Yamaha XT660R 2004 Service Manual Download Page 401 | Manualshive

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ELEC

ELECTRIC STARTING SYSTEM

EAS00757

TROUBLESHOOTING

Check:
1. main and ignition fuses
2. battery
3. starter motor
4. relay unit (starting circuit cut-off relay)
5. relay unit (diode)
6. starter relay
7. main switch
8. engine stop switch
9. neutral switch
10.sidestand switch
11.clutch switch
12.start switch
13.wiring connections

(of the entire starting system)

NOTE:

_

• Before troubleshooting, remove the following

part(s):

1. seat
2. battery cover
3. side panels (left and right)
4. fuel tank side covers (left and right)
5. fuel tank
• Troubleshoot with the following special

tool(s).

EAS00738

YES

NO

EAS00739

YES

NO

EAS00758

YES

NO

The starter motor fails to turn.

Pocket 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.

• Recharge or

replace the battery.

3. Starter motor

• Connect the positive battery terminal

1

and starter motor lead

2

with a jumper

lead

3

.

WARNING

_

• A wire that is used as a jumper lead

must have at least the same capacity or
more as that of the battery lead, other-
wise the jumper lead may burn.

• This check is likely to produce sparks,

therefore make sure nothing flammable
is in the vicinity.

• Does the starter motor turn?

Repair or replace the
starter motor.

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

email: [email protected]

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Summary of Contents for XT660R 2004

Page 1: ...2004 XT660R S XT660X S 5VK1 AE1 SERVICE MANUAL Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

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

Page 3: ...First edition December 2003 All rights reserved Any reproduction or unauthorized use without the written permission of MBK Industrie is expressly prohibited Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 4: ...ll 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 ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to fol...

Page 5: ...TMENTS 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 a disassembly step 6 Symbols indicate parts to be lubrica...

Page 6: ...ear 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 following N Apply locking agent LOCTITE O Replace the part 1 2 3 4...

Page 7: ...RIODIC 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

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

Page 9: ...GEN INFO 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 10: ...RTANT 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 11: ...GEN INFO Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 12: ...cation 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 13: ...nner 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 conditions detected by various sensors Adoption of the FI sy...

Page 14: ...uration 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 the crankshaft position sensor As a result the volume of ...

Page 15: ... 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 inferior in quality EAS00022 GASKETS OIL SEALS AND O RIN...

Page 16: ...ps 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 replace piston pin clips after one use When installing a cir...

Page 17: ...nnection Connect properly NOTE _ If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector NOTE _ Make sure all connections are tight 5 Check continuity with the pocket tester NOTE _ If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at most part stores Pocket tester 908...

Page 18: ...r 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 tighten the steering ring nuts Pot 90890 01274 Bolt 90890 0...

Page 19: ... 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 sys tem 90890 01701 Sheave holder This tool is used to hol...

Page 20: ...890 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 tools are used to install the mechanical seal Tool No Tool n...

Page 21: ...gine 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 Ignition checker This tool is used to check the ignition sys t...

Page 22: ...a bond No 1215 This bond is used to seal two mating sur faces e g crankcase mating surfaces Tool No Tool name Function Illustration Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 23: ...Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 24: ...SPEC 2 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 25: ...UE 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 26: ...SPEC Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 27: ...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 cargo rider passenger and accessories 186 kg 410 lb GENER...

Page 28: ...tal 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 filter replacement 2 60 L 2 29 Imp qt 2 75 US qt Oil filter ...

Page 29: ... 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 injector Model manufacturer 297500 0390 DENSO Quantity 1 Spa...

Page 30: ...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 system Automatic Item Standard Limit A B A B Manuals by Mot...

Page 31: ...take 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 5 945 mm 0 2341 in Exhaust 5 960 5 975 mm 0 2346 0 2352 i...

Page 32: ...th 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 Exhaust 2 5 1 8 mm 2 5 0 071 in Winding direction top view Inta...

Page 33: ... 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 Dimensions B T 1 20 3 80 mm 0 047 0 150 in End gap installed ...

Page 34: ...079 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 Balancer drive method Gear Item Standard Limit B T B T C C ...

Page 35: ...2 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 Secondary reduction system Chain drive Secondary reductio...

Page 36: ...rical 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 Throttle valve size 50 Item Standard Limit Manuals by Motoma...

Page 37: ...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 lateral wheel runout 2 0 mm 0 08 in Wheel axle bending li...

Page 38: ...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 90 198 lb Maximum load 225 kPa 2 25 kgf cm 33 psi XT660R 230...

Page 39: ... 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 in Minimum thickness 4 5 mm 0 18 in Maximum deflection 0 ...

Page 40: ... 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 fork leg 640 0 cm3 22 53 Imp oz 21 64 US oz XT660R 600 0...

Page 41: ... 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 in Maximum 15 link section 240 5 mm 9 47 in Item Standar...

