Yamaha XT660R 2007 Supplementary Service Manual Download

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FUEL INJECTION SYSTEM

Fault code No.

Er-1

Symptom

No signals are received from the ECU.

Used diagnostic code No. – –

Order

Item/components

Check or maintenance job

Restore method

Coupler connections

ECU coupler
Meter couplers

Check the couplers for any pins that may have
pulled out.
Check that the couplers are securely locked.

If there is a malfunction, repair it and connect it
securely.

Reinstated automati-
cally when it receives
a normal signal.

Malfunction in meter assembly

Replace the meter assembly.

Reinstated automati-
cally when it receives
a normal signal.

Malfunction in ECU

Replace the ECU.

Fault code No.

Er-2

Symptom

No signals are received from the ECU within the specified duration.

Used diagnostic code No. – –

Order

Item/components

Check or maintenance job

Restore method

Coupler connections

ECU coupler
Meter couplers

Check the couplers for any pins that may have
pulled out.
Check that the couplers are securely locked.

If there is a malfunction, repair it and connect it
securely.

Reinstated automati-
cally when it receives
a normal signal.

Malfunction in meter assembly

Replace the meter assembly.

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

Coupler connections

ECU coupler
Meter couplers

Check the couplers for any pins that may have
pulled out.
Check that the couplers are securely locked.

If there is a malfunction, repair it and connect it
securely.

Reinstated automati-
cally when it receives
a normal signal.

Malfunction in meter assembly

Replace the meter assembly.

Malfunction in ECU

Replace the ECU.

Fault code No.

Er-4

Symptom

Non-registered data has been received from the meter.

Used diagnostic code No. – –

Order

Item/components

Check or maintenance job

Restore method

Coupler connections

ECU coupler
Meter couplers

Check the couplers for any pins that may have
pulled out.
Check that the couplers are securely locked.

If there is a malfunction, repair it and connect it
securely.

Reinstated automati-
cally when it receives
a normal signal.

Malfunction in meter assembly

Replace the meter assembly.

Malfunction in ECU

Replace the ECU.

Summary of Contents for XT660R 2007

Page 1: ...2007 XT660R W XT660X W SUPPLEMENTARY SERVICE MANUAL 5VK F8197 E2 ...

Page 2: ...es it is necessary to use this Supplementary Service Manual together with the following manual XT660R S XT660X S 2004 SERVICE MANUAL 5VK1 AE1 XT660R W XT660X W 2007 SUPPLEMENTARY SERVICE MANUAL 2006 by MBK Industrie First edition July 2006 All rights reserved Any reproduction or unauthorized use without the written permission of MBK Industrie is expressly prohibited ...

Page 3: ...and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE _ Designs and specifications are subject to change without notice EAS00004 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following The Safety Alert Symbol means ATT...

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

Page 5: ...g fluid B Lubricant C Special tool D Tightening torque E Wear limit clearance F Engine speed G Electrical data Symbols H to M in the exploded diagrams indicate the types of lubricants and lubrication points H Engine oil I Gear oil J Molybdenum disulfide oil K Wheel bearing grease L Lithium soap based grease M Molybdenum disulfide grease Symbols N to O in the exploded diagrams indicate the followin...

Page 6: ... 32 REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET 32 REAR WHEEL 32 REMOVING THE REAR WHEEL XT660R 34 REMOVING THE REAR WHEEL XT660X 35 INSTALLING THE REAR WHEEL XT660R 35 INSTALLING THE REAR WHEEL XT660X 36 SWINGARM AND DRIVE CHAIN 38 ENGINE 41 ENGINE REMOVAL 41 EXHAUST PIPES AND MUFFLERS 41 CYLINDER HEAD 42 CYLINDER AND PISTON 44 COOLING SYSTEM 46 RADIATOR 46 FUEL INJECTION SYSTEM 48 FUEL INJECTI...

