Yamaha XT660 2004 Service Manual Download Page 409

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ELEC

STARTER MOTOR

b. If any resistance is out of specification,

replace the starter motor.

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Pocket tester

90890-03112

Armature coil

Commutator resistance

0.025 ~ 0.035

Ω

at 20 °C (68 °F)

Insulation resistance

Above 1 M

Ω

at 20 °C (68 °F)

5. Measure:

• brush length

Out of specification

→

Replace the brushes

as a set.

Brush length wear limit

5.00 mm (0.20 in)

6. Measure:

• brush spring force

Out of specification

→

Replace the brush

springs as a set.

7. Check:

• gear teeth

Damage/wear

→

Replace the gear.

8. Check:

• bearing
• oil seal

Damage/wear

→

Replace the defective

part(s).

Brush spring force

7.65 ~ 10.01 N
(780 ~ 1,021 gf, 27.51 ~ 36.01 oz)

Summary of Contents for XT660 2004

Page 1: ...2004 XT660R S XT660X S 5VK1 AE1 SERVICE MANUAL ...

Page 2: ...This manual is brought to you by www magnamaniac com Here you can find Service Manuals for over 200 different motorcycles ...

Page 3: ......

Page 4: ...60R S XT660X S 2004 SERVICE MANUAL 2003 by MBK Industrie First edition December 2003 All rights reserved Any reproduction or unauthorized use without the written permission of MBK Industrie is expressly prohibited ...

Page 5: ...and significant 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 EAS00004 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following The Safety Alert Symbol means ATT...

Page 6: ...of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number indicates...

Page 7: ...g fluid B Lubricant C Special tool D Tightening torque E Wear limit clearance F Engine speed G Electrical data Symbols H to M in the exploded diagrams indicate the types of lubricants and lubrication points H Engine oil I Gear oil J Molybdenum disulfide oil K Wheel bearing grease L Lithium soap based grease M Molybdenum disulfide grease Symbols N to O in the exploded diagrams indicate the followin...

Page 8: ...S GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 CHASSIS CHAS 4 ENGINE ENG 5 COOLING SYSTEM COOL 6 FUEL INJECTION SYSTEM FI 7 ELECTRICAL SYSTEM ELEC 8 TROUBLESHOOTING TRBL SHTG 9 ...

Page 9: ......

Page 10: ...GEN INFO 1 ...

Page 11: ...ODEL LABEL 1 1 FEATURES 1 2 OUTLINE 1 2 FI SYSTEM 1 3 IMPORTANT INFORMATION 1 4 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 4 REPLACEMENT PARTS 1 4 GASKETS OIL SEALS AND O RINGS 1 4 LOCK WASHERS PLATES AND COTTER PINS 1 5 BEARINGS AND OIL SEALS 1 5 CIRCLIPS 1 5 CHECKING THE CONNECTIONS 1 6 SPECIAL TOOLS 1 7 ...

Page 12: ...GEN INFO ...

Page 13: ...S00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS00018 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts MOTORCYCLE IDENTIFICATION ...

Page 14: ...l the air fuel ratio in a more precise and finely tuned manner To accommodate this need this model has adopted an electronically controlled fuel injection FI sys tem in place of a 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 co...

Page 15: ...esser the volume of fuel that is supplied The injection duration and the injection timing are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor intake air tem perature sensor and coolant temperature sensor enable the ECU to determine the injection dura tion The injection timing is determined through the signal from ...

Page 16: ... all of the parts and place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but...

Page 17: ...sible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appro priate 1 Oil seal CAUTION _ Do not spin the bearing with compressed air because this will damage the bearing surfaces 1 Bearing EAS00025 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always rep...

Page 18: ...disconnect sev eral times 3 Check all connections Loose 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 r...

Page 19: ...Slide hammer bolt Weight These tools are used to remove or install the rocker arm shafts 90890 01135 Crankcase separating tool This tool is used to remove the crank shaft Attachment 90890 01243 Compressor 90890 04019 Valve spring compressor attachment Valve spring compressor These tools are used to remove or install the valve assemblies 90890 01268 Ring nut wrench This tool is used to loosen or ti...

Page 20: ...ight Fork seal driver attachment ø43 These tools are used to install the oil seal dust seal and the outer tube bush ing of the front fork legs 90890 01403 Steering nut wrench This tool is used to loosen or tighten the steering ring nuts 90890 01496 Radiator tester adapter This tool is used to check the cooling sys tem 90890 01497 Radiator cap tester adapter This tool is used to check the cooling s...

Page 21: ...g light This tool is used to check the ignition tim ing 90890 03153 Pressure gauge This tool is needed to measure fuel pres sure 90890 03174 Digital circuit tester This tool is used to check electrical sys tem 90890 03176 Fuel pressure adapter This tool is needed to measure fuel pres sure Driver 90890 04058 Installer 90890 04132 Middle driven shaft bearing driver Mechanical seal installer These to...

Page 22: ...aptor Compression gauge This tool is needed to measure engine compression 90890 04086 Universal clutch holder This tool is needed to hold the clutch boss when removing or installing the boss nut 90890 04101 Valve lapper This tool is used for lapping the valve Adapter 90890 04130 Spacer 90890 04144 Adapter Spacer crankshaft installer These tools are used to install the crank shaft 90890 06754 Ignit...

Page 23: ...1 11 GEN INFO SPECIAL TOOLS 90890 85505 Yamaha bond No 1215 This bond is used to seal two mating sur faces e g crankcase mating surfaces Tool No Tool name Function Illustration ...

Page 24: ......

Page 25: ...SPEC 2 ...

Page 26: ...CATIONS 2 16 CONVERSION TABLE 2 19 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 19 TIGHTENING TORQUE 2 20 ENGINE TIGHTENING TORQUE 2 20 CHASSIS TIGHTENING TORQUES 2 23 LUBRICATION POINTS AND LUBRICANT TYPES 2 25 ENGINE 2 25 CHASSIS 2 27 COOLING SYSTEM DIAGRAMS 2 28 LUBRICATION CHART 2 30 LUBRICATION DIAGRAMS 2 31 CABLE ROUTING 2 35 ...

Page 27: ...SPEC ...

Page 28: ...n XT660X Overall height 1 230 mm 48 4 in XT660R 1 210 mm 47 6 in XT660X Seat height 865 mm 34 1 in XT660R 870 mm 34 3 in XT660X Wheelbase 1 505 mm 59 3 in XT660R 1 490 mm 58 7 in XT660X Minimum ground clearance 210 mm 8 27 in XT660R 205 mm 8 07 in XT660X Minimum turning radius 2 400 mm 94 5 in Weight Wet with oil and a full fuel tank 181 kg 399 lb XT660R 186 kg 410 lb XT660X Maximum load total of ...

Page 29: ...fuel Premium unleaded gasoline only Fuel tank capacity Total including reserve 15 0 L 3 30 Imp gal 3 96 US gal Reserve only 5 0 L 1 10 Imp gal 1 32 US gal Engine oil Lubrication system Dry sump Recommended oil Refer to the chart for engine oil grade API service SE SF SG type or higher Quantity Total amount 2 90 L 2 55 Imp qt 3 07 US qt Periodic oil change 2 50 L 2 20 Imp qt 2 64 US qt With oil fil...

Page 30: ...Pa 1 10 1 40 kg cm2 16 0 20 3 psi Radiator core Width 280 0 mm 11 02 in Height 158 0 mm 6 22 in Depth 23 0 mm 0 91 in Coolant reservoir Capacity 0 25 L 0 22 Imp 0 26 US qt From low to full level 0 15 L 0 13 Imp 0 16 US qt Water pump Water pump type Single suction centrifugal pump Reduction ratio 27 28 0 964 Maximum impeller shaft tilt 0 15 mm 0 006 in Starting system type Electric starter Fuel inj...

Page 31: ...aust camshaft lobe dimensions Measurement A 43 129 43 229 mm 1 6980 1 7019 in 42 983 mm 1 6922 in Measurement B 37 007 37 107 mm 1 4570 1 4609 in 36 886 mm 1 4522 in Valve timing Intake open B T D C 25 Intake closed A B D C 55 Exhaust open B B D C 60 Exhaust closed A T D C 20 Overlap angle A 45 Maximum camshaft runout 0 040 mm 0 0016 in Timing chain Model number of links 98 RH2010 126 Tensioning s...

Page 32: ...aust 31 90 32 10 mm 1 2559 1 2638 in Valve face width B Intake 2 260 mm 0 0890 in Exhaust 1 91 2 62 mm 0 075 0 103 in Valve seat width C Intake 1 00 1 20 mm 0 0394 0 0472 in 1 6 mm 0 06 in Exhaust 1 00 1 20 mm 0 0394 0 0472 in 1 6 mm 0 06 in Valve margin thickness D Intake 0 80 1 20 mm 0 0315 0 0472 in Exhaust 0 80 1 20 mm 0 0315 0 0472 in Valve stem diameter Intake 5 975 5 990 mm 0 2352 0 2358 in...

Page 33: ...mm 0 0394 0 0472 in 1 6 mm 0 06 in Valve springs Free length Intake 40 38 mm 1 59 in 38 36 mm 1 51 in Exhaust 40 38 mm 1 59 in 38 36 mm 1 51 in Installed length valve closed Intake 35 00 mm 1 38 in Exhaust 35 00 mm 1 38 in Compressed spring force installed Intake 171 197 N 17 44 20 09 kg 38 44 44 29 lb Exhaust 171 197 N 17 44 20 09 kg 38 44 44 29 lb Spring tilt Intake 2 5 1 8 mm 2 5 0 071 in Exhau...

Page 34: ...352 3 9358 in Height H 10 0 mm 0 39 in Piston pin bore in the piston Diameter 23 004 23 015 mm 0 9057 0 9061 in 23 045 mm 0 9073 in Offset 0 50 mm 0 0197 in Offset direction Intake side Piston pin Outside diameter 22 991 23 000 0 9052 0 9055 in 22 971 mm 0 9044 in Piston pin to piston pin bore clear ance 0 004 0 024 mm 0 0002 0 0009 in 0 074 mm 0 0029 in Piston rings Top ring Ring type Barrel Dime...

Page 35: ... 3 40 mm 0 098 0 134 in End gap installed 0 20 0 70 mm 0 0079 0 0276 in Ring side clearance 0 060 0 150 mm 0 0024 0 0059 in Crankshaft Width A 74 95 75 00 mm 2 9508 2 9528 in Maximum runout C 0 04 mm 0 0016 in Big end side clearance D 0 350 0 650 mm 0 0138 0 0256 in 1 0 mm 0 04 in Big end radial clearance E 0 010 0 025 mm 0 0004 0 0010 in Small end free play F 0 16 0 40 0 0063 0 0157 in Balancer B...

Page 36: ...tes 3 inside dia 128 mm Thickness 2 90 3 10 mm 0 114 0 122 in 2 80 mm 0 110 in Plate quantity 1 Clutch plates Thickness 1 50 1 70 mm 0 059 0 067 in Plate quantity 6 Maximum warpage 0 20 mm 0 0079 in Clutch spring Free length 55 6 mm 2 19 in 52 82 mm 2 08 in Spring quantity 5 Transmission Transmission type Constant mesh 5 speed Primary reduction system Spur gear Primary reduction ratio 75 36 2 083 ...

Page 37: ...r type Oil coated paper element Fuel pump Pump type Electrical Model manufacturer 5VK DENSO Consumption amperage maximum 3 5 A Output pressure 294 kPa 2 94 kg cm2 41 8 psi Throttle body Model manufacturer quantity 44EHS MIKUNI 1 Intake vacuum pressure 37 6 40 2 kPa 282 302 mmHg 11 1 11 9 inHg Throttle cable free play at the flange of the throttle grip 3 0 5 0 mm 0 12 in 0 20 mm ID mark 5VK1 00 Thr...

Page 38: ...luminum Wheel travel 225 mm 8 86 in XT660R 200 mm 7 87 in XT660X Wheel runout Maximum radial wheel runout 2 0 mm 0 08 in Maximum lateral wheel runout 2 0 mm 0 08 in Wheel axle bending limit 0 25 mm 0 01 in Rear wheel Wheel type Spoke wheel Rim Size 17M C MT2 75 XT660R 17M C MT4 25 XT660X Material Aluminum Wheel travel 200 0 mm 7 87 in Wheel runout Maximum radial wheel runout 2 0 mm 0 08 in Maximum...

Page 39: ...er and accessories Off road riding 200 kPa 2 00 kgf cm 29 psi XT660R Minimum tire tread depth 1 6 mm 0 063 in Rear tire Tire type With tube Size 130 80 17M C 65S 130 80 17M C 65T XT660R 160 60R 17M C 69H XT660X Model manufacturer TOURANCE METZELER SIRAC A MICHELIN XT660R DRAGON PIRELLI XT660X Tire pressure cold 0 90 kg 0 198 lb 200 kPa 2 00 kgf cm 29 psi XT660R 210 kPa 2 10 kgf cm 30 psi XT660X 90...

Page 40: ... cylinder inside diameter 12 7 mm 0 50 in Caliper cylinder inside diameter 32 00 mm 1 1 26 in 1 and 30 00 mm 1 1 18 in 1 XT660R 34 00 mm 2 1 34 in 2 and 30 00 mm 2 1 18 in 2 XT660X Rear brake Brake type Single disc brake Operation Right foot operation Brake pedal position below the top of the rider footrest 12 0 mm 0 47 in Recommended fluid DOT 4 Brake discs Diameter thickness 245 5 0 mm 9 65 0 20...

Page 41: ...60R 3 75 N mm 0 38 kg mm 21 41 lb in XT660X Spring stroke K1 0 120 0 mm 0 4 72 in XT660R 0 120 0 mm 0 4 72 in XT660X Spring rate K2 6 00 N mm 0 61 kg mm 34 26 lb in XT660R 6 00 N mm 0 61 kg mm 34 26 lb in XT660X Spring stroke K2 120 0 225 0 mm 4 72 8 86 in XT660R 120 0 200 0 mm 4 72 7 87 in XT660X Optional spring available No Fork oil Recommended oil Fork oil 10 W or equivalent Quantity each front...

Page 42: ...h 206 0 mm 8 11 in Spring rate K1 125 00 N mm 12 75 kg mm 713 75 lb in Spring stroke K1 0 65 0 mm 0 2 56 in Optional spring available No Standard spring preload gas air pres sure 980 kPa 9 8 kg cm2 139 4 psi Swingarm Free play at the end of the swingarm Radial 1 0 mm 0 04 in Axial 1 0 mm 0 04 in Drive chain Type manufacturer DID520VP DAIDO Link quantity 110 Drive chain slack 40 0 55 0 mm 1 57 2 17...

Page 43: ...nce 10 0 kΩ at 20 C 68 F Charging system System type A C magneto Model manufacturer LMX51 DENSO Nominal output 14 0 V 20 8 A at 5 000 r min Stator coil resistance color 0 224 0 336 Ω at 20 C 68 F white white Rectifier regulator Regulator type Semiconductor short circuit Model manufacturer SH713AA SHINDENGEN No load regulated voltage 14 1 14 9 V Rectifier capacity 35 0 A Withstand voltage 200 0 V B...

Page 44: ... 36 01 oz Commutator diameter 28 0 mm 1 10 in 27 mm 1 06 in Mica undercut 0 70 mm 0 028 in Starter relay Model manufacturer MS5F 561 JIDECO Amperage 180 0 A Coil resistance 4 18 4 62 Ω at 20 C 68 F Horn Horn type Plane Model manufacturer quantity YF 12 NIKKO 1 Maximum amperage 3 0 A Performance 105 120 db 2 m 6 6 ft Coil resistance 1 15 1 25 Ω at 20 C 68 F Turn signal hazard relay Relay type Full ...

Page 45: ...NSO Resistance 2 21 2 69 kΩ at 20 C 68 F 0 290 0 354 kΩ at 80 C 176 F Coolant temperature sensor Model manufacturer 5PS1 DENSO Resistance 2 32 2 59 kΩ at 20 C 68 F 0 310 0 326 kΩ at 80 C 176 F 0 140 0 145 kΩ at 110 C 230 F Fuses amperage quantity Main fuse 30 A 1 Signaling system fuse 10 A 1 Headlight fuse 20 A 1 Ignition fuse 10 A 1 Fuel injection system fuse 10 A 1 Radiator fan motor fuse 7 5 A ...

Page 46: ...fied tightening torque specifications require clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in METRIC TO IMPERIAL Tighten ing torque Metric unit Multiplier Imperial unit m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb o...

Page 47: ...6 2 10 1 0 7 2 Tappet cover exhaust side Bolt M6 4 10 1 0 7 2 Tappet cover intake side Bolt M6 4 10 1 0 7 2 Camshaft sprocket cover Bolt M6 2 10 1 0 7 2 Camshaft sprocket Bolt M7 2 20 2 0 14 Camshaft retainer Bolt M6 2 10 1 0 7 2 LT Valve adjusting screw Nut M6 4 14 1 4 10 Balancer driven gear Nut M18 1 70 7 0 50 Use a lock washer Primary drive gear Nut M20 1 80 8 0 58 Use the lock washer Timing c...

Page 48: ...olt M6 4 10 1 0 7 2 Exhaust pipe and exhaust pipe bracket Bolt M8 2 27 2 7 19 Exhaust pipe bracket and frame Bolt M8 2 23 2 3 17 Exhaust pipe and muffler Bolt M8 1 12 1 2 8 7 Exhaust pipe Nut M8 4 20 2 0 14 Muffler Bolt M8 4 27 2 7 19 Exhaust pipe and muffler Bolt M8 2 20 2 0 14 LT Air cut off valve outlet pipe Bolt M6 2 10 1 0 7 2 Clutch cover Bolt M6 7 10 1 0 7 2 Clutch cable holder Bolt M6 2 10...

Page 49: ...motor yoke Nut M6 1 11 1 1 8 Starter motor assembly Bolt M5 2 5 0 5 3 6 Drive axle oil seal retainer Nut M6 2 10 1 0 7 2 Sealant Drive sprocket Nut M18 1 120 12 0 85 Use the lock washer Neutral switch Bolt M6 2 4 0 4 2 9 LT Speed sensor Bolt M6 1 10 1 0 7 2 Shift pedal Bolt M6 1 16 1 6 11 Intake air pressure sensor Nut M6 2 7 0 7 5 1 Cylinder head tightening sequence Part to be tightened Part name...

Page 50: ... M6 7 0 7 5 1 Stabilizer XT660X M6 7 0 7 5 1 Chain protector and swingarm M6 7 0 7 5 1 Drive sprocket cover M6 10 1 0 7 2 Upper bracket pinch bolt M8 23 2 3 17 Lower handlebar holder and upper bracket M10 32 3 2 23 Steering stem nut M22 130 13 0 94 Lower ring nut steering stem M25 See NOTE Upper handlebar holder and lower handlebar holder M8 23 2 3 17 Front brake master cylinder holder M6 7 0 7 5 ...

Page 51: ... Front fender and frame M6 7 0 7 5 1 Front fork protector and front cowling assembly M6 8 0 8 5 8 Front brake disc and wheel M8 23 2 3 17 LT Front wheel axle M16 59 5 9 43 Front wheel axle pinch bolt M8 18 1 8 13 Front brake caliper M10 40 4 0 29 Brake caliper bleed screw M10 14 1 4 10 Rear wheel axle nut M16 105 10 5 75 Chain drive adjusting locknut M8 16 1 6 11 Rear wheel sprocket and hub M10 69...

Page 52: ...ust M Valve stem ends intake and exhaust M Rocker arm shaft E Camshaft lobes M Decompressor lever pin E Decompressor lever spring E Water pump impeller shaft E Oil pump rotors inner and outer E Oil pump shaft E Torque limiter E Starter clutch idle gear thrust surface E Starter clutch idle gear inner surface E Starter clutch gear inner and outer E Starter clutch assembly E Primary drive gear tighte...

Page 53: ...TYPES Crankcase mating surface Yamaha bond No 1215 A C magnet lead grommet A C magneto cover Yamaha bond No 1215 Oil seal holder tightening bolt Yamaha bond No 1215 Oil delivery hose 2 tightening bolt Yamaha bond No 1215 Lubrication Point Symbol ...

Page 54: ...mounting bolt outer surface LS Relay arm and swingarm oil seal lips LS Relay arm and connecting arm mounting bolt outer surface LS Relay arm and connecting arm oil seal lips LS Brake pedal outer surface LS Rear brake master cylinder pin outer surface LS Steering head pipe bearings upper and lower LS Steering head pipe bearing races upper and lower LS Tube guide throttle grip inner surface LS Clutc...

Page 55: ...OOLING SYSTEM DIAGRAMS EAS00033 COOLING SYSTEM DIAGRAMS 1 Water jacket joint 2 Water pump outlet hose 3 Water pump outlet pipe 4 Water pump È From the radiator É To the cylinder 5VK 5VK00 È È É A 1 1 2 3 2 3 4 A 4 ...