Page 42: ...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 Battery Battery type manufacturer GT9B 4 GS Battery voltag...

Page 43: ...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 transistor Model manufacturer FE218BH DENSO Self cancelli...

Page 44: ...t 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 1 Parking lighting fuse 10 A 1 Backup fuse immobilizer un...

Page 45: ...reads 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 oz Speed km hr 0 6214 mph Distance km m m cm mm 0 6214 3 28...

Page 46: ...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 chain tensioner Bolt M6 2 10 1 0 7 2 Timing chain tensioner...

Page 47: ...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 1 0 7 2 Clutch spring Bolt M6 5 9 0 9 6 5 E Clutch boss N...

Page 48: ...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 Thread size Q ty Tightening torque Remarks Nm m kg ft lb...

Page 49: ...tor 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 1 Clutch lever holder M5 7 0 7 5 1 Front brake master cyl...

Page 50: ...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 6 9 50 Rear brake disc and wheel M6 13 1 3 9 4 LT Left si...

Page 51: ...t 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 tightening nut M Primary driven gear E Clutch boss tightening nu...

Page 52: ...net 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 53: ... 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 Clutch lever pivot bolt outer surface LS Sidestand sliding sur...

Page 54: ...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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 55: ...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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 56: ...enge 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 57: ...AGRAMS EAS00034 LUBRICATION DIAGRAMS 1 Oil delivery hose 2 2 Oil strainer 3 Oil delivery hose 1 A A A A 1 3 2 2 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 58: ...CATION 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 59: ...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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 60: ...N 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 61: ...ead 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 62: ...n 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 assembly lead and finally the main switch lead and immo bil...

Page 63: ...rness 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 front cowling assembly Manuals by Motomatrix www motomatrix ...

Page 64: ...he 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co ...

Page 65: ...le 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle ...

Page 66: ...he 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 that it is not pinched between the frame and right side p...

Page 67: ...ght 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 between the air filter case and the frame 9 8 7 6 Ì È 1 È ...

Page 68: ...rottle 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 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 ...

Page 69: ...light 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 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...

Page 70: ...tch 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 plastic clamp B B C C E D E F F A A B B C C D F F E E È É Ó...

Page 71: ...ebar 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 72: ...tive 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 73: ...se 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 74: ...er 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 holder A A Î Í 1 2 3 4 9 8 7 6 5 0 A Ì Ë Ï Ê È É A A CABLE ROU...

Page 75: ...ame 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 76: ...rs 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 77: ...ling 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 78: ...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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk...

Page 79: ...CHK ADJ 3 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 80: ...AS 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 CHECKING THE THROTTLE BODY JOINT 3 29 CHECKING THE FUEL ...

Page 81: ...G 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 THE BATTERY 3 53 CHECKING THE FUSES 3 58 REPLACING THE HEAD...

Page 82: ...lve 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 Replace brake pads Whenever worn to the limit 8 Brake hose...

Page 83: ...n 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 Check operation 26 Moving parts and cables See page 3 52 Lub...

Page 84: ... 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 85: ...t 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 86: ...nk 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost ...

Page 87: ...on 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 Remove fuel pump CAUTION Do not drop the fuel pump or gi...

Page 88: ...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 hose in the direction of the arrow shown a FUEL TANK Manua...

Page 89: ...ed 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 connector 4 Disconnect AIR FILTER CASE Manuals by Motoma...

Page 90: ... 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 91: ...n 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 Disconnect 11 Air filter case to air cut off valve hose 1 Disconne...

Page 92: ... 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost M...

Page 93: ...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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 94: ...oke 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 spark plug 2 1 2 5 Remove timing mark accessing screw 1 cr...

Page 95: ...wn 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 clearance cold Intake valve 0 09 0 13 mm 0 0035 0 0051 i...

Page 96: ...rk 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 Locknut 14 Nm 1 4 m kg 10 ft lb T R 13 Nm 1 3 m kg 9 4 ft...

Page 97: ...fter 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 _ The CO adjustment volume appears on the odometer fuel rese...

Page 98: ...rew 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 grip 3 0 5 0 mm 0 12 0 20 in EAS00056 ADJUSTING THE THROT...

Page 99: ...ighten 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 obtained Direction a Throttle cable free play is increased Direc...

Page 100: ...y 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 wire brush Spark plug type manufacturer CR7E NGK 6 Measure...

Page 101: ...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 magneto rotor Incorrect firing range Check the ignition sy...

Page 102: ...LVE 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 compression gauge 2 Compression gauge 90890 03081 Adaptor compressi...

Page 103: ...on 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 cm2 99 6 psi Compression pressure with oil applied into the...

Page 104: ...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 CON SERVING II d or higher Do not allow foreign materials ...

Page 105: ... 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 1 along with the gasket 7 Remove oil filter element drain...