Page 7: ...75 mm 85 6 in XT660X Overall width 845 mm 33 3 in XT660R 860 mm 33 9 in XT660X Overall height 1 230 mm 48 4 in XT660R 1 170 mm 46 1 in XT660X Seat height 865 mm 34 1 in XT660R 875 mm 34 4 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 GENERAL SPECIFICATIONS ...

Page 8: ...10W 40 SAE 15W40 SAE 20W40 or SAE 20W 50 Refer to the chart for engine oil grade Recommended engine oil grade API service SG type or higher JASO standard MA 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 pump Oil pump type Trochoid Inner rotor to outer rotor tip clear ance 0 03 0 08...

Page 9: ...ust camshaft lobe dimensions Measurement A 43 129 43 229 mm 1 6980 1 7019 in 43 029 mm 1 6941 in Measurement B 37 007 37 107 mm 1 4570 1 4609 in 36 907 mm 1 4530 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 98XRH2010 126 Tensioning sy...

Page 10: ...052 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 0 20 0 35 mm 0 0079 0 0138 in 0 60 mm 0 0236 in Ring side clearance 0 030 0 080 mm 0 0012 0 0031 in 0 13 mm 0 0051 in 2nd ring Ring type Taper Dimensions B T 1 20 4 00 mm 0 0...

Page 11: ... in Ring side clearance 0 060 0 150 mm 0 0024 0 0059 in 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 5VK8 10 Throttle valve size 50 Item Standard Limit B T ...

Page 12: ... tube Size 90 90 21M C 54S 90 90 21M C 54T XT660R 120 70R 17M C 58 H 120 70ZR 17M C 58W 120 70ZR 17M C 58W XT660X Model manufacturer TOURANCE FRONT METZELER SIRAC MICHELIN XT660R DRAGON PIRELLI SPORTEC M1 METZELER RADIAL PILOT SPORT MICHELIN 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 200 kPa 2 00 kgf cm 29 p...

Page 13: ... PIRELLI SPORTEC M1 METZELER RADIAL PILOT SPORT MICHELIN 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 kPa 2 30 kgf cm 33 psi XT660X Load is the total weight of the cargo rider passenger and accessories Off road riding 200 kPa 2 00 kgf cm 29 psi XT660R Minimum tire tread de...

Page 14: ... senor resistance color 192 288 Ω at 20 C 68 F blue yellow green white Transistorized coil ignition unit model manufacturer TBDF36 DENSO Part to be tightened Part name Thread size Q ty Tightening torque Remarks Nm m kg ft lb O2 sensor M18 1 45 4 5 32 O2 sensor protector Bolt M6 2 10 1 0 7 2 Part to be tightened Thread size Tightening torque Remarks Nm m kg ft lb Engine mounting Engine upper bracke...

Page 15: ... Headlight lead 6 Sub wire harness È Fasten the sub wire harness and meter assem bly lead with a plastic band Fasten the sub wire harness at the white tape Face the end of the plastic band forward É Make sure that there is no slack in the meter assembly lead between the meter assembly and the plastic band The rubber boot on the meter assembly can be bent as shown ...

Page 16: ...h a plastic locking tie and then cut off the excess end of tie Ì Pass the left and right front turn signal light leads in front of the headlight stay Í Only the left side is shown in this illustration Route the right front turn signal light lead in the same way Î Pass the left and right front turn signal light leads between the headlight stay and front fork protec tor Ï XT660R Ð 0 5 mm 0 0 20 in f...

Page 17: ...n motor relay 9 Relay unit È Fasten the wire harness and negative battery lead to the frame with a plastic locking tie É Fasten the wire harness negative battery lead and rear brake light switch lead to the frame with a plastic locking tie Ê Fasten the rear brake light switch lead to the frame with a plastic locking tie Ë Fasten the wire harness to the frame at the white tape with a plastic lockin...

