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Yamaha XT660Z 2008, Service Manual

The Yamaha XT660Z 2008 service manual is a comprehensive guide that enables riders to take proper care of their motorcycle. This manual is available for free download on our website, providing users with the necessary information to maintain and repair their XT660Z with ease.

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5-11

CYLINDER HEAD

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. Install:

• Dowel pins
• Cylinder head gasket 

2. Install:

• Cylinder head
• Washers
• Cylinder head bolts

NOTE:

• Lubricate the cylinder head bolt threads and

muting surface with engine oil.

• Install the washers with their blunt surface

facing the bolt seat.

3. Tighten:

• Cylinder head bolts

New

New

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

4. Install:

• Camshaft sprocket

(onto the camshaft)

NOTE:

Make sure that the projection “a” on the de-
compressor lever is in the position shown in the
illustration.

Cylinder head bolts “1” 
L = 135 mm (5.31 in)

50 Nm (5.0 m·kg, 36 ft·lb)

Cylinder head bolts “2” 
L = 145 mm (5.71 in)

50 Nm (5.0 m·kg, 36 ft·lb)

Cylinder head bolts “3”

45 Nm (4.5 m·kg, 32 ft·lb)

Cylinder head bolts “4”

10 Nm (1.0 m·kg, 7.2 ft·lb)

NOTE:

Tighten the cylinder head bolts in the proper
tightening sequence as shown and torque
them in two stages.

a. Turn the primary pulley counterclockwise.
b. Align the “I” mark “b” on the A.C. magneto ro-

tor with the stationary pointer “c” on the A.C.
magneto cover.

Summary of Contents for XT660Z 2008

Page 1: ...SERVICE MANUAL 2008 11D F8197 E0 XT660Z ...

Page 2: ...MANUAL 2008 by Yamaha Motor Italia S p A First edition May 2008 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Italia S p A is expressly prohibited Printed in Italy ...

Page 3: ...dels Modifications and sig nificant 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 EAS00040 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following The Safety Aler...

Page 4: ...h page Sub section titles 2 appear in smaller print than the section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a dis assembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instru...

Page 5: ...e mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening torque 6 Wear limit clearance 7 Engine speed 8 Electrical data 9 Engine oil 10 Gear oil 11 Molybdenum disulfide oil 12 Wheel bearing grease 13 Lithium soap based grease 14 Molybdenum disulfide grease 15 Apply locking agent LOCTITE 16 Replace the part with a new one New 1 2 3 4 5 7 8 6 9 11 10 12 14 13 15 16 ...

Page 6: ...GENERAL INFORMATION TABLE OF CONTENTS 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL INJECTION SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 ...

Page 7: ... THE FI SYSTEM 1 2 FI SYSTEM 1 3 INSTRUMENT FUNCTIONS 1 4 IMPORTANT INFORMATION 1 7 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 7 REPLACEMENT PARTS 1 7 GASKETS OIL SEALS AND O RINGS 1 7 LOCK WASHERS PLATES AND COTTER PINS 1 7 BEARINGS AND OIL SEALS 1 8 CIRCLIPS 1 8 CHECKING THE CONNECTIONS 1 9 SPECIAL TOOLS 1 10 1 ...

Page 8: ......

Page 9: ...ICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS00180 MODEL LABEL The model label 1 is affixed to the frame under the seat This information will be needed to or der spare parts ...

Page 10: ...ssary to control the air fuel ratio in a more precise and finely tuned manner To accommodate this need this model has adopted an electroni cally controlled fuel injection FI system 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 engi...

Page 11: ...is supplied The injection duration and the injection timing are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor intake air temper ature sensor coolant temperature sensor and O2 sensor enable the ECU to determine the injection duration The injection timing is determined through the signal from the crankshaft positi...

Page 12: ...e the bottom segment of the fuel meter started flashing a clock a fuel meter a self diagnosis device NOTE Be sure to turn the key to ON before using the SELECT and RESET buttons For the U K only To switch the speedometer and odometer tripmeter displays between kilometers and miles push the SELECT and RESET buttons together and turn the key to ON When the digits start flashing on the display push t...

Page 13: ... tripmeter manually it will reset itself au tomatically and the display will return to the prior mode after refueling and traveling 5 km 3 mi Clock mode 1 Clock 2 SELECT button 3 RESET button NOTE The clock is displayed even when the key is turned to OFF To set the clock 1 Push the SELECT button for at least four seconds 2 When the hour digits start flashing push the RESET button to set the hours ...

Page 14: ... 8 29 However if the indica tor light slowly flashes five times and then quickly flashes two times repeatedly this error could be caused by signal interference If this occurs try the following 1 Use the code re registering key to start the engine NOTE Make sure there are no other immobilizer keys close to the main switch and do not keep more than one immobilizer key on the same key ring Immobilize...

Page 15: ...correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals a...

Page 16: ...rease Oil bearings liberally when installing if appropriate ECA13300 CAUTION Do not spin the bearing with compressed air because this will damage the bearing surfaces EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned op...

Page 17: ...sconnect sev eral times 3 Check All connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector NOTE Make sure all connections are tight 5 Check Continuity with the pocket tester Pocket tester 90890 03112 NOTE If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick reme...

Page 18: ...bers or both may differ depending on the country When placing an order refer to the list provided below to avoid any mistakes Tool name Tool No Illustration Reference pages Pocket tester 90890 03112 Digital circuit tester 90890 03174 Fuel injection system tester 90890 03182 Timing light 90890 03141 Ignition checker 90890 06754 Compression gauge 90890 03081 Adaptor Compression gauge 90890 04082 5 5...

Page 19: ...890 03176 Radiator cap tester 90890 01325 Radiator cap tester adaptor 90890 01352 Radiator cap tester adapter 90890 01497 Radiator tester adapter 90890 01496 Thickness gauge 90890 03079 Valve spring compressor attachment 90890 01243 Valve spring compressor 90890 04019 7 8 7 8 6 2 6 3 6 2 6 2 6 3 6 2 6 3 3 4 5 20 5 25 ...

Page 20: ...01083 Weight 90890 01084 Piston pin puller set 90890 01304 Valve guide remover ø 6 90890 04064 Valve guide installer ø 6 90890 04065 Valve guide reamer ø 6 90890 04066 Valve lapper 90890 04101 Flywheel puller 90890 01362 Sheave holder 90890 01701 5 15 5 17 5 27 5 21 5 21 5 21 5 53 5 53 5 55 ...

Page 21: ... 90890 01274 Crankshaft installer bolt 90890 01275 Adapter 90890 04130 Spacer crankshaft installer 90890 04144 Middle driven shaft bearing driver 90890 04058 Mechanical seal installer 90890 04132 Steering nut wrench 90890 01403 Ring nut wrench 90890 01268 T handle 90890 01326 Damper rod holder 90890 01460 5 35 5 37 5 67 5 68 5 68 6 10 3 24 4 59 4 60 4 59 4 51 4 53 ...

Page 22: ...4 SPECIAL TOOLS Tool name Tool No Illustration Reference pages Fork seal driver weight 90890 01367 Fork seal driver attachment ø 43 90890 01374 Yamaha bond No 1215 90890 85505 4 53 4 54 5 55 5 62 5 64 6 10 ...

Page 23: ...ICATIONS 2 13 TIGHTENING TORQUES 2 16 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 16 ENGINE TIGHTENING TORQUES 2 17 CHASSIS TIGHTENING TORQUES 2 21 LUBRICATION POINTS AND LUBRICANT TYPES 2 25 ENGINE 2 25 CHASSIS 2 27 COOLING SYSTEM DIAGRAMS 2 28 LUBRICATION CHART 2 32 LUBRICATION DIAGRAMS 2 33 CABLE ROUTING 2 41 2 ...

Page 24: ......

Page 25: ...Overall length 2246 mm 88 42 in Overall width 864 mm 34 01 in Overall height 1477 mm 58 14 in Seat height 896 mm 35 27 in Wheelbase 1500 mm 59 05 in Ground clearance 260 mm 10 23 in Minimum turning radius 1958 mm 77 08 in Weight With oil and fuel 208 5 kg 459 lb Maximum load 190 kg 419 lb ...

Page 26: ... sump Oil type SAE10W30 or SAE10W40 or SAE15W40 or SAE20W40 or SAE20W50 Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Total amount 2 90 L 2 55 Imp qt 3 07 US qt Without oil filter element replacement 2 50 L 2 19 Imp qt 2 64 US qt With oil filter element replacement 2 60 L 2 26 Imp qt 2 73 US qt Oil filter Oil filter type Paper Air filter Air filter...

Page 27: ... type Single suction centrifugal pump Reduction ratio 27 28 0 964 Maximum impeller shaft tilt 0 15 mm 0 006 in Spark plug Manufacturer Model NGK CR7E Spark plug gap 0 7 0 8 mm 0 028 0 031 in Cylinder head Volume 59 10 60 50 cm3 3 61 3 69 cu in Maximum warpage 0 03 mm 0 0012 in Camshaft Drive system Chain drive left Camshaft lobe dimensions Intake A 43 488 43 588 mm 1 7121 1 7161 in Limit 43 338 mm...

Page 28: ...c Rocker arm rocker arm shaft Rocker arm inside diameter 12 000 12 018 mm 0 4724 0 4731 in Limit 12 036 mm 0 4739 in Rocker arm shaft outside diameter 11 981 11 991 mm 0 4717 0 4721 in Limit 11 955 mm 0 4707 in Rocker arm to rocker arm shaft clearance 0 009 0 037 mm 0 0004 0 0015 in Limit 0 081 mm 0 0032 in Valves valve seats valve guides Valve clearance cold Intake 0 09 0 13 mm 0 0035 0 0051 in E...

Page 29: ...315 0 0472 in Valve stem diameter intake 5 975 5 990 mm 0 2352 0 2358 in Limit 5 945 mm 0 2341 in Valve stem diameter exhaust 5 960 5 975 mm 0 2346 0 2352 in Limit 5 930 mm 0 2335 in Valve guide inside diameter intake 6 000 6 012 mm 0 2362 0 2367 in Limit 6 05 mm 0 2382 in Valve guide inside diameter exhaust 6 000 6 012 mm 0 2362 0 2367 in Limit 6 05 mm 0 2382 in Valve stem to valve guide clearanc...

Page 30: ...mm 1 38 in Installed length valve closed exhaust 35 00 mm 1 38 in Spring rate K1 intake 34 18 N mm Spring rate K2 intake 44 14 N mm Spring rate K1 exhaust 34 18 N mm Spring rate K2 exhaust 44 14 N mm Installed compression spring force 171 00 197 00 N 38 44 44 29 lb intake 17 44 20 09 kg Installed compression spring force 171 00 197 00 N 38 44 44 29 lb exhaust 17 44 20 09 kg Spring tilt intake 2 5 ...

Page 31: ... in Piston ring Top ring Ring type Barrel Dimensions B x T 1 20 x 3 80 mm 0 047 x 0 150 in End gap installed 0 20 0 35 mm 0 0079 0 0138 in Limit 0 60 mm 0 0236 in Ring side clearance 0 030 0 080 mm 0 0012 0 0031 in Limit 0 13 mm 0 0051 in 2nd ring Ring type Taper Dimensions B x T 1 20 x 4 00 mm 0 047 x 0 157 in End gap installed 0 35 0 50 mm 0 0138 0 0197 in Limit 0 85 mm 0 0335 in Ring side clear...

Page 32: ...lease method Outer pull rack and pinion pull Operation Left hand operation Clutch cable free play at the end of the clutch lever 10 0 15 0 mm 0 39 0 59 in Friction plates 1 thickness 2 90 3 10 mm 0 114 0 122 in inside dia 120 mm Limit 2 80 mm 0 110 in Plate quantity 5 Friction plates 2 thickness 2 92 3 08 mm 0 115 0 121 in Limit 2 80 mm 0 110 in Plate quantity 2 Friction plates 3 thickness 2 90 3 ...

Page 33: ...runout limit 0 08 mm 0 0031 in Shifting mechanism Shift mechanism type Shift drum and guide bar Shift fork thickness 5 76 5 89 mm 0 2267 0 23188 in Decompression device Device type Auto decompression Air filter Air filter type Paper Fuel pump Pump type Electrical Model manufacturer 11D DENSO Maximum consumption amperage 3 8 A Output pressure 324 0 kPa 3 31 kg cm2 46 1 psi Throttle body Model manuf...

Page 34: ...re Tire type With tube Size 90 90 21M C 54S 90 90 21M C 54T Manufacturer model METZELER TOURANCE FRONT MICHELIN SIRAC 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 Manufacturer model METZELER TOURANCE MICHELIN SIRAC A Minimum tire tread depth 1 6 mm 0 063 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb F...

Page 35: ... and 28 0 mm x 2 1 10 in x 2 Rear brake Brake type Single disc brake Operation Right foot operation Brake pedal position 26 8 mm 1 05 in below the top of the rider footrest Recommended fluid DOT 4 Brake disc Diameter x thickness 245 x 5 0 mm 9 65 x 0 20 in Minimum thickness 4 5 mm 0 18 in Maximum deflection 0 10 mm 0 004 in Pad lining thickness inner 5 5 mm 0 216 in Limit 1 0 mm 0 04 in Pad lining...

Page 36: ...0079 in Rear suspension Suspension type Swingarm link suspension Rear shock absorber assembly type Coil spring gas oil damper Rear shock absorber assembly travel 95 0 mm 3 74 in Spring Free length 194 0 mm 7 63 in Limit 165 5 mm 6 51 in Installed length 180 0 mm 7 08 in Spring rate K1 70 00 N mm 399 70 lb in 7 14 kg mm Spring stroke K1 0 0 90 0 mm 0 3 54 in Optional spring available No Standard sp...

Page 37: ...ry coil resistance 3 40 4 60 Ω at 20 C 68 F Secondary coil resistance 10 4 15 6 kΩ at 20 C 68 F Spark plug cap Material Resin Resistance 10 0 kΩ at 20 C 68 F Charging system System type A C magneto Model manufacturer LMX51 DENSO Nominal output 14 0 V 20 8 A at 5000 r min Stator coil resistance color 0 224 0 336 Ω at 20 C 68 F white white Rectifier regulator Regulator type Semi conductor short circ...

Page 38: ...ype Constant mesh Starter motor Model manufacturer SM 13 MITSUBA Power output 0 80 kW Armature coil resistance 0 025 0 035 Ω at 20 C 68 F Brushes Overall length 12 5 mm 0 49 in Limit 5 00 mm 0 20 in Spring force 7 65 10 01 N 27 51 36 01 oz 780 1 021 gf Commutator diameter 28 0 mm 1 10 in Limit 27 0 mm 1 06 in Mica undercut depth 0 70 mm 0 028 in Starter relay Model manufacturer MS5F 561 JIDECO Amp...

Page 39: ...ke air temperature sensor Model manufacturer 5VU1 DENSO Resistance 2 21 2 69 kΩ at 20 C 68 F 0 290 0 354 kΩ at 80 C 176 F Coolant temperature sensor Model manufacturer 5PS1 DENSO Resistance 2 28 2 63 kΩ at 20 C 68 F 0 305 0 331 kΩ at 80 C 176 F 0 138 0 145 kΩ at 110 C 230 F Fuel injector Model manufacturer 297500 0390 DENSO Circuit breaker Circuit breaker type Fuse Fuses amperage Main fuse 30 A He...

Page 40: ... avoid warpage tighten multi fastener assemblies in a criss cross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifi cations require clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A B General tightening nut bolt torques Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 ...