Page 56: ...oir breather hose 3 Coolant reservoir hose 4 Radiator cap 5 Radiator 6 Coolant reservoir cap 7 Coolant reservoir 8 Radiator outlet hose 9 Water pump 0 Radiator fan A Radiator inlet hose È From the fast idle plunger É To the cylinder Ê From the thermostat È 1 9 2 3 4 8 5 6 7 0 A 5 Ê É ...

Page 57: ...ATION CHART LUBRICATION CHART Pressure feed Splashed scavenge Oil strainer Oil pump rotor 2 Check ball Oil filter Cylinder head Drive axle Crankshaft Camshaft Oil tank Main axle Oil pan Oil pump rotor 1 Connecting rod ...

Page 58: ...2 31 SPEC LUBRICATION DIAGRAMS EAS00034 LUBRICATION DIAGRAMS 1 Oil delivery hose 2 2 Oil strainer 3 Oil delivery hose 1 A A A A 1 3 2 2 ...

Page 59: ...2 32 SPEC LUBRICATION DIAGRAMS 1 Oil delivery pipe 2 2 Oil delivery pipe 1 3 Oil filter 4 Oil pump A A A 1 4 3 3 2 A ...

Page 60: ...2 33 SPEC LUBRICATION DIAGRAMS 1 Oil delivery hose 2 2 Oil delivery pipe 2 3 Oil filter 4 Oil pump rotor 1 5 Oil pump rotor 2 6 Main axle 7 Oil delivery pipe 3 È To oil tank 1 7 3 2 6 4 5 È ...

Page 61: ...2 34 SPEC LUBRICATION DIAGRAMS 1 Camshaft 2 Oil delivery pipe 1 3 Oil filter 4 Main axle 5 Drive axle 6 Crankshaft 2 3 5 4 1 6 ...

Page 62: ...BLE ROUTING 1 Left handlebar switch lead 2 Clutch switch lead 3 Clutch cable 4 Front brake light switch lead 5 Right handlebar switch lead 6 Throttle cable 7 Headlight lead 8 Meter assembly lead 9 Main switch lead 0 Immobilizer unit lead ...

Page 63: ...ard Ê Fasten the clutch cable with a cable holder Ë Fasten the left handlebar switch lead and clutch switch lead with a plastic band Face the end of the plastic band forward Ì Route the throttle cables left handlebar switch lead right handlebar switch lead front brake light switch lead and clutch switch lead in front of the steering column then the clutch cable then the headlight lead and meter as...

Page 64: ...assem bly lead with a plastic band Fasten the sub wire harness at the white tape Face the end of the plastic band forward É Make sure that there is no slack in the meter assembly lead between the meter assembly and the plastic band The rubber boot on the meter assembly can be bent as shown Ê Place the slack of the left and right front turn sig nal light leads between the headlight assembly and fro...

Page 65: ...eft and right front turn signal light leads in front of the headlight stay Í Only the left side is shown in this illustration Route the right front turn signal light lead in the same way Î Pass the left and right front turn signal light leads between the headlight stay and front fork protec tor Ï 0 5 mm 0 0 20 in for both left and right sides ...

Page 66: ...utch cable 0 Oil delivery pipe 1 A Wire harness B Fast idle plunger outlet hose È Fasten the fast idle plunger outlet hose and igni tion coil leads with a hose holder Install the hose holder with its fastener facing down É Fasten the wire harness main switch lead and immobilizer unit lead to the frame with a plastic band A A B B A A B B 9 0 5 6 Ì 7 Î 8 9 Ê 4 A B 3 2 É È 1 Ë Ï Í ...

Page 67: ...ine oil filler cap To fasten the leads and cable connect the couplers and then turn the handlebar completely to the left Ì Fasten the clutch cable to the horn bracket with a cable holder Í Install the cable holder as high as possible Î Fasten the clutch cable and oil delivery pipe 1 with a cable holder Ï Route the fast idle plunger outlet hose to the inside of the line shown in the illustration so...

Page 68: ... the wire harness negative battery lead and rear brake light switch lead to the frame with a plastic locking tie É Fasten the rear brake light switch lead to the frame with a plastic locking tie Ê Fasten the wire harness to the frame at the white tape with a plastic locking tie Ë Route the negative battery lead behind the lean angle cut off switch bracket Ì Route the rear brake light switch lead b...

Page 69: ...hose B Oil delivery hose 2 C Radiator fan motor lead D Throttle cable E Headlight lead F Meter assembly lead G Left handlebar switch lead H Right handlebar switch lead I Front brake light switch lead J Clutch switch lead K Immobilizer unit lead L Clutch cable M Main switch lead N Air filter to air cut off valve hose O Wire harness B B C C E D E F F A A B B C C D F F E E È É Ó Ò Ñ Ð Ï Ê Ë Ì Î Í J B...

Page 70: ...ft handlebar switch lead right han dlebar switch lead headlight lead meter assem bly lead front brake light switch lead clutch switch lead radiator fan motor lead and throttle cables with a plastic locking tie To fasten the leads and cables connect the couplers and then turn the handlebar completely to the right Ê Route the oil tank breather hose on the outside of the throttle cables B B C C E D E...

Page 71: ...witch lead crankshaft posi tion sensor lead sidestand switch lead speed sensor lead starter motor lead and A C mag neto lead with a plastic band Ð Fasten the neutral switch lead crankshaft posi tion sensor lead sidestand switch lead speed sensor lead and starter motor lead with a plastic band Ñ Fasten the air filter to air cut off valve hose oil tank breather hose and oil delivery hose 2 with a pl...

Page 72: ...lamp Ó Fasten the left handlebar switch lead right han dlebar switch lead headlight lead meter assem bly lead front brake light switch lead and clutch switch lead with a plastic band B B C C E D E F F A A B B C C D F F E E È É Ó Ò Ñ Ð Ï Ê Ë Ì Î Í J B 8 B N O A D D 1 D C B A 0 9 8 2 3 4 5 7 6 D I G H E C F E F G M L K J I H A A ...

Page 73: ...ead 5 Rear turn signal light lead 6 Seat lock cable 7 Positive battery lead 8 Starter relay lead 9 Rectifier regulator lead È Fasten the wire harness and starter motor lead to the frame with a plastic locking tie É 45 Ê Fasten the wire harness to the frame with a plas tic band È Ê É É 1 3 2 4 5 6 7 8 9 ...

Page 74: ... Fuel pump lead 5 Fuel sender lead 6 Oil tank breather hose È 0 10 mm 0 0 39 in É 30 40 mm 1 18 1 57 in Ê 5 15 mm 0 20 0 59 in Ë Fasten the wire harness to the frame with a plas tic locking tie Ì To the fuel tank Í 0 5 mm 0 0 20 in È È Ê É Í Í Ê Ë 2 1 6 Ë 5 4 Ì 3 A For F GB A 1 CABLE ROUTING ...

Page 75: ...ight lead with two plastic locking ties so that the coupler is positioned to the inside of where the relays turn signal hazard relay headlight relay radiator fan motor relay and relay unit branch off from the wire harness É To relays turn signal hazard relay headlight relay radiator fan motor relay and relay unit Ê Fasten the rear turn signal light leads and tail brake light lead with a lead holde...

Page 76: ...and rear fender cover Ì Fasten the wire harness to the frame with a plas tic locking tie Í 0 5 mm 0 0 20 in Î 0 10 mm 0 0 39 in Ï The tail brake light coupler and the rear turn sig nal light lead should not be lower than the line shown in the illustration A A Î Í 1 2 3 4 9 8 7 6 5 0 A Ì Ë Ï Ê È É A A ...

Page 77: ...aliper 5 Front fork boss È To install the brake hose holders align the edge of each holder with the upper edge of the recess in the brake hose É Route the front brake hose so that its alignment mark is facing toward the rear of the motorcycle Ê 30 50 Ë Fasten the front brake hose with the brake hose holders ...

Page 78: ...rd and between the bosses on the front fork Í When installing the brake hose onto the brake caliper make sure that the brake pipe touches the brake caliper as shown Î When installing the brake hose onto the brake caliper make sure that the brake pipe touches the projection on the brake caliper ...

Page 79: ...ake hose 6 Rear brake caliper È When installing the brake hose onto the brake master cylinder make sure that the brake pipe touches the brake master cylinder as shown É Fasten the rear brake hose with the brake hose holder Ê When installing the brake hose onto the brake caliper make sure that the brake pipe touches the brake caliper as shown ...

Page 80: ...CHK ADJ 3 ...

Page 81: ...DJUSTING THE VALVE CLEARANCE 3 13 ADJUSTING THE EXHAUST GAS VOLUME 3 16 ADJUSTING THE ENGINE IDLING SPEED 3 17 ADJUSTING THE THROTTLE CABLE FREE PLAY 3 17 CHECKING THE SPARK PLUG 3 19 CHECKING THE IGNITION TIMING 3 20 MEASURING THE COMPRESSION PRESSURE 3 21 CHECKING THE ENGINE OIL LEVEL 3 23 CHANGING THE ENGINE OIL 3 24 ADJUSTING THE CLUTCH CABLE FREE PLAY 3 27 CHECKING THE AIR FILTER ELEMENT 3 28...

Page 82: ...CHAIN SLACK 3 42 LUBRICATING THE DRIVE CHAIN 3 44 CHECKING AND ADJUSTING THE STEERING HEAD 3 44 CHECKING THE FRONT FORK 3 46 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3 47 CHECKING THE TIRES 3 48 CHECKING AND TIGHTENING THE SPOKES 3 51 CHECKING AND LUBRICATING THE CABLES 3 52 LUBRICATING THE LEVERS AND BRAKE PEDAL 3 52 LUBRICATING THE SIDESTAND 3 52 ELECTRICAL SYSTEM 3 53 CHECKING AND CHARGING TH...

Page 83: ...on Clean and regap Replace 3 Valves See page 3 13 Check valve clearance Adjust 4 Air filter element See page 3 28 Replace 5 Clutch See page 3 27 Check operation Adjust 6 Front brake See page 3 37 3 38 Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 7 Rear brake See page 3 36 3 37 3 38 Check operation fluid level and vehicle for fluid leakage ...

Page 84: ...See page 4 78 Check operation 21 Electronic fuel injection See page 3 17 Adjust engine idling speed 22 Engine oil See page 3 23 3 24 Change Check oil level and vehicle for oil leakage 23 Engine oil filter element See page 3 24 Replace 24 Cooling system See page 3 31 3 32 Check coolant level and vehicle for coolant leak age Change Every 3 years 25 Front and rear brake switches See page 3 38 8 5 Che...

Page 85: ... m kg 17 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 Order Job Part Q ty Remarks Removing the cover Remove the parts in the order listed 1 Seat 1 2 Left side panel 1 3 Right side panel 1 4 Grab bar 2 5 Rear cover 1 For installation reverse the removal pro cedure ...

Page 86: ...oving the cowling Remove the parts in the order listed Seat side panels left and right Refer to COWLING AND COVER Fuel tank Refer to FUEL TANK 1 Front fender 1 2 Front fork protector 1 3 Meter assembly coupler 2 Disconnect 4 Sub wire harness coupler 1 Disconnect 5 Front cowling assembly 1 For installation reverse the removal pro cedure ...

Page 87: ... and right Refer to COWLING AND COVER Fuel Drain 1 Fuel tank left side cover 1 2 Fuel tank right side cover 1 3 Intake air guide 1 4 Fuel tank plate 1 5 Damper 1 1 6 Fuel pump coupler 1 Disconnect 7 Fuel sender coupler 1 Disconnect 8 Fuel hose 1 Refer to REMOVING THE FUEL TANK and INSTALLING THE FUEL HOSE 9 Fuel tank 1 10 Damper 2 1 For installation reverse the removal pro cedure FUEL TANK ...

Page 88: ...e slide the cover a on the end of the hose in the direction of the arrow shown and then remove the hose Before removing the hose place a few rags in the area under where it will be removed 3 Remove fuel tank NOTE Do not set the fuel tank down so that the instal lation surface of the fuel pump is directly under the tank Be sure to lean the fuel tank in an upright position a REMOVING THE FUEL PUMP 1...

Page 89: ...ump bracket Tighten the bolts to the specified torque in the proper tightening sequence as shown Install the fuel pump in the direction shown in the illustration T R 4 Nm 0 4 m kg 2 9 ft lb INSTALLING THE FUEL HOSE 1 Install fuel hose CAUTION When installing the fuel hose be sure to securely connect it NOTE To install the fuel hose from the fuel injection pipe slide the cover a on the end of the h...

Page 90: ... guard and rear fender Remove the parts in the order listed Seat side panels left and right rear cover Refer to COWLING AND COVER Fuel tank Refer to FUEL TANK Muffler Refer to ENGINE in chapter 5 1 Battery cover 1 2 Battery lead 2 Disconnect CAUTION First disconnect the negative battery lead then the positive battery lead 3 Battery 1 4 Tali brake light coupler 1 Disconnect 5 Rear turn signal light...

Page 91: ... 6 7 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 Order Job Part Q ty Remarks 6 Fuse box 2 1 7 Rear mud guard 1 8 Rear fender 1 For installation reverse the removal pro cedure ...

Page 92: ...y Remarks Removing the air filter case Remove the parts in the order listed Rear wheel Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET in chapter 4 1 ECU 1 2 Rectifier regulator 1 3 Intake air temperature sensor 1 4 Fuse box 1 1 5 Starter relay 1 6 Intake air chamber case 1 7 Air filter case cover right 1 8 Air filter element 1 9 Air filter case breather hose 1 10 Pilot air hose 1 Disconnec...

Page 93: ... 4 7 14 16 12 11 10 9 17 3 13 2 4 5 8 6 1 Order Job Part Q ty Remarks 12 Air filter to crankcase breather cham ber hose 1 Disconnect 13 Drive chain tensioner 1 14 Air filter case joint clamp screw 1 Loosen 15 Air filter case 1 16 Air filter case joint clamp 1 Refer to INSTALLING THE AIR FILTER CASE JOINT CLAMP 17 Check hose 1 For installation reverse the removal pro cedure AIR FILTER CASE ...

Page 94: ...INSTALLING THE AIR FILTER CASE JOINT CLAMP 1 Install air filter case joint clamp 1 NOTE To install the air filter case joint clamp align its slot a with the projection b on the air filter case 1 a b AIR FILTER CASE ...

Page 95: ...ton must be at top dead center TDC on the compression stroke 1 Remove seat side panels left and right Refer to COWLING AND COVER fuel tank Refer to FUEL TANK radiator Refer to RADIATOR in chapter 6 air filter to air cut off valve hose Refer to AIR INDUCTION SYSTEM in chapter 7 2 Remove intake tappet cover exhaust tappet cover 1 camshaft sprocket cover 2 2 1 3 Disconnect spark plug cap 1 4 Remove s...

Page 96: ...with the stationary pointer d on the cylinder head as shown in the illustration c Measure the valve clearance with a thick ness gauge 1 Out of specification Adjust 7 Adjust valve clearance a Loosen the locknut 1 b Insert a thickness gauge 2 between the end of the adjusting screw and the valve tip c Turn the adjusting screw 3 in direction a or b until the specified valve clearance is obtained Valve...

Page 97: ...essing screw crankshaft end accessing screw 9 Install spark plug 10 Connect spark plug cap 11 Install camshaft sprocket cover O rings 1 intake tappet cover exhaust tappet cover 12 Install air filter to air cut off valve hose Refer to AIR INDUCTION SYSTEM in chapter 7 radiator Refer to RADIATOR in chapter 6 fuel tank Refer to FUEL TANK side panels left and right seat Refer to COWLING AND COVER T R ...

Page 98: ... the CO adjustment mode Co or the diagnostic mode dIAG 4 After selecting Co simultaneously press the SELECT and RESET buttons for 2 seconds or more to execute the selection NOTE _ The tachometer mode is executed and it is displayed on the tripmeter 1 LCD C1 appears on the odometer fuel reserve tripmeter tripmeter 2 LCD 5 Press the SELECT and RESET buttons to change the CO adjustment volume NOTE _ ...

Page 99: ... 3 Adjust engine idling speed a Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained 4 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY Engine idling speed 1 300 1 500 r min Direction a Engine idling speed is increased Direction b Engine idling speed is decreased Throttle cable free play at the flange of the throttle ...

Page 100: ...il the specified throttle cable free play is obtained c Tighten the locknut NOTE _ If the specified throttle cable free play cannot be obtained on the throttle body end of the cable adjust the free play at the handlebar end of the cable using the adjusting nut Handlebar end a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtaine...

Page 101: ...ark plug CAUTION _ Before removing the spark plug blow away any dirt accumulated in the spark plug well with compressed air to prevent it from fall ing into the cylinder 3 Check spark plug type Incorrect Change 4 Check electrode 1 Damage wear Replace the spark plug insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 5 Clean spark plug with a spark plug cleaner or ...

Page 102: ...ignition sys tem Make sure all connections are tight and free of corrosion 1 Remove timing mark accessing screw 1 2 Connect timing light onto the spark plug lead Timing light 90890 03141 1 3 Check ignition timing a Start the engine warm it up for several min utes and then let it run at the specified engine idling speed b Check that the stationary pointer a is within the firing range b on the A C m...

Page 103: ...ance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE 2 Start the engine warm it up for several min utes and then turn it off 3 Disconnect spark plug cap 4 Remove spark plug CAUTION _ Before removing the spark plug blow away any dirt accumulated in the spark plug well with compressed air to prevent it from fall ing into the cylinder 5 Install compression gauge 1 adaptor compressi...

Page 104: ...the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the minimum specification pour a teaspoonful of engine oil into the spark plug bore and measure it again Refer to the following table Compression pressure at sea level Minimum 600 kPa 6 0 kg cm2 85 3 psi Standard 650 kPa 6 5 kg cm2 92 4 psi Maximum 700 kPa 7 0 kg c...

Page 105: ...er level NOTE _ Before checking the engine oil level wait a few minutes until the oil has settled Do not screw the dipstick 1 in when check ing the oil level CAUTION _ Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD c or higher and do not use oils labeled ENERGY ...

Page 106: ... several min utes and then turn it off 2 Place a container under the engine 3 Remove engine oil filler cap 1 camshaft sprocket cover 2 4 Install the engine oil drain attachment 1 under the engine oil drain bolt of the crank case NOTE engine oil drain attachment is a part of the owner s tool kit 5 Remove engine oil drain bolt crankcase 2 along with the gasket 6 Remove engine oil drain bolt oil tank...

Page 107: ...lter element drain bolt 12 Fill oil tank with the specified amount of the recom mended engine oil CAUTION _ The engine oil tank must be filled with engine oil in two steps First fill the engine oil tank with 1 9 L 1 67 Imp qt 2 00 US qt of the recommended engine oil Then start the engine race it five or six times turn it off and then add the remainder of the engine oil T R Oil filter element cover...

Page 108: ...sure a Slightly loosen the bleed bolt 1 b Start the engine and keep it idling until engine oil starts to seep from the bleed bolt 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 element and the oil pump for damage or leakage Refer to OIL PUMP in chapter 5 d Start the engine after correcting the prob lem s and ...

Page 109: ...inal posi tion NOTE _ If the specified clutch cable free play cannot be obtained on the handlebar end of the cable adjust the free play at the engine end of the cable using the adjusting nut Engine end a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until the specified clutch cable free play is obtained c Tighten the locknuts Clutch cable free play at the end of the clutch le...

Page 110: ...e cover right 1 3 Remove air filter element 1 4 Check air filter element Damage Replace 5 Install air filter element 1 air filter case cover right CAUTION _ Never operate the engine without the air fil ter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect the throttle body tuning lea...

Page 111: ... 1 Check throttle body joint 1 Cracks damage Replace Refer to FUEL INJECTION SYSTEM in chapter 7 1 EAS00096 CHECKING THE FUEL HOSE 1 Remove seat side panels left and right Refer to COWLING AND COVER fuel tank Refer to FUEL TANK 2 Check fuel hose 1 Cracks damage Replace Loose connection Connect properly 3 Install fuel tank Refer to FUEL TANK side panels left and right seat Refer to COWLING AND COVE...

Page 112: ...G THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets 1 Check exhaust pipes 1 mufflers 2 Cracks damage Replace gaskets 3 Exhaust gas leaks Replace 2 Check tightening torques T R Exhaust pipe nut 4 20 Nm 2 0 m kg 14 ft lb Exhaust pipe bolt 5 27 Nm 2 7 m kg 19 ft lb Muffler bolt 6 27 Nm 2 7 m kg 19 ft lb Exhaust pipe and muffler bolt 7 20 Nm 2 0 m kg 14 ft lb E...

Page 113: ...oper level CAUTION _ Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis tilled water is not available soft water may be used 3 Start the engine warm it up for several min utes and then turn it off 4 Check coolant level NOTE...

Page 114: ...er pump outlet pipe 5 water pump outlet hose 6 Cracks damage Replace Refer to COOLING SYSTEM in chapter 6 3 Install fuel tank Refer to FUEL TANK side panels left and right seat Refer to COWLING AND COVER 3 3 2 1 4 5 6 3 EAS00105 CHANGING THE COOLANT 1 Remove seat right side panel Refer to COWLING AND COVER fuel tank right side cover Refer to FUEL TANK ...