Page 18: ...C CABLE ROUTING Ì Route the negative battery lead behind the lean angle cut off switch bracket Í Route the rear brake light switch lead between the air filter case and the frame 9 8 7 6 Í È 1 É Ê 2 Ë 3 4 5 Ì Ê ...

Page 19: ...livery hose 2 C Radiator fan motor lead D Throttle cable E Headlight lead F Meter assembly lead G Left handlebar switch lead H Right handlebar switch lead I Front brake light switch lead J Clutch switch lead K Immobilizer unit lead L Clutch cable M Main switch lead N O2 sensor lead O Air filter to air cut off valve hose P Wire harness A A B B C C D J I G H E C F B B C C E D É Ê Ë Ì 1 2 34 5 7 6 A ...

Page 20: ... handlebar switch lead right han dlebar switch lead headlight lead meter assem bly lead front brake light switch lead clutch switch lead radiator fan motor lead and throttle cables with a plastic band 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 A A B B C C D J I G H ...

Page 21: ... lead crankshaft posi tion sensor lead sidestand switch lead speed sensor lead starter motor lead and A C mag neto lead with a plastic band Ð Fasten the neutral switch lead crankshaft posi tion sensor lead sidestand switch lead speed sensor lead and starter motor lead with a plastic band Ñ Fasten the air filter to air cut off valve hose oil tank breather hose and oil delivery hose 2 with a plastic...

Page 22: ...right and then fasten the left handlebar switch lead right handlebar switch lead headlight lead meter assembly lead front brake light switch lead and clutch switch lead next to the steering head pipe with the plastic band Be sure to connect the couplers before fastening the leads Ô Fasten the O2 sensor lead and air filter to air cut off valve hose with a holder as shown in the illustration A A B B...

Page 23: ...el pump lead 5 Fuel sender lead 6 Oil tank breather hose È 0 10 mm 0 0 39 in É 30 40 mm 1 18 1 57 in Ê 5 15 mm 0 20 0 59 in Ë Fasten the wire harness to the frame with a plas tic locking tie Ì To the fuel tank Í 0 5 mm 0 0 20 in Î Europe ZA Í Í Ë 2 Ë 5 4 Ì 3 È È Ê É 6 1 A Ê 1 A Î CABLE ROUTING ...

Page 24: ...ear fender cover È Fasten the tail brake light lead with two plastic locking ties so that the coupler is positioned to the inside of where the relays turn signal hazard relay headlight relay radiator fan motor relay and relay unit branch off from the wire harness É To relays turn signal hazard relay headlight relay radiator fan motor relay and relay unit A A Ï Î 1 2 3 4 9 8 7 6 5 A Í Ì Ð Ë È A A É...

Page 25: ...battery lead coupler Ë Fasten the rear turn signal light leads and tail brake light lead with a lead holder Ì Connect the couplers so that they are not pinched between the rear fender and rear fender cover Í Fasten the wire harness to the frame with a plas tic locking tie Î 0 5 mm 0 0 20 in Ï 0 10 mm 0 0 39 in Ð The tail brake light coupler and the rear turn sig nal light lead should not be lower ...

Page 26: ... brake hose 6 Rear brake caliper È When installing the brake hose onto the brake master cylinder make sure that the brake pipe touches the brake master cylinder as shown É Fasten the rear brake hose with the brake hose holder Ê When installing the brake hose onto the brake caliper make sure that the brake pipe touches the brake caliper as shown ...

Page 27: ...rake caliper È When installing the brake hose onto the brake master cylinder make sure that the brake pipe touches the brake master cylinder as shown É Fasten the rear brake hose with the brake hose holder Ê When installing the brake hose onto the brake caliper make sure that the brake pipe touches the brake caliper as shown A B B B B C A B C 1 2 3 4 5 5 5 6 È É Ê ...