Page 41: ...g 7 2 ft lb Tappet cover exhaust side M6 4 10 Nm 1 0 m kg 7 2 ft lb Tappet cover intake side M6 4 10 Nm 1 0 m kg 7 2 ft lb Camshaft sprocket cover M6 2 10 Nm 1 0 m kg 7 2 ft lb Camshaft sprocket M7 2 20 Nm 2 0 m kg 14 ft lb Camshaft retainer M6 2 10 Nm 1 0 m kg 7 2 ft lb Valve adjusting screw M6 4 14 Nm 1 4 m kg 10 ft lb Use a lock Balancer driven gear M18 1 70 Nm 7 0 m kg 50 ft lb washer Use the ...

Page 42: ... 18 Nm 1 8 m kg 13 ft lb Oil delivery hose 1 M6 1 10 Nm 1 0 m kg 7 2 ft lb Oil delivery hose 2 M6 2 10 Nm 1 0 m kg 7 2 ft lb Sealant Throttle body joint clamp screw M4 2 6 Nm 0 6 m kg 4 3 ft lb Air filter case joint clamp screw M5 1 4 Nm 0 4 m kg 2 9 ft lb Air filter case M6 4 10 Nm 1 0 m kg 7 2 ft lb Exhaust pipe joint M8 2 18 Nm 1 8 m kg 13 ft lb Exhaust pipe and frame M8 1 25 Nm 2 5 m kg 18 ft ...

Page 43: ...arter clutch M8 3 30 Nm 3 0 m kg 22 ft lb Stator coil M6 3 10 Nm 1 0 m kg 7 2 ft lb Crankshaft position sensor M5 2 7 Nm 0 7 m kg 5 1 ft lb Starter motor and crankcase M6 2 10 Nm 1 0 m kg 7 2 ft lb Starter motor lead M6 1 5 Nm 0 5 m kg 3 6 ft lb Brush holder and starter motor yoke M6 1 11 Nm 1 1 m kg 8 ft lb Starter motor assembly M5 2 5 Nm 0 5 m kg 3 6 ft lb Drive axle oil seal retainer M6 2 10 N...

Page 44: ...2 20 TIGHTENING TORQUES Cylinder head tightening sequence 2 4 3 1 ...

Page 45: ...shion Pivot shaft and frame M16 1 92 Nm 9 2 m kg 66 ft lb Suspension and arm relay M10 1 45 Nm 4 5 m kg 33 ft lb Suspension and frame M12 1 60 Nm 6 0 m kg 44 ft lb Arm relay and frame M12 1 60 Nm 6 0 m kg 44 ft lb Arm relay and connecting road M12 1 50 Nm 5 0 m kg 36 ft lb Connecting road and rear arm M12 1 50 Nm 5 0 m kg 36 ft lb Chain case and rear arm M6 4 7 Nm 0 7 m kg 5 1 ft lb Seal guard and...

Page 46: ...ame M8 2 21 Nm 2 1 m kg 15 4 ft lb Fuel tank rear and frame M8 2 20 Nm 2 0 m kg 14 4 ft lb Fuel tank and fuel pump M6 6 7 Nm 0 7 m kg 5 1 ft lb Fuel tank and air scoop M6 6 7 Nm 0 7 m kg 5 1 ft lb Fuel tank and stay fuel tank 1 2 M6 6 6 Nm 0 6 m kg 4 3 ft lb Fuel tank cap and fuel tank M5 5 6 Nm 0 6 m kg 4 3 ft lb Pipe breather joint and fuel tank M6 1 0 5 Nm 0 05 m kg 0 3 ft lb 572 or 222 Scoop a...

Page 47: ...6 2 7 Nm 0 7 m kg 5 1 ft lb Clutch wire and engine M8 2 7 Nm 0 7 m kg 5 1 ft lb Wire throttle and throttle body M6 1 4 Nm 0 4 m kg 2 9 ft lb Footrest and pedal Side stand and frame M10 2 63 Nm 6 3 m kg 46 ft lb 243 Side stand switch and side stand bracket M5 2 4 Nm 0 4 m kg 2 9 ft lb Side stand and bracket side stand M10 1 56 Nm 5 6 m kg 41 ft lb Bracket rear footrest and frame M8 4 30 Nm 3 0 m kg...

Page 48: ...lt and swingarm M8 2 16 Nm 1 6 m kg 11 5 ft lb Rear wheel and disc brake M6 6 14 Nm 1 4 m kg 10 ft lb Union bolt tightening rear caliper M10 1 30 Nm 3 0 m kg 22 ft lb Idrostop and rear master cylinder M10 1 24 Nm 2 4 m kg 17 5 ft lb Bleeder tightening rear M10 1 14 Nm 1 4 m kg 10 ft lb TIGHTENING TORQUES NOTE 1 First tighten the lower ring nut approximately 45 Nm 4 5 m kg 33 ft lb by using the tor...

Page 49: ...and exhaust Valve stem ends intake and exhaust Rocker arm shaft Camshaft lobes Decompressor lever pin Decompressor lever spring Water pump impeller shaft Oil pump rotors inner and outer Oil pump shaft Torque limiter Starter clutch idle gear thrust surface Starter clutch idle gear inner surface Starter clutch gear inner and outer Starter clutch assembly Primary drive gear tightening nut Primary dri...

Page 50: ...ion point Lubricant Shift shaft spacer Crankcase mating surface Yamaha bond No 1215 A C magnet lead grommet A C magneto cover Yamaha bond No 1215 Oil seal holder tightening bolt Yamaha bond No 1215 Oil delivery hose 2 tightening bolt Yamaha bond No 1215 ...

Page 51: ...ing bolt outer surface Rear arm and rear shock absorber oil seal lips Brake pedal outer surface Rear brake master cylinder pin outer surface Steering head pipe bearings upper and lower Steering head pipe bearing races upper and lower Tube guide throttle grip inner surface Clutch lever pivot bolt outer surface Sidestand sliding surface and collar outer surface Footrest pivoting point Footrest sprin...

Page 52: ...2 28 COOLING SYSTEM DIAGRAMS EAS00033 COOLING SYSTEM DIAGRAMS 5VK 5VK00 A 4 A B 4 3 2 1 2 3 1 A A A ...

Page 53: ...2 29 COOLING SYSTEM DIAGRAMS 1 Water jacket joint 2 Water pump outlet hose 3 Water pump outlet pipe 4 Water pump A From the radiator B To the cylinder ...

Page 54: ...2 30 COOLING SYSTEM DIAGRAMS 1 2 3 4 5 6 7 9 10 11 12 5 8 11 A ...

Page 55: ...r outlet hose 2 Coolant reservoir hose 3 Coolant reservoir breather hose 4 Radiator cap 5 Radiator 6 Coolant reservoir cap 7 Coolant reservoir 8 Radiator outlet hose 9 Water pump 10 Radiator fan 11 Radiator inlet hose 12 Thermostat A To the cylinder ...

Page 56: ...ION CHART LUBRICATION CHART 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 Pressure feed Splashed scavenge ...

Page 57: ...2 33 LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 A A A A B B B A A B 3 2 2 4 1 1 5 5 ...

Page 58: ...2 34 LUBRICATION DIAGRAMS 1 Oil delivery hose 2 2 Oil strainer 3 Oil delivery hose 1 4 Oil tank 5 Breather hose ...

Page 59: ...2 35 LUBRICATION DIAGRAMS A A A A 3 1 2 3 4 ...

Page 60: ...2 36 LUBRICATION DIAGRAMS 1 Oil delivery pipe 2 2 Oil delivery pipe 1 3 Oil filter 4 Oil pump ...

Page 61: ...2 37 LUBRICATION DIAGRAMS 1 7 2 3 4 5 6 A ...

Page 62: ...2 38 LUBRICATION DIAGRAMS 1 Oil delivery hose 2 2 Oil delivery pipe 2 3 Oil filter 4 Oil pump rotor 1 5 Oil pump rotor 2 6 Main axle 7 Oil delivery pipe 3 A To oil tank ...

Page 63: ...2 39 LUBRICATION DIAGRAMS 1 6 5 4 3 2 ...

Page 64: ...2 40 LUBRICATION DIAGRAMS 1 Camshaft 2 Oil delivery pipe 1 3 Oil filter 4 Main axle 5 Drive axle 6 Crankshaft ...

Page 65: ...2 41 CABLE ROUTING CABLE ROUTING ...

Page 66: ...ration 1 Front flasher light lead wire R 2 Front flasher R 3 Switch handle lead R 4 Front brake light switch lead 5 Throttle cables 6 Clamp 7 Clutch switch lead 8 Switch handle lead L 9 Clutch cable 10 To headlight assembly 11 Speed meter assembly 12 Front flasher L 13 Front flasher light lead wire L ...

Page 67: ...2 43 CABLE ROUTING ...

Page 68: ...cable 6 Clutch cable 7 Switch handle lead L 8 Front flasher L 9 Front flasher light lead wire L 10 Clamp 11 To wire harness 12 Front flasher light lead wire R 13 Front flasher R 14 Front brake light switch lead 15 Switch handle lead R 16 High beam 17 Stay 1 18 Auxiliary light 19 Wire harness flasher light ...

Page 69: ...2 45 CABLE ROUTING ...

Page 70: ...2 46 CABLE ROUTING 1 Front brake hose 2 Bolt union 3 Front brake hose holder F Stop the turning of brake hose end by this boss G Stop the turning of brake hose end by this surface ...

Page 71: ...2 47 CABLE ROUTING ...

Page 72: ...or lead 4 Ignition coil lead 5 Ignition coil 6 Air Induction System lead wire 7 Air Induction System lead 8 Main switch lead 9 Main switch 10 Clutch wire 11 Spark plug lead 12 Horn lead 13 Horn 14 Rectifier regulator 15 A C magneto lead 16 Neutral switch wire 17 Side stand switch lead ...

Page 73: ...2 49 CABLE ROUTING ...

Page 74: ...s 4 ECU 5 Clamp 6 Wire minus lead 7 Speed sensor lead 8 Rear stop switch 9 Radiator fan motor relay 10 Rear stop switch lead 11 Headlight relay 12 Battery box 13 Starter relay 14 Lean angle cut off switch 15 Fuel injection diagnostic connector 16 Anti theft alarm coupler ...

Page 75: ...2 51 CABLE ROUTING ...

Page 76: ...motor lead 13 A C magneto lead wire 14 Speed sensor lead 15 Speed sensor 16 Neutral switch lead wire 17 Sonda Lambda wire 18 Clamp 19 Fun motor lead 20 Auxiliary light lead 21 High beam 22 Low beam 23 Cover 24 Clamp B Put speed sensor lead and neutral switch lead wire passing through the clamp C Put neutral switch lead wire under cover D Neutral switch lead wire shall be under speed sensor lead ...

Page 77: ...2 53 CABLE ROUTING ...

Page 78: ...2 54 CABLE ROUTING 1 Fuse box 2 Clamp 3 Clamp 4 Clamp 5 Tail light 6 License light 7 License light lead wire 8 Clamp 9 Rear flasher light lead wire 10 Battery box 11 ECU 12 Battery ...

Page 79: ...2 55 CABLE ROUTING ...

Page 80: ...stop switch lead 2 Clamp 3 Throttle wire 4 Clamp 5 Wire harness 6 Speed sensor lead 7 Fuel pump lead 8 Clamp 9 Fuel hose 10 Air temperature sensor 11 Fuel injector lead 12 Fuel injector 13 To fuel tank 14 Clamp 15 Clutch wire 16 Switch handle lead L ...

Page 81: ...2 57 CABLE ROUTING ...

Page 82: ...switch lead wire 10 Clamp 11 Tail light 12 Rear flasher R 13 Rear flasher light lead wire R 14 Clamp 15 License light lead wire 16 License light 17 Rear flasher light lead wire L 18 Rear flasher L 19 Clamp 20 Clamp 21 Flasher relay 22 Starter motor lead 23 Fuse box 24 Battery 25 Wire minus lead from battery 26 Main fuse spare 27 Relay unit 28 Frame 29 Reinforcement compl 30 Tail light lead wire ...

Page 83: ...2 59 CABLE ROUTING ...

Page 84: ...2 60 CABLE ROUTING 1 Bolt union 2 Brake hose 3 Rear stop switch 4 Clamp hose A Add Loctite 243 ...

Page 85: ...CRANKCASE BREATHER HOSES 3 13 CHECKING THE EXHAUST SYSTEM 3 14 CHECKING THE COOLANT LEVEL 3 14 CHECKING THE COOLING SYSTEM 3 15 CHANGING THE COOLANT 3 16 CHASSIS 3 18 ADJUSTING THE FRONT BRAKE 3 18 ADJUSTING THE REAR BRAKE PEDAL 3 18 CHECKING THE BRAKE FLUID LEVEL 3 19 CHECKING THE FRONT AND REAR BRAKE PADS AND BRAKE PAD PINS 3 20 CHECKING THE FRONT AND REAR BRAKE HOSES 3 20 BLEEDING THE HYDRAULIC...

Page 86: ... 29 ELECTRICAL SYSTEM 3 30 CHECKING AND CHARGING THE BATTERY 3 30 CHECKING THE FUSES 3 30 REPLACING THE HEADLIGHT BULB 3 30 REPLACING AN AUXILIARY LIGHT BULB 3 31 TAIL BRAKE LIGHT 3 31 REPLACING A TURN SIGNAL LIGHT BULB 3 32 REPLACING THE LICENSE PLATE LIGHT BULB 3 32 ADJUSTING THE HEADLIGHT BEAM 3 32 ...

Page 87: ...Adjust 4 Air filter element Replace See page 3 12 5 Clutch Check operation See page 3 11 Adjust Front brake Check operation fluid level and vehicle for fluid 6 See page 3 19 3 20 leakage Replace brake pads Whenever worn to the limit Rear brake Check operation fluid level and vehicle for fluid 7 See page 3 19 3 20 leakage Replace brake pads Whenever worn to the limit 8 Brake hoses Check for cracks ...

Page 88: ...ange Every 3 years 25 Front and rear Check operation brake switches Moving parts and 26 cables Lubricate See page 3 28 Throttle grip Check operation and free play 27 housing and cable Adjust the throttle cable free play if necessary See page 3 5 Lubricate the throttle grip housing and cable Air induction Check the air cut off valve reed valve and hose 28 system for damage Check fuel hoses for crac...

Page 89: ...ter to air cut off valve hose Refer to AIR INDUCTION SYSTEM on page 7 11 2 Remove Intake tappet cover Exhaust tappet cover 1 Camshaft sprocket cover 2 3 Disconnect Spark plug cap 1 4 Remove Spark plug 2 2 1 5 Remove Timing mark accessing screw 1 Crankshaft end accessing screw 2 6 Valve clearance Out of specification Adjust 1 2 1 2 Valve clearance cold Intake valve 0 09 0 13 mm 0 0035 0 0051 in Exh...

Page 90: ... or b until the specified valve clearance is obtained Direction a Valve clearance is increased Direction b Valve clearance is decreased d Hold the adjusting screw to prevent it from moving and tighten the locknut to the speci fied torque a b e Measure the valve clearance again f If the valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the spec...

Page 91: ...nutes 2 Check Engine idling speed Out of specification Adjust Engine idling speed 1400 1600 r min Direction a Engine idling speed is increased Direction b Engine idling speed is decreased 3 Adjust Engine idling speed a Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained 1 a b 4 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE...