Page 115: ...slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape When the hissing sound has stopped press down on the radiator cap and turn it counterclockwise to remove 3 Remove coolant reservoir cap 3 coolant reservoir 4 4 Drain coolant from the coolant reservoir 5 Install coolant reservoir T R 5 Nm 0 5 m kg 3 6 ft lb 6 Remove coolant drain bolt 1 along wi...

Page 116: ... of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with water Do not mix different types of antifreeze Recommended a...

Page 117: ...oolant reservoir cap 14 Start the engine warm it up for several min utes and then turn it off 15 Check coolant level Refer to CHECKING THE COOLANT LEVEL NOTE _ Before checking the coolant level wait a few minutes until the coolant has settled 16 Install fuel tank right side cover Refer to FUEL TANK right side panel seat Refer to COWLING AND COVER a T R 7 Nm 0 7 m kg 5 1 ft lb ...

Page 118: ... A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance and could result in loss of control and possibly an accident Therefore check and if neces sary bleed the brake system CAUTION _ After adjusting the ...

Page 119: ...ids may cause the piston 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 boiling point of the brake flui...

Page 120: ... brake pads as a set Refer to REPLACING THE FRONT BRAKE PADS in chapter 4 3 Measure rear brake pads Wear limit 3 reached Replace the brake pads as a set Refer to REPLACING THE REAR BRAKE PADS in chapter 4 4 Check brake pad pins Damage wear Replace È Front brake XT660R É Front brake XT660X Ê Rear brake XT660R XT660X Rear brake pad wear limit 1 0 mm 0 04 in È É 3 Ê EAS00128 ADJUSTING THE REAR BRAKE ...

Page 121: ...ght comes on at the proper time Direction a Brake light comes on sooner Direction b Brake light comes on later EAS00131 CHECKING THE FRONT AND REAR BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps 1 Check front brake hose 1 rear brake hoses 2 Cracks damage wear Replace 2 Check brake hose clamp Loose Tighten the clamp bolt 3 Hold the motorcycle upright and...

Page 122: ...ir to enter the hydraulic brake system considerably length ening the bleeding procedure If bleeding is difficult 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 diaphragm...

Page 123: ...om the brake fluid in the plastic hose j Tighten the bleed screw to the specified torque k Fill the brake fluid reservoir to the proper level with the recommended brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL WARNING _ After bleeding the hydraulic brake system check the brake operation T R Bleed screw 14 Nm 1 4 m kg 10 ft lb ADJUSTING THE SHIFT PEDAL 1 Check shift pedal position distance a f...

Page 124: ...ust be checked at the tightest point on the chain CAUTION _ 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 swingarm or cause an accident Therefore keep the drive chain slack within the speci fied limits 1 Stand the motorcycle on a level surface WARNING _ Securely support the motorcycle so that there is no danger of i...

Page 125: ...2 c Turn both adjusting nuts 3 in direction a or b until the specified drive chain slack is obtained NOTE _ To maintain the proper wheel alignment adjust both sides evenly d Tighten both locknuts to the specified torque e Tighten the wheel axle nut to the specified torque Direction a Drive chain is tightened Direction b Drive chain is loosened T R Locknut 16 Nm 1 6 m kg 11 ft lb T R Wheel axle nut...

Page 126: ...ly kerosene to clean the drive chain Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suit able 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 Recommended lubricant Engine oil or chain lubricant suitable for O ring chains EAS00146 CHECKING AND ADJUSTING THE STEERING HE...

Page 127: ...asher 1 the upper ring nut 2 and the rubber washer 3 b Loosen the lower ring nut 4 and then tighten it to the specified torque with a steering nut wrench 5 NOTE _ Set the torque wrench at a right angle to the steering nut wrench c Loosen the lower ring nut completely and then tighten it to the specified torque WARNING _ Do not overtighten the lower ring nut Steering nut wrench 90890 01403 T R Lowe...

Page 128: ...ing 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 7 Install upper bracket washer steering stem 8 Tighten upper bracket pinch bolts 9 Install handlebar upper handlebar holders handlebar holder caps handlebar protector XT660X handlebar protector cover XT660X Refer to HANDLEBAR in chapter 4 EAS00149 CHECKING...

Page 129: ...ING _ Securely support the motorcycle so that there is no danger of it falling over Spring preload CAUTION _ Never go beyond the maximum or mini mum adjustment positions 1 Adjust spring preload a Adjust the spring preload with the special wrench provided in the owner s tool kit b Turn the adjusting ring 1 in direction a or b c Align the desired position on the adjusting ring with the stopper 2 Dir...

Page 130: ...to the total weight including cargo rider passenger and accessories and the anticipated riding speed Operation of an overloaded motorcycle could cause tire damage an accident or an injury NEVER OVERLOAD THE MOTORCYCLE XT660R Basic weight with oil and a full fuel tank 181 0 kg 399 lb Maximum load 186 0 kg 410 lb Cold tire pressure Front Rear Up to 90 kg load 200 kPa 2 00kgf cm2 29 psi 200 kPa 2 00k...

Page 131: ...be tires to avoid tire failure and personal injury from sudden deflation When using tube tires be sure to install the correct tube Always replace a new tube tire and a new tube as a set To avoid pinching the tube make sure the wheel rim band and tube are centered in the wheel groove Basic weight with oil and a full fuel tank 186 0 kg 410 lb Maximum load 186 0 kg 410 lb Cold tire pressure Front Rea...

Page 132: ...e same design No guarantee concerning han dling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle Front tire XT660R Rear tire XT660R Front tire XT660X Rear tire XT660X Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire Manufacturer Model Size METZELER TOU RANCE FRONT 90 90 21M C 54S MICHELIN SIRAC 90 90 21M C 54T Manufacture...

Page 133: ...k 1 Install the tire with the mark pointing in the direction of wheel rotation Align the mark 2 with the valve installation point EAS00169 CHECKING AND TIGHTENING THE SPOKES The following procedure applies to all of the spokes 1 Check spoke 1 Bends damage Replace Loose Tighten Tap the spokes with a screwdriver NOTE _ A tight spoke will emit a clear ringing tone a loose spoke will sound flat 2 Tigh...

Page 134: ...le 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 suitable lubricating device Recommended lubricant Engine oil or a suitable cable lubricant EAS00171 LUBRICATING THE LEVERS AND BRAKE PEDAL Lubricate the pivoting point and metal to metal moving parts of the levers and brake pedal Reco...

Page 135: ...yte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention CAUTION _ This is a sealed battery Never remove the sealing cap...

Page 136: ...ket tester to the battery termi nals NOTE _ The charge state of an MF battery can be checked by measuring its open circuit volt age i e the voltage when the positive bat tery terminal is disconnected No charging is necessary when the open cir cuit voltage equals or exceeds 12 8 V b Check the charge of the battery as shown in the charts and the following example Example c Open circuit voltage 12 0 ...

Page 137: ...attery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery termi nal and that they are not shorted A cor roded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at an...

Page 138: ...THE BATTERY If the amperage does not exceed the standard charging amperage after 5 minutes replace the battery If the required charging time exceeds 5 hours it is advisable to check the charging amperage after 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging amperage Leave the battery unused for more than 30 minutes before measuring its open circu...

Page 139: ...rge the battery until the charging voltage reaches 15 V This type of battery charger cannot charge an MF battery A variable volt age charger is recommended Leave the battery unused for more than 30 minutes before measuring its open cir cuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Replace the battery Constant amperage chargers are not suitable for chargin...

Page 140: ...lean with a wire brush Loose connection Connect properly 9 Lubricate battery terminals 10 Install battery cover Refer to AIR FILTER CASE seat Refer to COWLING AND COVER Recommended lubricant Dielectric grease 1 2 EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses CAUTION _ To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Re...

Page 141: ...w 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 Pocket tester 90890 03112 Fuses Amperage rating Q ty Main 30 A 1 Headlight 20 A 1 Signaling system 10 A 1 Ignition 10 A 1 Fuel injection system 10 A 1 Parking lighting system 10 A 1 Radiator fan motor 7 5 A 1 Backup immobi...

Page 142: ...ms to malfunction and could possibly cause a fire 4 Install left side panel seat Refer to COWLING AND COVER EAS00182 REPLACING THE HEADLIGHT BULB 1 Remove front fender front fork protector front cowling Refer to COWLING AND COVER 2 Disconnect headlight coupler 1 3 Remove headlight bulb holder cover 2 4 Remove headlight bulb holder 1 headlight bulb 2 WARNING _ Since the headlight bulb gets extremel...

Page 143: ...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 6 Connect headlight coupler 7 Install front cowling front fork protector front fender Refer to COWLING AND COVER New EAS00186 ADJUSTING THE HEADLIGHT BEAM 1 Adjust headlight beam vertically a Turn the adjusting screw 1 in direction a...

Page 144: ... together for at least two seconds c When the hour digits start flashing push the RESET button to set the hours d Push the SELECT button and the minute digits will start flashing e Push the RESET button to set the min utes f Push the SELECT button to start the clock NOTE _ After reconnecting the battery the clock indi cation is 1 00 and must be set to the correct time ...

Page 145: ...CHAS 4 ...

Page 146: ...S 4 19 FRONT BRAKE PADS XT660R 4 19 FRONT BRAKE PADS XT660X 4 20 REAR BRAKE PADS 4 21 REPLACING THE FRONT BRAKE PADS 4 22 REPLACING THE REAR BRAKE PADS 4 24 FRONT BRAKE MASTER CYLINDER 4 26 REAR BRAKE MASTER CYLINDER 4 29 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 32 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 32 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS 4 33 ASSEMBLING AND INSTAL...

Page 147: ...ERING HEAD 4 71 INSTALLING THE STEERING HEAD 4 72 REAR SHOCK ABSORBER ASSEMBLY 4 74 HANDLING THE REAR SHOCK ABSORBER 4 76 DISPOSING OF A REAR SHOCK ABSORBER 4 76 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 77 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 78 CHECKING THE CONNECTING ARMS AND RELAY ARM 4 78 INSTALLING THE RELAY ARM 4 78 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 79 SWINGARM AND DRIV...

Page 148: ...ront wheel and brake disc Remove the parts in the order listed NOTE _ Place the motorcycle on a suitable stand so that the front wheel is elevated 1 Brake caliper 1 Refer to REMOVING THE FRONT WHEEL and INSTALLING THE FRONT WHEEL 2 Wheel axle pinch bolt 2 Loosen 3 Front wheel axle 1 4 Front wheel 1 5 Spacer left 1 6 Spacer right 1 7 Front brake disc 1 For installation reverse the removal pro cedur...

Page 149: ...KE DISC EAS00518 FRONT WHEEL LS LS New New 1 2 3 2 1 Order Job Part Q ty Remarks Disassembling the front wheel Remove the parts in the order listed 1 Oil seal 2 2 Bearing 2 3 Spacer 1 For assembly reverse the disassembly procedure ...

Page 150: ...t wheel is elevated 2 Remove brake caliper NOTE _ Do not apply the brake lever when removing the brake caliper 3 Elevate front wheel NOTE _ Place the motorcycle on a suitable stand so that the front wheel is elevated EAS00526 CHECKING THE FRONT WHEEL 1 Check wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING _ Do not attempt to straighten a bent wheel axle 2 Check tire front wh...

Page 151: ... 3 Nm 0 3 m kg 2 2 ft lb 5 Measure radial wheel runout 1 lateral wheel runout 2 Over the specified limits Replace radial wheel runout limit 2 0 mm 0 08 in lateral wheel runout limit 2 0 mm 0 08 in 6 Check collars Damage wear Replace WARNING _ After mounting a new tire ride conserva tively for a while to become accustomed to the feel of the new tire and to allow the tire to seat itself properly in ...

Page 152: ...screwdriver NOTE _ To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel sur face c Remove the wheel bearings 3 with a gen eral bearing puller d Install the new wheel bearings and oil seals in the reverse order of disassembly CAUTION _ Do not contact the wheel bearing inner race 4 or balls 5 Contact should be made only with the outer race 6 NOTE _ Use a socket 7 that ma...

Page 153: ...asuring the front brake disc deflection turn the handlebar to the left or right to ensure that the front wheel is sta tionary c Remove the brake caliper d Hold the dial gauge at a right angle against the brake disc surface e Measure the deflection 3 0 mm 0 12 in below the edge of the brake disc Brake disc deflection limit maxi mum 0 15 mm 0 006 in 3 Measure brake disc thickness Measure the brake d...

Page 154: ...sscross pattern d Measure the brake disc deflection e If out of specification repeat the adjustment steps until the brake disc deflection is within specification f If the brake disc deflection cannot be brought within specification replace the brake disc T R Brake disc bolt 23 Nm 2 3 m kg 17 ft lb LOCTITE EAS00542 INSTALLING THE FRONT WHEEL 1 Lubricate oil seal lips Recommended lubricant Lithium s...

Page 155: ...s to the specified torque and then tighten the outer bolt to the specified torque again 3 Install brake caliper bolts WARNING _ Make sure the brake hose is routed prop erly T R 59 Nm 5 9 m kg 43 ft lb T R 18 Nm 1 8 m kg 13 ft lb T R 40 Nm 4 0 m kg 29 ft lb EAS00548 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE _ After replacing the tire wheel or both the front wheel static balance should be adjust...

Page 156: ...to rest at the same spot g The spot where all the marks come to rest is the front wheel s heavy spot X 3 Adjust front wheel static balance a Install a balancing weight 1 onto the rim exactly opposite the heavy spot X NOTE _ Start with the lightest weight b Turn the front wheel 90 so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier wei...

Page 157: ... 9 10 11 12 13 14 14 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks Removing the rear wheel Remove the parts in the order listed NOTE _ Place the motorcycle on a suitable stand so that the rear wheel is elevated 1 Stabilizer 1 XT660X 2 Chain cover 1 XT660X 3 Chain cover 1 XT660R 4 Locknut 2 Loosen 5 Adjusting nut 2 Loosen 6 Wheel axle nut 1 Refer to INSTALLING ...

Page 158: ... 2 5 4 4 7 6 8 9 10 11 12 13 14 14 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks 10 Rear wheel 1 Refer to REMOVING THE REAR WHEEL and INSTALLING THE REAR WHEEL 11 Spacer left 1 12 Spacer right 1 13 Brake caliper 1 Refer to REMOVING THE REAR WHEEL and INSTALLING THE REAR WHEEL 14 Chain puller 2 For installation reverse the removal pro cedure ...

Page 159: ...m 6 9 m kg 50 ft Ib LS 7 5 2 4 3 1 6 6 New Order Job Part Q ty Remarks Removing the brake disc and rear wheel sprocket Remove the parts in the order listed 1 Oil seal 1 2 Rear wheel sprocket 1 3 Bearing 1 4 Rear wheel drive hub 1 5 Spacer 1 6 Rear wheel drive hub damper 4 7 Rear brake disc 1 For installation reverse the removal pro cedure ...

Page 160: ...WHEEL BRAKE DISC AND REAR WHEEL SPROCKET Order Job Part Q ty Remarks Disassembling the rear wheel Remove the parts in the order listed 1 Bearing 2 2 Oil seal 1 3 Spacer 1 For assembly reverse the disassembly procedure ...

Page 161: ... that the rear wheel is elevated 2 Loosen locknut 1 adjusting nut 2 3 Remove stabilizer XT660X chain cover wheel axle nut 3 washer N wheel axle washer O rear wheel NOTE _ Push the rear wheel forward and remove the drive chain from the rear wheel sprocket 4 Remove brake caliper NOTE _ Do not depress the brake pedal when remov ing the brake caliper EAS00566 CHECKING THE REAR WHEEL 1 Check wheel axle...

Page 162: ... CHECKING THE REAR BRAKE DISC 1 Check brake disc Damage galling Replace 2 Measure brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the motorcycle on a suitable stand so that the rear wheel is elevated b Remove the brake caliper c Hold the dial gauge at a right angle against the brake disc surface d Measure the deflection 1 5 mm 0 06 in ...

Page 163: ...ll the brake disc NOTE _ Tighten the brake disc bolts in stages and in a crisscross pattern d Measure the brake disc deflection e If out of specification repeat the adjustment steps until the brake disc deflection is within specification f If the brake disc deflection cannot be brought within specification replace the brake disc T R Brake disc bolt 13 Nm 1 3 m kg 9 4 ft lb LOCTITE EAS00567 CHECKIN...

Page 164: ...ket 2 Replace rear wheel sprocket a Remove the self locking nuts and the rear wheel sprocket b Clean the rear wheel drive hub with a clean cloth especially the surfaces that contact the sprocket c Install the new rear wheel sprocket NOTE _ Tighten the self locking nuts in stages and in a crisscross pattern T R Rear wheel sprocket self locking nut 69 Nm 6 9 m kg 50 ft lb EAS00571 INSTALLING THE REA...

Page 165: ...NG THE DRIVE CHAIN SLACK in chapter 3 4 Tighten wheel axle nut 5 Install chain cover chain cover bolts stabilizer XT660X EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE _ After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust rear wheel static balance Refer to...

Page 166: ...1 4 m kg 10 ft Ib 1 1 5 4 5 2 6 3 Order Job Part Q ty Remarks Removing the front brake pads Remove the parts in the order listed 1 Brake caliper bolt 2 Refer to REPLACING THE FRONT BRAKE PADS 2 Brake pad clip 1 3 Brake pad pin 1 4 Brake pad 2 5 Brake pad spring 2 6 Bleed screw 1 For installation reverse the removal pro cedure ...

Page 167: ...r Job Part Q ty Remarks Removing the front brake pads Remove the parts in the order listed 1 Brake caliper bolt 2 Refer to REPLACING THE FRONT BRAKE PADS 2 Brake pad clip 2 3 Brake pad pin 2 4 Brake pad spring 1 5 Brake pad 2 6 Bleed screw 1 For installation reverse the removal pro cedure FRONT AND REAR BRAKES ...

Page 168: ...y Remarks Removing the rear brake pads Remove the parts in the order listed Rear wheel Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET 1 Brake pad pin 1 Refer to REPLACING THE REAR BRAKE PADS 2 Retaining bolt 1 3 Brake pad 2 4 Brake pad spring 2 5 Bleed screw 1 For installation reverse the removal pro cedure ...

Page 169: ...ke components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury FIRST AID FOR BRAKE FLUID ENTERING THE EYES Flush with water for 15 minutes and get immediate medical attention EAS00581 REPLACING THE FRONT BRAKE PADS NOTE _ When replacing the brake p...

Page 170: ...É 4 Install brake pad springs brake pads NOTE _ Always replace the 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 È XT660R É XT660X b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw T R Bleed screw 14 Nm 1 4 m kg 1...

Page 171: ...RAKE FLUID LEVEL in chapter 3 7 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 EAS00583 REPLACING THE REAR BRAKE PADS NOTE _ When replacing the brake pads it is not neces sary to disconnect the brake hose or disas semble the brake caliper 1 Remove rear wheel brake caliper Refer to REAR WHEEL BRAKE DISC AND REAR WH...

Page 172: ...he brake caliper with your finger c Tighten the bleed screw d Install new brake pads and new brake pad springs 5 Install brake pad pin brake pad clip brake caliper rear wheel Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET 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 in chapter 3 7 Check ...

Page 173: ...m kg 4 3 ft Ib 5 7 8 6 1 4 3 2 9 10 12 11 LS New Order Job Part Q ty Remarks Removing the front brake master cylinder Remove the parts in the order listed Brake fluid Drain 1 Rearview mirror right 1 2 Brake master cylinder reservoir cap 1 3 Brake master cylinder reservoir dia phragm holder 1 4 Brake master cylinder reservoir dia phragm 1 ...

Page 174: ...rake light switch 1 Disconnect Refer to DISASSEM BLING THE FRONT BRAKE MASTER CYLIN DER and ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 6 Union bolt 1 7 Copper washer 2 8 Brake hose 1 Disconnect 9 Brake lever 1 10 Spring 1 11 Brake master cylinder holder 1 12 Brake master cylinder 1 For installation reverse the removal pro cedure FRONT AND REAR BRAKES ...

Page 175: ... Order Job Part Q ty Remarks Disassembling the front brake mas ter cylinder Remove the parts in the order listed 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder 1 For assembly reverse the disassembly procedure ...

Page 176: ...rear brake master cyl inder Remove the parts in the order listed Brake fluid Drain 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir 1 5 Brake fluid reservoir hose 1 6 Union bolt 1 Refer to DISASSEM BLING THE REAR BRAKE MASTER CYLIN DER and INSTALLING THE REAR BRAKE MAS TER CYLINDER 7 Copper washer 2 8 Brake hose 1 ...

Page 177: ...18 Nm 1 8 m kg 13 ft Ib New New LS 9 5 4 1 2 3 10 12 11 6 7 8 13 Order Job Part Q ty Remarks 10 Cotter pin 1 Refer to INSTALLING THE REAR BRAKE MASTER CYLINDER 11 Washer 1 12 Pin 1 13 Master cylinder 1 For installation reverse the removal pro cedure FRONT AND REAR BRAKES ...