Page 28: ...T R 7 Nm 0 7 m kg 5 1 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks Removing the cover XT660X Remove the parts in the order listed 1 Seat 1 2 Left side panel 1 3 Right side panel 1 4 Grab bar 2 5 Rear cover 1 For installation reverse the removal pro cedure ...

Page 29: ...g the cowling XT660X Remove the parts in the order listed Seat side panels left and right Refer to COWLING AND COVER Fuel tank Refer to FUEL TANK 1 Front fender 1 2 Front fork protector 1 3 Meter assembly coupler 2 Disconnect 4 Sub wire harness coupler 1 Disconnect 5 Front cowling assembly 1 For installation reverse the removal pro cedure ...

Page 30: ...t side panels left and right Refer to COWLING AND COVER Fuel Drain 1 Fuel tank left side cover 1 2 Fuel tank right side cover 1 3 Intake air guide 1 4 Fuel tank plate 1 5 Damper 1 1 6 Fuel pump coupler 1 Disconnect 7 Fuel sender coupler 1 Disconnect 8 Fuel hose 1 Refer to REMOVING THE FUEL TANK and INSTALLING THE FUEL HOSE in chapter 3 Manual No 5VK1 AE1 9 Fuel tank 1 FUEL TANK ...

Page 31: ... 25 CHK ADJ 1 7 6 8 10 5 4 9 3 2 T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks 10 Damper 2 1 For installation reverse the removal pro cedure FUEL TANK ...

Page 32: ...amage 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 stand so that the rear wheel is elevated 2 Spin the rear wheel several times and find the tightest position of the drive c...

Page 33: ...til 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 È XT660R É XT660X 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 È 1 a b ...

Page 34: ...o the total weight including cargo rider passenger and accessories and the anticipated riding speed Operation of an overloaded motorcycle could cause tire damage an accident or an injury NEVER OVERLOAD THE MOTORCYCLE XT660R Basic weight with oil and a full fuel tank 181 0 kg 399 lb Maximum load 186 0 kg 410 lb Cold tire pressure Front Rear Up to 90 kg load 200 kPa 2 00kgf cm2 29 psi 200 kPa 2 00kg...

Page 35: ...be tires to avoid tire failure and personal injury from sudden deflation When using tube tires be sure to install the correct tube Always replace a new tube tire and a new tube as a set To avoid pinching the tube make sure the wheel rim band and tube are centered in the wheel groove Basic weight with oil and a full fuel tank 186 0 kg 410 lb Maximum load 186 0 kg 410 lb Cold tire pressure Front Rea...

Page 36: ...design No guarantee concerning han dling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle Front tire XT660R Rear tire XT660R Front tire XT660X 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 TO...

Page 37: ...d be traveled at normal speed before any high speed riding is done NOTE _ For tires with a direction of rotation mark 1 Install the tire with the mark pointing in the direction of wheel rotation Align the mark 2 with the valve installation point Manufacturer Model Size PIRELLI DRAGON 160 60R 17M C 69H METZELER SPORTEC M1 160 60ZR 17M C 69W MICHELIN RADIAL PILOT SPORT 160 60ZR 17M C 69W ...

Page 38: ...Remarks Removing the rear wheel XT660X Remove the parts in the order listed 1 Stabilizer 1 2 Chain cover 1 3 Locknut 2 4 Adjusting bolt 2 5 Wheel axle nut 1 Refer to REMOVING THE REAR WHEEL XT660X and INSTALLING THE REAR WHEEL XT660X 6 Washer 1 7 Wheel axle 1 8 Rear wheel 1 9 Collar left 1 10 Collar right 1 11 Rear brake caliper 1 Refer to REMOVING THE REAR WHEEL XT660X REAR WHEEL BRAKE DISC AND R...

Page 39: ... T R 16 Nm 1 6 m kg 11 ft Ib T R 105 Nm 10 5 m kg 75 ft lb LS Order Job Part Q ty Remarks 12 Chain puller left 1 Refer to INSTALLING THE REAR WHEEL XT660X 13 Chain puller right 1 For installation reverse the removal pro cedure REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET ...