Page 92: ...WARNING After adjusting the throttle cable free play start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change EAS00060 CHECKING THE SPARK PLUG 1 Disconnect Spark plug cap 2 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 ...

Page 93: ... wiring connections of the entire ignition sys tem Make sure all connections are tight and free of corrosion a Start the engine warm it up for several min utes and then let it run at the specified en gine idling speed b Check that the stationary pointer a is with in the firing range b on the A C magneto rotor Incorrect firing range Check the ignition system 1 Remove Timing mark accessing screw 1 2...

Page 94: ... cm2 85 3 psi Standard 650 kPa 6 5 kg cm2 92 4 psi Maximum 700 kPa 7 0 kg cm2 99 6 psi a Set the main switch to ON and the engine stop switch to I b With the throttle wide open crank the engine until the reading on the compression gauge stabilizes WARNING To prevent sparking ground the spark plug lead before cranking the engine c If the compression pressure is above the maximum specification check...

Page 95: ... ECA10010 CAUTION Do not operate the vehicle until you know that the engine oil level is sufficient EWA10360 WARNING Never remove the engine oil tank cap after high speed operation otherwise hot engine oil could spout out and cause damage or injury Always let the engine oil cool down sufficiently before removing the oil tank cap Recommended oil Refer to the chart for the engine oil grade which is ...

Page 96: ...filter element drain bolt 1 1 2 1 1 7 Drain Engine oil completely from the crankcase and the oil tank 8 If the oil filter element is also to be replaced perform the following procedure a Remove the oil filter element cover 1 and oil filter element 2 b Check the O rings 3 and replace them if they are cracked or damaged c Install the new oil filter element and the oil fil ter element cover 9 Check E...

Page 97: ... page 3 9 16 Check Engine oil pressure Quantity Total amount 2 90 L 2 56 Imp qt 3 06 US qt Without oil filter element replacement 2 50 L 2 19 Imp qt 2 64 US qt With oil filter element replacement 2 60 L 2 26 Imp qt 2 73 US qt a Slightly loosen the bleed bolt 1 b Start the engine and keep it idling until en gine oil starts to seep from the bleed bolt If no engine oil comes out after one minute turn...

Page 98: ... play is obtained c Tighten the locknuts 1 2 b a Direction a Clutch cable free play is increased Direction b Clutch cable free play is decreased EAS00086 REPLACING THE AIR FILTER ELEMENT AND CLEANING THE CHECK HOSE Replacing the air filter element 1 Remove Seat Screws 1 Air filter case cover 2 2 Remove Air filter element 1 3 Install Air filter element CAUTION Make sure that the air filter element ...

Page 99: ... Cracks damage Replace Loose connection Connect properly 3 Install Fuel tank Refer to FUEL TANK on page 7 1 Seat Refer to GENERAL CHASSIS on page 4 1 CHECKING THE FUEL TANK BREATHER HOSE 1 Check Fuel tank breather hose 1 Loose connection Connect properly Cracks damage Replace CAUTION Make sure that the end of the fuel tank breather hose is not blocked and clean it if necessary Make sure that the e...

Page 100: ...and muffler bolt 7 18 Nm 1 8 m kg 13 ft lb Muffler stay and muffler bolt 8 22 Nm 2 2 m kg 16 ft lb Muffler stay and frame bolt 9 22 Nm 2 2 m kg 16 ft lb Cover bolt 10 8 Nm 0 8 m kg 5 8 ft lb Protector bolt 11 6 Nm 0 6 m kg 4 3 ft lb O2 sensor 12 45 Nm 4 5 m kg 32 ft lb EAS00102 CHECKING THE COOLANT LEVEL 1 Stand the motorcycle on a level surface NOTE Place the motorcycle on a suitable stand Make s...

Page 101: ...in utes and then turn it off 4 Check Coolant level NOTE Before checking the coolant level wait a few minutes until it settles EAS00104 CHECKING THE COOLING SYSTEM 1 Remove Seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 2 Check Radiator 1 Radiator outlet hose 2 Radiator inlet hose 3 Water pump assembly Water pump outlet pipe 4 Water pump outlet hose 5 Cracks dama...

Page 102: ...ockwise toward the detent to allow any residual pressure to escape When the hissing sound has stopped press down on the radiator cap and turn it counterclockwise to remove Coolant reservoir cap 2 Coolant reservoir 3 2 Drain Coolant from the coolant reservoir 3 Install Coolant reservoir Coolant reservoir bolt 5 Nm 0 5 m kg 3 6 ft lb 5 Drain Coolant from the engine and radiator 6 Check Coolant drain...

Page 103: ...get immediate medical attention CAUTION Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with ...

Page 104: ...or spongy feeling in the brake lever can indicate the presence of air in the brake system Before the vehicle is operat ed the air must be removed by bleeding the brake system Air in the brake system will considerably reduce braking perform ance and could result in loss of control and possibly an accident Therefore check the brake system and bleed if necessary 2 Adjust Brake pedal position b a c 2 ...

Page 105: ...el Below the minimum level mark a Add the recommended brake fluid to the proper level Recommended brake fluid DOT 4 A Front brake B Rear brake A a WARNING Use only the designated brake fluid Other brake fluids may cause the piston seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in ...

Page 106: ...reached Replace the brake pads as a set Refer to REPLACING THE REAR BRAKE PADS on page 4 36 Rear brake pad wear limit 1 0 mm 0 04 in 4 Check Brake pad pins Damage wear Replace 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 hoses Rear brake hoses Cracks damage wear Replace 2 Check Brake hose clamp ...

Page 107: ...or brake fluid reservoir c Connect a clear plastic hose 1 tightly to the bleed screw d Place the other end of the hose into a con tainer e Slowly apply the brake several times f Fully pull the brake lever or fully press down the brake pedal and hold it in position g Loosen the bleed screw NOTE Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle gri...

Page 108: ... specification Wheel axle nut 105 Nm 10 5 m kg 75 ft lb EAA01140 ADJUSTING THE DRIVE CHAIN SLACK NOTE The drive chain slack must be checked at the tightest point on the chain CAUTION A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swingarm or cause an accident Therefore keep the drive chain slack within the specified ...

Page 109: ...the drive chain since they may contain sol vents that could damage the O rings EAS00146 CHECKING AND ADJUSTING THE STEERING HEAD 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 front wheel is elevated 2 Check Steering head Grasp the bottom of the front fork legs...

Page 110: ...orque wrench at a right angle to the steering nut wrench c Swing full stroke the steering two or three times d Loosen the lower ring nut completely and then tighten it to the specified torque WARNING Do not overtighten the lower ring nut e Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt re move the lower bracket and c...

Page 111: ... equipped with spring preload adjusting bolt Spring preload WARNING Always adjust both fork legs equally other wise poor handling and loss of stability may result 1 Adjust Spring preload NOTE Use the 10 mm hexagon wrench included in the owner s tool kit to turn the adjusting bolts a Turn the adjusting bolt 1 on each fork leg fully in direction a b Turn the adjusting bolt 1 on each fork leg in dire...

Page 112: ...t the spring preload with the special wrench included in the owner s tool kit a Turn the adjusting ring 1 in direction a or b NOTE Align the appropriate notch in the adjusting ring 1 with the position indicator 2 on the shock absorber Spring preload setting Minimum soft 1 Standard 2 Maximum hard 9 Direction a Spring preload is increased suspension is harder Direction b Spring preload is decreased ...

Page 113: ...w have been approved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by the same manufacturer and of the same design No guarantee con cerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire Minimum tire tread depth 1 6 mm 0 063 in F...

Page 114: ...ode and interfere with its movement Replace damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricate NOTE Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device EAS00171 LUBRICATING THE LEVERS AND BRAKE PEDAL Lubricate the pivoting point and metal to ...

Page 115: ...of the rear suspension must be lubricated at the intervals specified in the pe riodic maintenance and lubrication chart LUBRICATING THE SWINGARM PIVOTS The swingarm pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricant Lithium soap based grease ...

Page 116: ...b Do not touch the glass part of the head light bulb to keep it free from oil other wise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not...

Page 117: ...xiliary lights 1 Replace Auxiliary light bulb a Remove Panel mounting screws 1 Panel 2 New c Install Auxiliary light bulb into the socket by push ing it in Auxiliary light socket together with the bulb by pushing it in Panel 1 Panel mounting screws TAIL BRAKE LIGHT This model is equipped with an LED type of tail brake light Refer to ELECTRICAL COMPONENTS on page 8 47 1 New 1 b Remove Auxiliary lig...

Page 118: ...rew otherwise the lens may break REPLACING THE LICENSE PLATE LIGHT BULB 1 Replace License plate light bulb a Remove License plate light bulb socket 1 by pulling it out License plate light bulb 2 by pulling it out NOTE When removing the license plate light bulb socket be careful not to pull too hard New b Install License plate light bulb into the socket by pushing it in License plate light bulb soc...

Page 119: ...REAR WHEEL DRIVE HUB 4 18 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 4 18 ASSEMBLING THE REAR WHEEL 4 18 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 18 CHECKING THE REAR BRAKE DISC 4 18 INSTALLING THE REAR WHEEL REAR BRAKE DISC 4 19 FRONT BRAKE 4 20 INTRODUCTION 4 25 CHECKING THE FRONT BRAKE DISCS 4 25 REPLACING THE FRONT BRAKE PADS 4 26 REMOVING THE FRONT BRAKE CALIPERS 4 27 CHECKING THE FRONT ...

Page 120: ...RONT FORK LEGS 4 55 STEERING HEAD 4 57 REMOVING THE LOWER BRACKET 4 59 CHECKING THE STEERING HEAD 4 59 INSTALLING THE STEERING HEAD 4 59 REAR SHOCK ABSORBER ASSEMBLY 4 61 HANDLING THE REAR SHOCK ABSORBER 4 62 DISPOSING OF A REAR SHOCK ABSORBER 4 62 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 62 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 62 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 62 SWINGARM...

Page 121: ...RAL CHASSIS Order Job Parts to remove Q ty Remarks 1 Key 1 Turn counterclockwise 2 Seat 1 3 Tail cover 1 4 Assist grip right and left 2 5 Cover right and left 2 6 Cover 1 For installation reverse the removal procedure Removing the seat and the assist grips ...

Page 122: ... ty Remarks 1 Windshield 1 2 Panel 1 3 Headlight Front turn signal light left and right couplers 1 1 1 Disconnect 4 Panel left 1 5 Panel right 1 6 Headlight assembly 1 7 Front fender 1 For installation reverse the removal procedure Removing the cowling and the front fender ...

Page 123: ... 3 GENERAL CHASSIS Removing the headlight Order Job Parts to remove Q ty Remarks 1 Cowling body 1 2 Headlight assembly 1 3 Meter assembly 1 4 Stay 1 For installation reverse the removal procedure 1 2 3 4 ...

Page 124: ...t and right couplers 6 Tail Brake light assembly 1 7 Bracket 1 8 Bracket 1 9 License bracket 1 For installation reverse the removal procedure Removing the rear fender cover license bracket and tail brake light assembly CAUTION When removing the battery First dis connect the negative battery lead and then positive battery lead When installing the battery First con nect the positive battery lead and...

Page 125: ...temperature sensor coupler 1 Disconnect 3 Air filter case to air cut off valve hose 1 Disconnect 4 Crankcase breather chamber 1 5 Pilot air hose 1 Disconnect 6 Check hose 1 Disconnect 7 Air filter case cover left 1 8 Air filter case cover right 1 9 Air filter case 1 10 Air cleaner joint 1 11 Air cleaner duct 1 12 Air cleaner element 1 For installation reverse the removal procedure Removing the air...

Page 126: ...NERAL CHASSIS INSTALLING THE AIR FILTER CASE JOINT CLAMP 1 Install Air filter case joint clamp 1 NOTE To install the air filter case joint clamp align slot a with the projection b on the air filter case 1 a b ...

Page 127: ...t brake caliper left and right 2 2 Front wheel axle pinch bolt 2 Loosen 3 Front wheel axle 1 4 Collar left and right 2 5 Front wheel 1 6 Front brake disc left and right 2 For installation reverse the removal procedure CAUTION Be sure the right brake disc is positioned exactly in the middle of the caliper pads to prevent any brake drag Tap the side of the right fork leg to position the disc cor rec...

Page 128: ...4 8 FRONT WHEEL Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 For assembly reverse the disassembly procedure ...

Page 129: ...pers 4 Remove Front wheel axle Front wheel EAS21910 DISASSEMBLING THE FRONT WHEEL 1 Remove Oil seals Wheel bearings a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver NOTE To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface 2 3 1 c Remove the wheel bearings 3 with a gen eral bearing puller EAS21920 CHECKING THE FRO...

Page 130: ...its Replace 6 Check Wheel bearings Front wheel turns roughly or is loose Re place the wheel bearings Oil seals Damage wear Replace EAS21960 ASSEMBLING THE FRONT WHEEL 1 Install Wheel bearings Oil seals a Install the new wheel bearings and oil seals in the reverse order of disassembly EC5YU1001 CAUTION Do not contact the wheel bearing inner race 1 or balls 2 Contact should be made only with the out...

Page 131: ...rk is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps d through f several times until all the marks come to rest at the same spot g The spot where all the marks come to rest is the front wheel s heavy spot X 3 Adjust Front wheel static balance a Install a balancing weight 1 onto the rim ex actly opposite the heavy spot X...

Page 132: ...ed grease 3 Lubricate Oil seal lips Collars 4 Install Front wheel NOTE Install the tire and wheel with the mark 1 pointing in the direction of wheel rotation 5 Install Front wheel axle Front brake calipers Front brake caliper bolts NOTE Make sure that there is enough space between the brake pads before installing the brake calipers onto the brake discs 6 Lower the front wheel so that it is on the ...

Page 133: ...nch bolt 3 CAUTION Apply the front brake several times and then while holding the brake lever in push down hard on the handlebar several times to check for proper fork operation EWA13500 WARNING Make sure the brake hose is routed proper ly 2 4 1 3 Front wheel axle pinch bolt 18 Nm 1 8 m kgf 13 ft lbf ...

Page 134: ...cle on a suitable stand so that the front wheel is elevated 1 Rear wheel axle nut 1 2 Drive chain adjusting locknut left and right 2 Loosen 3 Drive chain adjusting bolt left and right 2 Loosen 4 Drive chain 1 Remove from the rear sprocket 5 Rear wheel axle 1 6 Rear wheel 1 For installation reverse the removal procedure ...

Page 135: ... Job Parts to remove Q ty Remarks 1 Rear brake disc 1 2 Rear wheel sprocket 1 3 Collar brake disc side 1 4 Collar wheel sprocket side 1 5 Spacer 1 6 Oil seal 1 7 Bearing 1 8 Rear wheel drive hub 1 9 Rear wheel drive hub damper 4 For installation reverse the removal procedure ...

Page 136: ...4 16 REAR WHEEL Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Bearing 2 2 Spacer 1 3 Oil seal 1 For installation reverse the removal procedure ...

Page 137: ...embled 8 Remove Wheel axle 5 Wheel NOTE Support the brake caliper bracket 6 while pulling the wheel axle out Do not apply the brake after the wheel has been removed together with the brake disc EAS22080 DISASSEMBLING THE REAR WHEEL 1 Remove Oil seals Wheel bearings Refer to DISASSEMBLING THE FRONT WHEEL on page 4 8 EAS22090 CHECKING THE REAR WHEEL 1 Check Rear wheel axle Rear wheel Wheel bearings ...