Page 178: ...y Remarks Disassembling the rear brake mas ter cylinder Remove the parts in the order listed 1 Hose joint 1 2 Brake master cylinder kit 1 Refer to ASSEMBLING THE REAR BRAKE MASTER CYLINDER 3 Brake master cylinder 1 For assembly reverse the disassembly procedure ...

Page 179: ...ake light switch from the brake master cylinder 2 Remove union bolt 1 copper washers 2 brake hose 3 NOTE _ To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose 3 1 2 EAS00589 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 1 Remove union bolt 1 copper washers 2 brake hose 3 NOTE _ To collect any remaining brake fluid place a container under th...

Page 180: ...ront É Rear È 1 É 2 Check brake master cylinder kit Damage scratches wear Replace as a set È Front É Rear È É 3 Check front brake master cylinder reservoir 1 Cracks damage Replace front brake master cylinder reservoir dia phragm 2 Damage wear Replace front brake master cylinder reservoir dia phragm holder 3 Damage wear Replace 1 2 3 4 Check rear brake fluid reservoir 1 Cracks damage Replace rear b...

Page 181: ...h the UP mark a facing up Align the end of the brake master cylinder holder with the punch mark b on the handle bar First tighten the upper bolt then the lower bolt 2 Install copper washers brake hose union bolt WARNING _ Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING in chapter 2 NOTE _ Install the brake hose within the range shown Turn the handl...

Page 182: ...er does not enter the brake master cylinder reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION _ Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check brake fluid level Below the minimum...

Page 183: ...piston seals and dust seals 1 Install brake master cylinder kit joint 1 NOTE _ Turn the adjusting bolt 2 until the clearance a is within the specified limits when install the joint 1 2 Tighten nut 3 Recommended brake fluid DOT 4 Clearance 2 1 mm 0 08 in a 2 3 1 T R 18 Nm 1 8 m kg 13 ft lb INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install brake master cylinder pin 1 washer 2 cotter pin 3 NOTE Ins...

Page 184: ...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 boil...

Page 185: ...brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 6 Adjust brake pedal position a Refer to ADJUSTING THE REAR BRAKE PEDAL in chapter 3 7 Adjust rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH in chapter 3 Brake pedal position below the top of the rider footrest 12 0 mm 0 47 in FRONT AND REAR BRAKES ...

Page 186: ...New 5 3 1 2 4 2 Order Job Part Q ty Remarks Removing the front brake caliper Remove the parts in the order listed Brake fluid Drain 1 Union bolt 1 Refer to INSTALLING THE FRONT BRAKE CALIPER 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Front brake caliper bolt 2 5 Brake caliper 1 For installation reverse the removal pro cedure ...

Page 187: ...LS Order Job Part Q ty Remarks Disassembling the front brake cali per Remove the parts in the order listed 1 Brake pad clip 1 Refer to INSTALLING THE FRONT BRAKE CALIPER 2 Brake pad pin 1 3 Brake pad 2 4 Brake pad spring 2 5 Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 188: ...t Q ty Remarks Removing the front brake caliper Remove the parts in the order listed Brake fluid Drain 1 Union bolt 1 Refer to INSTALLING THE FRONT BRAKE CALIPER 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Front brake caliper bolt 2 5 Brake caliper 1 For installation reverse the removal pro cedure FRONT AND REAR BRAKES ...

Page 189: ...s Disassembling the front brake cali per Remove the parts in the order listed 1 Brake pad clip 2 Refer to INSTALLING THE FRONT BRAKE CALIPER 2 Brake pad pin 2 3 Brake pad spring 1 4 Brake pad 2 5 Bleed screw 1 For assembly reverse the disassembly procedure FRONT AND REAR BRAKES ...

Page 190: ... Part Q ty Remarks Removing the rear brake caliper Remove the parts in the order listed Brake fluid Drain Rear wheel Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET 1 Brake caliper protector 1 2 Union bolt 1 Refer to INSTALLING THE REAR BRAKE CALI PER 3 Copper washer 2 4 Brake hose 1 Disconnect 5 Brake caliper 1 For installation reverse the removal pro cedure ...

Page 191: ... Part Q ty Remarks Disassembling the rear brake cali per Remove the parts in the order listed 1 Brake caliper bracket 1 2 Brake pad clip 1 Refer to INSTALLING THE REAR BRAKE CALIPER 3 Brake pad pin 1 4 Brake pad 2 5 Brake pad spring 2 6 Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 192: ...tainer and pump out the brake fluid carefully È XT660R É XT660X 1 3 4 2 È 4 1 3 2 É EAS00626 REMOVING THE REAR BRAKE CALIPER NOTE _ Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove brake caliper protector 2 Remove union bolt 1 copper washers 2 brake hose 3 brake caliper 4 _rear wheel Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET NOTE Put the en...

Page 193: ...Brake fluid Every two years and whenever the brake is disassem bled 1 Check brake caliper pistons 1 Rust scratches wear Replace the brake caliper brake caliper body 2 Cracks damage Replace the brake cali per brake caliper Brake fluid leakage Replace the brake caliper È Front XT660R É Front XT660X Ê Rear XT660R XT660X 2 Check brake caliper bracket Cracks damage Replace 2 1 È 2 1 É 2 1 Ê ...

Page 194: ...brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING in chapter 2 CAUTION _ XT660R When installing the brake hose onto the brake caliper 1 make sure the brake pipe a touches the brake caliper body b XT660X When installing the brake hose onto the brake caliper 1 make sure the brake pipe a touches the projection c on the brake caliper È XT660R É XT660X 4 3 1 2 È...

Page 195: ...er does not enter the brake master cylinder reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION _ Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check brake fluid level Below the minimum...

Page 196: ... is essential to insure safe motorcycle operation Refer to CABLE ROUTING in chapter 2 CAUTION _ When installing the brake hose onto the brake caliper 3 make sure the brake pipe a touches the projection b on the brake caliper 3 Install brake caliper protector brake caliper protector bolt 1 brake caliper protector bolt 2 3 2 1 a b New T R 30 Nm 3 0 m kg 22 ft lb 1 2 T R 7 Nm 0 7 m kg 5 1 ft lb T R 4...

Page 197: ...fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION _ Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 6 Check brake fluid level Below the minimum level mark a Add the recommended brake...

Page 198: ...ty Remarks Removing the front fork legs Remove the parts in the order listed The following procedure applies to both of the front fork legs Front fender Refer to COWLING AND COVER in chapter 3 Front fork protector Front cowling assembly Front wheel Refer to FRONT WHEEL AND BRAKE DISC 1 Front mud guard 1 XT660R 2 Front mud guard stay 2 XT660R 3 Stabilizer 1 XT660X 4 Front mud guard 1 XT660X 5 Brake...

Page 199: ...R 18 Nm 1 8 m kg 13 ft Ib 5 2 2 1 4 3 9 7 10 8 6 4 Order Job Part Q ty Remarks 6 Upper bracket pinch bolt 2 Loosen Refer to REMOVING THE FRONT FORK LEGS and INSTALLING THE FRONT FORK LEGS 7 Cap bolt 1 Loosen 8 Lower bracket pinch bolt 2 Loosen 9 Front fork leg 1 XT660R 10 Front fork leg 1 XT660X For installation reverse the removal pro cedure FRONT FORK ...

Page 200: ...mbling the front fork legs Remove the parts in the order listed NOTE The following the procedure applies to both of the front fork legs 1 Cap bolt 1 2 O ring 1 3 Spring seat 1 4 Fork spring 1 5 Dust seal 1 Refer to DISASSEMBLING THE FRONT FORK LEGS and ASSEM BLING THE FRONT FORK LEGS 6 Oil seal clip 1 7 Damper rod bolt copper washer 1 1 8 Damper rod 1 9 Rebound spring 1 0 Inner tube 1 ...

Page 201: ...b 7 F G 0 E D 5 6 A B C 8 9 4 3 2 1 Order Job Part Q ty Remarks A Oil seal 1 Refer to ASSEMBLING THE FRONT FORK LEGS B Washer 1 C Outer tube bushing 1 D Oil flow stopper 1 E Inner tube bushing 1 F Outer tube 1 XT660R G Outer tube 1 XT660X For assembly reverse the disassembly procedure FRONT FORK ...

Page 202: ..._ Place the motorcycle on a suitable stand so that the front wheel is elevated 2 Remove brake hose holders 1 1 3 Loosen upper bracket pinch bolts 1 cap bolt 2 lower bracket pinch bolts 3 WARNING _ Before loosening the upper and lower bracket pinch bolts support the front fork leg 4 Remove front fork leg 1 2 3 EAS00652 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the...

Page 203: ...ssembly with the damper rod holder 2 and T handle 3 loosen the damper rod bolt 1 5 Remove inner tube a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the inner tube from the outer tube by pulling the inner tube forcefully but care fully CAUTION _ Excessive force will damage the oil seal and the inner tube bushing A damaged oil se...

Page 204: ...re applies to both of the front fork legs 1 Check inner tube 1 outer tube 2 Bends damage scratches Replace WARNING _ Do not attempt to straighten a bent inner tube as this may dangerously weaken it È XT660R É XT660X 2 1 È 2 1 É 2 Measure spring free length a Out of specification Replace Spring free length XT660R 633 0 mm 24 92 in Limit 620 mm 24 41 in XT660X 593 0 mm 23 35 in Limit 581 mm 22 87 in...

Page 205: ...ING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING _ Make sure 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 inner tube bushing outer tube bushing oil seal dust seal Before assembling the front fork le...

Page 206: ...with the damper rod holder 2 and T handle 3 tighten the damper rod bolt T R Damper rod bolt 30 Nm 3 0 m kg 22 ft lb LOCTITE Damper rod holder 90890 01460 T handle 90890 01326 1 LT New 4 Install outer tube bushing 1 with the fork seal driver weight 3 and fork seal driver attachment 4 washer 2 Fork seal driver weight 90890 01367 Fork seal driver attachment ø43 90890 01374 New ...

Page 207: ...lips with lithium soap based grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag 4 to pro tect the oil seal during installation New 6 Install oil seal clip 1 NOTE _ Adjust the oil seal clip so that it fits into the outer tube s groove 7 Install dust seal 1 with the fork seal driver weight 2 Fork se...

Page 208: ...ch front fork leg XT660R 640 0 cm3 22 53 Imp oz 21 64 US oz XT660X 600 0 cm3 21 12 Imp oz 20 29 US oz Recommended oil Fork oil 10 W or equivalent Front fork leg oil level from the top of the inner tube with the inner tube fully compressed and without the fork spring 125 0 mm 4 92 in 10 Install spring 1 spring seat 2 O ring cap bolt NOTE _ Install the spring with the smaller pitch facing up Before ...

Page 209: ...f the bevel on the upper bracket as shown b a 2 Tighten lower bracket pinch bolts 1 cap bolt 2 upper bracket pinch bolts 3 WARNING _ Make sure the brake hose is routed prop erly 3 Install brake hose holders front mud guard WARNING _ Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING in chapter 2 1 3 2 T R 23 Nm 2 3 m kg 17 ft lb T R 18 Nm 1 8 m kg 13 ...

Page 210: ... Removing the handlebar Remove the parts in the order listed 1 Rearview mirror left and right 2 2 Plastic band 2 3 Front brake light switch 1 Disconnect Refer to REMOVING THE HANDLE BAR 4 Brake master cylinder holder 1 Refer to INSTALLING THE HANDLEBAR 5 Brake master cylinder 1 6 Grip end 2 7 Throttle cable holder 1 8 Right handlebar switch 1 9 Throttle cable 2 10 Throttle grip 1 Disconnect 11 Clu...

Page 211: ... 2 17 14 6 15 13 12 11 1 1 Order Job Part Q ty Remarks 13 Clutch lever 1 Refer to INSTALLING THE HANDLE BAR 14 Left handlebar switch 1 15 Handlebar grip 1 Refer to REMOVING THE HANDLE BAR and INSTALLING THE HANDLE BAR 16 Upper handlebar holder 2 Refer to INSTALLING THE HANDLE BAR 17 Handlebar 1 For installation reverse the removal pro cedure HANDLEBAR ...

Page 212: ...stener to remove the clutch switch from the clutch lever 3 Remove handlebar grip 1 NOTE _ Blow compressed air between the handlebar and the handlebar grip and gradually push the grip off the handlebar EAS00668 CHECKING THE HANDLEBAR 1 Check handlebar 1 Bends cracks damage Replace WARNING _ Do not attempt to straighten a bent handle bar as this may dangerously weaken it 1 EAS00671 INSTALLING THE HA...

Page 213: ...alled with the arrow marks a facing for ward Align the match mark b on the handlebar with the upper surface of the lower handlebar holders 3 Install handlebar grip 1 grip end 2 a Apply a thin coat of rubber adhesive onto the left end of the handlebar b Slide the handlebar grip over the left end of the handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING _ Do not touch the handl...

Page 214: ...2 right handlebar switch 3 grip end NOTE _ Lubricate the inside of the throttle grip with a thin coat of lithium soap based grease and install it onto the handlebar Route the throttle cables through the slot in the right handlebar switch and then install the cables Align the projection a on the right handlebar switch with the hole b in the handlebar There should be 1 3 mm 0 04 0 12 in of clearance...

Page 215: ...ble free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY in chapter 3 10 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 Clutch cable free play at the end of the clutch lever 10 0 15 0 mm 0 39 0 59 in Throttle cable free play at the flange of the throttle grip 3 0 5 0 mm 0 12 0 20 in ...

Page 216: ... 1 T R 32 Nm 3 2 m kg 23 ft Ib Order Job Part Q ty Remarks Removing the lower bracket Remove the parts in the order listed Front wheel Refer to FRONT WHEEL AND BRAKE DISC Front fork legs Refer to FRONT FORK Handlebar Refer to HANDLEBAR 1 Lower handlebar holder 2 2 Immobilizer unit coupler 1 Disconnect 3 Main switch coupler 2 Disconnect 4 Steering stem nut 1 Refer to REMOVING THE LOWER BRACKET and ...

Page 217: ...R 23 Nm 2 3 m kg 17 ft Ib T R 32 Nm 3 2 m kg 23 ft Ib LS LS 15 13 16 10 14 12 11 9 8 7 6 2 3 5 1 4 1 T R 32 Nm 3 2 m kg 23 ft Ib Order Job Part Q ty Remarks 11 Bearing cover 1 12 Upper bearing 1 Refer to INSTALLING THE STEERING HEAD 13 Lower bearing 1 14 Upper bearing outer race 1 15 Lower bearing outer race 1 16 Dust seal 1 For installation reverse the removal pro cedure STEERING HEAD ...

Page 218: ...lower bracket NOTE _ Hold the lower ring nut with the steering nut wrench 3 and then remove the upper ring nut with the ring nut wrench 4 WARNING _ Securely support the lower bracket so that there is no danger of it falling Steering nut wrench 90890 01403 Ring nut wrench 90890 01268 3 4 2 1 EAS00681 CHECKING THE STEERING HEAD 1 Wash bearings bearing races 2 Check bearings bearing races Damage pitt...

Page 219: ...ly the steering head pipe could be damaged NOTE _ Always replace the bearings and bearing races as a set Whenever the steering head is disassem bled replace the dust seal 4 Check upper bracket lower bracket along with the steering stem Bends cracks damage Replace EAS00683 INSTALLING THE STEERING HEAD 1 Lubricate upper bearing lower bearing bearing races Recommended lubricant Lithium soap based gre...

Page 220: ...ONT FORK LEGS NOTE _ Temporarily tighten the lower bracket pinch bolts 5 Tighten steering stem nut 6 Install lower handlebar holders lower handlebar holder nuts NOTE Temporarily tighten the lower handlebar nuts 7 Install handlebar upper handlebar holder Refer to HANDLEBAR 8 Tighten lower handlebar holder nuts T R 130 Nm 13 0 m kg 94 ft lb T R 32 Nm 3 2 m kg 23 ft lb ...

Page 221: ...shock absorber assembly Remove the parts in the order listed Seat side panels left and right rear cover Refer to COWLING AND COVER in chapter 3 Fuel tank Refer to FUEL TANK in chapter 3 Rear fender air filter case Refer to AIR FILTER CASE in chapter 3 Rear wheel Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET 1 Self locking nut washer bolt 2 2 2 Refer to REMOVING THE REAR SHOCK ABSORBER ASS...

Page 222: ...er nut 1 1 1 Refer to REMOVING THE REAR SHOCK ABSORBER ASSEMBLY and INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 5 Relay arm 1 6 Self locking nut washer bolt 1 2 1 7 Self locking nut washer bolt 1 1 1 8 Rear shock absorber assembly 1 9 Oil seal bearing spacer 2 1 2 Refer to INSTALLING THE RELAY ARM 10 Oil seal bearing spacer 2 1 1 11 Oil seal bearing spacer 2 1 1 For installation reverse the remova...

Page 223: ... open the rear shock absorber Do not subject the rear shock absorber to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pressure Do not deform or damage the rear shock absorber in any way Rear shock absorber damage will result in poor damping performance EAS00688 DISPOSING OF A REAR SHOCK ABSORBER Gas pressure must be released before dispos ing ...

Page 224: ...cle on a suitable stand so that the rear wheel is elevated 2 Remove connecting arm bolt 1 rear shock absorber assembly lower bolt 2 NOTE While removing the rear shock absorber assembly lower bolt hold the swingarm so that it does not drop down 2 1 3 Remove rear shock absorber assembly upper bolt 1 rear shock absorber assembly 2 NOTE Raise the swingarm and then remove the rear shock absorber assemb...

Page 225: ...sorber assembly bolts Bends damage wear Replace CHECKING THE CONNECTING ARMS AND RELAY ARM 1 Check connecting arms 1 relay arm 2 Damage wear Replace 2 Check spacers oil seals bearings Damage pitting scratches Replace 2 1 INSTALLING THE RELAY ARM 1 Install bearings 1 to the relay arm and swingarm bearing 2 to the relay arm 3 Swingarm 4 Rear shock absorber 5 Relay arm 6 Connecting arm 7 Frame Instal...

Page 226: ...rber assembly upper nut rear shock absorber assembly lower nut relay arm to frame nut relay arm to connecting arm nuts connecting arm to swingarm nut 4 Adjust drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 Recommended lubricant Lithium soap based grease Drive chain slack 40 0 55 0 mm 1 57 2 17 in T R 59 Nm 5 9 m kg 43 ft lb T R 42 Nm 4 2 m kg 30 ft lb T R 59 Nm 5 9 m kg 43...

Page 227: ... LS LS LS LS New New 1 4 2 3 6 7 8 9 10 11 14 15 17 18 18 16 15 14 19 10 T R 10 Nm 1 0 m kg 7 2 ft Ib 5 Order Job Part Q ty Remarks Removing the swingarm and drive chain Remove the parts in the order listed Rear wheel Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET 1 Right side heel plate 1 2 Brake master cylinder 1 3 Rear brake light switch 1 4 Right footrest brake pedal assembly 1 5 Left ...

Page 228: ...5 17 18 18 16 15 14 19 10 T R 10 Nm 1 0 m kg 7 2 ft Ib 5 Order Job Part Q ty Remarks 10 Nut washer bolt 1 1 1 Refer to REMOVING THE DRIVE SPROCKET and INSTALLING THE SWINGARM 11 Cap pivot shaft nut pivot shaft 2 1 1 12 Swingarm 1 Refer to REMOVING THE SWINGARM and INSTALLING THE SWINGARM 13 Drive chain guide 1 14 Dust cover oil seal 2 2 Refer to INSTALLING THE SWING ARM 15 Bearing 2 16 Spacer 1 17...

Page 229: ...htening torque of the pivot shaft nut b Measure the swingarm side play È by mov ing the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bearings and dust covers d Check the swingarm vertical movement É by moving the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the spacers bearings and dust covers 3 R...

Page 230: ...Remove drive sprocket nut 1 lock washer 2 drive sprocket 3 3 2 1 a EAS00704 REMOVING THE DRIVE CHAIN 1 Stand the motorcycle on a level surface WARNING _ Securely support the motorcycle so that there is no danger of it falling over NOTE _ Place the motorcycle on a suitable stand so that the rear wheel is elevated 2 Remove drive chain EAS00707 CHECKING THE SWINGARM 1 Check swingarm Bends cracks dama...

Page 231: ...earings bushings Damage pitting Replace Recommended cleaning solvent Kerosene EAS00709 CHECKING THE DRIVE CHAIN 1 Measure a 15 link section a of the drive chain Out of specification Replace the drive chain NOTE _ While measuring the 15 link section push down on the drive chain to increase its ten sion Measure the length between drive chain roller 1 and F as shown Perform this measurement at two or...

Page 232: ...a coarse brush to clean the drive chain High pressure methods could force dirt or water into the internal sections of the drive chain and solvents will deteriorate the O rings A coarse brush can also damage the O rings Therefore use only kerosene to clean the drive chain Don t soak the drive chain in kerosine for more than ten minutes otherwise the O rings can be damaged 4 Check O rings 1 Damage R...