Page 40: ...ger of it falling over NOTE _ Place the motorcycle on a suitable stand so that the rear wheel is elevated 2 Loosen locknut 1 adjusting nut 2 3 Remove 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 cali...

Page 41: ...tand so that the rear wheel is elevated 2 Loosen locknut 1 adjusting nut 2 3 Remove stabilizer chain cover wheel axle nut 3 washer wheel axle 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 1 3 2 EAS00571 INSTALLING THE REAR WHEEL XT660R 1 Lubricate wh...

Page 42: ...d side of the vehicle Be sure to install both washers with the marks facing outward 3 Adjust drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK 4 Tighten wheel axle nut 5 Install chain cover chain cover bolts Drive chain slack 40 0 55 0 mm 1 57 2 17 in T R 105 Nm 10 5 m kg 75 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb EAS00571 INSTALLING THE REAR WHEEL XT660X 1 Lubricate wheel axle oil seal lips Re...

Page 43: ...E Install the chain puller with the mark a on the left side of the swingarm 3 Adjust drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK 4 Tighten wheel axle nut 5 Install chain cover chain cover bolts stabilizer Drive chain slack 40 0 55 0 mm 1 57 2 17 in a 1 2 T R 105 Nm 10 5 m kg 75 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb ...

Page 44: ...1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 10 Order Job Part Q ty Remarks Removing the swingarm and drive chain XT660X 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 s...

Page 45: ... ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 10 Order Job Part Q ty Remarks 10 Nut washer bolt 1 2 1 Refer to REMOVING THE DRIVE SPROCKET and INSTALLING THE SWINGARM in chapter 4 Manual No 5VK1 AE1 11 Cap pivot shaft nut pivot shaft 2 1 1 12 Swingarm 1 Refer to REMOVING THE SWINGARM and INSTALLING THE SWINGARM in chapter 4 Manual No 5VK1 AE1 13 Drive ...

Page 46: ...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 48 Nm 4 8 m kg 35 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 10 Order Job Part Q ty Remarks 19 Drive chain 1 Refer to REMOVING THE DRIVE CHAIN in chapter 4 Manual No 5VK1 AE1 For installation reverse the removal pro cedure REAR WHEEL BRAKE DISC AND REAR WHEE...

Page 47: ...ft Ib T R 27 Nm 2 7 m kg 19 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib 4 T R 20 Nm 2 0 m kg 14 ft Ib LS 5 New New 5 6 4 LT LT Order Job Part Q ty Remarks Removing the exhaust pipes and mufflers Remove the parts in the order listed 1 O2 sensor coupler 1 Disconnect 2 O2 sensor 1 3 Muffler left and right 2 4 Exhaust pipe left and right 2 5 Gasket 5 6 Exh...

Page 48: ... kg 7 2 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 50 Nm 5 0 m kg 36 ft Ib Order Job Part Q ty Remarks Removing the cylinder head Remove the parts in the order listed Engine Refer to ENGINE REMOVAL in chapter 5 Manual No 5VK1 AE1 Timing mark accessing screw crank shaft end accessing screw Refer to ADJUSTING THE VALVE CLEARANCE in chapter 3 Manual No 5VK1 AE1 1 Spark plug 1 2...

Page 49: ...9 4 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 50 Nm 5 0 m kg 36 ft Ib Order Job Part Q ty Remarks 7 Timing chain tensioner cap bolt 1 Refer to REMOVING THE CYLINDER HEAD and INSTALLING THE CYLIN DER HEAD in chapter 5 Manual No 5VK1 AE1 8 Timing chain tensioner gasket 1 1 9 Camshaft sprocket 1 10 Cylinder head 1 11 Cylinder head gasket 1 12 Dowel...