Page 138: ...THE REAR BRAKE DISC Refer to CHECKING THE REAR BRAKE DISC on page 4 37 New New EAS22110 CHECKING THE REAR WHEEL DRIVE HUB 1 Check Rear wheel drive hub 1 Cracks damage Replace Rear wheel drive hub dampers 2 Damage wear Replace EAS22120 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1 Check Rear wheel sprocket More than 1 4 tooth a wear Replace the rear wheel sprocket Bent teeth Replace the rear whe...

Page 139: ...to CHECKING THE REAR BRAKE DISC on page 4 37 3 Lubricate Oil seal lips Collars 4 Install Collar wheel sprocket side Collar brake disc side Rear brake caliper bracket on the swingarm Rear wheel on the swingarm Drive chain on the rear sprocket Rear wheel axle Rear wheel axle nut 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 22 Recommended lubricant Lithium soap based ...

Page 140: ... Job Parts to remove Q ty Remarks The following procedure applies to both of the front brake calipers 1 Brake hose holder 1 2 Front brake caliper 1 3 Pin retainer 1 4 Pad fastening pin 1 5 Front brake pad 2 6 Brake pad spring 2 For installation reverse the removal procedure ...

Page 141: ...RAKE SYSTEM on page 3 21 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake lever 1 5 Front brake light switch connector 2 Disconnect 6 Front brake light switch 1 7 Front brake hose union bolt 1 8 Copper washer 2 9 Front brake master cylinder holder 1 10 Front brake master cylinder 1 ...

Page 142: ...assembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Master cylinder kit 1 4 Spring 1 5 Master cylinder 1 6 Push rod 1 For assembly reverse the disassembly procedure ...

Page 143: ... both of the front brake calipers Drain Brake fluid Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 21 1 Brake hose holder 1 2 Front brake hose union bolt 1 3 Copper washer 2 4 Front brake hose 1 5 Front brake caliper 1 6 Front brake pad 2 7 Front brake caliper bracket 1 For installation reverse the removal procedure ...

Page 144: ... Job Parts to remove Q ty Remarks The following procedure applies to both of the front brake calipers 1 Pin retainer 1 2 Pad fastening pin 1 3 Front brake pad 2 4 Brake pad spring 2 5 Caliper braket 1 6 Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 145: ... applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 7 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Brake disc deflection limit 0 10 mm 0 0039 in a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc ...

Page 146: ...ad wear limit a Out of specification Replace the brake pads as a set Brake pad lining thickness inner 4 55 mm 0 18 in Limit 1 0 mm 0 04 in Brake pad lining thickness outer 4 55 mm 0 18 in Limit 1 0 mm 0 04 in 2 Install Brake pad spring Brake pads NOTE Always install new brake pads and a brake pad spring as a set a a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of t...

Page 147: ...stem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 21 a EAS22300 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers NOTE Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose holder 1 Front brake hose union bolt 2 Copper washers 3 Front brake hose 4 NOTE Put the end of the brake hose into a con...

Page 148: ...nents as they will cause the piston seals to swell and distort Recommended fluid DOT 4 EAS22450 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Install Brake pads Brake caliper 1 Brake hose holder 2 Copper washers 3 Front brake hose 4 Front brake hose union bolt 5 New Brake caliper bolt 40 Nm 4 0 m kg 29 ft lb Front brake hose union bolt 30 Nm 3 ...

Page 149: ...lt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 21 4 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper lev el Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 19 a 5 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page ...

Page 150: ...22540 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Front brake master cylinder 1 Front brake master cylinder holder 2 Front brake master cylinder holder bolt 7 Nm 0 7 m kg 5 1 ft lb EAS22520 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER EWA13520 WARNING Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on inter...

Page 151: ... to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake flu ids may result in a harmful chemical reac tion 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...

Page 152: ...2550 REAR BRAKE Order Job Parts to remove Q ty Remarks Rear wheel Refer to REMOVING THE REAR WHEEL on page 4 17 1 Brake pad clip 1 2 Brake pad pin 1 3 Rear brake pad 2 4 Brake pad spring 2 5 Blade screw 1 For installation reverse the removal procedure ...

Page 153: ...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 Rear brake switch 1 7 Copper washer 2 8 Rear brake hose 1 Disconnect 9 Right side plate 1 10 Cotter pin 1 11 Washer 1 12 Pin 1 13 Rear brake master cylinder 1 For installation reverse the removal procedure ...

Page 154: ...KE Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake hose joint 1 2 Brake master cylinder kit 1 3 Brake master cylinder body 1 For assembly reverse the disassembly procedure ...

Page 155: ... Remarks Drain Brake fluid Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 21 Rear wheel Refer to REMOVING THE REAR WHEEL on page 4 17 1 Rear brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Rear brake caliper 1 For installation reverse the removal procedure ...

Page 156: ...ling the rear brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper bracket 1 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 procedure ...

Page 157: ...14 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 25 Brake disc deflection limit 0 10 mm 0 0039 in 4 Measure Brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace Refer to CHECKING THE...

Page 158: ...d the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 19 5 Check Brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 21 EAS22590 REMOVING THE REAR BRAKE CALIPER NOTE Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Rear wheel Rear br...

Page 159: ...acks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air EWA13610 WARNING Whenever a brake caliper is disassembled replace the brake caliper piston seals 2 Check Brake caliper bracket 1 Cracks damage Replace EAS22650 ASSEMBLING THE REAR BRAKE CALIPER EWA13620 WARNING Before installation all internal brake com ponents s...

Page 160: ...ng brake flu ids may result in a harmful chemical reac tion 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 ECA13540 CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediatel...

Page 161: ...hoses Cracks damage wear Replace EAS22730 ASSEMBLING THE REAR BRAKE MASTER CYLINDER EWA13520 WARNING Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents Whenever a master cylinder is disassem bled replace the piston seals and dust seals Recommended fluid DOT 4 1 Install Brake master cylin...

Page 162: ... with the same type of brake fluid that is already in the system Mixing brake flu ids may result in a harmful chemical reac tion 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 ECA13540 CAUTION Brake fluid may damage painted surfaces and pla...

Page 163: ...and 4 3 Front brake light switch coupler 1 Disconnect 4 Brake master cylinder holder 1 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 11 Clutch switch coupler 1 Disconnect 12 Clutch lever holder 1 13 Clutch lever 1 14 Left handlebar switch 1 15 Handlebar grip 1 ...

Page 164: ...4 44 HANDLEBAR Removing the handlebar Order Job Parts to remove Q ty Remarks 16 Upper handlebar holder 2 17 Handlebar 1 For installation reverse the removal procedure ...

Page 165: ...20 WARNING Securely support the vehicle so that there is no danger of it falling over 2 Install Throttle grip 1 on the handlebar NOTE Align the projection 2 on the handlebar switch with the hole in the handlebar Handlebar switch bolt 1 5 Nm 0 15 m kg 1 05 ft lb NOTE Check the throttle grip for smooth action WARNING Proper cable routing is essential to assure safe motorcycle operation Refer to CABL...

Page 166: ...2 42 6 Install Left handlebar switch 1 NOTE Align the projection a on the left handlebar switch with the hole in the handlebar Handlebar switch bolt 1 5 Nm 0 15 m kg 1 05 ft lb WARNING Proper cable routing is essential to assure safe motorcycle operation Refer to CABLE ROUTING on page 2 42 7 Install Clutch cable 1 Cable boot 2 NOTE Lubricate the pivoting part a of the clutch lever Turn in the adju...

Page 167: ...the middle of the caliper pads to prevent any brake drag Tap the side of the right fork leg to position the disc correctly 1 2 9 Install Handlebar grip 1 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 EWA13700 WARNING Do not touch the handlebar grip until ...

Page 168: ...ng procedure applies to both of the front fork legs Front wheel Refer to FRONT WHEEL on page 4 7 Front fender Refer to GENERAL CHASSIS on page 4 1 1 Cap bolt 1 Loosen 2 Upper bracket pinch bolt 2 Loosen 3 Lower bracket pinch bolt 2 Loosen 4 Front fork leg 1 For installation reverse the removal procedure 1 2 3 4 2 3 ...

Page 169: ...ocedure applies to both of the front fork legs 1 Cap bolt 1 2 O ring 1 3 Spacer 1 4 Washer 1 5 Front fork spring 1 6 Piston ring 1 7 Damper rod assembly 1 8 Inner tube 1 9 Inner tube bushing 1 10 Clamp 1 11 Rubber protector 1 12 Oil flow stopper 1 13 Dust seal 1 14 Oil seal clip 1 15 Oil seal 1 16 Washer 1 ...

Page 170: ...FORK Disassembling the front fork legs Order Job Parts to remove Q ty Remarks 17 Outer tube bushing 1 18 Outer tube 1 19 Copper washer 1 20 Damper rod assembly bolt 1 For assembly reverse the disassembly procedure ...

Page 171: ... The following procedure applies to both of the front fork legs 1 Remove Rubber protector Cap bolt Washer Spacer Fork spring 2 Drain Fork oil NOTE Stroke the inner tube several times while drain ing the fork oil 1 2 3 3 Remove Dust seal 1 Oil seal clip 2 with a flat head screwdriver CAUTION Do not scratch the inner tube 4 Remove Damper rod assembly bolt NOTE While holding the damper rod assembly w...

Page 172: ...pt to straighten a bent inner tube as this may dangerously weaken it 2 Measure Spring free length a Out of specification Replace 1 2 Spring free length 580 0 mm 22 83 in 3 Check Damper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air Oil flow stopper 2 Damage Replace CAUTION The front fork leg has a built in damper ad justing rod and a very sophisticated ...

Page 173: ...pper washer WARNING Always use new copper washer CAUTION Allow the damper rod assembly to slide slowly down the inner tube 3 until it pro trudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate Inner tube s outer surface New Recommended lubricant Fork oil 10W or equivalent 3 Tighten Damper rod assembly bolt 1 Damper rod assembly bolt 30 Nm 3 0 m kg 22 ft lb LOC...

Page 174: ...during installation 6 Install Oil seal clip 1 1 Fork seal driver weight 90890 01367 NOTE Adjust the oil seal clip so that it fits into the out er tube s groove 7 Install Dust seal 1 with the fork seal driver weight Quantity each front fork leg 650 0 cm3 21 97 US oz 22 87 Imp oz Recommended oil Fork oil 10W or equivalent 8 Fill Front fork leg with the specified amount of the recom mended fork oil 1...

Page 175: ...ll the spring with the smaller pitch a fac ing up Before installing the cap bolt lubricate its O ring with lithium soap based grease Temporarily tighten the cap bolt b Larger pitch EAS00662 I IN NS ST TA AL LL LI IN NG G T TH HE E F FR RO ON NT T F FO OR RK K L LE EG GS S The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and under...

Page 176: ...4 56 FRONT FORK WARNING Make sure the brake hoses are routed prop erly 1 2 3 ...

Page 177: ... 7 Front fender Refer to GENERAL CHASSIS on page 4 1 Front fork legs Refer to FRONT FORK on page 4 48 Headlight assembly Multi function meter unit Refer to GENERAL CHASSIS on page 4 2 Handlebar Refer to HANDLEBAR on page 4 43 1 Lower handlebar holder 2 2 Steering stem nut 1 3 Washer 1 4 Upper bracket 1 5 Lock washer 1 6 Upper ring nut 1 7 Plain washer 1 8 Lower ring nut 1 9 Lower bracket 1 ...

Page 178: ...4 58 STEERING HEAD Removing the lower bracket Order Job Parts to remove Q ty Remarks 10 Bearing cover 1 11 Bearing 1 12 Lower bearing 1 For installation reverse the removal procedure ...

Page 179: ...y support the lower bracket so that there is no danger of it falling Recommended cleaning solvent Kerosene EAS00681 CHECKING THE STEERING HEAD 1 Wash Bearings 2 Check Bearings Damage pitting Replace 3 Replace Bearings NOTE Whenever the steering head is disassembled replaced the dust seal 4 Check Upper bracket Lower bracket along with the steering stem Bends cracks damage Replace EAS00683 INSTALLIN...

Page 180: ... felt remove the lower bracket and check the upper and lower bearings Refer to CHECKING THE STEERING HEAD e Install the plain washer 2 f Install the upper ring nut 3 g Finger tighten the upper ring nut 3 and then align the slots of both ring nuts If nec essary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 NOTE Make sure the lock wa...

Page 181: ...the rear shock absorber assembly EAS23160 REAR SHOCK ABSORBER ASSEMBLY Order Job Parts to remove Q ty Remarks 1 Flange nut 1 2 Bolt 1 3 Flange nut 1 4 Flange bolt 1 5 Rear shock absorber assembly 1 For installation reverse the removal procedure ...

Page 182: ... a 2 3 mm 0 079 0 118 in hole through the rear shock ab sorber at a point 15 20 mm 0 6 0 8 in from its end as shown EWA13760 WARNING Wear eye protection to prevent eye damage from released gas or metal chips EAS23230 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehi...

Page 183: ... 63 REAR SHOCK ABSORBER ASSEMBLY 4 Install Rear shock absorber assembly 1 onto the arm relay Bolt 4 Flange nut 5 5 Tighten Flange nut 5 Rear shock absorber assembly nut arm relay 45 Nm 4 5 m kg 33 ft lb ...

Page 184: ...EL on page 4 14 Rear shock absorber assembly Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 62 1 Special nut 1 Loosen 2 Self locking nut Plain washer 2 2 3 Bolt 2 4 Arm 2 5 Nut Plain washer 1 1 6 Bolt 1 7 Relay arm 1 8 Oil seal 8 9 Bearing 7 10 Collar 4 11 Rear brake hose clamp 1 12 Drive chain case 1 13 Flange nut 1 14 Pivot shaft Plain washer 1 1 ...

Page 185: ...Job Parts to remove Q ty Remarks 15 Swingarm 1 16 Drive chain 1 From the swingarm 17 Guard seal 1 18 Thrust cover 2 19 Oil seal 2 20 Bush 2 21 Bearing 2 22 Solid bush 2 23 Oil seal 2 24 Chain puller 2 25 Bolt 2 26 Flange nut 2 For installation reverse the removal procedure ...

Page 186: ...g the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bearings washers and dust covers Swingarm side play at the end of the swingarm 1 0 mm 0 04 in d Check the swingarm vertical movement b by moving the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the spacers bearings washers and dust covers 4 Remove...

Page 187: ...Bushes 1 press in their seats 3 Install Bearings 2 press in their seats 4 Install Oil seals 3 Collars 4 Thrust covers 5 5 Install Swingarm locate it in its position on frame Plate washer Pivot shaft Flange nut 6 Tighten Special nut 6 Recommended lubricant Lithium soap based grease Location a of bushes right and left 8 mm 0 314 in Location b of bearings right and left 12 mm 0 472 in Special nut 8 N...

Page 188: ...of bearings right and left 5 mm 0 196 in Nut arm relay to frame bolt 60 Nm 6 0 m kg 44 ft lb Self locking nut arm bolt 50 Nm 5 0 m kg 36 ft lb 10 Install Rear shock absorber assembly Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 62 Rear wheel Refer to REAR WHEEL on page 4 14 11 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 22 Drive chain slack 50 0 60 0 mm 1 96 2 36...

Page 189: ... page 4 14 Rear shock absorber assembly Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 62 Swingarm Refer to SWINGARM on page 4 65 Shift pedal Refer to ADJUSTING THE SHIFT PEDAL on page 3 21 1 Drive sprocket cover Drive chain guard 1 1 2 Drive sprocket nut 1 3 Lock washer 1 4 Drive sprocket 1 5 Drive chain 1 For installation reverse the removal procedure ...