Page 233: ... drive chain sprockets as a set Bent teeth Replace the drive chain sprockets as a set b Correct 1 Drive chain roller 2 Drive chain sprocket EAS00711 INSTALLING THE SWINGARM 1 Lubricate spacers dust covers pivot shaft 2 Install bushings 1 bearings 2 spacers 3 to swingarm Recommended lubricant Lithium soap based grease Installed depth of bearing a 4 mm 0 16 in Installed depth of bushing b 8 mm 0 31 ...

Page 234: ...he drive sprocket nut 6 Bend the lock washer tab a along a flat side of the nut 7 Adjust drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 8 Adjust brake pedal position Refer to ADJUSTING THE REAR BRAKE PEDAL in chapter 3 9 Adjust rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH in chapter 3 Drive chain slack 40 0 55 0 mm 1 57 2 17 in Brake ped...

Page 235: ......

Page 236: ...ENG 5 ...

Page 237: ...MS AND CAMSHAFT 5 16 REMOVING THE ROCKER ARMS AND CAMSHAFT 5 18 CHECKING THE CAMSHAFT 5 18 CHECKING THE DECOMPRESSION SYSTEM 5 19 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 5 20 INSTALLING THE CAMSHAFT AND ROCKER ARMS 5 21 VALVES AND VALVE SPRINGS 5 23 REMOVING THE VALVES 5 24 CHECKING THE VALVES AND VALVE GUIDES 5 25 CHECKING THE VALVE SEATS 5 27 CHECKING THE VALVE SPRINGS 5 29 INSTALLING THE...

Page 238: ...MBLING THE OIL PUMP 5 54 INSTALLING THE OIL PUMP 5 55 BALANCER DRIVEN GEAR 5 56 REMOVING THE BALANCER DRIVEN GEAR AND BALANCER DRIVE GEAR 5 58 CHECKING THE BALANCER DRIVEN GEAR WATER PUMP DRIVE GEAR PRIMARY DRIVE GEAR AND BALANCER DRIVE GEAR 5 58 INSTALLING THE BALANCER DRIVEN GEAR AND BALANCER DRIVE GEAR 5 59 SHIFT SHAFT 5 60 SHIFT SHAFT AND STOPPER LEVER 5 60 CHECKING THE SHIFT SHAFT 5 62 CHECKI...

Page 239: ...CHECKING THE CRANKCASE 5 73 ASSEMBLING THE CRANKCASE 5 74 CRANKSHAFT 5 76 CRANKSHAFT AND BALANCER 5 76 REMOVING THE CRANKSHAFT ASSEMBLY 5 77 CHECKING THE CRANKSHAFT 5 77 INSTALLING THE CRANKSHAFT 5 78 TRANSMISSION 5 79 MAIN AXLE 5 80 DRIVE AXLE 5 81 CHECKING THE SHIFT FORKS 5 82 CHECKING THE SHIFT DRUM ASSEMBLY 5 82 CHECKING THE TRANSMISSION 5 82 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 83 INSTAL...

Page 240: ...ENG ...

Page 241: ...27 Nm 2 7 m kg 19 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib 3 3 3 2 2 1 1 3 3 4 Order Job Part Q ty Remarks Removing the exhaust pipes and mufflers Remove the parts in the order listed 1 Muffler left and right 2 2 Exhaust pipe left and right 2 3 Gasket 5 4 Exhaust pipe bracket 1 For installatio...

Page 242: ...Removing the leads cables hoses and ignition coil Remove the parts in the order listed Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Seat side panels left and right rear cover Refer to COWLING AND COVER in chapter 3 Fuel tank side covers left and right fuel tank Refer to FUEL TANK in chapter 3 Rear wheel Refer to REAR WHEEL ...

Page 243: ...r to AIR FILTER CASE in chapter 3 Throttle body fast idle plunger inlet hose Refer to THROTTLE BODY ASSEM BLY in chapter 7 Thermostat thermo sensor Refer to THERMOSTAT in chapter 6 Radiator Refer to RADIATOR in chapter 6 Water pump assembly water pump outlet hose Refer to WATER PUMP in chapter 6 Air cut off valve assembly air filter to air cut off valve hose Refer to AIR INDUCTION SYSTEM in chapte...

Page 244: ... 1 Disconnect 4 Oil tank breather hose 1 Disconnect 5 Crankcase to crankcase breather chamber hose 1 6 A C magneto coupler 2 Disconnect 7 Neutral switch connector 1 Disconnect 8 Speed sensor coupler 1 Disconnect 9 Ignition coil lead 2 Disconnect 10 Ignition coil 1 11 Intake air pressure sensor coupler 1 Disconnect 12 Vacuum hose 1 13 Intake air pressure sensor 1 14 Clutch cable 1 For installation ...

Page 245: ...ngine Remove the parts in the order listed NOTE _ Place a suitable stand under the frame and engine CAUTION Install all of the nuts and bolt and then tighten them to specified torques 1 Engine front mounting bracket bolt nut 2 2 Refer to INSTALLING THE ENGINE 2 Engine front bracket bolt nut 2 2 3 Engine front bracket 1 4 Engine rear mounting bolt nut 1 1 5 Engine upper bracket bolt nut 2 2 6 Engin...

Page 246: ...lb T R 55 Nm 5 5m kg 40 ft Ib 5 5 7 6 2 8 6 5 5 2 3 1 1 4 4 1 1 9 Order Job Part Q ty Remarks 7 Engine upper bracket right 1 Refer to INSTALL ING THE ENGINE 8 Engine upper bracket left 1 9 Engine 1 NOTE Remove the engine from the right side of the motorcycle For installation reverse the removal pro cedure ...

Page 247: ... upper bracket right 8 engine upper bracket bolts nuts 9 engine upper mounting bolt nut 0 NOTE Do not fully tighten the bolts 2 Tighten engine front bracket bolts nuts 2 5 engine front mounting bolts nuts 3 6 engine rear mounting bolt nut 4 engine upper bracket bolts nuts 9 engine upper mounting bolt nut 0 9 9 8 0 2 5 7 0 9 9 5 2 1 3 6 4 4 6 3 T R 73 Nm 7 3 m kg 53 ft lb T R 73 Nm 7 3 m kg 53 ft l...

Page 248: ... 8 7 9 10 11 3 3 4 3 12 4 3 E E Order Job Part Q ty Remarks Removing the cylinder head Remove the parts in the order listed Engine Refer to ENGINE REMOVAL Timing mark accessing screw crank shaft end accessing screw Refer to ADJUSTING THE VALVE CLEARANCE in chapter 3 1 Spark plug 1 2 Camshaft sprocket cover O ring 1 1 3 Tappet cover O ring 2 2 4 Air cut off valve outlet pipe 1 5 Gasket 1 6 Oil deli...

Page 249: ...Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 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 New New New LS New New New New LS New New LS New New E 1 2 5 4 6 8 7 9 10 11 3 3 4 3 12 4 3 E E Order Job Part Q ty Remarks 11 Cylinder head gasket 1 12 Dowel pin 2 For installation reverse the removal pro cedure CYLINDER HEAD ...

Page 250: ...d on the cylinder head a b c d 2 Loosen camshaft sprocket bolts 1 NOTE While holding the A C magneto rotor nut with a wrench remove the bolt 3 Loosen timing chain tensioner cap bolt 4 Remove timing chain tensioner along with the gasket camshaft sprocket timing chain NOTE _ To prevent the timing chain from falling into the crankcase fasten it with a wire 1 5 Remove cylinder head NOTE _ Loosen the b...

Page 251: ... deposits rust Eliminate 3 Measure cylinder head warpage Out of specification Resurface the cylin der head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern NOTE ...

Page 252: ...Check one way cam operation Rough movement Replace the timing chain tensioner housing 3 Check timing chain tensioner cap bolt copper washer spring one way cam gasket timing chain tensioner rod Damage wear Replace the defective part s New New CHECKING THE CAMSHAFT SPROCKET 1 Check camshaft sprocket Wear damage Replace the camshaft sprocket and timing chain as a set a 1 4 of a tooth b Correct 1 Roll...

Page 253: ...OTE _ Tighten the cylinder head bolts in the proper tightening sequence as shown and torque them in two stages New 3 1 2 4 1 2 4 4 3 3 T R 50 Nm 5 0 m kg 36 ft lb T R 50 Nm 5 0 m kg 36 ft lb T R 45 Nm 4 5 m kg 32 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 4 Install camshaft sprocket onto the camshaft NOTE Make sure that the projection a on the decom pressor lever is in the position shown in the illustrati...

Page 254: ...t end of the chain Align the projection on the camshaft with the slot in the camshaft sprocket CAUTION _ Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing e Remove the wire from the timing chain d e 1 2 3 5 Install timing chain tensioner a Remove the timing chain tensioner cap bolt 1 copper washer 2 and spring 3 b Release the timing chain tensioner on...

Page 255: ...sprocket is aligned with the stationary pointer d on the cylinder head Out of alignment Correct Repeat steps 4 7 if necessary 8 Tighten camshaft sprocket bolts CAUTION _ Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine 9 Measure valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE C...

Page 256: ...g the rocker arms and cam shaft Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Bearing retainer 1 Refer to REMOV ING THE ROCKER ARMS AND CAM SHAFT and INSTALLING THE CAMSHAFT AND ROCKER ARMS 2 Rocker arm shaft 2 3 Rocker arm 2 4 Locknut valve adjuster 4 4 5 Camshaft 1 CAUTION Do not disas semble the cam shaft assembly 6 Decompressor lever 1 ROCKER ARMS AND CAMSHAFT ...

Page 257: ...4 Nm 1 4 m kg 10 ft Ib 4 4 3 3 2 8 2 7 5 6 1 4 4 M M Order Job Part Q ty Remarks 7 Decompressor lever pin 1 Refer to REMOVING THE ROCKER ARMS AND CAMSHAFT and INSTALLING THE CAMSHAFT AND ROCKER ARMS 8 Bearing 1 For installation reverse the removal pro cedure ROCKER ARMS AND CAMSHAFT ...

Page 258: ...e rocker arm shaft exhaust rocker arm shaft intake rocker arm exhaust rocker arm NOTE _ Remove the rocker arm shafts with the slide hammer bolt 1 and weight 2 4 Remove camshaft Slide hammer bolt 90890 01083 Weight 90890 01084 1 2 EAS00205 CHECKING THE CAMSHAFT 1 Check camshaft lobes Blue discoloration pitting scratches Replace the camshaft and camshaft sprocket ...

Page 259: ...Exhaust a 43 129 43 229 mm 1 6980 1 7019 in Limit 42 983 mm 1 6922 in b 37 007 37 107 mm 1 4570 1 4609 in Limit 36 886 mm 1 4522 in Camshaft runout limit 0 040 mm 0 0016 in CHECKING THE DECOMPRESSION SYSTEM 1 Check decompression system a Check the decompression system with the camshaft sprocket installed on and the decompressor pin installed in the camshaft b Check that the decompressor lever pin ...

Page 260: ...r arm shaft Blue discoloration excessive wear pitting scratches Replace or check the lubrica tion system 3 Measure rocker arm inside diameter Out of specification Replace Rocker arm inside diameter 12 000 12 018 mm 0 4724 0 4731 in Limit 12 036 mm 0 4739 in 4 Measure rocker arm shaft outside diameter Out of specification Replace Rocker arm shaft outside diame ter 11 981 11 991 mm 0 4717 0 4721 in ...

Page 261: ...ocker arm to rocker arm shaft clearance 0 009 0 037 mm 0 0004 0 0015 in Limit 0 081 mm 0 0032 in EAS00220 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1 Install bearing 1 onto the camshaft NOTE Apply engine oil to the bearing Install the bearing so that the seal is facing a the camshaft 2 Lubricate camshaft decompressor lever pin decompressor lever Installed depth b 0 mm 0 in Recommended lubricant Cams...

Page 262: ...icate rocker arm shafts 6 Install exhaust rocker arm 1 exhaust rocker arm shaft 2 intake rocker arm intake rocker arm shaft NOTE _ Use a slide hammer bolt 3 to install the rocker arm shaft Make sure the rocker arm shaft intake and exhaust is completely pushed into the cylin der head 7 Install camshaft retainer camshaft retainer bolts Recommended lubricant Engine oil Slide hammer bolt 90890 01083 1...

Page 263: ...prings Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD Rocker arms rocker arm shafts cam shaft Refer to ROCKER ARMS AND CAM SHAFT 1 Valve cotter 8 Refer to REMOVING THE VALVES and INSTALLING THE VALVES 2 Valve spring retainer 4 3 Valve spring 4 4 Exhaust valve 2 5 Intake valve 2 6 Valve stem seal 4 7 Valve spring seat 4 For installation reverse the removal pro cedure ...

Page 264: ...at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal NOTE _ There should be no leakage at the valve seat 1 2 Remove valve cotters NOTE _ Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring c...

Page 265: ...HECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides 1 Measure valve stem to valve guide clearance Out of specification Replace the valve guide Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance Intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 08 mm 0 0031 in Exhaust 0 025 0...

Page 266: ...th the valve guide reamer 3 to obtain the proper valve stem to valve guide clearance NOTE _ After replacing the valve guide reface the valve seat 3 Eliminate 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 Valve guide remover ø6 90890 04064 Valv...

Page 267: ...lve seat 2 Check valve seat Pitting wear Replace the cylinder head 3 Measure valve seat width a Out of specification Replace the cylinder head a Apply Mechanic s blueing dye Dykem 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 ...

Page 268: ...t 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 between your hands e Apply a fine lapping compound to the valve face and repeat the steps above f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s b...

Page 269: ...th Intake 40 38 mm 1 59 in Limit 38 36 mm 1 51 in Exhaust 40 38 mm 1 59 in Limit 38 36 mm 1 51 in 2 Measure compressed valve spring force a Out of specification Replace the valve spring b Installed length Compressed valve spring force installed 171 197 N at 35 00 mm 17 44 20 09 kg at 35 00 mm 38 44 44 29 lb at 1 38 in 3 Measure valve spring tilt a Out of specification Replace the valve spring Spri...

Page 270: ...one 2 Lubricate valve stem 1 valve stem seal 2 with the recommended lubricant Recommended lubricant Molybdenum disulfide oil 3 Install valve 1 valve spring seat 2 valve stem seal 3 valve spring 4 valve spring retainer 5 into the cylinder head NOTE _ Install the valve spring with the larger pitch a facing up Install the valve spring with its painted end facing up b Smaller pitch ...

Page 271: ...e valve spring compressor 1 and the valve spring compressor attach ment 2 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION _ Hitting the valve tip with excessive force can damage the valve Valve spring compressor 98090 04019 Valve spring compressor attach ment 90890 01243 ...

Page 272: ... 6 10 11 12 Order Job Part Q ty Remarks Removing the cylinder and piston Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Timing chain guide exhaust 1 2 Water jacket joint 1 3 O ring 1 4 Cylinder 1 Refer to INSTALLING THE PISTON AND CYLINDER 5 Cylinder gasket 1 6 Dowel pin 2 7 Piston pin clip 2 Refer to REMOVING THE CYLINDER AND PISTON and INSTALLING THE PISTON AND CYLIN...

Page 273: ...m kg 36 ft lb T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 2 3 4 5 7 7 9 8 6 6 10 11 12 Order Job Part Q ty Remarks 11 2nd ring 1 Refer to REMOVING THE CYLINDER AND PISTON and INSTALLING THE PISTON AND CYLINDER 12 Oil ring 1 For installation reverse the removal pro cedure CYLINDER AND PISTON ...

Page 274: ...ston pin deburr the piston pin clip s groove and the piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 4 Piston pin puller set 90890 01304 1 2 3 2 Remove top ring 2nd ring oil ring NOTE _ When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EA...

Page 275: ...bottom edge of the pis ton d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula f If out of specification replace the cylinder and the piston and piston rings as a set Cylinder bore C 100 000 100 010 mm 3 9370 3 9374 in Taper limit T 0 05 mm 0 002 in Out of round R 0 05 mm 0 002 in C maximum of D1 D2 T maximu...

Page 276: ...th the piston crown a 40 mm 1 57 in 3 Measure piston ring end gap Out of specification Replace the piston ring NOTE _ The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings Piston ring side clearance Top ring 0 030 0 080 mm 0 0012 0 0031 in Limit 0 13 mm 0 0051 in 2nd ring 0 030 0 070 mm 0 0012 0 0028 in Limit 0 11 mm 0 004...

Page 277: ... in Limit 22 971 mm 0 9044 in 3 Measure piston pin bore inside diameter b Out of specification Replace the piston Piston pin bore inside diameter 23 004 23 015 mm 0 9057 0 9061 in Limit 23 045 mm 0 9073 in 4 Calculate piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set Piston pin to piston pin bore clearance Piston pin bore inside diameter b Pist...

Page 278: ...l piston 1 piston pin 2 piston pin clips 3 NOTE _ Apply engine oil to the piston pin Make sure the punch mark a on the piston points towards the exhaust side of the cylin der Before installing the piston pin clips cover the crankcase opening with a clean rag to prevent the clip from falling into the crank case 3 Install cylinder gasket dowel pins 4 Lubricate piston piston rings cylinder with the r...

Page 279: ...the cylinder with the other hand Pass the timing chain and timing chain guide exhaust side through the timing chain cav ity 7 Install washers cylinder bolts NOTE Lubricate the cylinder bolt threads and mut ing surface with engine oil Install the washers with their blunt surface facing up 1 New 8 Tighten cylinder bolts 116 mm 4 57 in 1 cylinder bolts 109 mm 4 29 in 2 cylinder bolts timing chain sid...

Page 280: ...b Part Q ty Remarks Removing the clutch cover Remove the parts in the order listed Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Clutch cable 1 2 Clutch cable holder 1 3 Clutch cover 1 Refer to REMOVING THE CLUTCH and INSTALLING THE CLUTCH 4 Gasket 1 5 Dowel pin 2 For installation reverse the removal pro cedure ...

Page 281: ...der Job Part Q ty Remarks Removing the pull lever shaft Remove the parts in the order listed 1 Circlip 1 2 Circlip 1 3 Washer 2 4 Pull lever 1 5 Pull lever spring 1 6 Pull lever shaft 1 7 Oil seal 1 8 Bearing 2 For installation reverse the removal pro cedure CLUTCH ...

Page 282: ...e the parts in the order listed 1 Clutch spring 5 Refer to INSTALLING THE CLUTCH 2 Pressure plate 1 3 Pull rod 1 4 Friction plate 1 4 Inside diameter plate with notched tabs 119 mm 4 69 in 5 Clutch plate 6 6 Friction plate 2 2 Inside diameter plate with no notched tabs 119 mm 4 69 in 7 Friction plate 3 1 Inside diameter plate with notched tabs 128 mm 5 04 in 8 Clutch damper spring 1 9 Clutch dampe...

Page 283: ... 4 6 4 7 4 4 6 5 5 5 5 5 5 8 9 10 11 12 13 14 5 5 E E Order Job Part Q ty Remarks 10 Clutch boss nut 1 Refer to REMOVING THE CLUTCH and INSTALLING THE CLUTCH 11 Lock washer 1 12 Clutch boss 1 13 Thrust washer 1 14 Clutch housing 1 For installation reverse the removal pro cedure CLUTCH ...

Page 284: ...her tab 3 Loosen clutch boss nut 1 NOTE _ While holding the clutch boss 2 with the uni versal clutch holder 3 loosen the clutch boss nut 4 Remove clutch boss nut lock washer clutch boss Universal clutch holder 90890 04086 3 2 1 EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates 1 Check friction plate 1 friction plate 2 friction plate 3 Damage wear R...

Page 285: ...riction plate 3 thickness 2 90 3 10 mm 0 114 0 122 in Limit 2 80 mm 0 110 in EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates 1 Check clutch plate Damage Replace the clutch plates as a set 2 Measure clutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clutch plates as a set Clutch plate warpage limit 0 20 mm...

Page 286: ...utch housing dogs will cause erratic clutch operation EAS00285 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 erratic clutch operation EAS00286 CHECKING THE PRESSURE PLATE 1 Check pressure plate 1 Cracks damage Replace bearing 2 Damage wear Replace 1 2 EAS00287 CHECKING THE PULL LEVER SHAFT AND P...

Page 287: ... primary drive gear and clutch housing as a set EAS00299 INSTALLING THE CLUTCH 1 Install clutch boss lock washer clutch boss nut 1 NOTE Lubricate the crankshaft end threads with engine oil 2 Tighten clutch boss nut NOTE _ While holding the clutch boss 2 with the uni versal clutch holder 3 tighten the clutch boss nut 3 Bend the lock washer tab along a flat side of the nut Universal clutch holder 90...

Page 288: ...friction plate 1 5 so that the tab with two notches a is between the two punch marks b on the clutch housing as shown Install friction plate 1 7 so that the tab with two notches c is between the two punch marks d on the clutch housing as shown 6 Install clutch springs clutch spring bolts NOTE _ Lubricate the clutch spring threads with engine oil Tighten the clutch spring bolts in stages and in a c...