Page 50: ...Job Part Q ty Remarks Removing the cylinder and piston Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Timing chain guide exhaust 1 2 Water jacket joint 1 3 O ring 1 4 Cylinder 1 Refer to INSTALLING THE PISTON AND CYLINDER Manual No 5VK1 AE1 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 CYLI...

Page 51: ...10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 1st 15Nm 1 5 m kg 11 ft lb 2nd 50Nm 5 0m kg 5 1 ft lb Order Job Part Q ty Remarks 11 2nd ring 1 Refer to REMOVING THE CYLINDER AND PISTON and INSTALLING THE PISTON AND CYLINDER Manual No 5VK1 AE1 12 Oil ring 1 For installation reverse the removal pro cedure ...

Page 52: ...the order listed Seat side panels left and right Refer to COWLING AND COVER Fuel tank side covers left and right fuel tank Refer to FUEL TANK Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Manual No 5VK1 AE1 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 RAD...

Page 53: ... 5 1 ft Ib Order Job Part Q ty Remarks 7 Radiator outlet hose 1 Refer to INSTALLING THE RADIATOR in chapter 6 Manual No 5VK1 AE1 8 Radiator inlet hose 1 9 Radiator fan motor coupler 1 Disconnect 10 Radiator guard 1 11 Radiator 1 12 Radiator fan 1 For installation reverse the removal pro cedure ...

Page 54: ...Fuel hose 7 Fuel injector 8 Throttle position sensor 9 Intake air temperature sensor 0 Air filter case A Fuel injection system relay B Battery C Catalytic converter D ECU E Lean angle cut off switch F Fast idle plunger G Crankshaft position sensor H Coolant temperature sensor I Spark plug J O2 sensor K Intake air pressure sensor L Ignition coil 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I K L J FUEL INJE...

Page 55: ... 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 Br G L R W BB Y L B BB B1 BB3 BB4 BB2 Y Lg Ch G B Y Br R L L W Br W L...

Page 56: ...ant tempera ture to 80 C 176 F Yes Yes 22 Intake air temperature sensor Open or short circuit is detected Fixes the intake air tem perature to 20 C 68 F Yes Yes 24 O2 sensor No normal signal is received from the O2 sensor Yes Yes 30 Lean angle cut off switch latch up detected The motorcycle has over turned No No 31 O2 sensor The amount of air fuel ratio feedback compensation is maintained continuo...

Page 57: ...s detected with the fault code of No 12 19 33 41 or 50 Engine trouble warning light flashes when the start switch is turned ON No No Fault code No Item Symptom Fail safe action Startability Driveability Er 1 ECU internal malfunc tion output signal error No signals are received from the ECU No No Er 2 ECU internal malfunc tion output signal error No signals are received from the ECU within the spec...

Page 58: ...G 5 After selecting dIAG simultaneously press the SELECT and RESET buttons for 2 seconds or more to execute the selection 6 Set the engine stop switch to 7 Select the diagnostic code number that applies to the item that was verified with the fault code number by pressing the SELECT and RESET buttons NOTE _ The diagnostic code number appears on the odometer fuel reserve tripmeter tripmeter 2 LCD 01...

Page 59: ... tions of the sensor appears on the odome ter fuel reserve tripmeter tripmeter 2 LCD Actuator operation Set the engine stop switch to to oper ate the actuator NOTE _ If the engine stop switch is set to set it to and then set it to again 9 Set the main switch to OFF to cancel the diagnostic mode FUEL INJECTION SYSTEM ...

Page 60: ...detected in the coolant temperature sensor Open or short circuit in wire harness Defective coolant temperature sensor Disconnected coolant temperature sensor coupler Malfunction in ECU Improperly installed coolant temperature sensor 06 22 Open or short circuit is detected in the intake air temperature sensor Open or short circuit in wire harness Defective intake air temperature sensor Disconnected...