Page 190: ...two or three dif ferent places 2 Check Drive chain Stiffness Clean and lubricate or replace 3 Clean Drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and remove any remaining dirt c Remove the drive chain from the kerosene and completely dry it EC5YU1022 CAUTION This vehicle has a drive chain with small rubber O rings 1 between the drive chain side plates Neve...

Page 191: ... Drive sprocket cover Drive chain guard 2 Straighten the lock washer tab a 3 Remove Drive sprocket nut 1 Lock washer 2 Drive sprocket 3 EAS23460 CHECKING THE DRIVE SPROCKET 1 Check Drive sprocket More than 1 4 tooth a wear Replace the drive chain sprockets as a set Bent teeth Replace the drive chain sprock ets as a set b Correct 1 Drive chain roller 2 Drive chain sprocket EAS23470 CHECKING THE REA...

Page 192: ...ve sprock et nut 3 in the direction shown While applying the rear brake tighten the drive sprocket nut 3 Bend the lock washer tab a along a flat side of the nut 4 Install Shift pedal Refer to ADJUSTING THE SHIFT PEDAL on page 3 21 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 22 New 3 1 3 2 1 a Drive chain slack 50 0 60 0 mm 1 96 2 36 in ...

Page 193: ...GS 5 19 REMOVING THE VALVES 5 20 CHECKING THE VALVES AND VALVE GUIDES 5 20 CHECKING THE VALVE SEATS 5 22 CHECKING THE VALVE SPRINGS 5 23 INSTALLING THE VALVES 5 24 CYLINDER AND PISTON 5 26 REMOVING THE CYLINDER AND PISTON 5 27 CHECKING THE CYLINDER AND PISTON 5 27 CHECKING THE PISTON RINGS 5 28 CHECKING THE PISTON PIN 5 29 INSTALLING THE PISTON AND CYLINDER 5 29 CLUTCH 5 32 CLUTCH COVER 5 32 PULL ...

Page 194: ... THE STATOR COIL AND CRANKSHAFT POSITION SENSOR 5 53 CHECKING THE STARTER CLUTCH 5 54 CHECKING THE TORQUE LIMITER 5 54 INSTALLING THE A C MAGNETO ROTOR 5 54 ELECTRIC STARTER 5 56 CHECKING THE STARTER MOTOR 5 58 ASSEMBLING THE STARTER MOTOR 5 59 CRANKCASE 5 60 CRANKCASE BEARINGS 5 62 SEPARATING THE CRANKCASE 5 63 CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE 3 5 63 CHECKING THE TIMING CHAIN AND T...

Page 195: ...n page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Radiator cover right and left Refer to RADIATOR on page 6 1 Rear mud guard and rear fender Refer to GENERAL CHASSIS on page 4 1 1 Muffler 1 2 Cover 1 3 Protector 1 4 Exhaust pipe 3 1 5 O2 sensor cable holder 2 6 O2 sensor coupler 1 Disconnect 7 Exhaust pipe 1 2 1 1 8 Gasket 5 For installation reverse the removal procedure ...

Page 196: ...r Job Parts to remove Q ty Remarks Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 10 1 Engine guard 1 2 Oil tank outlet pipe 1 3 Oil tank inlet pipe 1 4 Oil tank breather hose 1 Disconnect For installation reverse the removal procedure ...

Page 197: ...n page 4 65 Starter motor Refer to ELECTRIC STARTER on page 5 57 Air filter case Refer to AIR FILTER CASE on page 4 5 Throttle body fast idle plunger inlet hose Refer to THROTTLE BODY ASSEMBLY on page 7 4 Thermostat thermo sensor Refer to THERMOSTAT on page 6 4 Water pump assembly water pump outlet hose Refer to WATER PUMP on page 6 7 Air cut off valve assembly air filter to air cut Refer to AIR I...

Page 198: ...Neutral switch connector 1 Disconnect 5 Speed sensor coupler 1 Disconnect 6 Ignition coil lead 2 Disconnect 7 Ignition coil 1 8 Intake air pressure sensor coupler 1 Disconnect 9 Vacuum hose 1 10 Intake air pressure sensor 1 11 Clutch cable 1 For installation reverse the removal procedure 1 2 3 4 5 6 7 8 9 10 11 ...

Page 199: ...gine upper mounting bolt nut cap 1 1 1 3 Engine upper bracket left 1 4 Engine upper bracket right 1 5 Engine front mounting bracket bolt nut 2 2 6 Engine front bracket bolt nut 2 2 CAUTION When install the engine install first all of the nuts and bolts and then tighten them to specified torques Refer to INSTAL LING THE ENGINE on page 5 7 CAUTION When remove the engine loosen first all of the nuts ...

Page 200: ... 3 4 7 9 6 5 1 2 5 6 ENGINE REMOVAL Removing the engine Order Job Parts to remove Q ty Remarks 7 Engine front bracket 1 8 Engine rear mounting bolt nut 1 1 9 Engine 1 For installation reverse the removal procedure ...

Page 201: ...r mounting bolt nut 8 tighten the nut until just touching the bracket NOTE Do not fully tighten the bolts 3 Tighten Engine rear mounting bolt nut 1 Engine front bracket bolt nut upper 3 Engine front bracket bolt nut lower 3 Engine front mounting bracket bolt nut upper 4 Engine front mounting bracket bolt nut lower 4 Engine upper bracket bolt nut front 7 Engine upper bracket bolt nut rear 7 Engine ...

Page 202: ...USTING THE VALVE end accessing screw CLEARANCE on page 3 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 7 Timing chain tensioner cap bolt 1 8 Timing chain tensioner gasket 1 1 9 Camshaft sprocket 1 10 Cylinder head 1 11 Cylinder head gasket 1 12 Dowel pin 2 For installation reverse the removal proce...

Page 203: ...tionary pointer d on the cylinder head 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 5 Remove Cylinder head NOTE Loosen the bolts in the proper sequence as shown Loosen each bolt 1 2 of a turn at a time After all of the bolts are ful...

Page 204: ... surface plate and resurface the cylinder head using a figure eight sanding pattern NOTE To ensure an even surface rotate the cylinder head several times EAS00212 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER 1 Check Tappet covers 1 Camshaft sprocket cover 2 O rings 3 Damage wear Replace the defective part s EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1 Check Timing chain tensioner Crack...

Page 205: ...at 3 Tighten Cylinder head bolts New New 4 Install Camshaft sprocket onto the camshaft NOTE Make sure that the projection a on the de compressor lever is in the position shown in the illustration Cylinder head bolts 1 L 135 mm 5 31 in 50 Nm 5 0 m kg 36 ft lb Cylinder head bolts 2 L 145 mm 5 71 in 50 Nm 5 0 m kg 36 ft lb Cylinder head bolts 3 45 Nm 4 5 m kg 32 ft lb Cylinder head bolts 4 10 Nm 1 0 ...

Page 206: ...shaft 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 Timing chain tensioner bolt 10 Nm 1 0 m kg 7 2 ft lb 5 Install Timing chain tensioner Timing chain tensioner cap bolt 20 Nm 2 0 m kg 14 ft lb a Remove the timing chain tensioner cap bolt 1 copper washer 2 and spring 3 b Release the timing c...

Page 207: ...y pointer d on the cylinder head Out of alignment Correct Repeat steps 4 7 if necessary 8 Tighten Camshaft sprocket bolts b a Camshaft sprocket bolts 20 Nm 2 0 m kg 14 ft lb 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...

Page 208: ... Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 8 1 Bearing retainer 1 2 Rocker arm shaft 2 3 Rocker arm 2 4 Locknut valve adjuster 4 4 5 Camshaft 1 6 Decompressor lever 1 7 Decompressor lever pin 1 8 Bearing 1 For installation reverse the removal procedure CAUTION Do not disassemble the camshaft assembly ...

Page 209: ... Weight 90890 01084 4 Remove Camshaft EAS00205 CHECKING THE CAMSHAFT 1 Check Camshaft lobes Blue discoloration pitting scratches Replace the camshaft and camshaft sprock et 2 Measure Camshaft lobe dimensions a and b Out of specification Replace the cam shaft Camshaft lobe dimensions Intake a 43 488 43 588 mm 1 7121 1 7161 in Limit 43 338 mm 1 7062 in b 36 959 37 059 mm 1 4551 1 4590 in Limit 36 85...

Page 210: ...edure applies to both of the rocker arms and rocker arm shafts 1 Check Rocker arm Damage wear Replace 2 Check Rocker arm shaft Blue discoloration excessive wear pitting scratches Replace or check the lubrica tion system 3 Measure Rocker arm inside diameter Out of specification Replace Rocker arm inside diameter 12 000 12 018 mm 0 4724 0 4731 in Limit 12 036 mm 0 4739 in Rocker arm shaft outside di...

Page 211: ...d lubricant Camshaft Molybdenum disulfide oil Camshaft bearing Engine oil 3 Install Decompressor lever pin 1 Decompressor lever 2 NOTE Install the decompressor lever pin 1 and de compressor lever 2 in the camshaft 3 as shown in the illustration 4 Install Camshaft 1 NOTE Install the camshaft on the slot a facing up 5 Lubricate Rocker arm shafts 1 a 2 1 3 Recommended lubricant Engine oil 6 Install E...

Page 212: ...5 18 ROCKER ARMS AND CAMSHAFT 7 Install Camshaft retainer Camshaft retainer bolts 1 2 3 Camshaft retainer bolts 10 Nm 1 0 m kg 7 2 ft lb LOCTITE ...

Page 213: ...o CYLINDER HEAD on page 5 8 Rocker arms rocker arm shafts camshaft Refer to ROCKER ARMS AND CAMSHAFT on page 5 14 1 Valve cotter 8 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 procedure New M M New New M M M 7 6 5 5 4 4 3 2 1 6 7 7 6 3 2 3 2 1 2 3 6 7 ...

Page 214: ...at 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 04019 Valve spring compressor attachment 90890 01243 3 Remove Valve spring retainer 1 Valve spring 2 Valve stem seal 3 Valve spring seat 4 Valve 5 NOTE Identify the position of each part very careful...

Page 215: ...ng the valve guide bore the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide clearance NOTE After replacing the valve guide reface the valve seat Valve guide remover ø6 90890 04064 Valve guide installer ø6 90890 04065 Valve guide reamer ø6 90890 04066 a Remove the valve guide with the valve guide remover 1 2 Replace Valve guide NOTE To ease valve guide remov...

Page 216: ...e stem seal Valve stem runout 0 010 mm 0 0004 in EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head Valve seat width Intake 1 00 1 20 mm 0 0394 0 0472 ...

Page 217: ...ck and forth be tween 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 valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to mak...

Page 218: ...ilt a Out of specification Replace the valve spring Spring tilt limit 2 5 1 8 mm 2 5 0 071 in EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components 1 Deburr Valve stem end with an oil stone 2 Lubricate Valve stem 1 Valve stem seal 2 with the recommended lubricant Recommended lubricant Molybdenum disulfide oil 3 Install Valve 1 Valve spring seat ...

Page 219: ...E Install 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 98090 04019 Valve spring compressor attachment 90890 01243 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a softface hammer CAUTION Hitting the valve tip with excessive force can damage the valve ...

Page 220: ...ve Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 8 1 Timing chain guide exhaust 1 2 Water jacket joint 1 3 O ring 1 4 Cylinder 1 5 Cylinder gasket 1 6 Dowel pin 2 7 Piston pin clip 2 8 Piston pin 1 9 Piston 1 10 Top ring 1 11 2nd ring 1 12 Oil ring 1 For installation reverse the removal procedure ...

Page 221: ...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 wall Cylinder wall Vertical scratches Replace the cylinder and the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure cylinder bore C with the cylinde...

Page 222: ...0 0012 0 0022 in Limit 0 13 mm 0 0051 in f If out of specification replace the cylinder and the piston and piston rings as a set EAS00263 CHECKING THE PISTON RINGS 1 Measure Piston ring side clearance Out of specification Replace the piston and piston rings as a set NOTE Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings Pis...

Page 223: ...lace the piston pin Piston pin outside diameter 22 991 23 000 mm 0 9052 0 9055 in Limit 22 971 mm 0 9044 in 3 Measure Piston pin bore inside diameter b Out of specification Replace the piston Piston pin bore inside diameter 23 004 23 015 mm 0 9057 0 9061 in Limit 23 045 mm 0 9073 in 4 Calculate Piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set ...

Page 224: ... with the recommended lubricant New New Recommended lubricant Engine oil 5 Offset piston ring end gaps a Top ring b Upper oil ring rail c Oil ring expander d Lower oil ring rail e 2nd ring f 20 mm 0 79 in å Exhaust side 6 Install Cylinder 1 Timing chain guide exhaust NOTE While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chai...

Page 225: ... m kg 11 ft lb 2nd 50 Nm 5 0 m kg 36 ft lb Cylinder bolts 2 L 109 mm 4 29 in 1st 15 Nm 1 5 m kg 11 ft lb 2nd 50 Nm 5 0 m kg 36 ft lb Cylinder bolts timing chain side 3 10 Nm 1 0 m kg 7 2 ft lb NOTE Tighten the cylinder bolts in the proper tighten ing sequence as shown and torque them in two stages ...

Page 226: ...0273 CLUTCH Order Job Parts to remove Q ty Remarks Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 10 1 Clutch cable 1 2 Clutch cable holder 1 3 Clutch cover 1 4 Gasket 1 5 Dowel pin 2 For installation reverse the removal procedure ...

Page 227: ...t Order Job Parts to remove Q ty Remarks 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 procedure New New New E 2 3 4 5 7 8 8 6 3 1 E ...

Page 228: ... 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 10 Clutch boss nut 1 11 Lock washer 1 12 Clutch boss 1 13 Thrust washer 1 14 Clutch housing 1 For installation reverse the removal procedure ...

Page 229: ...s nut 1 NOTE While holding the clutch boss 2 with the uni versal clutch holder 3 loosen the clutch boss nut 1 4 Remove Clutch boss nut Lock washer Clutch boss 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 2 Measure Friction plate 1 ...

Page 230: ...Out of specification Replace the clutch springs as a set Clutch spring free length 55 60 mm 2 19 in Limit 52 82 mm 2 08 in EAS00284 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE Pitting on the clutch housing dogs will cause er ratic clutch operation EAS00285 CHECKING THE CLUTCH BOSS The following proced...

Page 231: ...od bearing Damage wear Replace EAS00292 CHECKING THE PRIMARY DRIVEN GEAR 1 Check Primary driven gear Damage wear Replace the primary drive gear and clutch housing as a set Excessive noise during operation Replace the primary drive gear and clutch housing as a set 2 1 2 1 EAS00299 INSTALLING THE CLUTCH 1 Install Clutch boss Lock washer Clutch boss nut 1 NOTE Lubricate the crankshaft end threads wit...

Page 232: ... 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 3 6 5 7 4 2 1 5 6 Install Clutch springs Clutch spring bolts c a 3 5 b d 7 Clutch spring bolts 9 Nm 0 9 m kg 6 5 ft lb NOTE Lubricate the clutch spring threads with en gine oil Tighten the clutch spring bolts in stages and in a crisscross pattern 7 Install Dowel pins Gaske...

Page 233: ...able 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 1 a b 2 Clutch cable length 65 6 73 9 mm 2 58 2 91 in 11 Adjust Clutch cable length NOTE Move the pull lever a notch until the cable length is within specification b c 1 a 12 Adjust Clutch cable free play Refer to ADJUSTING THE C...