Page 106: ...ed 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 bolt 10 Nm 1 0 m kg 7 2 ft lb Quantity Total amount 2 90...

Page 107: ...e 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 check the engine oil pressure again e Tighten the bleed b...

Page 108: ...lay 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 lever 10 0 15 0 mm 0 39 0 59 in Direction b Clutch cable fre...

Page 109: ...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 leading to poor engine performance and possible overheat ing ...

Page 110: ... 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 COVER 1 Manuals by Motomatrix www motomatrix co uk The Solutio...

Page 111: ...ll 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 Exhaust pipe bolt 8 12 Nm 1 2 m kg 8 7 ft lb Exhaust pipe ...

Page 112: ...s 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 _ Before checking the coolant level wait a few minutes un...

Page 113: ...ge 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motoma...

Page 114: ...etent 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 with the copper washer 7 Drain coolant from the engine and r...

Page 115: ...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 antifreeze High quality ethylene glycol antifreeze contain...

Page 116: ...veral 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Cod...

Page 117: ...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 brake pedal position make sure there is no brake drag Brak...

Page 118: ...age 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 fluid and could cause vapor lock CAUTION _ Brake fluid may dam...

Page 119: ...ADS 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 LIGHT SWITCH NOTE _ The rear brake light switch is operat...

Page 120: ...mes 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 apply the brake several times 4 Check brake hoses Brake f...

Page 121: ...h 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 brake master cylinder reservoir or brake fluid reservoir...

Page 122: ...d 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 from the top of the rider foot rest to the top of the shif...

Page 123: ..._ 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 it falling over NOTE _ Place the motorcycle on a suitable s...

Page 124: ...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 105 Nm 10 5 m kg 75 ft lb Manuals by Motomatrix www moto...

Page 125: ... 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 HEAD 1 Stand the motorcycle on a level surface WARNING _ Se...

Page 126: ...osen 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 Lower ring nut initial tightening torque 43 Nm 4 3 m kg 31 ft...

Page 127: ...asher 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 THE FRONT FORK 1 Stand the motorcycle on a level surface ...

Page 128: ... 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 Direction a Spring preload is increased suspension is harder...

Page 129: ...cessories 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 00kgf cm2 29 psi 90 kg maxi mum load 200 kPa 2 00kgf cm2 29 p...

Page 130: ...udden 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 Rear Up to 90 kg load 210 kPa 2 10kgf cm2 30 psi 210 kPa 2 1...

Page 131: ...stics 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 Manufacturer Model Size METZELER TOU RANCE 130 80 17M C 65S MICHELIN ...

Page 132: ...ion 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 Tighten spoke with a spoke wrench 2 NOTE _ Be sure to tighten...

Page 133: ...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 Recommended lubricant Lithium soap based grease EAS00172 LUBR...

Page 134: ...IRST 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 caps because the balance between cells will not be maintained...

Page 135: ...te 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 V d Charging time 6 5 hours e Charge of the battery 20 30 ...

Page 136: ... 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 any time during the charging process disconnect the battery ...

Page 137: ...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 circuit voltage 12 8 V Charging is complete 12 0 12 7 V Rechar...

Page 138: ...is 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 charging MF batteries CAUTION NOTE Leave the battery unused for m...

Page 139: ... 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 Remove seat left side panel Refer to COWLING AND COVER Manua...

Page 140: ...s 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 immobilizer unit meter assembly 10 A 1 Reserve 30 A 1 Reserve 20...

Page 141: ...ll 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 extremely hot keep flammable products and your hands away from th...

Page 142: ... 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 or b Direction a Headlight beam is low ered Direction b ...

Page 143: ... 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys...

Page 144: ...CHAS 4 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 145: ...0X 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 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 34 ASSEMBLING THE ...

Page 146: ...OCK 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 DRIVE CHAIN 4 80 REMOVING THE SWINGARM 4 82 REMOVING THE DRIV...

Page 147: ...sted 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 cedure FRONT WHEEL AND BRAKE DISC Manuals by Motomatrix www mot...

Page 148: ... 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 149: ...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 wheel Damage wear Replace Refer to CHECKING THE TIRES in ch...

Page 150: ...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 the rim Failure to do so could lead to an accident with p...

Page 151: ...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 matches the diameter of the wheel bearing outer race and oi...

Page 152: ... 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 disc thickness at a few different locations Out of specific...

Page 153: ...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 soap based grease Manuals by Motomatrix www motomatrix co ...

Page 154: ... 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 adjusted Adjust the front wheel static balance with the brake d...

Page 155: ...me 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 weight d Repeat steps b and c until the front wheel is balanc...

Page 156: ...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 THE REAR WHEEL 7 Washer N 1 8 Rear wheel axle 1 9 Washer O...

Page 157: ...t 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle C...