Page 61: ... or read from the internal memory 60 46 Power supply to the fuel injection sys tem relay is not normal Open circuit in wire harness Malfunction in rectifier regulator Malfunction in A C magneto rotor Refer to CHARGING SYSTEM in chapter 8 Manual No 5VK1 AE1 09 50 Faulty ECU memory When this mal function is detected the code number might not appear on the meter Malfunction in ECU The program and dat...

Page 62: ... 4 V Overturned 3 7 4 4 V 09 Fuel system voltage bat tery voltage Displays the fuel system voltage battery voltage Set the engine stop switch to Approximately 12 0 V 20 Sidestand switch Displays that the switch is on or off When the gear is in a position other than neutral Stand retracted On Stand extended Off 21 Neutral switch Displays that the switch is on or off Neutral On In gear Off 30 Igniti...

Page 63: ...engine stop switch is set to 60 E2PROM fault code dis play Transmits the abnormal portion of the data in the E2PROM that has been detected as fault code 44 01 00 is displayed when there is no malfunction 61 Malfunction history code display Displays the codes of the history of the self diag nosis malfunctions i e a code of a malfunction that occurred once and which has been corrected If multiple ma...

Page 64: ...ed Refer to DIAGNOS TIC MODE Fault code No 12 Symptom No normal signals are received from the crankshaft position sensor Used diagnostic code No Order Item components Check or maintenance job Restore method 1 Crankshaft position sensor installa tion Check the sensor for looseness or pinching Reinstated by crank ing the engine 2 Coupler connections Crankshaft position sensor cou pler ECU coupler Ch...

Page 65: ...nstated by crank ing the engine 2 Open or short circuit in the wire har ness Repair or replace if there is an open or short cir cuit between the wire harnesses Black Blue Black Blue Pink White Pink White Blue Blue 3 Defective intake air pressure sen sor Execute the diagnostic mode Code No 03 Replace the sensor if it is defective 1 Connect the pocket tester DC 20 V to the intake air pressure sensor...

Page 66: ...e throttle position senor Used diagnostic code No 01 throttle position sensor Order Item components Check or maintenance job Restore method 1 Throttle position sensor installation Check the sensor for looseness or pinching Check that the sensor is installed in the specified position Reinstated by set ting the main switch to ON 2 Coupler connections Throttle position sensor coupler ECU coupler Chec...

Page 67: ...stated by retracting the sidestand If the transmission is in neutral it is rein stated by reconnect ing the wiring 2 Open or short circuit in the wire har ness Repair or replace if there is an open or short cir cuit between the ECU and sidestand switch Blue Black 3 Defective sidestand switch Execute the diagnostic mode Code No 20 Replace the switch if it is defective Refer to CHECKING THE SWITCHES...

Page 68: ...ness Repair or replace if there is an open or short cir cuit between the wire harnesses Black Blue Black Blue Brown White Brown White 4 Defective intake air temperature sensor Execute the diagnostic mode Code No 05 Replace the sensor if it is defective 1 Remove the intake air temperature sensor from the air filter case 2 Connect the pocket tester Ω 100 to the intake air temperature sensor terminal...

Page 69: ...fer to THROTTLE BODY ASSEMBLY in chapter 7 Manual No 5VK1 AE1 5 Defective O2 sensor Replace if defective Fault code No 30 Symptom The motorcycle has overturned Used diagnostic code No 08 lean angle cut off switch Order Item components Check or maintenance job Restore method 1 The motorcycle has overturned Raise the motorcycle upright Reinstated by set ting the main switch to ON the engine cannot b...

Page 70: ... chapter 7 Manual No 5VK1 AE1 5 Defective O2 sensor Unable to output a rich signal Replace if defective Fault code No 32 Symptom The amount of air fuel ratio feedback compensation is maintained continuously in the vicinity of the lower limit air fuel ratio is rich Used diagnostic code No Order Item components Check or maintenance job Restore method 1 Installed state of O2 sensor Check for loosenes...

