...

Page 807: ...tion in rectifier regulator Replace if defective Refer to CHARGING SYS TEM on page 7 11 4 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between battery and main switch red red Between main switch and igni tion fuse brown blue brown blue Between ignition fuse and ECU red white red white Fault code No 50 Symptom Faulty ECU memory When this malfunction i...

Page 808: ... 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 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between muffler cooling fan temperature sensor coupler and ECU coupler black blue black blue brown yellow brown ...

Page 809: ... fan tem perature sensor and its surrounding parts changed due to deformed parts near sensor Muffler cooling fan temperature sen sor detected a temperature of 120 C 248 F or higher Check that the parts near the muffler cooling fan temperature sensor are not deformed and that the sensor and its sur rounding parts are in their cor rect positions Repair or replace if necessary Fault code No Er 1 Symp...

Page 810: ...nction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 3 Symptom Data from the ECU cannot be received correctly Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Main wire harness ECU coupler Main wire harness meter assembly coupler Check the coupler for any pins that may be pul...

Page 811: ...er 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 Turning the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between meter assembly cou pler and ECU coupler yellow blue yellow blue 3 Malfunction in meter assembly Replace the meter a...

Page 812: ...FUEL INJECTION SYSTEM 7 66 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 813: ... B B R W R W R L L B Y Br B B B L L B G Y Br W R B L BB3 BB2 BB1 BB4 B B B B G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y Y BLACK L B Sb B Sb R L L R L Y B R L W1 Sb W Sb R L BLACK BLACK B R B B B R R Br L Br L Br R Br R R R B R B R L L R W B G Y Y G R W W Y Y Br Y Br W L Br B L L Y L W Gy W Lg Dg Ch L G R G R L B L R W Gy G Gy W B B W L R L Gy W Gy G B L Br G Br W Br W B G B R B G B R ...

Page 814: ... 4 Battery 5 Fuel injection system fuse 8 Main fuse 10 ECU fuse 15 Fuel pump relay 17 Fuel pump 29 ECU electronic control unit 73 Engine stop switch 81 Ignition fuse Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 815: ...replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 89 Replace the main switch immobilizer unit 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 7 89 Replace the right handlebar switch 5 Check the relay unit fuel pump re lay Refer to CHECKING THE RE LAYS on page 7 96 Replace the relay unit 6 Check the fuel pump Refer to CHECKING THE FUEL PUMP o...

Page 816: ...FUEL PUMP SYSTEM 7 70 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 817: ...R R R R R R B Br W B B R R R B B R W R W R L L B Y Br B B B L L B G Y Br W R B L BB3 BB2 BB1 BB4 B B B B G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y Y BLACK L B Sb B Sb R L L R L Y B R L W1 Sb W Sb R L BLACK BLACK B R B B B R R Br L Br L Br R Br R R R B R B R L L R W B G Y Y G R W W Y Y Br Y Br W L Br B L L Y L W Gy W R L Gy G B B W L R L Gy W Gy G B L Br G Br W Br W B G B R G R Y L G ...

Page 818: ...use 9 Muffler cover fan fuse 10 ECU fuse 26 Muffler cooling fan temperature sensor 29 ECU electronic control unit 78 Muffler cooling fan motor 79 Muffler cooling fan motor relay Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 819: ...oling fan mo tor Refer to CHECKING THE MUF FLER COOLING FAN MOTOR on page 7 108 Replace the muffler cooling fan motor 4 Check the muffler cooling fan motor relay Refer to CHECKING THE RE LAYS on page 7 96 Replace the muffler cooling fan motor re lay 5 Check the muffler cooling fan tem perature sensor Refer to CHECKING THE MUF FLER COOLING FAN TEMPERA TURE SENSOR on page 7 108 Replace the muffler c...

Page 820: ...MUFFLER COOLING SYSTEM 7 74 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 821: ... WIRE HARNESS2 SUB WIRE HARNESS3 W G B Gy B Gy W G BLACK BLACK B Ch B B Dg Ch B B Dg C L L Y Y Br Br D Y Br B B B L L B G Y Br W R B L BB3 BB2 BB1 BB4 B B B B Y Y G G L R L R B B GRAY GRAY BLACK BLACK Dg B B L Ch B B Ch B B Ch B Dg Dg BLACK BLACK B B B Dg Dg G G Y B R Y G L R Y B1 BB4 BB3 BB2 BB1 Br W B L B L L P Y Y BLACK L B Sb B Sb R L L R L Y B R L W1 Sb W Sb R L BLACK BLACK B R B B B R R Br L...

Page 822: ... ECU fuse 11 Immobilizer unit 12 Backup fuse odometer clock and immobilizer system 29 ECU electronic control unit 44 Multi function meter 46 Immobilizer system indicator light 81 Ignition fuse Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 823: ...n the standard keys is 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...

Page 824: ...er system turn the ignition 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 Im...

Page 825: ...econds to activate the 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 register...