Page 158: ...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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 159: ...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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 160: ...ting 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 rear wheel wheel bearings oil seals Refer to CHECKING TH...

Page 161: ...lling 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 below the edge of the brake disc Brake disc deflection lim...

Page 162: ...tages 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 CHECKING THE REAR WHEEL DRIVE HUB 1 Check rear wheel drive hub 1 ...

Page 163: ...ng 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 REAR WHEEL 1 Lubricate wheel axle oil seal lips Recommended ...

Page 164: ...e 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 ADJUSTING THE FRONT WHEEL STATIC BALANCE Drive chain sla...

Page 165: ...rks 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 166: ...ove 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 167: ...n 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 168: ...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 pads it is not neces sary to disconnect the brake hose or d...

Page 169: ...lace 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 0 ft lb 2 1 È 2 1 É Manuals by Motomatrix www motomatrix ...

Page 170: ...n 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 WHEEL SPROCKET 2 Remove brake pad clip 1 brake pad pin 2 bra...

Page 171: ...ew 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 brake pedal operation Soft or spongy feeling Bleed the br...

Page 172: ...b 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 173: ... 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys ema...

Page 174: ...e 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 175: ...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 Disconnect 9 Right side heel plate 1 Manuals by Motomatrix...

Page 176: ... 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 177: ...move 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 178: ...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 the master cylinder and the end of the brake hose 2 Remove ...

Page 179: ... 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 brake fluid reservoir diaphragm 2 Cracks damage Replace rea...

Page 180: ...r 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 handlebar to the left and right to make sure the brake hose doe...

Page 181: ...er 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 level mark a Add the recommended brake fluid to the prope...

Page 182: ...r 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 Install the cotter pin and bend the ends as shown 1 2 3 New N...

Page 183: ... 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 fluid and could cause vapor lock C...

Page 184: ...KE 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys em...

Page 185: ...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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 186: ...ake 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 187: ... 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 188: ...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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 189: ... 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys e...

Page 190: ...emove 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 191: ...T660X 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 end of the brake hose into a container and pump out the brak...

Page 192: ...ssem 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Moto...

Page 193: ...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 1 4 2 3 É a c É a b È T R 40 Nm 4 0 m kg 29 ft lb New T R...

Page 194: ...er 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 level mark a Add the recommended brake fluid to the prope...

Page 195: ...o 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 Nm 0 4 m kg 2 9 ft lb 4 Fill brake fluid reservoir with ...

Page 196: ... 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 fluid to the proper level Refer to CHECKING THE BRAKE FLU...

Page 197: ...n 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 hose holder 2 Refer to INSTALLING THE FRONT FORK LEGS Man...

Page 198: ...ob 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info moto...

Page 199: ...isted 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motor...

Page 200: ...marks 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 201: ...ont 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 front fork legs 1 Remove cap bolt spring seat fork sprin...

Page 202: ...n 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 seal or inner tube bushing must be replaced Damper rod hold...

Page 203: ...be 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 Manuals by Motomatrix www motomatrix co uk The Solution F...

Page 204: ... 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 leg make sure all of the components are clean 1 Install damp...

Page 205: ...mper 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded...

Page 206: ...rface 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 seal driver weight 90890 01367 Manuals by Motomatrix www mot...

Page 207: ...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 installing the cap bolt lubricate its O ring with lithium...

Page 208: ...ower 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 ft lb T R 23 Nm 23 m kg 17 ft lb T R 10 Nm 1 0 m kg 7 2 f...

Page 209: ...ed 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 Clutch switch 1 12 Clutch lever holder 1 Manuals by Motomatri...

Page 210: ... 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motom...

Page 211: ...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 HANDLEBAR 1 Stand the motorcycle on a level surface WARNING...

Page 212: ...ch 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 handlebar grip until the rubber adhesive has fully dried NOTE _...

Page 213: ...nside 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 c between the throttle grip and the grip end 7 Install th...

Page 214: ...Y 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 215: ... 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 INSTALLING THE STEERING HEAD 5 Upper bracket 1 6 Lock wash...

Page 216: ...S 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Moto...

Page 217: ...ring 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 pitting Replace Recommended cleaning solvent Kerosene Manuals ...

Page 218: ...eplace 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 grease 2 Install lower ring nut 1 rubber washer 2 upper ring ...

Page 219: ...t 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys e...

Page 220: ...ed 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 ASSEMBLY and INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 2 Co...

Page 221: ...SEMBLY 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 removal pro cedure REAR SHOCK ABSORBER ASSEMBLY Manuals by Moto...

Page 222: ...ck 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 of a rear shock absorber To release the gas pressure dril...

Page 223: ... 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 assembly from between the swingarm and relay arm 1 2 Manuals by ...

Page 224: ...HE 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 Installed depth a 7 2 8 2 mm 0 28 0 32 in Installed depth b 4 0 ...