Page 71: ... Test the primary and secondary coils for continu ity Replace the coil if it is defective Refer to IGNITION SYSTEM in chapter 8 Manual No 5VK1 AE1 Fault code No 41 Symptom Open or short circuit is detected in the lean angle cut off switch Used diagnostic code No 08 lean angle cut off switch Order Item components Check or maintenance job Restore method 1 Coupler connections Lean angle cut off switc...

Page 72: ... 2 Open or short circuit in the wire har ness Repair or replace if there is an open or short cir cuit between the wire harnesses Blue Blue White White Black Blue Black Blue A 3 Gear for detecting vehicle speed has broken Replace the gear if it is defective Refer to TRANSMISSION in chapter 5 Manual No 5VK1 AE1 A 4 Defective speed sensor Execute the diagnostic mode Code No 07 Replace the sensor if i...

Page 73: ...cuit between the wire harnesses between neutral switch and relay unit Sky blue Sky blue between relay unit and ECU Blue Yellow Blue Black B 3 Faulty shift drum neutral detection area Replace if defective Refer to TRANSMISSION in chapter 5 Manual No 5VK1 AE1 B 4 Defective neutral switch Execute the diagnostic mode Code No 21 Replace the switch if it is defective Refer to CHECKING THE SWITCHES in ch...

Page 74: ...n fuel injection system fuse and fuel injec tion system relay Brown Brown between fuel injection system relay and ECU Red Blue Red Blue between battery and main switch Red Red between main switch and ignition fuse Brown Blue Brown Blue between ignition fuse and engine stop switch Red Red between engine stop switch and fuel injection system relay Red Black Red Black between fuel injection system re...

Page 75: ...ATTERY in chapter 3 Manual No 5VK1 AE1 Reinstated by start ing the engine and operating it at idle 2 Open or short circuit in the wire har ness Execute 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 inject...

Page 76: ...ed automati cally when it receives a normal signal 2 Malfunction in meter assembly Replace the meter assembly 3 Malfunction in ECU Replace the ECU Fault code No Er 3 Symptom Data from the ECU cannot be received correctly Used diagnostic code No Order Item components Check or maintenance job Restore method 1 Coupler connections ECU coupler Meter couplers Check the couplers for any pins that may hav...

Page 77: ...7 Immobilizer unit 8 Main switch 9 Fuel pump 0 Clutch switch A Left handlebar switch B Throttle position sensor C Coolant temperature sensor D Fuel injector E Lean angle cut off switch F Turn signal hazard relay G Headlight relay H Radiator fan motor relay I Relay unit J Battery K Fuse box 1 8 7 3 2 1 4 9 0 A C B D E F G H I M J K L N O P Q S R T U V W X Z 5 Y 6 ELECTRICAL COMPONENTS ...

Page 78: ...ntake air temperature sensor R Sidestand switch S Neutral switch T Crankshaft position sensor U Stator coil V Rear brake light switch W Speed sensor X Starter motor Y Radiator fan motor Z Horn Air induction system solenoid O2 sensor 8 7 3 2 1 4 9 0 A C B D E F G H I M J K L N O P Q S R T U V W X Z 5 Y 6 ...

Page 79: ...Immobilizer system indicator light b Headlight relay c Turn signal hazard relay d Left handlebar switch e Horn switch f Pass switch g Dimmer switch h Turn signal switch i Hazard switch j Clutch switch k Horn l Headlight m Rear turn signal light left n Front turn signal light left o Front turn signal light right p Rear turn signal light right q Radiator fan motor relay r Radiator fan motor s Rear b...

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Page 81: ... B L L W P B W O R Br L R W G Y R L L W R Y Y B Br W Br W W W B R Br R Br R R Br L R Br L Br RR W R LR B Br W B L G R B L 5 2 1 3 4 z 0 A B v w x 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 s e d f g h i b c j r t u l m n o p A 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 ...

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