Page 234: ...n Refer to CHANGING THE COOLANT on page 3 16 Water pump assembly Refer to WATER PUMP on page 6 7 Clutch cable holder clutch housing Refer to CLUTCH on page 5 32 Right footrest brake pedal assembly 1 Oil filter element cover 1 2 Oil filter element 1 3 Union bolt 3 4 Oil delivery pipe 2 1 5 Crankcase cover right 1 6 Gasket 1 7 Dowel pin 2 8 Oil baffle plate 1 1 ...

Page 235: ...Removing the oil pump Order Job Parts to remove Q ty Remarks 9 Circlip 1 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 procedure ...

Page 236: ...ing 1 oil seal 1 1 2 Oil pump outer rotor 1 1 3 Dowel pin 1 4 Oil pump inner rotor 1 1 5 Oil pump housing cover oil seal 1 1 6 Dowel pin 2 7 Oil pump shaft 1 8 Dowel pin 1 9 Oil pump inner rotor 2 1 10 Oil pump outer rotor 2 1 11 Oil pump housing 2 1 For assembly reverse the disassembly procedure ...

Page 237: ...ousing Inner rotor to outer rotor tip clearance 0 025 mm 0 00098 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump housing clearance 0 090 0 150 mm 0 0035 0 0059 in Limit 0 22 mm 0 0087 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 movement Repeat steps 1 and 2 or replace the defective part s EAS...

Page 238: ...nt 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 OIL PUMP EAS00376 INSTALLING THE OIL PUMP 1 Install Oil pump gasket Oil pump Oil baffle plate 2 New Oil baffle plate 2 bolts 10 Nm 1 0 m kg 7 2 ft lb Oil pump driven gear 1 Oil pump driven gear circlip Oil baffle plate 1 New CA...

Page 239: ...housing Refer to CLUTCH on page 5 32 Crankcase cover right Refer to OIL PUMP on page 5 40 1 Balancer driven gear nut 1 2 Primary drive gear nut 1 3 Lock washer 1 4 Lock washer 1 5 Washer 1 6 Water pump drive gear 1 7 Primary drive gear 1 8 Balancer drive gear 1 9 Straight key 1 10 Washer 1 11 Balancer driven gear 1 12 Straight key 1 For installation reverse the removal procedure ...

Page 240: ...alancer driven gear Balancer drive gear Water pump drive gear Primary drive gear Damage wear Replace 3 4 2 a 1 3 4 a INSTALLING THE BALANCER DRIVEN GEAR AND BALANCER DRIVE GEAR 1 Install Washer Balancer drive gear 1 Straight key 2 Balancer driven gear 3 Straight key Primary drive gear Water pump drive gear NOTE Align the punch mark a on the balancer drive gear with the punch mark b on the balancer...

Page 241: ...5 47 BALANCER DRIVEN GEAR NOTE Place an aluminum plate a between the teeth of the balancer drive gear and balancer driven gear 3 Bend the lock washer tab 4 3 a 1 2 a ...

Page 242: ...rks Water pump assembly Refer to WATER PUMP on page 6 7 Clutch housing Refer to CLUTCH on page 5 32 Crankcase cover right Refer to OIL PUMP on page 5 40 1 Shift pedal 1 2 Circlip 1 3 Washer 1 4 Oil seal 1 5 Bearing 2 6 Shift shaft 1 7 Shift shaft spring 1 8 Spacer 1 9 Stopper lever spring 1 10 Circlip 1 11 Stopper lever 1 12 Spacer 1 ...

Page 243: ...5 49 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job Parts to remove Q ty Remarks 13 Washer 2 14 Shift shaft spring stopper 1 For installation reverse the removal procedure ...

Page 244: ...LING THE SHIFT SHAFT 1 Install Shift shaft spring stopper Shift shaft spring stopper 22 Nm 2 2 m kg 16 ft lb LOCTITE NOTE Hook the ends of the stopper lever spring on to 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 s...

Page 245: ...age 3 10 Starter motor Refer to ELECTRIC STARTER on page 5 56 Drive sprocket cover Refer to CHAIN DRIVE on page 4 70 Shift pedal 1 A C magneto coupler 2 Disconnect 2 Neutral switch connector lead 1 1 Disconnect 3 Torque limiter cover gasket 1 1 4 Torque limiter washer 1 2 5 Dowel pin 1 6 A C magneto cover gasket 1 1 7 Dowel pin 4 8 Crankshaft position sensor 1 9 Stator coil 1 10 Starter clutch idl...

Page 246: ...rter clutch and A C magneto Order Job Parts to remove Q ty Remarks 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 Bearing 1 17 Washer 1 For installation reverse the removal procedure ...

Page 247: ...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 1 Sheave holder 90890 01701 1 2 a 3 4 Remove A C magneto rotor 1 with the flywheel puller 2 Woodruff key NOTE Use the rotor puller CHECKING THE STATOR COIL AND CRANKSHAFT POSITION SENSOR 1 Check St...

Page 248: ...rning the starter clutch gear clock wise å it should turn freely otherwise the starter clutch is faulty and must be replaced c When turning the starter clutch gear coun terclockwise the starter clutch and the starter clutch gear should engage other wise the starter clutch is faulty and must be replaced CHECKING THE TORQUE LIMITER 1 Check Torque limiter Damage wear Replace EAS00354 INSTALLING THE A...

Page 249: ...f the crankshaft Lubricate crankshaft end threads with engine oil 5 Tighten A C magneto rotor nut 1 A C magneto rotor nut 80 Nm 8 0 m kg 58 ft lb NOTE While holding the A C magneto rotor 2 with the sheave holder 3 tighten the A C mag neto rotor nut Do not allow the sheave holder to touch the projection a on the A C magneto rotor Sheave holder 90890 01701 6 Install Gasket A C magneto cover 1 2 a 3 ...

Page 250: ...nkcase to crankcase breather chamber hose 1 Disconnect 2 Air filter to crankcase breather chamber 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 procedure ...

Page 251: ...Circlip 1 Disconnect 2 Starter motor gear 1 Disconnect 3 O ring 1 4 Front bracket 1 Disconnect 5 Shims 1 Disconnect 6 Lock washer 1 7 Rear bracket 1 8 Shims 1 9 Brush holder assembly 1 10 Brush 1 11 Armature coil 1 12 O ring 2 13 Starter motor yoke 1 For assembly reverse the disassembly procedure ...

Page 252: ...proper operation of the commutator 4 Measure Armature assembly resistances commuta tor and insulation Out of specification Replace the starter motor Pocket tester 90890 03112 a Measure the armature assembly resistances with the pocket tester Armature coil Commutator resistance 1 0 025 0 035 Ω at 20 C 68 F Insulation resistance 2 Above 1 M at 20 C 68 F b If any resistance is out of specification re...

Page 253: ...washer NOTE Align the tabs a on the lock washer with the groves in the front bracket 3 Install Rear bracket NOTE Align the slot a in the rear bracket with the tab b on the brush seat 4 Install Starter motor yoke 1 Front bracket 2 Rear bracket 3 O rings 4 Bolts New Starter motor bracket bolts 5 Nm 0 5 m kg 3 6 ft lb NOTE Align the alignment marks a on the starter motor yoke with the alignment marks...

Page 254: ...ND PISTON on page 5 26 A C magneto Refer to STARTER CLUTCH AND A C MAGNETO on page 5 51 Clutch Refer to CLUTCH on page 5 32 Balancer driven gear balancer drive gear Refer to BALANCER DRIVEN GEAR on page 5 45 Oil pump Refer to OIL PUMP on page 5 40 Shift shaft Refer to SHIFT SHAFT on page 5 48 1 Timing chain guide intake side 1 2 Timing chain 1 3 Neutral switch 1 4 Speed sensor 1 5 Lead holder 2 6 ...

Page 255: ...parating the crankcase Order Job Parts to remove Q ty Remarks 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 procedure ...

Page 256: ...der Job Parts to remove Q ty Remarks Crankshaft balancer Refer to CRANKSHAFT on page 5 66 Transmission Refer to TRANSMISSION on page 5 69 1 Oil seal holder 1 2 Oil seal 3 3 Bearing retainer 1 4 Bearing 7 For installation reverse the removal procedure ...

Page 257: ...f 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 CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE 3 1 Check Oil strainer Damage Replace Contaminants Clean with engine oil 2 Check Oil delivery pipe 3 Cracks damage Replace Oil de...

Page 258: ...ANKCASE 1 Lubricate Bearings Oil seals Recommended lubricant Bearing Engine oil Oil seal Lithium soap based grease 2 Install Bearings Bearing retainer 1 to the right crankcase Bearing retainer bolts New Bearing retainer bolts 10 Nm 1 0 m kg 7 2 ft lb NOTE Install the bearing retainer with the OUT mark a facing up 3 Thoroughly clean all the gasket mating sur faces and crankcase mating surfaces 4 Ap...

Page 259: ...hten Crankcase bolts follow the proper tightening sequence B A 1 Crankcase bolts 10 Nm 1 0 m kg 7 2 ft lb 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 Speed sensor bolts 10 Nm 1 0 m kg 7 2 ft lb Neutral switch Neutral switch screw ...

Page 260: ...ving the crankshaft and balancer EAS00381 CRANKSHAFT Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 60 1 Balancer 1 2 Crankshaft 1 For installation reverse the removal procedure 1 2 ...

Page 261: ...Crankshaft width a Out of specification Replace the crank shaft Crankshaft width 74 95 75 00 mm 2 9508 2 9528 in 3 Measure Crankshaft runout c Out of specification Replace the crank shaft bearing or both NOTE Turn the crankshaft slowly a The crankshaft 1 and the crankshaft pin 2 oil passages must be properly interconnect ed with a tolerance of less than 1 mm 0 04 in 4 Check Crankshaft sprocket Dam...

Page 262: ... 4 90890 04130 Spacer crankshaft installer 5 90890 04144 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 in staller bolt with the other Tu...

Page 263: ...419 TRANSMISSION Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 60 1 Shift fork C 1 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 procedure ...

Page 264: ...washer 1 4 Toothed washer retainer 1 5 5th pinion gear 1 6 Toothed spacer 1 7 Toothed washer 2 Refer to ASSEMBLY THE MAIN AXLE 8 Circlip 2 AND DRIVE AXLE on page 5 73 9 3rd pinion gear 1 10 4th pinion gear 1 11 Main axle 1st pinion gear 1 For assembly reverse the disassembly procedure M M M New New New M 11 10 7 8 9 8 7 6 5 4 3 2 1 ...

Page 265: ...efer to ASSEMBLY THE MAIN AXLE 3 1st wheel gear 1 AND DRIVE AXLE on page 5 73 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 10 Drive axle 1 11 O ring 1 For assembly reverse the disassembly procedure M M M New New New New LS 1 2 4 5 6 8 7 5 3 6 9 10 11 ...

Page 266: ...m grooves Damage scratches wear Replace the shift drum assembly Shift drum segment 1 Damage wear Replace the shift drum as sembly Shift drum bearing 2 Damage pitting Replace the shift drum as sembly 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 0031 in 2 Measure Driv...

Page 267: ...NG 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 wash er and gear Install the circlip so that both ends b are po sitioned in the center of each axle spline c New INSTALLING THE TRANSMISSION 1 Install Shift fork L 1 to drive axle Shift fork C 2 to main axle Shift fork R 3 to drive axle Shift...

Page 268: ...N 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 ...

Page 269: ...TOR 6 2 INSTALLING THE RADIATOR 6 2 THERMOSTAT 6 4 CHECKING THE THERMOSTAT 6 5 INSTALLING THE THERMOSTAT 6 5 WATER PUMP 6 7 DISASSEMBLING THE WATER PUMP 6 9 CHECKING THE WATER PUMP 6 9 ASSEMBLING THE WATER PUMP 6 10 INSTALLING THE WATER PUMP 6 11 6 ...

Page 270: ......

Page 271: ... CHANGING THE COOLANT on page 3 16 1 Radiator cover 2 2 Radiator cap 1 3 Coolant reservoir cap 1 4 Coolant reservoir hose 1 5 Coolant reservoir breather hose 1 6 Coolant throttle body hose 1 Disconnect 7 Coolant reservoir 1 8 Radiator inlet hose 1 9 Radiator outlet hose 1 10 Radiator fan motor coupler 1 Disconnect 11 Protector 1 12 Radiator 1 13 Radiator fan 1 For installation reverse the removal ...

Page 272: ...ply 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 on page 8 25 EAS00456 INSTALLING THE RADIATOR 1 Install Radiator inlet hose 1 Radiator outlet hose 2 Coolant throttle body hose 3 Coolant reservoir hose 4 Hose clamps 5 NOTE White painting mark a of hose shall be in stalled ...

Page 273: ... 1 c a b b a b 5 3 e 4 a Attach the radiator cap tester 1 and radia tor tester adapter 2 to the radiator b Apply 100 kPa 1 0 kg cm2 14 2233 psi of pressure and make sure there is no drop in pressure 1 2 4 Measure Radiator cap opening pressure Bellow the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 2 Radiator cap tester 90890 01325 Radiator tester adapter 908...

Page 274: ...marks Coolant Drain Refer to CHANGING THE COOLANT on page 3 16 1 Coolant temperature sensor coupler 1 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 procedure ...

Page 275: ...faulty thermostat could cause seri ous overheating or overcooling 2 Check Thermostat cover Thermostat housing cylinder head Cracks damage Replace EAS00466 INSTALLING THE THERMOSTAT 1 Install Thermostat 1 O ring 2 Thermostat cover 3 New Thermostat cover bolts 10 Nm 1 0 m kg 7 2 ft lb NOTE Install the thermostat with its breather hole a facing up Lubricate the O ring with a thin coat of lithium soap...

Page 276: ...sor Replace the sen sor if it is dropped or subjected to a strong impact 4 Fill Cooling system with the specified amount of the recommended coolant Refer to CHANGING THE COOLANT on page 3 16 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 on page 6 2 ...

Page 277: ...nless the coolant level is extremely low or the coolant contains engine oil Coolant Drain Refer to CHANGING THE COOLANT on page 3 16 1 Hose clamp 3 2 Radiator outlet hose 1 Disconnect 3 Water pump cover 1 4 Gasket 1 5 Water pump assembly 1 6 Water pump outlet pipe 1 7 O ring 1 8 Water pump outlet hose 1 For installation reverse the removal procedure ...

Page 278: ...e Q ty Remarks 1 Circlip 1 2 Impeller shaft gear 1 3 Pin 1 4 Washer 1 5 Impeller shaft assembly 1 6 Water pump seal 1 7 Oil seal 1 8 Bearing 1 9 O ring 1 10 Water pump housing 1 For assembly reverse the disassembly procedure New New New New LS E LS 5 6 7 10 9 3 8 4 2 1 ...

Page 279: ...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 Check ...

Page 280: ...al tools Before installing the water pump apply Yamaha bond No 1215 2 to the water pump housing 3 New New Mechanical seal installer 4 90890 04132 Middle driven shaft bearing driver 5 90890 04058 Yamaha bond No 1215 90890 85505 å Push down 3 Install Rubber damper 1 Rubber damper holder 2 NOTE Before installing the rubber damper apply tap water or coolant onto its outer surface 4 Measure Impeller sh...

Page 281: ...ng the water pump outlet pipe lubricate the O rings with a thin coat of lith ium soap based grease 2 Install Gasket Water pump assembly New Water pump cover 3 Install Radiator outlet hose 1 Hose clamp 2 NOTE Install the radiator outlet hose 1 so that the yellow painting mark contacts the projection a on the water pump cover Clamp portion shall be set downward 4 Fill Cooling system with the specifi...