Page 225: ... 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 ft lb T R 59 Nm 5 9 m kg 43 ft lb T R 59 Nm 5 9 m kg 43 f...

Page 226: ...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 side heel plate 1 6 Drive sprocket cover 1 Refer to REMOVI...

Page 227: ...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 Spacer 1 18 Oil seal bushing 2 2 19 Drive chain 1 Refer ...

Page 228: ...rm 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 Remove swingarm shaft nut pivot shaft swingarm T R Pivot sh...

Page 229: ... 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 damage Replace Manuals by Motomatrix www motomatrix co uk The ...

Page 230: ...ng 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 three different places 15 link drive chain section limit ...

Page 231: ...hods 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 Replace the drive chain drive chain rollers 2 Damage wear ...

Page 232: ...ve 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 in a b b a 2 31 1 3 2 Manuals by Motomatrix www motomatrix...

Page 233: ... 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 pedal position below the top of the rider footrest 12 0 mm 0 ...

Page 234: ...Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 235: ...ENG 5 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 236: ... 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 VALVES 5 30 CYLINDER AND PISTON 5 32 REMOVING THE CYLINDE...

Page 237: ...ANCER 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 CHECKING THE STOPPER LEVER 5 62 INSTALLING THE SHIFT SHAFT 5 62...

Page 238: ...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 INSTALLING THE TRANSMISSION 5 84 Manuals by Motomatrix www motom...

Page 239: ...ENG Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 240: ... 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 installation reverse the removal pro cedure ENGINE REMOVAL Manuals by...

Page 241: ...he 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 BRAKE DISC AND REAR WHEEL SPROCKET in chapter 4 ENGINE REM...

Page 242: ...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 chapter 7 Swingarm Refer to SWINGARM AND DRIVE CHAIN in chapter ...

Page 243: ...nkcase 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 reverse the removal pro cedure ENGINE REMOVAL Manuals by ...

Page 244: ... 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 Engine upper mounting bolt nut 1 1 Manuals by Motomatrix www m...

Page 245: ...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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 246: ...ngine 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 lb T R 73 Nm 7 3 m kg 53 ft lb T R 73 Nm 7 3 m kg 53 ft lb ...

Page 247: ...s 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 delivery pipe 1 1 7 Timing chain tensioner cap bolt 1 Refer to...

Page 248: ...m 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email inf...

Page 249: ...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 bolts in the proper sequence as shown Loosen each bolt 1 2 ...

Page 250: ...ut 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 _ To ensure an even surface rotate the cylinder head sever...

Page 251: ...ming 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 Roller 2 Sprocket EAS00231 INSTALLING THE CYLINDER HEAD 1 Ins...

Page 252: ...ening 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 illustration a Turn the primary pulley counterclockwise b Align the...

Page 253: ...th 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 one way cam 4 and push the timing chain tensioner rod 5 all ...

Page 254: ...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 CLEARANCE in chapter 3 T R Timing chain tensioner cap bolt...

Page 255: ...rder 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 Manuals by Motomatrix www motomatrix co uk The Solution For ...

Page 256: ...r 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 257: ...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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email i...

Page 258: ...m 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 1 projects from the camshaft c Check that the decompressor...

Page 259: ...tches 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 Limit 11 955 mm 0 4707 in Manuals by Motomatrix www motoma...

Page 260: ...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 Camshaft Molybdenum disulfide oil Camshaft bearing Engine oil...

Page 261: ...haust 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 a 3 2 1 T R 10 Nm 1 0 m kg 7 2 ft lb LT ROCKER ARMS AND ...

Page 262: ...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 Manuals by Motomatrix www motomatrix co uk The Solution For Lo...

Page 263: ...e 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 compressor attach ment 2 Valve spring compressor 90890 0401...

Page 264: ...re 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 0 052 mm 0 0010 0 0020 in Limit 0 10 mm 0 0039 in Manuals ...

Page 265: ...em 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 Valve guide installer ø6 90890 04065 Valve guide reamer ø6 90...

Page 266: ...nder 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 valve face contacted one another the blueing will have be...

Page 267: ...ompound 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 blueing dye Dykem b onto the valve face h Install the valv...

Page 268: ...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 Spring tilt limit 2 5 1 8 mm 2 5 0 071 in Manuals by Motomatri...

Page 269: ...ecommended 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle ...

Page 270: ...or 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 271: ...nder 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 CYLINDER 8 Piston pin 1 9 Piston 1 10 Top ring 1 Manuals by Mo...

Page 272: ...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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 273: ...on 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 EAS00255 CHECKING THE CYLINDER AND PISTON 1 Check piston wa...

Page 274: ...ce 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 maximum of D1 or D2 maximum of D5 or D6 R maximum of D1 D3 or D5...

Page 275: ... 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 0043 in Piston ring end gap Top ring 0 20 0 35 mm 0 0079 0 0...