Page 289: ...th the punch mark b on the clutch cover Install the pull lever spring 1 as shown 1 2 a b New 9 Install clutch cable 1 10 Check clutch cable length a Out of specification Adjust NOTE Push the pull lever in direction b and check the cable length a Bend the tab c on the pull lever to secure the clutch cable 11 Adjust clutch cable length NOTE Move the pull lever a notch until the cable length is withi...

Page 290: ...Order Job Part Q ty Remarks Removing the oil pump Remove the parts in the order listed Engine oil Drain Refer to CHECKING AND CHANGING THE ENGINE OIL in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Water pump assembly Refer to WATER PUMP in chapter 6 Clutch cable holder clutch housing Refer to CLUTCH Right footrest brake pedal assembly Refer to SWINGARM AND DRIVE CHAIN in cha...

Page 291: ... 2 0 m kg 14 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 4 3 5 7 7 6 8 10 9 11 12 9 13 1 2 3 3 14 Order Job Part Q ty Remarks 5 Crankcase cover right 1 6 Gasket 1 7 Dowel pin 2 8 Oil baffle plate 1 1 9 Circlip 1 Refer to INSTALLING THE OIL PUMP 10 Oil pump driven gear 1 11 Oil baffle plate 2 1 12 Oil pump 1 13 Oil pump gasket 1 14 O ring 2 For installation reverse the removal pro cedure OIL PUMP ...

Page 292: ...housing 1 oil seal 1 1 2 Oil pump outer rotor 1 1 3 Dowel pin 1 4 Oil pump inner rotor 1 1 5 Oil pump housing cover oil seal 1 1 6 Dowel pin 2 7 Oil pump shaft 1 8 Dowel pin 1 9 Oil pump inner rotor 2 1 Refer to ASSEMBLING THE OIL PUMP 0 Oil pump outer rotor 2 1 A Oil pump housing 2 1 For assembly reverse the disassembly procedure ...

Page 293: ... rotor and outer rotor clearance c Out of specification Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance 0 07 0 12 mm 0 0028 0 0047 in Limit 0 2 mm 0 008 in Outer rotor to oil pump housing clearance 0 03 0 08 mm 0 0012 0 0031 in Limit 0 15 mm 0 0059 in Oil pump housing to inner rotor and outer rotor clearance 0 03 0 08 mm 0 0012 0 0031 in...

Page 294: ...ump inner rotor 2 oil pump outer rotor 1 oil pump outer rotor 2 oil pump shaft with the recommended lubricant 2 Install oil pump outer rotor 2 1 oil pump inner rotor 2 2 to the oil pump housing 2 oil pump housing NOTE _ Install oil pump inner rotor 2 and outer rotor 2 with the alignment marks a facing up When installing the inner rotor align the pin in the oil pump shaft with the groove in the inn...

Page 295: ... pump driven gear circlip oil baffle plate 1 CAUTION _ After tightening the bolts make sure the oil pump turns smoothly NOTE _ Install the oil pump driven gear 1 in the direction shown Install the circlip with its blunt surface facing the engine 1 New T R 10 Nm 1 0 m kg 7 2 ft lb New T R 4 Nm 0 4 m kg 2 9 ft lb LT OIL PUMP ...

Page 296: ... Refer to WATER PUMP in chapter 6 Clutch housing Refer to CLUTCH Crankcase cover right Refer to OIL PUMP 1 Balancer driven gear nut 1 Refer to REMOVING THE BALANCER DRIVEN GEAR AND BALANCER DRIVE GEAR and INSTALLING THE BALANCER DRIVEN GEAR AND BAL ANCER DRIVE GEAR 2 Primary drive gear nut 1 3 Lock washer 1 4 Lock washer 1 Refer to REMOVING THE BALANCER DRIVEN GEAR AND BALANCER DRIVE GEAR and INST...

Page 297: ...Q ty Remarks 6 Water pump drive gear 1 7 Primary drive gear 1 8 Balancer drive gear 1 Refer to INSTALLING THE BALANCER DRIVEN GEAR AND BALANCER DRIVE GEAR 9 Straight key 1 10 Washer 1 11 Balancer driven gear 1 Refer to INSTALLING THE BALANCER DRIVEN GEAR AND BALANCER DRIVE GEAR 12 Straight key 1 For installation reverse the removal pro cedure ...

Page 298: ...inum plate a between the teeth of the balancer driven gear 3 and balancer drive gear 4 3 Remove balancer driven gear water pump drive gear primary drive gear balancer drive gear 4 1 a 3 4 2 a 3 CHECKING THE BALANCER DRIVEN GEAR WATER PUMP DRIVE GEAR PRIMARY DRIVE GEAR AND BALANCER DRIVE GEAR 1 Check balancer driven gear balancer drive gear water pump drive gear primary drive gear Damage wear Repla...

Page 299: ... on the balancer drive gear with the punch mark b on the bal ancer driven gear Install the key with its blunt surface facing c the crankshaft 1 3 2 a b 2 c 2 Install lock washer 1 primary drive gear nut 2 lock washer 3 balancer driven gear nut 4 NOTE Place an aluminum plate a between the teeth of the balancer drive gear and balancer driven gear 3 Bend the lock washer tab 2 1 a 4 a 3 New T R 80 Nm ...

Page 300: ... 1 14 Order Job Part Q ty Remarks Removing the shift shaft and stop per lever Remove the parts in the order listed Water pump assembly Refer to WATER PUMP in chapter 6 Clutch housing Refer to CLUTCH Crankcase cover right Refer to OIL PUMP 1 Shift pedal 1 2 Circlip 1 3 Washer 1 4 Oil seal 1 5 Bearing 2 6 Shift shaft 1 Refer to INSTALLING THE SHIFT SHAFT 7 Shift shaft spring 1 8 Spacer 1 ...

Page 301: ...6 12 8 7 13 11 10 13 5 9 14 5 4 3 2 1 14 Order Job Part Q ty Remarks 9 Stopper lever spring 1 Refer to INSTALLING THE SHIFT SHAFT 10 Circlip 1 11 Stopper lever 1 Refer to INSTALLING THE SHIFT SHAFT 12 Spacer 1 13 Washer 2 14 Shift shaft spring stopper 1 For installation reverse the removal pro cedure ...

Page 302: ...NSTALLING THE SHIFT SHAFT 1 Install shift shaft spring stopper 2 Install stopper lever 1 stopper lever spring 2 _shift shaft 3 NOTE Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss 4 Mesh the stopper lever with the shift drum segment assembly Lubricate the oil seal lips with lithium soap based grease Hook the end of the shift shaft spring onto the shift shaft...

Page 303: ...nt Yamaha bond No 1215 90890 85505 Order Job Part Q ty Remarks Removing the starter clutch and A C magneto Remove the parts in the order listed Engine oil Drain Refer to CHECKING AND CHANGING THE ENGINE OIL in chapter 3 Seat left side panel Refer to COWLING AND COVER in chapter 3 Starter motor Refer to STARTER MOTOR in chapter 8 Drive sprocket cover Refer to SWINGARM AND DRIVE CHAIN in chapter 4 S...

Page 304: ...7 16 13 E LS Apply sealant Yamaha bond No 1215 90890 85505 Order Job Part Q ty Remarks 4 Torque limiter washer 1 2 5 Dowel pin 1 6 A C magneto cover gasket 1 1 Refer to REMOVING THE A C MAG NETO ROTOR and INSTALLING THE A C MAGNETO ROTOR 7 Dowel pin 4 8 Crankshaft position sensor 1 9 Stator coil 1 10 Starter clutch idle gear shaft 1 11 Starter clutch idle gear 1 12 A C magneto rotor 1 13 Starter c...

Page 305: ...ss pattern After all of the bolts are fully loosened remove them 3 Remove A C magneto rotor nut 1 washer NOTE _ While holding the A C magneto rotor 2 with the sheave holder 3 loosen the A C mag neto rotor nut Do not allow the sheave holder to touch the projection a on the A C magneto rotor 4 Remove A C magneto rotor 1 with the flywheel puller 2 woodruff key NOTE Use the rotor puller Sheave holder ...

Page 306: ...ar Replace the defective part s 3 Check starter clutch gear s contacting surfaces a Damage pitting wear Replace the starter clutch gear 2 1 a 4 Check starter clutch operation a Install the starter clutch gear onto the starter clutch and hold the starter clutch b When turning the starter clutch gear clock wise È it should turn freely otherwise the starter clutch is faulty and must be replaced c Whe...

Page 307: ... the slits Yamaha bond No 1215 90890 85505 1 a b T R 10 Nm 1 0 m kg 7 2 ft lb LT T R 7 Nm 0 7 m kg 5 1 ft lb LT 1 3 Install starter clutch 1 to A C magneto rotor starter clutch bolts 4 Install woodruff key A C magneto rotor washer A C magneto rotor nut NOTE _ Clean the tapered portion of the crankshaft and the A C magneto rotor hub When installing the A C magneto rotor make sure the woodruff key i...

Page 308: ...to touch the projection a on the A C magneto rotor 6 Install gasket A C magneto cover NOTE Tighten the A C magneto cover bolts in stages using a crisscross pattern 7 Install neutral switch lead 1 NOTE Route the neutral switch lead so that it is taut and route it under the speed sensor lead 2 as shown a 5 mm or more Sheave holder 90890 01701 1 3 2 a T R 80 Nm 8 0 m kg 58 ft lb New T R 10 Nm 1 0 m k...

Page 309: ...b Part Q ty Remarks Separating the crankcase Remove the parts in the order listed Engine Refer to ENGINE REMOVAL Cylinder head Refer to CYLINDER HEAD Cylinder piston Refer to CYLINDER AND PISTON A C magneto Refer to STARTER CLUTCH AND A C MAGNETO Clutch Refer to CLUTCH Balancer driven gear balancer drive gear Refer to BALANCER DRIVEN GEAR Oil pump Refer to OIL PUMP Shift shaft Refer to SHIFT SHAFT...

Page 310: ... Ib New New New T R 10 Nm 1 0 m kg 7 2 ft Ib LT LS New LS New LT LS LS 1 2 3 4 8 9 9 10 6 7 5 5 12 11 12 3 Order Job Part Q ty Remarks 5 Lead holder 2 6 Crankcase right 1 Refer to SEPARATING THE CRANK CASE 7 Crankcase left 1 8 Dowel pin O ring 1 1 9 Dowel pin 2 10 Oil strainer 1 11 Oil delivery pipe 3 1 12 O ring 2 For installation reverse the removal pro cedure ...

Page 311: ...ply sealant Yamaha bond No 1215 90890 85505 Order Job Part Q ty Remarks Removing the crankcase bearings Remove the parts in the order listed Crankshaft balancer Refer to CRANKSHAFT Transmission Refer to TRANSMISSION 1 Oil seal holder 1 2 Oil seal 3 3 Bearing retainer 1 4 Bearing 7 For installation reverse the removal pro cedure ...

Page 312: ...ert a screwdriver or pry bar into the pry points in the crankcase and then carefully pry apart the crankcase halves CAUTION _ Use a soft hammer to tap on one side of the crankcase Tap only on reinforced portions of the crankcase Do not tap on the crank case mating surfaces Work slowly and carefully Make sure that the crankcase halves separate evenly c Remove the dowel pins and O ring 1 2 CHECKING ...

Page 313: ...n guide intake side Damage wear Replace EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1 Check bearings Clean and lubricate the bearings and then rotate the inner race with your finger Rough movement Replace 2 Check oil seals Damage wear Replace EAS00399 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating sur...

Page 314: ...acing up 3 Thoroughly clean all the gasket mating sur faces and crankcase mating surfaces Recommended lubricant Bearing Engine oil Oil seal Lithium soap based grease New 1 a T R 10 Nm 1 0 m kg 7 2 ft lb LT 4 Apply Yamaha bond No 1215 1 to the mating surfaces of both crankcase halves NOTE _ Do not allow any sealant to come into contact with the oil gallery 5 Install dowel pins O rings Yamaha bond N...

Page 315: ...all lead holder 1 crankcase bolts È Left crankcase É Right crankcase 8 Tighten crankcase bolts follow the proper tightening sequence NOTE _ Tighten the bolts in stages using a crisscross pattern 9 Apply 4 stroke engine oil to the crankshaft pin bearing and oil deliv ery hole 10 Check crankshaft and transmission operation Unsmooth operation Repair 11 Install speed sensor neutral switch neutral swit...

Page 316: ...Part Q ty Remarks Removing the crankshaft and bal ancer Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Balancer 1 2 Crankshaft 1 Refer to REMOVING THE CRANK SHAFT ASSEMBLY and INSTALLING THE CRANKSHAFT For installation reverse the removal pro cedure ...

Page 317: ...HE CRANKSHAFT 1 Measure big end side clearance D Out of specification Replace the big end bearing crankshaft pin or connecting rod 2 Measure crankshaft width A Out of specification Replace the crank shaft 3 Measure crankshaft runout C Out of specification Replace the crank shaft bearing or both NOTE _ Turn the crankshaft slowly Big end side clearance 0 350 0 650 mm 0 0138 0 0256 in Crankshaft widt...

Page 318: ...haft with the crankshaft installer pot crankshaft installer bolt adapter and spacer crankshaft installer CAUTION _ 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 _ Hold the connecting rod at the top dead center TDC on the compression stroke with one hand while turning the nut...

Page 319: ...ission shift drum and shift forks Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Shift fork C 1 Refer to INSTALLING THE TRANSMIS SION 2 Shift fork R 1 3 Shift fork L 1 4 Shift drum 1 5 Main axle assembly 1 6 Spacer 1 7 Drive axle assembly 1 For installation reverse the removal pro cedure ...

Page 320: ... parts in the order listed 1 Circlip 1 2 2nd pinion gear 1 3 Toothed lock washer 1 4 Toothed washer retainer 1 5 5th pinion gear 1 6 Toothed spacer 1 7 Toothed washer 2 Refer to ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 8 Circlip 2 9 3rd pinion gear 1 0 4th pinion gear 1 A Main axle 1st pinion gear 1 For assembly reverse the disassembly procedure ...

Page 321: ...ng the drive axle Remove the parts in the order listed 1 Circlip 1 Refer to ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 2 Washer 1 3 1st wheel gear 1 4 4th wheel gear 1 5 Circlip 2 6 Toothed washer 2 7 3rd wheel gear 1 8 5th wheel gear 1 9 2nd wheel gear 1 0 Drive axle 1 A O ring 1 For assembly reverse the disassembly procedure ...

Page 322: ...lace the shift forks EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check shift drum grooves Damage scratches wear Replace the shift drum assembly shift drum segment 1 Damage wear Replace the shift drum assembly shift drum bearing 2 Damage pitting Replace the shift drum assembly EAS00425 CHECKING THE TRANSMISSION 1 Measure main axle runout with a centering device and dial gauge 1 Out of specification...

Page 323: ...s 4 Check transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies 5 Check transmission gear movement Rough movement Replace the defective part s 6 Check circlips Bends damage looseness Replace ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1 Install toothed washer 1 circlip 2 NOTE _ Be sure the circlip shape edged corner a is positi...

Page 324: ...hift forks should face towards the right side of the engine and be in the following sequence R C and L Make sure that the shift fork cam follower is properly seated in the shift drum groove 3 1 4 2 2 Check shift operation Unsmooth operation Repair NOTE _ Apply engine oil to each gear and bearing thoroughly Before assembling the crankcase make sure that the transmission is in neutral and that the g...

Page 325: ...COOL 6 ...

Page 326: ...E RADIATOR 6 3 INSTALLING THE RADIATOR 6 4 THERMOSTAT 6 5 CHECKING THE THERMOSTAT 6 6 INSTALLING THE THERMOSTAT 6 6 WATER PUMP 6 8 DISASSEMBLING THE WATER PUMP 6 11 CHECKING THE WATER PUMP 6 11 ASSEMBLING THE WATER PUMP 6 12 INSTALLING THE WATER PUMP 6 14 ...

Page 327: ...COOL ...

Page 328: ... the order listed Seat side panels left and right Refer to COWLING AND COVER in chapter 3 Fuel tank side covers left and right fuel tank Refer to FUEL TANK in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Radiator cap retainer 2 2 Radiator cap 1 3 Coolant reservoir hose cap 1 1 4 Coolant reservoir breather hose 1 5 Fast idle plunger outlet hose 1 Disconnect 6 Coolant reservo...

Page 329: ...ew New 1 2 3 3 5 12 9 8 10 11 7 4 Order Job Part Q ty Remarks 7 Radiator outlet hose 1 Refer to INSTALLING THE RADIA TOR 8 Radiator inlet hose 1 9 Radiator fan motor coupler 1 Disconnect 10 Radiator guard 1 11 Radiator 1 12 Radiator fan 1 For installation reverse the removal pro cedure ...

Page 330: ...pressure Replace the radiator cap a Install the radiator cap tester 1 and radiator cap tester adaptor 2 and radiator cap tester adaptor 3 to the radiator cap 4 b Apply the specified pressure for ten sec onds and make sure there is no drop in pressure 4 Check radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM in chapter 8 Radiator cap opening pressure 110 0 140 0 kPa 1...

Page 331: ...coolant Refer to CHANGING THE COOLANT in chapter 3 1 3 a a 2 3 New New New 3 Check cooling system Leaks Repair or replace any faulty part a Attach the radiator cap tester 1 and radia tor tester adapter 2 to the radiator b Apply 100 kPa 1 0 kg cm 14 2233 psi of pressure and make sure there is no drop in pressure 4 Measure radiator cap opening pressure Bellow the specified pressure Replace the radia...

Page 332: ...hermostat Remove the parts in the order listed Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Coolant temperature sensor coupler 1 Refer to INSTALLING THE THERMOSTAT 2 Hose clamp 1 3 Radiator inlet hose 1 Disconnect 4 Thermostat cover 1 5 O ring 1 6 Thermostat 1 7 Coolant temperature sensor 1 8 Copper washer 1 For installation reverse the removal pro cedure ...

Page 333: ...eter 3 Water 4 Container È Fully closed É Fully open NOTE _ If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause seri ous overheating or overcooling 2 Check thermostat cover thermostat housing cylinder head Cracks damage Replace Opening mm Temperature EAS00466 INSTALLING THE THERMOSTAT 1 Install thermostat 1 O ring 2 thermostat cover 3 NOTE _ Install the thermos...

Page 334: ...ng the cool ant temperature sensor Replace the sen sor if it is dropped or subjected to a strong impact 4 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 5 Check cooling system Leaks Repair or replace any faulty part 6 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING TH...

Page 335: ... Job Part Q ty Remarks Removing the water pump Remove the parts in the order listed NOTE It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Hose clamp 3 Refer to INSTALLING THE WATER PUMP 2 Radiator outlet hose 1 Disconnect 3 Water pump cover 1 4 Gasket 1 ...

Page 336: ...1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 2 5 2 1 4 3 6 8 7 3 1 Order Job Part Q ty Remarks 5 Water pump assembly 1 Refer to INSTALLING THE WATER PUMP 6 Water pump outlet pipe 1 7 O ring 1 8 Water pump outlet hose 1 For installation reverse the removal pro cedure WATER PUMP ...

Page 337: ...arts in the order listed 1 Circlip 1 Refer to ASSEMBLING THE WATER PUMP 2 Impeller shaft gear 1 3 Pin 1 4 Washer 1 5 Impeller shaft assembly 1 Refer to DISASSEMBLING THE WATER PUMP and ASSEMBLING THE WATER PUMP 6 Water pump seal 1 7 Oil seal 1 8 Bearing 1 9 O ring 1 0 Water pump housing 1 For assembly reverse the disassembly procedure ...

Page 338: ...tion of the arrow shown 3 Water pump housing 3 Remove rubber damper holder 1 rubber damper 2 from the impeller with a thin flat head screwdriver NOTE _ Do not scratch the impeller shaft EAS00474 CHECKING THE WATER PUMP 1 Check water pump housing cover 1 water pump housing 2 impeller 3 rubber damper 4 rubber damper holder 5 Cracks damage wear Replace 2 Check water pump seal oil seal Cracks damage w...

Page 339: ...ant onto its outer surface Install the oil seal with a socket that matches its outside diameter New 2 Install water pump seal 1 CAUTION _ Never lubricate the water pump seal sur face with oil or grease NOTE _ Install the water pump seal with the special tools Before installing the water pump apply Yamaha bond No 1215 2 to the water pump housing 3 È Push down Mechanical seal installer 4 90890 04132...

Page 340: ...ure impeller shaft tilt Out of specification Repeat steps 3 and 4 CAUTION _ Make sure the rubber damper and rubber damper holder are flush with the impeller 1 Straightedge 2 Impeller Impeller shaft tilt limit 0 15 mm 0 006 in 5 Install impeller shaft assembly 1 washer pin impeller shaft gear circlip NOTE _ After installation check that the impeller shaft rotates smoothly 1 New ...

Page 341: ...ll gasket water pump cover water pump assembly 3 Install radiator outlet hose 1 hose clamp 2 NOTE Install the radiator outlet hose 1 so that it con tacts the projection a on the water pump cover 4 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 5 Check cooling system Leaks Repair or replace the faulty part 6 Measure radiator cap ...

Page 342: ...FI 7 ...