Page 282: ...6 12 WATER PUMP 6 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 2 ...

Page 283: ...HECKING THE FUEL PUMP 7 8 CHECKING THE THROTTLE POSITION SENSOR 7 9 ADJUSTING THE THROTTLE POSITION SENSOR 7 9 AIR INDUCTION SYSTEM 7 11 AIR INJECTION 7 11 AIR CUT OFF VALVE 7 11 AIR INDUCTION SYSTEM DIAGRAMS 7 12 AIR CUT OFF VALVE ASSEMBLY 7 13 CHECKING THE AIR INDUCTION SYSTEM 7 15 FUEL INJECTION SYSTEM 7 16 WIRING DIAGRAM 7 17 ECU S SELF DIAGNOSTIC FUNCTION 7 19 SELF DIAGNOSTIC FUNCTION TABLE 7...

Page 284: ......

Page 285: ...ERAL CHASSIS on page 4 1 Fuel Drain 1 Headlight panel right and left 2 2 Turn signal light coupler 2 Disconnect 3 Fuel tank panel right and left 2 4 Fuel pump coupler 1 Disconnect 5 Fuel sender coupler 1 Disconnect 6 Fuel tank overflow hose 1 Disconnect 7 Fuel hose 1 Disconnect 8 Fuel tank 1 9 Fuel pump 1 For installation reverse the removal procedure ...

Page 286: ...he fuel has been removed from the fuel tank be careful when removing the fuel hoses since there may be fuel remain ing in them NOTE Remove the fuel hose manually without using any tools Before removing the hoses place a few rags in the area under where they will be removed 6 Remove Fuel tank NOTE Do not set the fuel tank down on the installation surface of the fuel pump Be sure to lean the fu el t...

Page 287: ...irection shown in the illustration 2 Tighten Fuel pump bolts Fuel pump bolt 7 Nm 0 7 m kg 5 1 ft lb INSTALLING THE FUEL HOSE 1 Install Fuel hose CAUTION When installing the fuel hose be sure to securely connect it CHECKING THE FUEL SENDER This fuel meter is equipped with a selfdiagnosis system When the key is turned to ON all of the display segments of the fuel meter will appear one after the othe...

Page 288: ...ain Refer to CHANGING THE COOLANT on page 3 16 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 on page 7 7 4 Vacuum hose 1 Disconnect 5 Fast idle plunger outlet hose 1 Disconnect 6 Fast idle plunger inlet hose 1 7 Pilot air hose 1 8 Throttle body joint clamp screw 2 Loosen 9 Throttle b...

Page 289: ... 5 THROTTLE BODY ASSEMBLY Removing the throttle body assembly Order Job Parts to remove Q ty Remarks 10 Throttle body joint clamp 2 11 Throttle body joint 1 For installation reverse the removal procedure ...

Page 290: ...rder Job Parts to remove Q ty Remarks 1 Throttle position sensor 1 2 Fuel injection pipe 1 3 Fuel injector 1 Refer to AIR FILTER CASE on page 4 5 4 Throttle body 1 For assembly reverse the disassembly procedure CAUTION Do not disassemble the throttle body New New 3 4 1 2 ...

Page 291: ...3 CHECKING THE THROTTLE BODY 1 Check Throttle body Cracks damage Replace the throttle body 2 Check Fuel passages Obstructions Clean Fuel injector resistance 12 Ω at 20 C 68 F a Wash the throttle body in a petroleum based solvent CAUTION Do not use any caustic carburetor cleaning solution INSTALLING THE THROTTLE BODY ASSEMBLY 1 Install Throttle body joint clamps NOTE Align the projection a on the t...

Page 292: ...ing Do not smoke and keep away from open flames sparks or any other source of fire If you do accidentally spill gasoline wipe it up immediately with dry rags If gasoline touches the engine when it is hot a fire may occur Therefore make sure the engine is completely cool before per forming the following test 1 Check Fuel pump operation a b a Fill the fuel tank b Put the end of the fuel hose into an...

Page 293: ...stall Throttle position sensor to the throttle body EAS27030 ADJUSTING THE THROTTLE POSITION SENSOR NOTE Before adjusting the throttle position sensor the engine idling speed should be properly ad justed 1 Check Throttle position sensor Refer to CHECKING THE THROTTLE PO SITION SENSOR on page 7 9 2 Adjust Throttle position sensor angle a Connect the throttle position sensor coupler to the throttle ...

Page 294: ...g the throttle position sensor angle tighten the throttle position sensor screws 3 to specification Output voltage at idle 0 63 0 73 V c Turn the main switch to ON d Measure the throttle position sensor voltage e Adjust the throttle position sensor angle so that the voltage is within the specified range ...

Page 295: ... 700 C 1 112 to 1 292 F EAS00917 AIR CUT OFF VALVE The air cut off valve is controlled by the signals from the ECU in accordance with the combus tion conditions Ordinarily the air cut off valve opens to allow the air to flow during idle and closes to cut off the flow when the vehicle is be ing driven However if the coolant temperature is below the specified value the air cut off valve remains open...

Page 296: ...7 12 AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Air filter case 2 Reed valve 3 Air cut off valve 4 Exhaust port ...

Page 297: ...to remove Q ty Remarks Seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 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 procedure ...

Page 298: ...YSTEM Disassembling the air cut off valve assembly Order Job Parts to remove Q ty Remarks 1 Air cut off valve cover 1 2 Reed valve assembly 1 3 Air cut off valve 1 For assembly reverse the disassembly procedure LT LT 3 2 1 ...

Page 299: ... Air cut off valve Cracks damage Replace 4 Check Air induction system solenoid a Remove the air induction system solenoid coupler from the air cut off valve assembly b Connect the pocket tester Ω x 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 Br RR W 2 1 Positive tester pr...

Page 300: ...nt screw 7 Throttle position sensor 8 Intake air pressure sensor 9 Air filter case 10 ECU 11 Lean angle cut off switch 12 Catalytic converter 13 Fuel injection system relay 14 Battery 15 Intake air temperature sensor 16 Coolant temperature sensor 17 Fuel injector 18 Crankshaft position sensor 19 O2 sensor 20 Air induction system solenoid 21 Air cut off valve ...

Page 301: ...7 17 FUEL INJECTION SYSTEM WIRING DIAGRAM ...

Page 302: ...l injector 19 O2 sensor 20 Air induction system solenoid 21 Intake air temperature sensor 22 Coolant temperature sensor 23 ECU 24 Speed sensor 25 Throttle position sensor 26 Intake air pressure sensor 27 Lean angle cut off switch 28 Multi function meter unit 37 Engine trouble warning light 38 Fuel pump 39 Sidestand switch 42 Engine stop switch 67 Ignition fuse 70 Fuel injection system fuse ...

Page 303: ...n the system by the self diagnostic function this mode pro vides an appropriate substitute characteristic operation and alerts the rider of the detected malfunction by illuminating the engine trouble warning light After the engine has been stopped the low est fault code number displays on the FI diag nostic tool This fault code remains stored in the memory of the ECU until it is deleted Engine tro...

Page 304: ...ort circuit is Fixes the throttle position Yes Yes open or short circuit detected sensor to fully open 16 Throttle position The throttle position sensor Fixes the throttle position Yes Yes sensor stuck is detected stuck sensor to fully open Broken or discon Open circuit in the input line 19 nected blue black blue black of the ECU is No No lead of the ECU detected 21 Coolant temperature Open or sho...

Page 305: ...ty ECU memory When 50 malfunction this malfunction is detected No Yes memory check error the code number might not appear on the meter Start unable warning Relay is not turned ON even Engine trouble warning if the crank signal is input light flashes when the while the start switch is start switch is turned ON turned ON When the start No No switch is turned ON while an error is detected with the fa...

Page 306: ...atement action Refer to Rein statement method in TROUBLESHOOTING DETAILS Turn the main switch to OFF turn the main switch back to ON and then check if the fault code number is still displayed Repairs completed Fault code number not displayed Erasing the malfunction history The malfunction history is stored even if the main switch is turned OFF The malfunction history must be erased in the diagnost...

Page 307: ...own 3 Turn the main switch to ON and start the engine NOTE Coolant temperature and engine revolution appear on the LCD of the FI diagnostic tool POWER LED Green comes on If a malfunction is detected in the system WARNING LED Orange comes on 1 4 Stop the engine NOTE If a malfunction is detected in the system the fault code appears on the LCD of the FI diagnostic tool And also WARNING LED Orange com...

Page 308: ...the DOWN button Press the DOWN button for 1 second or longer to au tomatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the UP button Press the UP button for 1 second or longer to automatically increase the diagnostic code numbers 7 Verify the operation of the sensor or actua tor Sensor operation The data representing the operating condi tions of t...

Page 309: ...ted when Malfunction in ECU D20 the start switch is pushed Open or short circuit is detected in Open or short circuit in wire harness the coolant temperature sensor Defective coolant temperature sensor Disconnected coolant temperature sensor coupler D06 Malfunction in ECU Improperly installed coolant temperature sensor Open or short circuit is detected in Open or short circuit in wire harness the ...

Page 310: ...peed sensor detected unit D07 Defective neutral switch D21 Disconnected neutral switch connector Malfunction in the engine side of the neutral switch Malfunction in ECU Power supply to the injector and fuel Open circuit in wire harness pump is not normal The ECU is Malfunction in ECU D09 D50 unable to monitor the battery voltage Defective fuel injection system relay An error is detected while read...

Page 311: ...30 Ignition coil The engine stop switch is set to the ignition coil operates 5 times every second and the engine trouble warning light comes on Connect an ignition checker to the spark plug cap If the engine stop switch is set to set it to and then set it to again Check that sparks are generated 5 times with the engine stop switch is set to D36 Fuel injector The engine stop switch is set to the fu...

Page 312: ...e E2PROM that has been detected as fault code 44 01 00 is displayed when there is no malfunction D61 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 malfunctions have been detected differ ent codes are displayed at 2 second intervals and this process is rep...

Page 313: ...oseness 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 that the couplers are securely locked If necessary repair the coupler or securely con nect it 3 Open or short circuit in the wire har ness Repair or replace if there is an open or short cir cuit between the wire ...

Page 314: ...stated 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 315: ...d from the throttle position senor Used diagnostic code No 01 throttle position sensor Order Item components Check or maintenance job Restore method 1 Throttle position sensor installation Check the sensor for looseness or pinching Check that the sensor is installed in the specified position Reinstated by set ting the main switch to ON 2 Coupler connections Throttle position sensor coupler ECU cou...

Page 316: ...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 on pag...

Page 317: ...ss 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 to the intake air temperature sensor terminal as show...

Page 318: ...ITION SYSTEM on page 8 1 Used diagnostic code No Order Item components Check or maintenance job Restore method 1 Installed condition of O2 sensor Check the installed area for looseness or pinching Starting the engine warming it up until the coolant temperature is 60 C or more and then running it between 2000 3000 r min until the engine trouble indicator turns off 2 Connected state of connector Che...

Page 319: ...ode No 30 Test the primary and secondary coils for continu ity Replace the coil if it is defective Refer to IGNITION SYSTEM on page 8 1 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 switch coupler E...

Page 320: ... 6 mi h A 2 Open or short circuit in the wire har ness Repair or replace if there is an open or short cir cuit between the wire harnesses Blue Blue White White Black Blue Black Blue A 3 Gear for detecting vehicle speed has broken Replace the gear if it is defective Refer to TRANSMISSION on page 5 69 A 4 Defective speed sensor Execute the diagnostic mode Code No 07 Replace the sensor if it is defec...

Page 321: ...open or short cir cuit between the wire harnesses between neutral switch and relay unit Sky blue Sky blue between relay unit and ECU Blue Yellow Blue Black B 3 Faulty shift drum neutral detection area Replace if defective Refer to TRANSMISSION B 4 Defective neutral switch Execute the diagnostic mode Code No 21 Replace the switch if it is defective Refer to CHECKING THE SWITCHES Fault code No 42 Sy...

Page 322: ...r 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 fuel injection system fuse and fuel injec tion system relay Brown Brown between fuel injection system relay and ECU Red Blue Red Blue 4 Malfunction or open circuit in the fuel injection system relay Execute the diagnostic mode Code No ...

Page 323: ...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 3 Coupler connections ECU coupler Check the coupler for any pins that may have pulled out Check that the coupler is securely locked If necessary repair the coupler or securely con nect it Fault code No 50 Symptom Faulty ECU memory When this malfunction is detected in the...

Page 324: ......

Page 325: ...M 8 29 GENERAL INFORMATION 8 31 PART REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS 8 31 TROUBLESHOOTING 8 35 SELF DIAGNOSIS FAULT CODE INDICATION 8 35 ELECTRICAL COMPONENTS 8 39 CHECKING THE SWITCHES 8 43 CHECKING THE BULBS AND BULB SOCKETS 8 46 CHECKING THE LEDS 8 47 CHECKING THE FUSES 8 48 CHECKING AND CHARGING THE BATTERY 8 49 CHECKING THE RELAYS 8 51 CHECKING THE TURN SIGNAL HAZARD RELAY ...

Page 326: ...R 8 58 CHECKING THE SPEED SENSOR 8 58 CHECKING THE THROTTLE POSITION SENSOR 8 59 CHECKING THE FUEL PUMP 8 59 CHECKING THE INTAKE AIR PRESSURE SENSOR 8 60 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 8 60 CHECKING THE RADIATOR FAN MOTOR 8 60 CHECKING THE STARTER MOTOR 8 61 ...

Page 327: ...8 1 IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM ...

Page 328: ...ion sensor 3 Neutral switch 4 Main switch 7 Battery 8 Main fuse 13 Starting circuit cut off relay 16 Ignition coil 17 Spark plug 23 ECU 27 Lean angle cut off switch 39 Sidestand switch 42 Engine stop switch 46 Clutch switch 67 Ignition fuse ...

Page 329: ...E IGNITION SPARK GAP on page 8 55 7 Check the crankshaft position sensor Refer to CHECKING THE CRANKSHAFT POSITION SENSOR on page 8 55 3 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 6 5 Check the spark plug cap Refer to CHECKING THE SPARK PLUG CAP on page 8 54 6 Check the ignition coil Refer to CHECKING THE IGNITION COIL on page 8 54 Replace the fuse s Clean the battery terminal...

Page 330: ...eck the clutch switch Refer to CHECKING THE SWITCHES on page 8 43 OK OK NG NG NG NG NG OK OK 13 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RELAYS on page 8 51 NG 14 Check the lean angle cut off switch Refer to CHECKING THE LEAN ANGLE CUT OFF SWITCH on page 8 56 OK NG 15 Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM on page 8 1 Replace the neutral s...

Page 331: ...8 5 ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM ...

Page 332: ...EM 3 Neutral switch 4 Main switch 7 Battery 8 Main fuse 9 Starter relay 10 Starter motor 12 Relay unit 13 Starting circuit cut off relay 39 Sidestand switch 41 Start switch 42 Engine stop switch 46 Clutch switch 67 Ignition fuse ...

Page 333: ...er is pulled to the handlebar the clutch switch circuit is closed and the sidestand is up the sidestand switch circuit is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these con ditions has been met In this instance the starting circuit cut off relay stays open so current cannot reach the starter motor When at least one of the above conditions ...

Page 334: ... UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Relay unit starting circuit cut off relay 7 Relay unit diode 8 Clutch switch 9 Sidestand switch 10 Neutral switch 11 Start switch 12 Starter relay 13 Starter motor ...