Page 276: ...side 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 Piston pin outside diameter a Piston pin to piston clearance 0...

Page 277: ...ngine 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 recommended lubricant Recommended lubricant Engine oil 2 3...

Page 278: ... 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 side 3 T R Cylinder bolt 1st 15 Nm 1 5 m kg 11 ft lb 2nd 50 N...

Page 279: ...arts 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 280: ...emove 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 281: ...o 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 damper spring seat 1 Manuals by Motomatrix www motomatrix co u...

Page 282: ...er 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 283: ...he 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 Replace the friction plates as a set Manuals by Motomatrix...

Page 284: ...t 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 0 0079 in EAS00282 CHECKING THE CLUTCH SPRINGS The follow...

Page 285: ...0285 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 PULL ROD 1 Check pull lever shaft pinion gear teeth 1 pull ...

Page 286: ...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 90890 04086 3 2 1 New T R 90 Nm 9 0 m kg 65 ft lb Manuals b...

Page 287: ...etween 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 crisscross pattern 7 Install dowel pins gasket clutch cover...

Page 288: ...ever 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 within specification 12 Adjust clutch cable free play Refer to ...

Page 289: ...he 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 chapter 4 1 Oil filter element cover 1 2 Oil filter element 1...

Page 290: ... 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Mo...

Page 291: ...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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 292: ...eplace 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 Limit 0 15 mm 0 0059 in 3 Check oil pump operation Rough...

Page 293: ...otor 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 inner rotor 3 Check oil pump operation Refer to CHECKING THE...

Page 294: ...er 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 295: ...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 INSTALLING THE BAL ANCER DRIVEN GEAR AND BAL ANCER DRIVE GEAR ...

Page 296: ...r 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co u...

Page 297: ... 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 Replace Manuals by Motomatrix www motomatrix co uk The Solution...

Page 298: ...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 8 0 m kg 58 ft lb New T R 70 Nm 7 0 m kg 50 ft lb Manuals...

Page 299: ... 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Moto...

Page 300: ... 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 301: ...pper 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 spring stopper 5 3 Install shift pedal Refer to ADJUSTING...

Page 302: ...arks 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 Shift pedal Refer to SHIFT SHAFT 1 A C magneto coupler 2 Di...

Page 303: ...5 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 clutch 1 14 Woodruff key 1 15 Starter clutch gear 1 16 Bea...

Page 304: ...ve 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 90890 01701 Flywheel puller 90890 01362 1 3 2 a 2 1 Manua...

Page 305: ...ar 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 When turning the starter clutch gear coun terclockwise É the...

Page 306: ...m 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 is properly seated in the keyway of the crankshaft Lubrica...

Page 307: ...all 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 kg 7 2 ft lb Manuals by Motomatrix www motomatrix co uk Th...

Page 308: ...arts 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 1 Timing chain guide intake side 1 2 Timing chain 1 3 Ne...

Page 309: ...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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email ...

Page 310: ...t 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 311: ...rankcase 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 THE OIL STRAINER AND OIL DELIVERY PIPE 3 1 Check oil stra...

Page 312: ...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 surfaces 3 Check crankcase Cracks damage Replace oil delivery...

Page 313: ...es 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 No 1215 90890 85505 1 New Manuals by Motomatrix www motoma...

Page 314: ...t 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 switch screw 1 È É T R 10 Nm 1 0 m kg 7 2 ft lb T R 10 Nm 1 0...

Page 315: ...emove 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 316: ...ecification 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 width 74 95 75 00 mm 2 9508 2 9528 in Maximum crankshaft runou...

Page 317: ...r 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 of the crankshaft installer bolt with the other Turn the ...

Page 318: ... 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 319: ... 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co...

Page 320: ...irclip 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 321: ...MBLY 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 Replace the main axle Main axle runout limit 0 08 mm 0 00...

Page 322: ...o 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 positioned opposite side to the toothed washer and gear Install...

Page 323: ...ne 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 gears turn freely Manuals by Motomatrix www motomatrix co ...

Page 324: ...COOL 6 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 325: ... 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 326: ...COOL Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 327: ...o 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 reservoir 1 RADIATOR Manuals by Motomatrix www motomatrix co uk ...

Page 328: ...arks 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 329: ...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 10 1 40 kg cm2 16 0 20 3 psi Radiator cap tester 90890 0...

Page 330: ... 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 radiator cap Refer to CHECKING THE RADIATOR Radiator cap tester...

Page 331: ...ain 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Key...

Page 332: ... _ 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 thermostat with its breather hole a facing up Lubricate the O ri...

Page 333: ... 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 THE RADIATOR 1 2 a New New New T R 18 Nm 1 8 m kg 13 ft lb ...

Page 334: ... 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorc...