Page 343: ...DE 7 7 TROUBLESHOOTING DETAILS 7 12 THROTTLE BODY ASSEMBLY 7 23 CHECKING THE FUEL INJECTOR 7 26 CHECKING THE THROTTLE BODY 7 26 INSTALLING THE THROTTLE BODY ASSEMBLY 7 27 CHECKING THE FUEL PUMP 7 28 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 7 29 AIR INDUCTION SYSTEM 7 32 AIR INJECTION 7 32 AIR CUT OFF VALVE 7 32 AIR INDUCTION SYSTEM DIAGRAMS 7 33 AIR CUT OFF VALVE ASSEMBLY 7 34 CHECKING ...

Page 344: ...FI ...

Page 345: ...ator 6 Fuel hose 7 Fuel injector 8 Throttle position sensor 9 Intake air temperature sensor 0 Air filter case A Fuel injection system relay B Battery C Catalytic converter D ECU E Lean angle cut off switch F Fast idle plunger G Crankshaft position sensor H Coolant temperature sensor I Spark plug J Intake air pressure sensor K Ignition coil 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K FUEL INJECTION S...

Page 346: ...k s e d f g h i b c j r t u l m n o p È Gy L R Br L Br R G W R R R R R B B B B B R R B L B Br R B Y L G L Y Sb L R R L B Y L B R W Br R B L W L W B B B R L G W L G B W B P L R L R L R B Br Y Br R W L L B G Y W R G R R R Br R G Br Br L Br L Br L Br R R Br R L B L Y G L B L P W L B L B L G R B L Br W R W Br R R L R B G R L W B L Br W Br R R B R Gy L W R L L R B Y L B Y L Y B G Y O O R B W L B L Y Y ...

Page 347: ...ne trouble warning light comes on to alert the rider of the malfunction After the engine has been turned off the lowest fault code appears on the odometer fuel reserve tripmeter tripmeter 2 LCD Once a fault code has been displayed it remains stored in the mem ory of the ECU until it is deleted EAS00900 Engine trouble warning light indication and FI system operation The warning light flashes if any...

Page 348: ...FAIL SAFE ACTION TABLE Self diagnostic function Fault code No Item Symptom Fail safe action Startability Driveability 12 Crankshaft position sensor No normal signals are received from the sensor No No 13 Intake air pressure sensor open or short circuit Open or short circuit is detected Fixes the intake air pres sure to 101 kPa 760 mmHg 29 9 inHg Yes Yes 14 Intake air pressure sensor Intake air pre...

Page 349: ...ply to the fuel injec tion system relay is not nor mal Yes Yes 50 ECU internal malfunc tion memory check error Faulty ECU memory When this malfunction is detected the code number might not appear on the meter No Yes Start unable warning Relay is not turned ON even if the crank signal is input while the start switch is turned ON When the start switch is turned ON while an error is detected with the...

Page 350: ...ore method in TROUBLESHOOTING DETAILS Set the main switch to OFF set it back to ON and then check if the fault code number is still displayed on the meter Repairs completed No fault code number displayed Erase the malfunction history The malfunction history is stored even if the main switch is set to OFF The malfunction history must be erased in the diagnostic mode Refer to Diagnostic mode table D...

Page 351: ...G 5 After selecting dIAG simultaneously press the SELECT and RESET buttons for 2 seconds or more to execute the selection 6 Set the engine stop switch to 7 Select the diagnostic code number that applies to the item that was verified with the fault code number by pressing the SELECT and RESET buttons NOTE _ The diagnostic code number appears on the odometer fuel reserve tripmeter tripmeter 2 LCD 01...

Page 352: ... tions of the sensor appears on the odome ter fuel reserve tripmeter tripmeter 2 LCD Actuator operation Set the engine stop switch to to oper ate the actuator NOTE _ If the engine stop switch is set to set it to and then set it to again 9 Set the main switch to OFF to cancel the diagnostic mode FUEL INJECTION SYSTEM ...

Page 353: ...ort circuit is detected in the coolant temperature sensor Open or short circuit in wire harness Defective coolant temperature sensor Disconnected coolant temperature sensor coupler Malfunction in ECU Improperly installed coolant temperature sensor 06 22 Open or short circuit is detected in the intake air temperature sensor Open or short circuit in wire harness Defective intake air temperature sens...

Page 354: ... Malfunction in ECU Er 3 Data from the ECU cannot be received correctly Improper connection in sub wire harness Disconnected ECU coupler Malfunction in meter Malfunction in ECU Er 4 Non registered data has been received from the meter Improper connection in sub wire harness Disconnected ECU coupler Malfunction in meter Malfunction in ECU Diagnostic code Item Action Data displayed on meter referenc...

Page 355: ... to set it to and then set it to again Check that the operating sound of the fuel injection system relay is gener ated 5 times when the engine stop switch is set to 51 Radiator fan motor relay The engine stop switch is set to the radiator fan motor relay operates 5 times 5 seconds each time 2 seconds on 3 seconds off and the engine trouble warning light comes on If the engine stop switch is set to...

Page 356: ...er to DIAGNOS TIC MODE Fault code No 12 Symptom No normal signals are received from the crankshaft position sensor Used diagnostic code No Order Item components Check or maintenance job Restore method 1 Crankshaft position sensor installa tion Check the sensor for looseness or pinching Reinstated by crank ing the engine 2 Coupler connections Crankshaft position sensor cou pler ECU coupler Check th...

Page 357: ...instated by crank ing the engine 2 Open or short circuit in the wire har ness Repair or replace if there is an open or short cir cuit between the wire harnesses Black Blue Black Blue Pink White Pink White Blue Blue 3 Defective intake air pressure sen sor Execute the diagnostic mode Code No 03 Replace the sensor if it is defective 1 Connect the pocket tester DC 20 V to the intake air pressure senso...

Page 358: ... detected from the throttle position senor Used diagnostic code No 01 throttle position sensor Order Item components Check or maintenance job Restore method 1 Throttle position sensor installation Check the sensor for looseness or pinching Check that the sensor is installed in the specified position Reinstated by set ting the main switch to ON 2 Coupler connections Throttle position sensor coupler...

Page 359: ...tracting the sidestand If the transmission is in neutral it is rein stated by reconnect ing the wiring 2 Open or short circuit in the wire har ness Repair or replace if there is an open or short cir cuit between the ECU and sidestand switch Blue Black 3 Defective sidestand switch Execute the diagnostic mode Code No 20 Replace the switch if it is defective Refer to CHECKING THE SWITCHES in chap ter...

Page 360: ...ness Repair or replace if there is an open or short cir cuit between the wire harnesses Black Blue Black Blue Brown White Brown White 4 Defective intake air temperature sensor Execute the diagnostic mode Code No 05 Replace the sensor if it is defective 1 Remove the intake air temperature sensor from the air filter case 2 Connect the pocket tester Ω 100 to the intake air temperature sensor terminal...

Page 361: ...or for any pins that may have pulled out Check the connector and coupler are securely locked If necessary repair the coupler or securely con nect it Reinstated by start ing the engine and operating it at idle 2 Open or short circuit in the wire har ness Repair or replace if there is an open or short cir cuit between the wire harnesses Orange Orange 3 Defective ignition coil Execute the diagnostic ...

Page 362: ...8 6 mi h A 2 Open or short circuit in the wire har ness Repair or replace if there is an open or short cir cuit between the wire harnesses Blue Blue White White Black Blue Black Blue A 3 Gear for detecting vehicle speed has broken Replace the gear if it is defective Refer to TRANSMISSION in chapter 5 A 4 Defective speed sensor Execute the diagnostic mode Code No 07 Replace the sensor if it is defe...

Page 363: ... open or short cir cuit between the wire harnesses between neutral switch and relay unit Sky blue Sky blue between relay unit and ECU Blue Yellow Blue Black B 3 Faulty shift drum neutral detection area Replace if defective Refer to TRANSMISSION in chapter 5 B 4 Defective neutral switch Execute the diagnostic mode Code No 21 Replace the switch if it is defective Refer to CHECKING THE SWITCHES in ch...

Page 364: ...em fuse Red Red between fuel injection system fuse and fuel injec tion system relay Brown Brown between fuel injection system relay and ECU Red Blue Red Blue between battery and main switch Red Red between main switch and ignition fuse Brown Blue Brown Blue between ignition fuse and engine stop switch Red Red between engine stop switch and fuel injection system relay Red Black Red Black between fu...

Page 365: ...KING AND CHARGING THE BATTERY in chapter 3 Reinstated by start ing the engine and operating it at idle 2 Open or short circuit in the wire har ness Excute the diagnostic mode Code No 09 Repair or replace if there is an open or short cir cuit between battery and fuel injection system fuse Red Red between the fuel injection system fuse and fuel injection system relay Brown Brown between the fuel inj...

Page 366: ...ted automati cally when it receives a normal signal 2 Malfunction in meter assembly Replace the meter assembly 3 Malfunction in ECU Replace the ECU Fault code No Er 3 Symptom Data from the ECU cannot be received correctly Used diagnostic code No Order Item components Check or maintenance job Restore method 1 Coupler connections ECU coupler Meter couplers Check the couplers for any pins that may ha...

Page 367: ...n the order listed Seat Refer to COWLING AND COVER in chapter 3 Fuel tank Refer to FUEL TANK in chapter 3 Air filter case Refer to AIR FILTER CASE in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Fuel injector coupler 1 Disconnect 2 Throttle position sensor coupler 1 Disconnect 3 Throttle cable 2 Disconnect Refer to INSTALLING THE THROTTLE BODY ASSEMBLY 4 Vacuum hose 1 Disco...

Page 368: ...let hose 1 Disconnect 6 Fast idle plunger inlet hose 1 7 Pilot air hose 1 8 Throttle body joint clamp screw 2 Loosen 9 Throttle body assembly 1 Refer to INSTALLING THE THROT TLE BODY ASSEMBLY 10 Throttle body joint clamp 2 11 Throttle body joint 1 For installation reverse the removal pro cedure THROTTLE BODY ASSEMBLY ...

Page 369: ... Remarks Disassembling the throttle body assembly Remove the parts in the order listed 1 Throttle position sensor 1 2 Fuel injection pipe 1 3 Fuel injector 1 4 Throttle body 1 CAUTION Do not disassemble the throttle body For assembly reverse the disassembly procedure ...

Page 370: ...uel injector resistance Out of specification Replace the fuel injector Positive tester probe red black 1 Negative tester probe red blue 2 Fuel injector resistance 12 Ω at 20 C 68 F R L R B 1 2 EAS00913 CHECKING THE THROTTLE BODY 1 Check throttle body Cracks damage Replace the throttle body 2 Check fuel passages Obstructions Clean a Wash the throttle body in a petroleum based solvent CAUTION Do not...

Page 371: ...inder head with the slot b in the throttle body joint b a 3 Install throttle body assembly NOTE Align the projection a on the throttle body assembly with the slot b throttle body joint 4 Install throttle cable 5 Adjust throttle lever free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 6 Adjust engine idling speed Refer to ADJUSTING THE ENGINE IDLING SPEED in chapter 3 7 Check th...

Page 372: ...line wipe it up immediately with dry rags If gasoline touches the engine when it is hot a fire may occur Therefore make sure the engine is completely cool before performing the following test 1 Check fuel pump operation a Fill the fuel tank b Put the end of the fuel hose into an open container c Connect a battery DC 12 V to the fuel pump coupler as shown d If fuel flows out of the fuel hose the fu...

Page 373: ...Refer to FUEL TANK in chapter 3 e Set the main switch to ON and the engine stop switch to f Start the engine g Measure the fuel pressure Out of specification Replace the fuel pump Pressure gauge 90890 03153 Fuel pressure adapter 90890 03176 Fuel pressure 324 kPa 3 24 kg cm2 46 1 psi 1 2 3 4 5 EAS00502 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE Before adjusting the throttle position s...

Page 374: ...e check that the throttle position sensor resistance is within the specified range The resistance does not change or it changes abruptly Replace the throttle position sensor The slot is worn or broken Replace the throttle position sensor NOTE Check mainly that the resistance changes gradually when turning the throttle since the readings from closed to wide open throttle may differ slightly from th...

Page 375: ...nsor c Measure the throttle position sensor volt age d Adjust the throttle position sensor angle so the measured voltage is within the specified range e After adjusting the throttle position sensor angle tighten the throttle position sensor screws Positive tester probe yellow terminal 1 Negative tester probe black blue terminal 2 Digital circuit tester 90890 03174 Throttle position sensor voltage ...

Page 376: ...o 700 C 1 112 to 1 292 F EAS00917 AIR CUT OFF VALVE The air cut off valve is controlled by the signals from the ECU in accordance with the combus tion conditions Ordinarily the air cut off valve opens to allow the air to flow during idle and closes to cut off the flow when the vehicle is being driven However if the coolant tempera ture is below the specified value the air cut off valve remains ope...

Page 377: ...7 33 FI AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Air filter case 2 Reed valve 3 Air cut off valve 4 Exhaust port 1 2 4 3 4 ...

Page 378: ...rts in the order listed Right side panel Refer to COWLING AND COVER in chapter 3 Fuel tank right side cover Refer to FUEL TANK in chapter 3 1 Air induction system solenoid coupler 1 Disconnect 2 Air cut off valve outlet hose 1 3 Air filter to air cut off valve hose 1 4 Air cut off valve assembly 1 For installation reverse the removal pro cedure ...

Page 379: ...LT LT Order Job Part Q ty Remarks Disassembling the air cut off valve assembly Remove the parts in the order listed 1 Air cut off valve cover 1 2 Reed valve assembly 1 3 Air cut off valve 1 For assembly reverse the disassembly procedure ...

Page 380: ...eck air cut off valve Cracks damage Replace 4 Check Air induction system solenoid a Remove the air induction system solenoid coupler from the air cut off valve assembly b Connect the pocket tester Ω 1 to the air induction system solenoid terminal as shown c Measure the air induction system solenoid resistance Out of specification Replace the air cut off valve assembly Positive tester probe brown r...

Page 381: ...ELEC 8 ...

Page 382: ...HOOTING 8 13 ELECTRIC STARTING SYSTEM 8 17 CIRCUIT DIAGRAM 8 17 STARTING CIRCUIT CUT OFF SYSTEM OPERATION 8 18 TROUBLESHOOTING 8 19 STARTER MOTOR 8 23 CHECKING THE STARTER MOTOR 8 25 ASSEMBLING THE STARTER MOTOR 8 27 CHARGING SYSTEM 8 28 CIRCUIT DIAGRAM 8 28 TROUBLESHOOTING 8 29 LIGHTING SYSTEM 8 31 CIRCUIT DIAGRAM 8 31 TROUBLESHOOTING 8 32 CHECKING THE LIGHTING SYSTEM 8 34 SIGNALING SYSTEM 8 37 C...

Page 383: ...YSTEM 8 52 CIRCUIT DIAGRAM 8 52 GENERAL INFORMATION 8 53 KEY CODE REGISTRATION 8 54 SELF DIAGNOSIS MALFUNCTION CODES 8 57 TROUBLESHOOTING 8 58 CHECKING THE IMMOBILIZER SYSTEM 8 59 SELF DIAGNOSIS 8 63 TROUBLESHOOTING 8 64 ...

Page 384: ...7 Immobilizer unit 8 Main switch 9 Fuel pump 0 Clutch switch A Left handlebar switch B Throttle position sensor C Coolant temperature sensor D Fuel injector E Lean angle cut off switch F Turn signal hazard relay G Headlight relay H Radiator fan motor relay I Relay unit J Battery K Fuse box 1 8 7 3 2 1 4 9 0 A C B D E F G H I M J K L N O P Q S R T U V W X Z 5 Y 6 ELECTRICAL COMPONENTS ...

Page 385: ...U Q Intake air temperature sensor R Sidestand switch S Neutral switch T Crankshaft position sensor U Stator coil V Rear brake light switch W Speed sensor X Starter motor Y Radiator fan motor Z Horn Air induction system solenoid 8 7 3 2 1 4 9 0 A C B D E F G H I M J K L N O P Q S R T U V W X Z 5 Y 6 ...

Page 386: ...ity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration NOTE _ indicates a continuity of electricity between switch ter...

Page 387: ...8 4 ELEC CHECKING SWITCH CONTINUITY ...

Page 388: ...he ter minals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the switch ON R Br L Br R OFF P 1 2 3 4 5 6 7 B B B B R W L W R B B 9 0 8 D Br R R Br L R Y Br Br W G L B P Y Dg Ch Sb R W R B B L W P Br R Y Y Y L B G Ch Br W Dg Ch Br W Dg BLACK B B A B BLUE B B C ...

Page 389: ...n switch 2 Horn switch 3 Pass switch 4 Dimmer switch 5 Turn signal switch 6 Hazard switch 7 Clutch switch 8 Engine stop switch 9 Start switch 0 Front brake light switch A Sidestand switch B Neutral switch C Rear brake light switch D Fuses ...

Page 390: ... The bulbs used on this motorcycle are shown in the illustration on the left Bulbs A and B are used for the headlights and usually use a bulb holder that must be detached before removing the bulb The majority of these types of bulbs can be removed from their respective socket by turning them counterclockwise Bulb C is used for turn signal and tail brake lights and can be removed from the socket by...

Page 391: ...ther wise 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 2 Check bulb for continuity with the pocket tester No continuity Replace NOTE _ Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the positive...

Page 392: ...cribed in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the respective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb socket Pocket tester 90890 03112 CHECKING THE LEDs The following procedures applies to all of the LEDs 1 Check LED for prop...

Page 393: ... battery ter minal red white or yellow Negative battery ter minal black white Neutral indicator light Positive battery ter minal red white Negative battery ter minal black white or light green Back light Positive battery ter minal red white or red green Negative battery ter minal black white Coolant temperature warning light Engine trouble warn ing light Fuel level warning light Positive battery t...

Page 394: ...e make sure no flammable gas or fluid is in the vicinity CAUTION Do not connect the jumper lead battery voltage to the terminals green blue and black white for the immobilizer system indicator light LED The LED could be damaged c When the jumper leads are connected to the terminals the respective LED should illuminate Does not light Replace the meter assem bly CHECKING THE BULBS AND BULB SOCKETS ...

Page 395: ... L W R Y Y B Br W Br W W W B R Br R Br R R Br L R Br L Br R R W R LR B Br W B L G R B L 5 2 1 3 4 z 0 A B v w x y q a _ Z X L K F G 6 7 8 9 H I E D C J M N O P Q T U V R S W Y k s e d f g h i b c j r t u l m n o p È Gy L R Br L Br R G W R R R R R B B B B B R R B L B Br R B Y L G L Y Sb L R R L B Y L B R W Br R B L W L W B B B R L G W L G B W B P L R L R L R B Br Y Br R W L L B G Y W R G R R R Br R...

Page 396: ...rk or intermittent spark Pocket tester 90890 03112 Ignition checker 90890 06754 1 Main and ignition fuses Check the main and ignition fuses for con tinuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 2...

Page 397: ...witch and gradually increase the spark gap until a misfire occurs Minimum ignition spark gap 6 0 mm 0 24 in Is there a spark and is the spark gap within specification The ignition system is OK 5 Spark plug cap resistance Remove the spark plug cap from the spark plug lead Connect the pocket tester Ω 1k to the spark plug cap as shown Measure the spark plug cap resistance Spark plug cap resistance 10...

Page 398: ... Secondary coil resistance 10 4 15 6 kΩ at 20 C 68 F Is the ignition coil OK Replace the ignition coil 7 Crankshaft position sensor resistance Disconnect the crankshaft position sensor coupler from the wire harness Connect the pocket tester Ω 100 to the crankshaft position sensor terminal as shown Positive tester probe blue yellow 1 Negative tester probe green white 2 Measure the crankshaft positi...

Page 399: ... angle cut off switch terminals as shown Positive tester probe yellow green 1 Negative tester probe black blue 2 Lean angle cut off switch voltage Less than 65 a 0 4 1 4 V More than 65 b 3 7 4 4 V Is the lean angle cut off switch OK Replace the lean angle cut off switch a a b ON ON 11 Wiring Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM Is the ignition system s wiring properly...

Page 400: ...L R W B BB R G G W Y L B W Lg Br L R W G Y R L L W R Y Y B Br W Br W W W B R Br R Br R R Br L R Br L 5 2 1 3 4 z 0 A B v w x y q a _ Z X K F G 6 7 8 9 H I E D C J W Y s e d f g h i b c j r È Gy L R Br L Br R G W R R R R R B B B B B R R B L B Br R B Y L G L Y Sb L R R L B Y L B R W Br R B L W L W B B B R L G W L G Br Br R W L L B G Y W R G R R R Br R G Br Br L Br L Br L Br R R Br R L L Y Ch G G L G...

Page 401: ...arter motor from operating when neither of these conditions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above condi tions has been met the starting circuit cut off relay is closed and the engine can be started by pushing the start switch WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND T...

Page 402: ...ket tester 90890 03112 1 Main and ignition fuses Check the main and ignition fuses for con tinuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Re...