Page 826: ...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 registering key g Remaining standard key h R...

Page 827: ...ECKING THE SWITCHES on page 7 89 Replace the main switch immobilizer unit 4 Check the entire immobilizer sys tem wiring Refer to CIRCUIT DIAGRAM on page 7 75 Properly connect or repair the immobilizer system wiring Check the condition of the each im mobilizer system circuits Refer to SELF DIAGNOSIS FAULT CODE INDICATION on page 7 81 Fault code Part Symptom Cause Action 51 IMMOBILIZER UNIT Code can...

Page 828: ... Check the wire harness 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 pl...

Page 829: ...IMMOBILIZER SYSTEM 7 83 a b a Light on b Light off Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 830: ...IMMOBILIZER SYSTEM 7 84 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 831: ...ELECTRICAL COMPONENTS 7 85 EAS27970 ELECTRICAL COMPONENTS 4 3 5 7 6 8 9 10 12 13 14 15 1 2 11 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 832: ...nit 5 Intake solenoid 6 Cylinder 1 right ignition coil 7 Cylinder 1 left ignition coil 8 Muffler cooling fan temperature sensor 9 Muffler cooling fan motor 10 Speed sensor 11 Rear brake light switch 12 Neutral switch 13 Decompression solenoid 14 Rectifier regulator 15 Horn Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 833: ...ELECTRICAL COMPONENTS 7 87 3 4 6 5 8 7 9 11 12 13 14 15 16 17 18 1 2 10 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 834: ...Fuse box 7 Muffler cooling fan motor relay 8 ECU electronic control unit 9 Headlight relay 10 Relay unit 11 Turn signal hazard relay 12 Fuel injection system fuse 13 Starter relay 14 Lean angle cut off switch 15 Battery 16 EXUP servo motor 17 Crankshaft position sensor 18 Engine temperature sensor Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 835: ...P G Y B Dg Ch B B BLACK R W L W R B B B Y B BLUE BROWN B B BLUE B B B B B 11 12 13 8 5 6 9 10 1 2 7 3 B B R Y Y Y L B G Dg Br W Ch Dg Br W Ch P B Y B B R W R B L W B Y R Br L Br R 4 R Br L Br R ON OFF L W B Y Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 836: ...switch 3 Start switch 4 Main switch 5 Neutral switch 6 Sidestand switch 7 Rear brake light switch 8 Hazard switch 9 Turn signal switch 10 Horn switch 11 Clutch switch 12 Pass switch 13 Dimmer switch Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 837: ...switch back and forth 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 indication by There is contin...

Page 838: ...ng procedure applies to all of the bulbs 1 Remove Bulb WARNING EW5YU1009 Since headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down CAUTION EC5YU1020 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 b...

Page 839: ...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 circuit WARNING EWA13310 Never use a fuse with an amperage rating other than ...

Page 840: ...ing time charging amperage and charging voltage for an MF battery are dif ferent from those of conventional batteries The MF battery should be charged as ex plained in the charging method illustra tions If the battery is overcharged the electrolyte level will drop considerably Therefore take special care when charging the battery NOTE Since MF batteries are sealed it is not possible to check the c...

Page 841: ...d before measuring the open circuit voltage Charging method using a variable current voltage 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 NOTE Set the charging voltage at 16 17 V If the set ting is lower charging will be insufficient If too high ...

Page 842: ...tery lead 1 and then the negative battery lead 2 8 Check Battery terminals Dirt Clean with a wire brush Loose connection Connect properly 9 Lubricate Battery terminals 10 Install Seat Refer to GENERAL CHASSIS on page 4 1 EAS28040 CHECKING THE RELAYS Check each switch for continuity with the pocket tester If the continuity reading is incorrect re place the relay 1 Disconnect the relay from the wire...

Page 843: ...ty 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 Sb W L G L Y Sb B Y L W R L L R R B R L 1 3 2 4 Sb W L G L Y Sb B Y L W R L L R R B R L 1 3 2 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positiv...

Page 844: ...y 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 Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe brown green 1 Negative tester probe ground Turn signal hazard relay output voltage DC 12 V Pocket tester 90890 03112...

Page 845: ...on coil connectors from the ignition coil terminals 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 blue yellow 3 No continuity Positive tester probe blue yellow 3 Negative tester probe sky blue 1 Continuity Positive ...

Page 846: ... is within specification the ignition system circuit is operating normally a Disconnect the spark plug cap from the spark plug b Connect the ignition checker 1 as shown c Turn the main switch to ON and engine stop switch to d Measure the ignition spark gap a Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe black red 1 Negative tester probe orange or gray red or gray ...

Page 847: ...witch b Connect the pocket tester DC 20 V to the lean angle cut off switch coupler as shown c Turn the lean angle cut off switch to 65 d Measure the lean angle cut off switch output voltage EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the stator as sembly a Connect the pocket tester Ω 1 to the s...