Page 335: ...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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 336: ...HE 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 337: ...ber 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 wear Replace 3 Check bearing Rough movement Replace 4 Chec...

Page 338: ...cket 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 Middle driven shaft bearing driver 5 90890 04058 Yamaha ...

Page 339: ...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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Co...

Page 340: ...adiator 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 opening pressure Below the specified pressure Replace the ...

Page 341: ...FI 7 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 342: ...Y 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 THE AIR INDUCTION SYSTEM 7 36 Manuals by Motomatrix www m...

Page 343: ...FI Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 344: ...or 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 SYSTEM Manuals by Motomatrix www motomatrix co uk The Solu...

Page 345: ... 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 G P W Y L Lg Y Ch G G L G W R G R W B W Y L R W L W Lg B P...

Page 346: ...e 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 one of the following conditions is present and the start ...

Page 347: ...e 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 pressure sensor hose is clogged or discon nected causing the...

Page 348: ...s 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 fault code of No 12 19 33 41 or 50 Engine trouble warnin...

Page 349: ...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 Diagnostic code No 62 Operated when the engine trouble warn...

Page 350: ...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 70 To decrease the selected diagnostic code number press...

Page 351: ... 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 352: ... 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 sensor Disconnected intake air temperature sensor coupler Mal...

Page 353: ...ved 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 reference value 01 Throttle angle Displays the throttle angle Chec...

Page 354: ...ating 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 set it to and then set it to again Check that the operati...

Page 355: ... 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 the couplers for any pins that may have pulled out Check th...

Page 356: ...n 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 sensor coupler wire har ness end as shown 2 Set the main switch...

Page 357: ... 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 ECU coupler Check the connections of the couplers Check t...

Page 358: ...t 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 8 Fault code No 21 Symptom Open or short circuit is detec...

Page 359: ...uit 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 as shown 3 Measure the intake air temperature sensor res...

Page 360: ...or 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 mode Code No 30 Test the primary and secondary coils for c...

Page 361: ...epair 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 defective 1 Measure the speed sensor output voltage 2 Connect...

Page 362: ...n 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 chap ter 8 Fault code No 42 Symptom A No normal signals are...

Page 363: ...el 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 fuel injection system relay and ECU Blue Red Blue Red 4 Mal...

Page 364: ...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 injection system relay and ECU Red Blue Red Blue 3 Coupler c...

Page 365: ...unction 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 have pulled out Check that the couplers are securely locked ...

Page 366: ...ter 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 Disconnect Manuals by Motomatrix www motomatrix co uk The Solut...

Page 367: ...ilot 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 368: ...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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 369: ...uel 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 use any caustic carburetor cleaning solution b Blow out a...

Page 370: ... 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 throttle position sensor Refer to CHECKING AND ADJUSTING TH...

Page 371: ...hes 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 fuel pump is OK If fuel does not flow replace the fuel pump ...

Page 372: ...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 sensor the engine idling speed should be properly adjusted...

Page 373: ...ithin 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 those specified Positive tester probe blue terminal 1 Negat...

Page 374: ...just 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 0 63 0 73 V yellow black blue 1 L Y B L 2 THROTTLE BODY A...

Page 375: ...ir 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 open and allows the air to flow into the exhaust pipe until ...

Page 376: ... 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 377: ... 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix c...

Page 378: ...ut 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 379: ...duction 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 red 1 Negative tester probe red white 2 Air induction syste...

Page 380: ...ELEC 8 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 381: ... 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 CIRCUIT DIAGRAM 8 37 TROUBLESHOOTING 8 39 CHECKING THE SIGN...

Page 382: ...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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 383: ...tch 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motor...

Page 384: ...utral 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 385: ...ew 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 terminals i e a closed circuit at the respective switch posit...

Page 386: ...8 4 ELEC CHECKING SWITCH CONTINUITY Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 387: ...ear 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motoma...

Page 388: ...n 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 389: ...tration 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 pushing and turning the bulb counter clockwise Bulbs D a...

Page 390: ...ulb 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 tester probe to termi nal 1 and the negative tester prob...

Page 391: ...nstall 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 proper operation Improper operation Replace a Disconnect the ...

Page 392: ...r 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 ter minal red white Negative battery ter minal black white ...

Page 393: ...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 Manuals by Motomatrix www motomatrix co uk The Solution Fo...

Page 394: ...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 Br R R Br R L B L Y G L B L P W L B L...

Page 395: ...on 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 20 C 68 F Is the battery OK Clean the battery terminals Re...

Page 396: ...e 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 0 kΩ at 20 C 68 F Is the spark plug cap OK Replace the s...

Page 397: ...e 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 position sensor resistance Crankshaft position sensor resis tanc...

Page 398: ...robe 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 connected and without defects Replace the ECU Properly co...

Page 399: ... 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 W R G R W B Y R W L W Lg Br G L R W BB Y L B BB B1 BB3 BB...