Page 403: ...t from the wire harness Connect the pocket tester Ω 1 to the relay unit terminals as shown Measure the diode for continuity as fol lows Positive tester probe sky blue 1 Negative tester probe black yellow 2 Continuity Positive tester probe sky blue 1 Negative tester probe blue yellow 3 Positive tester probe blue green 4 Negative tester probe blue yellow 3 Positive tester probe black yellow 2 Negati...

Page 404: ... main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK Replace the main switch immobilizer unit R B R R R W L W 2 1 4 3 8 Engine stop switch Check the engine stop switch for continu ity Refer to CHECKING THE SWITCHES Is the engine stop switch OK Replace the right handlebar switch 9 Neutral switch Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is th...

Page 405: ...G THE SWITCHES Is the start switch OK Replace the right handlebar switch 13 Wiring Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM Is the starting system s wiring properly connected and without defects The starting system circuit is OK Replace the relay unit and properly connect or repair the starting system s wir ing ...

Page 406: ...otor Remove the parts in the order listed 1 Crankcase to crankcase breather chamber hose 1 Disconnect 2 Air filter to crankcase breather cham ber hose 1 Disconnect 3 Crankcase breather chamber 1 4 Starter motor lead 1 Disconnect 5 Negative battery lead 1 Disconnect 6 Crankcase breather chamber bracket 1 7 Starter motor 1 For installation reverse the removal pro cedure ...

Page 407: ...rts in the order listed 1 Circlip 1 2 Starter motor gear 1 3 O ring 1 4 Front bracket 1 5 Shims 6 Lock washer 1 7 Rear bracket 1 8 Shims 9 Brush holder assembly 1 0 Brush 1 A Armature coil 1 B O ring 2 C Starter motor yoke 1 For assembly reverse the disassembly procedure STARTER MOTOR ...

Page 408: ...ndercut a Out of specification Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator NOTE _ The mica of the commutator must be undercut to ensure proper operation of the commutator Mica undercut 0 70 mm 0 028 in 4 Measure armature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armatu...

Page 409: ...ance 2 Above 1 MΩ at 20 C 68 F 5 Measure brush length a Out of specification Replace the brushes as a set Brush length wear limit 5 00 mm 0 20 in 6 Measure brush spring force Out of specification Replace the brush springs as a set 7 Check gear teeth Damage wear Replace the gear 8 Check bearing oil seal Damage wear Replace the defective part s Brush spring force 7 65 10 01 N 780 1 021 gf 27 51 36 0...

Page 410: ... with the groves in the front bracket a 3 Install rear bracket NOTE Align the slot a in the rear bracket with the tab b on the brush seat b a 4 Install starter motor yoke 1 front bracket 2 rear bracket 3 O rings 4 bolts NOTE _ Align the alignment marks a on the starter motor yoke with the alignment marks b on the front and rear brackets 5 Install starter motor gear circlip 1 2 3 4 4 a b b New New ...

Page 411: ... W W W G W L Y Gy G W L B R B R B R W Lg Y L R G B2 B Y L G L R W B BB R G W W W B R Br R Br R R Br L R Br L 5 2 1 3 4 z 0 A B 6 7 8 9 Gy L R Br L Br R G W R R R R R B B B B B R W R G R R R Br R G Br R W L W G L R W BB Y L B W W W W W R B Sb 2 A C magneto 5 Rectifier regulator 6 Battery 7 Main fuse ...

Page 412: ... with the following special tool s EAS00738 YES NO EAS00739 YES NO The battery is not being charged Pocket tester 90890 03112 1 Main fuse Check the main fuse for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main fuse OK Replace the fuse 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at ...

Page 413: ...Stator coil resistance Disconnect the A C magneto coupler from the wire harness Connect the pocket tester Ω 1 to the charging coils as shown Positive tester probe white 1 Negative tester probe white 2 Positive tester probe white 1 Negative tester probe white 3 Measure the stator coil resistances Stator coil resistance 0 224 0 336 Ω at 20 C 68 F between white and white Is the stator coil OK Replace...

Page 414: ...W W W B R Br R Br R R Br L R Br L Br R R W R LR B Br W B L G R B L 5 2 1 3 4 z 0 A B v w x y q a _ Z X L K F G 6 7 8 9 H I E D C J M N O P Q T U V R S W Y k s e d f g h i b c j r t u l m n o p È Gy L R Br L Br R G W R R R R R B B B B B R R B L B Br R B Y L G L Y Sb L R R L B Y L B R W Br R B L W L W B B B R L G W L G B W B P L R L R L R B Br Y Br R W L L B G Y W R G R R R Br R G Br Br L Br L Br L ...

Page 415: ...g fail to come on headlight high beam indicator light tail brake light on auxiliary light Pocket tester 90890 03112 1 Main headlight and parking lighting fuses Check the main headlight and parking lighting fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main headlight and parking light ing fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECK...

Page 416: ...he pocket tester Ω 1 and bat tery 12 V to the headlight relay terminal as shown Check the headlight relay for continuity Battery positive terminal red yellow 1 Battery negative terminal yellow black 2 Positive tester probe red blue 3 Negative tester probe blue white 4 Does the headlight relay have continuity between red blue and blue white Replace the head light relay 7 Wiring Check the entire lig...

Page 417: ...ers as shown È When the dimmer switch is set to É When the dimmer switch is set to Headlight coupler wire harness end DC 20 V B Y G 2 1 3 È É Headlight Positive tester probe yellow 1 or green 2 Negative tester probe black 3 High beam indicator light Positive tester probe yellow 4 Negative tester probe black white 5 Meter assembly couplers wire harness end Set the main switch to ON Start the engine...

Page 418: ...end Is the voltage within specification This circuit is OK The wiring circuit from the main switch to the tail brake light coupler is faulty and must be repaired 1 2 B Y L R Y B L 1 Auxiliary light bulb and socket Check the auxiliary light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the auxiliary light bulb and socket OK Replace the auxiliary light bulb socket o...

Page 419: ...8 36 ELEC LIGHTING SYSTEM ...

Page 420: ...Y L R G B2 B Y L G L R W B BB R G G W Y L B W Lg B L L W P B W O R Br L R W G Y R L L W R Y Y B Br W Br W W W B R Br R Br R R Br L R Br L Br R R W R LR B Br W B L G R B L 5 2 1 3 4 z 0 A B v w x y q a _ Z X L K F G 6 7 8 9 H I E D C J M N O P Q T U V R S W Y k s e d f g h i b c j r t u l m n o p È Gy L R Br L Br R G W R R R R R B B B B B R R B L B Br R B Y L G L Y Sb L R R L B Y L B R W Br R B L W...

Page 421: ...Multifunction meter Z Coolant temperature warning light Engine trouble warning light Fuel level warning light _ Turn signal indicator light c Turn signal hazard relay e Horn switch h Turn signal switch i Hazard switch k Horn m Rear turn signal light left n Front turn signal light left o Front turn signal light right p Rear turn signal light right s Rear brake light switch u Tail brake light v Igni...

Page 422: ...ing and backup fuses Check the main ignition signaling system parking lighting and backup fuses for con tinuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition signaling system parking lighting and backup fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C...

Page 423: ...as shown Positive tester probe pink 1 Negative tester probe ground Set the main switch to ON Push the horn switch Measure the voltage DC 12 V of pink at the horn terminal Is the voltage within specification The wiring circuit from the main switch to the horn connector is faulty and must be repaired P B 1 3 Horn Disconnect the black connector at the horn terminal Connect a jumper lead 1 to the horn...

Page 424: ...efer to CHECKING THE SWITCHES Is the brake light switch OK Replace the brake light switch 3 Voltage Connect the pocket tester DC 20 V to the tail brake light coupler wire harness end as shown Positive tester probe yellow 1 Negative tester probe black 2 Set the main switch to ON Pull in the brake lever or push down on the brake pedal Measure the voltage DC 12 V of yellow 1 at the tail brake light c...

Page 425: ...ace the meter assembly 3 Turn signal switch Check the turn signal switch for continuity Refer to CHECKING THE SWITCHES Is the turn signal switch OK Replace the left han dlebar switch 4 Hazard switch Check the hazard switch for continuity Refer to CHECKING THE SWITCHES Is the hazard switch OK Replace the left han dlebar switch 5 Voltage Connect the pocket tester DC 20 V to the turn signal hazard re...

Page 426: ...harness end as shown È Front turn signal light É Rear turn signal light Ê Turn signal indicator light Left turn signal light Positive tester probe chocolate 1 Negative tester probe ground Right turn signal light Positive tester probe dark green 2 or green 3 Negative tester probe ground Set the main switch to ON Set the turn signal switch to or Measure the voltage DC 12 V of choco late 1 and dark g...

Page 427: ...HECKING THE SWITCHES Is the neutral switch OK Replace the neutral switch 3 Relay unit diode Disconnect the relay unit from the wire harness Connect the pocket tester Ω 1 to the relay unit terminals as shown Check the diode for continuity Positive tester probe sky blue 1 Negative tester probe light green 2 Continuity Positive tester probe light green 2 Negative tester probe sky blue 1 No conti nuit...

Page 428: ...uit is OK The wiring circuit from the main switch to the meter assem bly couplers is faulty and must be repaired Dg G L R W Ch R G Y B W Lg G WY L Ch R G Y G G L R W G WY L B W Lg 1 1 Fuel level warning light LED Check the LED of the fuel level warning light Refer to CHECKING THE BULBS AND BULB SOCKETS Is the fuel level warning light LED OK Replace the meter assembly 2 Fuel sender thermistor Disco...

Page 429: ...ng circuit from the main switch to the meter assem bly coupler is faulty and must be repaired Dg G L R W Ch R G Y B W Lg G WY L Ch R G Y G G L R W G WY L B W Lg 2 1 1 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler wire harness end as shown Positive tester probe yellow blue 1 Negative tester probe black white 2 Set the main switch to ON Elevate the rear wheel and slowly rot...

Page 430: ...Replace the speed sensor P O R B W L W B L 1 2 1 Coolant temperature warning light LED Check the LED of the coolant temperature warning light Refer to CHECKING THE BULBS AND BULB SOCKETS Is the coolant temperature warning light LED OK Replace the meter assembly 2 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler wire harness end as shown Positive tester probe yellow blue 1 Ne...

Page 431: ...ensor for continuity at the temperatures indicated in the table Test step Coolant temperature Resistance 1 20 C 68 F 2 32 2 59 kΩ 2 80 C 176 F 0 310 0 326 kΩ 3 110 C 230 F 0 140 0 145 kΩ WARNING _ Handle the coolant temperature sensor with special care Never subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dropped replace it T R Coolant temperature senso...

Page 432: ... B BB R G G W Y L B W Lg Br L R W G Y R L L W R Y Y B Br W Br W W W B R Br R Br R R Br L R Br L 5 2 1 3 4 z 0 A B v w x y q a _ Z X L K F G 6 7 8 9 H I E D C J O P Q R W Y s e d f g h i b c j r t m n o p È Gy L R Br L Br R G W R R R R R B B B B B R R B L B Br R B Y L G L Y Sb L R R L B Y L B R W Br R B L W L W B B B R L G W L G B W B P L R L R L R Br Y Br R W L L B G Y W R G R R R Br R G Br Br L B...

Page 433: ...NO The radiator fan motor fails to turn Pocket tester 90890 03112 1 Main radiator fan motor and ignition fuses Check the main radiator fan motor and ignition fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main radiator fan motor and igni tion fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minim...

Page 434: ...nnect the pocket tester Ω 1 and bat tery DC 12 V to the radiator fan motor ter minal as shown Check the radiator fan motor for continuity Battery positive terminal red white 1 Battery negative terminal green yellow 2 Positive tester probe brown 3 Negative tester probe blue 4 Does the radiator fan motor relay have con tinuity between brown and blue Replace the radiator fan motor relay 6 Wiring Chec...

Page 435: ... Lg Br L R W G Y R L L W R Y Y B Br W Br W W W B R Br R Br R R Br L R Br L 5 2 1 3 4 z 0 A B v w x y q a _ Z X L K F G 6 7 8 9 H I E D C J O P Q R W Y s e d f g h i b c j r t m n o p È Gy L R Br L Br R G W R R R R R B B B B B R R B L B Br R B Y L G L Y Sb L R R L B Y L B R W Br R B L W L W B B B R L G W L G B W B P L R L R L R Br Y Br R W L L B G Y W R G R R R Br R G Br Br L Br L Br L Br R R Br R ...

Page 436: ... production therefore registering the keys at purchase is not necessary CAUTION DO NOT LOSE THE CODE RE REGISTERING KEY If the code re registering key is lost reg istering new codes in the standard keys is impossible The standard keys can still be used to start the motorcycle however if code re registering is required i e if a new standard key is made or all keys are lost the entire immobilizer sy...

Page 437: ...egistering key 1 Set the main switch to ON with the code re registering key NOTE Check that the immobilizer system indicator light comes on for 1 second then goes off When the indicator light goes off the code re registering key has been registered 2 Check that the engine can be started 3 Register the standard keys Refer to Standard key registration Part to replace Required key registration Main s...

Page 438: ...istering key set the main switch to ON then to OFF and then remove the key within 5 seconds 3 Insert the standard key to be registered into the main switch and then set the main switch to ON within 5 seconds to activate the key registration mode NOTE If the two standard key codes are stored in memory they will be erased when the key registration mode is activated When the key registration mode is ...

Page 439: ...istration less than 5 0 s less than 5 0 s less than 5 0 s less than 5 0 s Registration of the second standard key is complete Second standard key Code re regis tering key First standard key Registration mode Immobilizer system indicator light stops flash ing when the registration of the second stan dard key is complete Main switch LED OFF ON On Off Standard key code voiding method If the immobiliz...

Page 440: ... unit at least 50 mm away from the transpon der of other motorcy cles 2 Register the standard key 53 Immobilizer unit Code cannot be transmitted between the ECU and immobilizer unit 1 Noise interference or discon nected lead cable 2 Obstruction due to radio wave noise 3 Disconnected communication harness 4 Immobilizer unit malfunction 5 ECU malfunction 1 Check the wire harness and connector 2 Repl...

Page 441: ...ition and backup fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition and backup fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C Is the battery OK Clean the battery terminals Recharge or replace the battery 3 Main switch Check the main ...

Page 442: ...ve tester probe green blue 1 Negative tester probe black white 2 Set the main switch to ON Measure the voltage 2 6 V between green blue and black white on the meter assembly couplers Is the voltage within specification Replace the meter assembly 3 Voltage Connect the pocket tester DC 20 V to the immobilizer unit coupler as shown Positive tester probe red green 1 Negative tester probe black 2 Set t...

Page 443: ...itch to the immobilizer unit is faulty and must be repaired B BB Y L G L R W R G R G B2 R W Lg Y L B 2 1 5 Voltage Connect the pocket tester DC 20 V to the immobilizer unit coupler as shown Positive tester probe green blue 1 Negative tester probe black 2 Set the main switch to ON Measure the voltage 2 6 V between green blue and black on the immobilizer unit coupler Is the voltage within specificat...

Page 444: ...reen 1 and red white 3 Negative tester probe black white 2 Turn the main switch to ON Measure the voltage DC 12 V meter assembly couplers wire harness end Is the voltage within specification Replace the meter assembly The wiring circuit from the main switch to the meter assem bly couplers is faulty and must be repaired Dg G L R W Ch R G Y B W Lg G WY L Ch R G Y G G L R W G WY L B W Lg 1 2 3 ...

Page 445: ...rect Set the main switch to ON with the code re registering key and check the immobilizer system indicator Malfunction Second standard key transpon der is defective Correct Re register the stan dard key Malfunc tion Replace the standard key Check if a self diagnosis code is dis played Displayed Read the malfunction code and check the corresponding part Refer to SELF DIAGNOSIS MAL FUNCTION CODES Ma...

Page 446: ... condition code will be displayed on the fuel level warning light when the main switch is set to ON irrespective of whether the engine is running or not 1 Condition code Fuel level warning light Circuit Defect s System response Condition code Fuel pump ther mistor Open circuit Short circuit The fuel warning light indicate the condition code Refer to 1 SELF DIAGNOSIS ...

Page 447: ...EAS00843 YES NO The fuel level warning light starts to indi cates the self diagnosis sequence Pocket tester 90890 03112 1 Fuel level warning light LED Check the LED of the fuel level warning light Refer to CHECKING THE BULBS AND BULB SOCKETS Is the fuel level warning light LED OK Replace the meter assembly 2 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM Is the wire ha...

Page 448: ...fuel sender coupler from the wire harness Connect the pocket tester kΩ 1 to the fuel sender as shown Positive tester probe green white 1 Negative tester probe black 2 Check the fuel sender for continuity Is the fuel sender OK Replace the meter assembly Replace the fuel pump assembly ...

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Page 450: ...TRBL SHTG 9 ...

Page 451: ...CE 9 3 ENGINE 9 3 FUEL SYSTEM 9 3 FAULTY GEAR SHIFTING 9 3 SHIFTING IS DIFFICULT 9 3 SHIFT PEDAL DOES NOT MOVE 9 3 JUMPS OUT OF GEAR 9 3 FAULTY CLUTCH 9 3 CLUTCH SLIPS 9 3 CLUTCH DRAGS 9 3 OVERHEATING 9 4 ENGINE 9 4 COOLING SYSTEM 9 4 FUEL SYSTEM 9 4 CHASSIS 9 4 ELECTRICAL SYSTEMS 9 4 OVERCOOLING 9 4 COOLING SYSTEM 9 4 POOR BRAKING PERFORMANCE 9 4 FAULTY FRONT FORK LEGS 9 5 LEAKING OIL 9 5 MALFUNC...

Page 452: ...NOT COME ON 9 6 HEADLIGHT BULB BURNT OUT 9 6 TAIL BRAKE LIGHT DOES NOT COME ON 9 6 TAIL BRAKE LIGHT BULB BURNT OUT 9 6 TURN SIGNAL DOES NOT COME ON 9 6 TURN SIGNAL FLASHES SLOWLY 9 6 TURN SIGNAL REMAINS LIT 9 6 TURN SIGNAL FLASHES QUICKLY 9 6 HORN DOES NOT SOUND 9 6 ...

Page 453: ...ged cylinder Incorrect valve clearance Improperly sealed valve Incorrect valve to valve seat contact Incorrect valve timing Faulty valve spring Seized valve Piston and piston ring s Improperly installed piston ring Damaged worn or fatigued piston ring Seized piston ring Seized or damaged piston Air filter Improperly installed air filter Clogged air filter element Crankcase and crankshaft Improperl...

Page 454: ...unded circuit Loose connections Starting system Faulty starter motor Faulty starter relay Faulty starting circuit cut off relay Faulty starter clutch EAS00846 INCORRECT ENGINE IDLING SPEED ENGINE Cylinder and cylinder head Incorrect valve clearance Damaged valve train components Air filter Clogged air filter element FUEL SYSTEM Throttle body Damaged or loose throttle body joint Improperly adjusted...

Page 455: ...n gears Improperly assembled transmission 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 EAS00851 FAULTY CLUTCH CLUTCH SLIPS Clutch Improperly assembled clutch Improperly adjusted clutch cable Loose or fatigued clutch spring Worn friction pla...

Page 456: ...rly connected hose Damaged pipe Improperly connected pipe FUEL SYSTEM Throttle body Faulty throttle body Damaged or loose throttle body joint Air filter Clogged air filter element CHASSIS Brake s Dragging brake ELECTRICAL SYSTEMS Spark plug Incorrect spark plug gap Incorrect spark plug heat range Ignition system Faulty ECU EAS00856 OVERCOOLING COOLING SYSTEM Thermostat Thermostat stays open EAS008...

Page 457: ...alled handlebar Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tightened ring nut Bent steering stem Damaged ball bearing or bearing race Front fork leg s Uneven oil levels both front fork legs Unevenly tensioned fork spring both front fork legs Broken fork spring Bent or damaged inner tube Bent or damaged outer tube Swingarm Worn bearing ...

Page 458: ... Wrong tail brake light bulb Faulty battery Incorrectly adjusted rear brake light switch Tail brake light bulb life expired TURN SIGNAL DOES NOT COME ON Faulty turn 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 t...

Page 459: ...tor light a Immobilizer system indicator light b Headlight relay c Turn signal hazard relay d Left handlebar switch e Horn switch f Pass switch g Dimmer switch h Turn signal switch i Hazard switch j Clutch switch k Horn l Headlight m Rear turn signal light left n Front turn signal light left o Front turn signal light right p Rear turn signal light right q Radiator fan motor relay r Radiator fan mo...

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Page 463: ...L G L R W B BB R G G W Y L B W Lg B L L W P B W O R Br L R W G Y R L L W R Y Y B Br W Br W W W B R Br R Br R R Br L R Br L Br RR W R LR B Br W B L G R B L 5 2 1 3 4 z 0 A B v w x y q a _ Z X L K F G 6 7 8 9 H I E D C J M N O P Q T U V R S W Y k s e d f g h i b c j r t u l m n o p È Gy L R Br L Br R G W R R R R R B B B B B R R B L B Br R B Y L G L Y Sb L R R L B Y L B R W Br R B L W L W B B B R L G...

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Yamaha XT660 2004, Service Manual

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