Page 848: ...rn leads from the horn ter minals b Connect the pocket tester Ω 1 to the horn terminals Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe black 1 Negative tester probe black 2 Positive tester probe black 1 Negative tester probe black 3 Positive tester probe black 2 Negative tester probe black 3 Charging voltage 14 V at 5000 r min Pocket tester 90890 03112 Analog pocke...

Page 849: ... a container filled with water 2 NOTE Make sure that the engine temperature sensor terminals do not 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 engine temperature sensor re sistance 3 Install Engine temperature sensor EAS28230 CHECKING THE FUEL SENDER 1 Disconnect Fuel pump coupler Fuel sender coupler from th...

Page 850: ...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 terminal as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe green 1 Negative tester probe black 2 Output voltage reading cycle 0 6 V to 4 8 V to 0 6 V to 4 8...

Page 851: ... Fuel pump coupler Fuel sender coupler from the wire harness 2 Remove Fuel tank 3 Check Fuel pump operation Faulty rough movement Replace a Insert a plug 1 into the fuel return hose end b Fill the fuel tank c Put the end of the fuel hose 2 into an open container d Connect the battery DC 12 V to the fuel pump terminal as shown e Check the fuel pump operation EAS28360 CHECKING THE EXUP SERVO MOTOR 1...

Page 852: ... solenoid coupler as shown c Measure the decompression solenoid ther mistor resistance 2 Check Decompression solenoid resistance Out of specification Replace a Connect the pocket tester Ω 1 to the de compression solenoid coupler as shown b Measure the decompression solenoid resis tance EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSORS The following procedure applies to both of the in take air pres...

Page 853: ...sure that the air temperature sensor termi nals do not 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 air temperature sensor resis tance ET5YU1008 CHECKING THE INTAKE SOLENOID 1 Check Intake solenoid resistance Out of specification Replace a Disconnect the intake solenoid coupler from the intake solenoid b Conne...

Page 854: ...erature sensor resis tance Out of specification Replace a Connect the pocket tester Ω 1k to the muf fler cooling fan temperature sensor terminal as shown b Immerse the muffler cooling fan temperature sensor 3 in a container filled with water 4 NOTE Make sure that the muffler cooling fan tempera ture sensor terminals do not get wet c Place a thermometer 5 in the water d Slowly heat the water then l...

Page 855: ...ELECTRICAL COMPONENTS 7 109 3 Install Muffler cooling fan temperature sensor Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 856: ... AND HIGH SPEED PERFORMANCE 8 2 FAULTY GEAR SHIFTING 8 2 SHIFT PEDAL DOES NOT MOVE 8 2 JUMPS OUT OF GEAR 8 2 FAULTY CLUTCH 8 2 OVERHEATING 8 3 POOR BRAKING PERFORMANCE 8 3 FAULTY FRONT FORK LEGS 8 3 UNSTABLE HANDLING 8 3 FAULTY LIGHTING OR SIGNALING SYSTEM 8 3 Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 857: ...el pump relay 3 Throttle body ies Deteriorated or contaminated fuel 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...

Page 858: ...mission 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 drum groove Transmission Worn gear dog EAS28570 FAULTY CLUTCH Clutch slips 1 Clutch Improperly assembled clutch Improperly assembled clu...

Page 859: ...ube Damaged fork spring Worn or damaged outer tube bushing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS28670 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handlebar 2 Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tightened ring nut Bent steering stem Damaged ball bearing or bearing race 3 Front f...

Page 860: ... does not come on Faulty turn signal switch Faulty turn signal hazard relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signal flashes slowly Faulty turn signal hazard relay Faulty main switch Faulty turn signal switch Incorrect turn signal bulb Turn signal remains lit Faulty turn sig...

Page 861: ...ht relay 55 Left handlebar switch 56 Clutch switch 57 Pass switch 58 Dimmer switch 59 Hazard switch 60 Turn signal switch 61 Horn switch 62 Front left turn signal light 63 Front right turn signal light 64 Rear right turn signal light 65 Rear left turn signal light 66 Headlight assembly 67 Auxiliary light 68 Headlight high beam 69 Headlight low beam 70 Auto decompression fuse 71 Right handlebar swi...

Page 862: ...Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 863: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN Manuals by Motomatrix www motomatrix co uk Email info motomatrix co uk ...

Page 864: ... BLUE BLACK BLACK R R GRAY GRAY R W L W R B B B Y B BLUE Y L W1 B R R W Br Y L B L Y B L Y B Br L L B Br L Br L Br L R B G Y R W Br R Br G R Gy R R R B R R R B Br W B B R R R B B R W R W R L L B O O B R O O B R A WIRE HARNESS WIRE HARNESS WIRE HARNESS WIRE HARNESS SUB WIRE HARNESS1 SUB WIRE HARNESS2 SUB WIRE HARNESS2 SUB WIRE HARNESS3 W G B Gy B Gy W G BLACK BLACK B Ch B B Dg Ch B B Dg C L L Y Y B...

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