Page 400: ...ns 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 THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Ma...

Page 401: ... 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 Recharge or replace the battery 3 Starter motor Connect the ...

Page 402: ...he 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 Negative tester probe sky blue 1 No conti nuity Positive tester ...

Page 403: ...S 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 the neutral switch OK Replace the neutral switch 10 Sidesta...

Page 404: ...andlebar 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 405: ...rankcase 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys ...

Page 406: ... 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 407: ...er 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 armature assembly resis tances with the pocket tester Manuals by...

Page 408: ...t 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 Manuals by Motomatrix www motomatrix co uk The Soluti...

Page 409: ...acket 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 New T R 5 Nm 0 5 m kg 3 6 ft lb Manuals by Motomatrix www...

Page 410: ...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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 411: ...9 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 20 C 68 F Is the battery OK Clean the battery terminals Re...

Page 412: ...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 the crank shaft position sensor stator assembly 5 Wiring ...

Page 413: ... 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 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...

Page 414: ...l 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 CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open ci...

Page 415: ...elay 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 lighting system s wiring Refer to CIRCUIT DIAGRAM Is the lig...

Page 416: ...e 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 Set the dimmer switch to or Measure the voltage DC 12 V ...

Page 417: ...K 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 or both 2 Voltage Connect the pocket tester DC 20 V to the...

Page 418: ...8 36 ELEC LIGHTING SYSTEM Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 419: ...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 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 ...

Page 420: ...ngine 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 Ignition fuse w Signaling system fuse y Parking lighting fuse...

Page 421: ...tem 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 68 F Is the battery OK Clean the battery terminals Rechar...

Page 422: ...be 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 ter minal and ground the jumper lead Set the main switch...

Page 423: ...K 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 coupler wire har ness end Is the voltage within specificat...

Page 424: ...n 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 relay coupler wire har ness end as shown Positive tester pr...

Page 425: ... 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 green 2 or green 3 at the turn signal light connectors or m...

Page 426: ... 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 nuity NOTE When you switch the positive and negative tester p...

Page 427: ...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 Disconnect the fuel sender coupler from the fuel pump Connect ...

Page 428: ...upler 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 rotate it Measure the voltage DC 5 V of yellow blue 1 at the...

Page 429: ...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 Negative tester probe black white 2 Set the main switch to ...

Page 430: ... 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 sensor 18 Nm 1 8 m kg 13 ft lb Does the coolant temperature se...

Page 431: ... 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 L G R Br W Br R R B G R L W B L Br W ...

Page 432: ...90 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 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is th...

Page 433: ...adiator 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 Check the entire cooling system s wiring Refer to CIRCUIT DIA...

Page 434: ... 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 L G R Br W Br R R B G R L W B L Br W Br R R B R Gy L W R L...

Page 435: ... 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 system must be replaced Therefore it is highly recommended ...

Page 436: ...e 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 switch Standard key ECU Accessory lock 2 and key Immobilize...

Page 437: ...n 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 activated the immobilizer system indicator light flashes r...

Page 438: ...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 immobilizer system indicator light stops flashing 5 seconds after t...

Page 439: ...otorcy 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 Replace the main switch immobilizer unit 3 Replace the ECU 54 ...

Page 440: ...HE 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 switch for continuity Refer to CHECKING THE SWITCHES Is t...

Page 441: ...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 the main switch to ON Measure the voltage 12 V between red...

Page 442: ...d 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 specification The wiring circuit from the immobilizer unit to the me...

Page 443: ...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 Manuals by Motomatrix www motomatrix co uk The Solution For Los...

Page 444: ...g 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 Malfunction Not displayed Immobilizer unit or ECU malfunctio...

Page 445: ...g 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys em...

Page 446: ...i 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 harness OK Repair or replace the wire harness BLUE DARK GREE...

Page 447: ...et 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 448: ...Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 449: ...TRBL SHTG 9 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 450: ... 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 MALFUNCTION 9 5 UNSTABLE HANDLING 9 5 Manuals by Motomatrix www m...

Page 451: ...IGHT 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 452: ...alve 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 Improperly assembled crankcase Seized crankshaft FUEL SYSTEM Fuel t...

Page 453: ...arter 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 engine idling speed throttle stop screw Improper throttl...

Page 454: ...AR 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 plate Worn clutch plate Engine oil Incorrect oil level Incor...

Page 455: ... 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 EAS00857 POOR BRAKING PERFORMANCE Worn brake pad Worn brake dis...

Page 456: ...lled 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 or bushing Bent or damaged swingarm Rear shock absorber a...

Page 457: ...djusted 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 turn signal hazard relay Faulty main switch Faulty turn si...

Page 458: ...t 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 motor s Rear brake light switch t Auxiliary light u Tail br...

Page 459: ...Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 460: ...Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 461: ...Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 462: ... 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 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...

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