Page 335: ...fer to CHECKING THE RELAYS on page 8 51 7 Check the main switch Refer to CHECKING THE SWITCHES on page 8 43 3 Check the starter motor Refer to CHECKING THE STARTER MOTOR on page 8 61 5 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 53 6 Check the starter relay Refer to CHECKING THE RELAYS on page 8 51 Replace the fuse s Clean the battery terminals Recharge or replace t...

Page 336: ...h Refer to CHECKING THE SWITCHES on page 8 43 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 43 12 Check the start switch Refer to CHECKING THE SWITCHES on page 8 43 OK OK NG NG NG NG NG OK 13 Check the entire starting system wiring Refer to CIRCUIT DIAGRAM on page 8 5 Replace the sidestand switch Replace the clutch switch Replace the right handlebar switch Properly connect or...

Page 337: ...8 11 CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ...

Page 338: ...8 12 CHARGING SYSTEM 2 A C magneto 5 Rectifier regulator 7 Battery 8 Main fuse ...

Page 339: ... to CHECKING AND CHARGING THE BATTERY on page 8 49 4 Check the rectifier regulator 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 56 Replace the fuse s Clean the battery terminals Recharge or replace the battery Replace the rectifier regulator Replace the stator assembly OK OK OK OK NG NG NG NG 5 Check the entire charging system wiring Refer to CIRCUIT DIAGRAM on page 8 11 Pro...

Page 340: ...8 14 CHARGING SYSTEM ...

Page 341: ...8 15 LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM ...

Page 342: ...TING SYSTEM 4 Main switch 7 Battery 8 Main fuse 23 ECU 33 High beam indicator light 44 Headlight relay 49 Dimmer switch 50 Pass switch 57 Headlight 59 Tail brake light 64 Parking lighting fuse 65 Headlight fuse ...

Page 343: ...headlight high beam headlight low beam high beam indicator light taillight license plate light auxiliary light or meter light NOTE Before troubleshooting remove the following part s 1 Seat 2 Side panels left and right 3 Fuel tank 4 Headlight assembly 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 43 Replace the main switch immobilizer unit OK NG 5 Check the dimmer switch Refer to...

Page 344: ...8 15 Properly connect or repair the lighting system wiring NG OK 8 Check the high beam indicator light LED Refer to CHECKING THE LEDS on page 8 47 Replace the meter assembly NG 9 Check the meter light LED Refer to CHECKING THE LEDS on page 8 47 Replace the meter assembly OK NG OK This circuit is OK ...

Page 345: ...8 19 SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...

Page 346: ... light 37 Engine trouble warning light 38 Fuel pump 40 Front brake light switch 45 Turn signal hazard relay 47 Hazard switch 48 Turn signal switch 51 Horn switch 53 Rear turn signal light right 54 Front turn signal light right 55 Front turn signal light left 56 Rear turn signal light left 58 Horn 59 Tail brake light 61 Rear brake light switch 64 Parking lighting fuse 66 Signaling system fuse 67 Ig...

Page 347: ...OTING Any of the following fail to light turn signal light brake light or indicator light NOTE Before troubleshooting remove the following part s 1 Seat 2 Side panels left and right 3 Fuel tank 4 Headlight assembly 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 43 Replace the main switch immobilizer unit OK NG Check the condition of each of the signaling system s circuits Refer t...

Page 348: ...m wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signaling system wiring NG OK The circuit is OK OK OK 1 Check the turn signal light bulbs and sockets Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 46 Replace the turn signal light bulb socket or both NG 2 Check the turn signal switch Refer to CHECKING THE SWITCHES on page 8 43 Replace the left handlebar switch ...

Page 349: ...Replace the neutral switch NG 3 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 53 Replace the relay unit NG OK 2 Check the neutral indicator light LED Refer to CHECKING THE LEDS on page 8 47 Replace the meter assembly NG The neutral indicator light fails to come on OK 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or r...

Page 350: ... connect or repair the signaling system wiring NG The speedometer fails to operate OK The circuit is OK The circuit is OK 1 Check the coolant temperature warning light LED Refer to CHECKING THE LEDS on page 8 47 Replace the meter assembly NG OK 2 Check the coolant temperature sensor Refer to CHECKING THE COOLANT TEMPERATURE SENSOR on page 8 57 Replace the coolant temperature sensor NG The coolant ...

Page 351: ...8 25 COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM ...

Page 352: ...8 26 COOLING SYSTEM 4 Main switch 7 Battery 8 Main fuse 23 ECU 62 Radiator fan motor 63 Radiator fan motor relay 67 Ignition fuse 68 Radiator fan motor fuse ...

Page 353: ...E RELAYS on page 8 51 Replace the radiator fan motor relay NG EAS27570 TROUBLESHOOTING If the radiator fan motor fails to operate NOTE Before troubleshooting remove the following part s 1 Seat 2 Side panels left and right 3 Fuel tank 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 43 Replace the main switch immobilizer unit OK NG OK OK 6 Check the coolant temperature sensor Refer ...

Page 354: ...8 28 COOLING SYSTEM ...

Page 355: ...8 29 IMMOBILIZER SYSTEM ET5YU1002 IMMOBILIZER SYSTEM ET5YU1003 CIRCUIT DIAGRAM ...

Page 356: ...in switch 7 Battery 8 Main fuse 23 ECU 28 Multi function meter unit 35 Immobilizer system indicator light 67 Ignition fuse 69 Backup fuse immobilizer unit multi function meter unit 71 Anti theft alarm optional 72 Immobilizer unit ...

Page 357: ...key is lost regis tering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made or all keys are lost the entire immobilizer system must be replaced Therefore it is highly recommended to use either standard key for driving and to keep the code re registering key in a safe plac...

Page 358: ...ey registration When the immobilizer unit or ECU is replaced the code re registering key must be registered to the unit To register a code re registering key 1 Turn the main switch to ON with the code re registering key NOTE Check that the immobilizer system indicator light comes on for one second then goes off When the immobilizer system indicator light goes off the code re registering key has be...

Page 359: ...e key within 5 seconds 3 Insert the first standard key to be registered into the main switch then turn the key to ON within 5 seconds to activate the key registration mode NOTE The existing standard key code is erased from the memory when the key registration mode is acti vated When the key registration mode is activated the immobilizer system indicator light flashes rapidly 4 While the indicator ...

Page 360: ...If a standard key has been lost it is possible to disable its use by re registering the remain ing standard key Standard key registration erases the stored standard key code from the memory thus disabling the lost standard key To re register refer to Standard key registra tion Standard key code voiding method a Main switch ON b Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registe...

Page 361: ...E Before troubleshooting remove the following part s 1 Seat 2 Side panels left and right 3 Fuel tank 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 43 Replace the main switch immobilizer unit OK NG 4 Check the immobilizer system indicator light LED Refer to CHECKING THE LEDS on page 8 47 Replace the meter assembly NG OK 5 Check the entire immobilizer system wiring Refer to CIRCUI...

Page 362: ...R Codes cannot be Noise interference or 1 Check the wire UNIT transmitted between disconnected harness and the ECU and the lead cable connector immobilizer unit 1 Interference due to 2 Replace the radio wave noise main switch 2 Disconnected immobilizer unit communication 3 Replace the harness ECU 3 Immobilizer unit malfunction 4 ECU malfunction 54 IMMOBILIZER Codes transmitted Noise interference o...

Page 363: ...ce 1 Check the wire is received or disconnected harness and lead cable connector 1 Obstruction due to 2 Replace the radio wave noise main switch 2 Error by disconnection immobilizer unit of the communication 3 Replace the harness ECU Immobilizer system indicator light fault code indication Units of 10 Cycles of on for 1 second and off for 1 5 seconds Units of 1 Cycles of on for 0 5 second and off ...

Page 364: ...8 38 IMMOBILIZER SYSTEM ...

Page 365: ...8 39 ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS ...

Page 366: ...Fuel pump 5 Starter relay 6 Main fuse 7 ECU Electronic Control Unit 8 Turn signal hazard relay 9 Headlight relay 10 Radiator fan motor relay 11 Relay unit 12 Lean angle cut off switch 13 Battery 14 Sidestand switch 15 Stator coil 16 Crankshaft position sensor 17 O2 sensor 18 Rectifier regulator 19 Horn ...

Page 367: ...8 41 ELECTRICAL COMPONENTS ...

Page 368: ... handlebar switch 5 Front brake light switch 6 Left handlebar switch 7 Clutch switch 8 Spark plug 9 Plug cap 10 Ignition coil 11 Intake air pressure sensor 12 Fuse box 13 Intake air temperature sensor 14 Rear brake light switch 15 Speed sensor 16 Neutral switch 17 Starter motor 18 Radiator fan motor ...

Page 369: ...8 43 ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES ...

Page 370: ...tch 2 Clutch switch 3 Horn switch 4 Pass switch 5 Dimmer switch 6 Turn signal switch 7 Hazard switch 8 Sidestand switch 9 Front brake light switch 10 Engine stop switch 11 Start switch 12 Neutral switch 13 Rear brake light switch 14 Fuses ...

Page 371: ...t the pocket tester to 0 and to the Ω x 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between...

Page 372: ... the condition of the bulbs The following procedure applies to all of the bulbs 1 Remove Bulb WARNING Since headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down CAUTION Be sure to hold the socket firmly when re moving the bulb Never pull the lead oth erwise it may be pulled out of the terminal in the coupler Avoid touching the glass pa...

Page 373: ...sconnect the meter assembly coupler meter assembly end b Connect two jumper leads 1 from the bat tery terminals to the respective coupler ter minal as shown Pocket tester 90890 03112 Positive battery Turn signal terminal chocolate indicator light left Negative battery terminal black white Positive battery Turn signal terminal green indicator light right Negative battery terminal black white Positi...

Page 374: ... CHECKING THE FUSES The following procedure applies to all of the fuses EC5YU1013 CAUTION To avoid a short circuit always turn the main switch to OFF when checking or replacing a fuse The main fuse and the fuse box which contains the fuses for the individual circuits are located under the seat 1 Remove Seat 2 Check Fuse a Connect the pocket tester to the fuse and check the continuity NOTE Set the ...

Page 375: ...T 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 ECA13660 CAUTION This is a sealed battery Never remove the sealing caps because the balance be tween cells will not be maintained and bat tery performance...

Page 376: ...rger until the battery charger leads are connected to the bat tery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may ...

Page 377: ...rger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery NOTE If the current is lower than the standard charg ing current written on the battery this type of battery charger cannot charge the MF battery A variable voltage charger is recommended d Charge the battery until the battery s charg ing voltage is ...

Page 378: ... B R R R W L W 3 4 2 1 Result Continuity between 3 and 4 Relay unit starting circuit cut off relay 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 Headlight relay 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 Fuel inje...

Page 379: ...d relay output voltage Out of specification Replace Turn signal hazard relay output voltage DC 12 V a Connect the pocket tester DC 20 V to the turn signal hazard relay terminal as shown Pocket tester 90890 03112 Positive tester probe brown white 1 Negative tester probe ground EAS28050 CHECKING THE RELAY UNIT DIODE 1 Check Relay unit diode Out of specification Replace Pocket tester 90890 03112 NOTE...

Page 380: ... 20 C 68 F a Disconnect the ignition coil connectors from the ignition coil terminals b Connect the pocket tester Ω x 1 to the igni tion coil as shown Pocket tester 90890 03112 Positive tester probe red black 1 Negative tester probe orange 2 Continuity Positive tester probe sky blue 1 Negative tester probe black yellow 2 No continuity Positive tester probe black yellow 2 Negative tester probe sky ...

Page 381: ...spark plug lead 2 Crankshaft position sensor resistance 192 288 Ω at 20 C 68 F blue yellow green white a Disconnect the spark plug cap 2 from the spark plug b Connect the ignition checker 1 as shown Ignition checker 90890 06754 Minimum ignition spark gap 6 0 mm 0 24 in NOTE If the ignition spark gap is within specification the ignition system circuit is operating normally 2 Spark plug cap c Turn t...

Page 382: ...itch to 65 d Measure the lean angle cut off switch output voltage Stator coil resistance 0 224 0 336 Ω at 20 C 38 F EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the stator assembly a Connect the pocket tester Ω x 1 to the sta tor coil coupler as shown Pocket tester 90890 03112 Positive tester pr...

Page 383: ... 12 V to the horn termi nals 3 Check Horn sound Faulty sound Replace the horn c Set the main switch to ON d Push the horn switch e Measure the voltage DC 12 V of pink at the horn terminal EAS28210 CHECKING THE COOLANT TEMPERATURE SENSOR 1 Remove Coolant temperature sensor from the engine WARNING Handle the coolant temperature sensor with special care Never subject the coolant temperature sensor to...

Page 384: ...stance 1 35 1 65 kΩ at 25 C 77 F b Measure the fuel sender resistance Output voltage reading cycle 0 6 V to 4 8 V to 0 6 V to 4 8 V EAS28240 CHECKING THE SPEED SENSOR 1 Check Speed sensor output voltage Out of specification Replace a Connect the pocket tester Ω x 1k to the fu el sender terminal as shown Pocket tester 90890 03112 Positive tester probe green white 1 Negative tester probe black 2 a C...

Page 385: ...CKING THE FUEL PUMP EWA13850 WARNING Gasoline is extremely flammable and under certain circumstances there can be a dan ger of an explosion or fire Be extremely careful and note the following points Stop the engine before refueling Do not smoke and keep away from open flames sparks or any other source of fire If you do accidentally spill gasoline wipe it up immediately with dry rags If gasoline to...

Page 386: ...sensor is dropped replace it 2 Check Intake air temperature sensor resistance Out of specification Replace Intake air temperature sensor resistance 2 21 2 69 Ω at 20 C 68 F a Connect the pocket tester Ω x 100 to the intake air temperature sensor terminal as shown Pocket tester 90890 03112 Positive tester probe brown white 1 Negative tester probe black blue 2 b Measure the intake air temperature se...

Page 387: ...rter 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 otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure nothing flammable is in the vicinity b Check the radiator fan motor movement ...

Page 388: ......

Page 389: ...S 9 1 INCORRECT ENGINE IDLING SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 3 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 9 ...

Page 390: ......

Page 391: ... 3 Throttle body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Faulty spark plug cap 4 Ignition coil Cracked or broken ignition c...

Page 392: ...rum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groo...

Page 393: ...brake system Leaking brake fluid Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS28660 FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high Loose damper rod assembly bolt ...

Page 394: ...nded circuit Faulty main switch Headlight bulb life expired Tail brake light does not come on Too many electrical accessories Incorrect connection Burnt out tail brake light led s Wrong tail brake light Faulty battery Tail brake bulb burnt out Wrong tail brake light led Faulty battery Tail brake light led life expired Turn signal does not come on Faulty turn signal switch Faulty turn signal hazard...

Page 395: ...rature warning light 35 Immobilizer system indicator light 36 Multi function meter light 37 Engine trouble warning light 38 Fuel pump 39 Sidestand switch 40 Front brake light switch 41 Start switch 42 Engine stop switch 43 Right handlebar switch 44 Headlight relay 45 Turn signal hazard relay 46 Clutch switch 47 Hazard switch 48 Turn signal switch 49 Dimmer switch 50 Pass switch 51 Horn switch 52 L...

Page 396: ...COLOR CODE ...

Page 397: ......

Page 398: ...YAMAHA MOTOR ITALIA S P A ...

Page 399: ...XT660Z 2008 WIRING DIAGRAM ...

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