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Yamaha XVS1300A 2007, Service Manual

The Yamaha XVS1300A 2007 Service Manual is an essential resource for motorcycle enthusiasts. This comprehensive manual provides detailed instructions and diagrams, allowing riders to perform maintenance and repairs on their XVS1300A. Download this invaluable manual for free from manualshive.com, empowering you to confidently service your bike.

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2007

SERVICE MANUAL

XVS1300A(W)

11C-28197-E0

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

email: [email protected]

Summary of Contents for XVS1300A 2007

Page 1: ...2007 SERVICE MANUAL XVS1300A W 11C 28197 E0 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 2: ...t edition September 2006 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 3: ...cations or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice EAS20080 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS I...

Page 4: ...ion title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a disas sembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction chart 6 accompanies the exploded diagram providing the orde...

Page 5: ...unted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening torque 6 Wear limit clearance 7 Engine speed 8 Electrical data 9 Engine oil 10 Gear oil 11 Molybdenum disulfide oil 12 Wheel bearing grease 13 Lithium soap based grease 14 Molybdenum disulfide grease 15 Apply locking agent LOCTITE 16 Replace the part with a new one Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcy...

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

Page 7: ...PECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

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

Page 9: ... 4 IMPORTANT INFORMATION 1 6 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 6 REPLACEMENT PARTS 1 6 GASKETS OIL SEALS AND O RINGS 1 6 LOCK WASHERS PLATES AND COTTER PINS 1 6 BEARINGS AND OIL SEALS 1 7 CIRCLIPS 1 7 CHECKING THE CONNECTIONS 1 8 SPECIAL TOOLS 1 9 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 10: ...tion number 1 is stamped into the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts 1 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 11: ...uel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions ...

Page 12: ...tle position sensor crankshaft position sensor intake air pressure sensor air temperature sensor coolant temperature sensor lean angle sensor speed sensor and O2 sensor enable the ECU to deter mine the injection duration The injection timing is determined through the signals from the crankshaft position sensor As a result the volume of fuel that is required by the engine can be supplied at all tim...

Page 13: ...to zero in order to test the electrical circuit Odometer tripmeter and fuel reserve trip meter modes Push the side of the SELECT switch to switch the display between the odometer mode ODO the tripmeter modes TRIP 1 and TRIP 2 and the clock mode in the following order ODO TRIP 1 TRIP 2 Clock ODO NOTE Push the side of the SELECT switch to switch the display in the reverse order If the fuel level war...

Page 14: ... model is equipped with a self diagnosis de vice for various electrical circuits If any of those circuits are defective the engine trouble warning light will come on and then the odometer tripmeter clock display will indicate a two digit error code e g 12 13 14 If the odometer tripmeter clock display indicates any error codes note the code number and then check the vehicle Refer to FUEL INJEC TION...

Page 15: ...rom any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals and O rings All gasket surfac es oil seal lips and O rings...

Page 16: ...e CAUTION ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfac es EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives Manuals by ...

Page 17: ...properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector NOTE Make sure all connections are tight 5 Check Continuity with the pocket tester NOTE If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at most part stores Pocket tester 90890 03112 Analog pocket ...

Page 18: ... part numbers starting with YM YU or ACC For others use part numbers starting with 90890 Tool name Tool No Illustration Reference pages Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 8 5 63 8 85 8 86 8 87 8 91 8 92 8 93 8 94 8 95 8 96 8 97 8 98 8 99 8 100 8 101 8 102 Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 3 4 3 5 Tappet adjusting tool 90890 04154 YM 04154 3 5 Vacuum g...

Page 19: ...890 01460 4 51 4 53 T handle 90890 01326 T handle 3 8 drive 60 cm long YM 01326 4 51 4 53 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 53 4 54 Rotor holding tool 90890 01235 Universal magneto rotor holder YU 01235 5 14 5 20 5 21 Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 5 15 Tool name Tool No Illustration Reference pages 66 8 Manuals by Motomat...

Page 20: ...5 32 Valve guide remover ø6 90890 04064 Valve guide remover 6 0 mm YM 04064 A 5 28 Valve guide installer ø6 90890 04065 Valve guide installer 6 0 mm YM 04065 A 5 28 Valve guide reamer ø6 90890 04066 Valve guide reamer 6 0 mm YM 04066 5 28 Tool name Tool No Illustration Reference pages YU 01083 3 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motom...

Page 21: ... 5 53 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 42 Yamaha bond No 1215 90890 85505 Three Bond No 1215 5 44 5 70 6 10 Universal clutch holder 90890 04086 YM 91042 5 50 5 54 Tool name Tool No Illustration Reference pages YU 01304 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 22: ...90890 04078 Water pump seal installer YM 33221 A 6 10 Middle driven shaft bearing driver 90890 04058 Bearing driver 40 mm YM 04058 6 10 Pressure gauge 90890 03153 YU 03153 7 9 Fuel pressure adapter 90890 03176 YM 03176 7 9 Tool name Tool No Illustration Reference pages YU 24460 01 YU 33984 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix ...

Page 23: ...imeter with tachometer YU A1927 7 9 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 8 95 Tool name Tool No Illustration Reference pages Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 24: ...SPECIAL TOOLS 1 15 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 25: ... ENGINE TIGHTENING TORQUES 2 16 CHASSIS TIGHTENING TORQUES 2 20 LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ENGINE 2 24 CHASSIS 2 25 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 ENGINE OIL LUBRICATION CHART 2 27 LUBRICATION DIAGRAMS 2 29 COOLING SYSTEM DIAGRAMS 2 37 CABLE ROUTING 2 43 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 26: ...l width 980 mm 38 6 in Overall height 1115 mm 43 9 in Seat height 715 mm 28 1 in Wheelbase 1690 mm 66 5 in Ground clearance 145 mm 5 71 in Minimum turning radius 3500 mm 137 8 in Weight With oil and fuel 303 0 kg 668 lb Maximum load 210 kg 463 lb Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 27: ... Imp qt Without oil filter cartridge replacement 3 20 L 3 38 US qt 2 82 Imp qt With oil filter cartridge replacement 3 40 L 3 59 US qt 2 99 Imp qt Oil filter Oil filter type Cartridge paper Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance Less than 0 12 mm 0 0047 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump housing clearance 0 09 0 19 mm 0 0035 0 0075 in Limit 0 26 mm...

Page 28: ... limit 0 15 mm 0 006 in Spark plug s Manufacturer model NGK LMAR7A 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Cylinder head Volume 44 20 46 40 cm 2 70 2 83 cu in Warpage limit 0 03 mm 0 0012 in Camshaft Drive system Chain drive left and right Camshaft journal diameter 20 959 20 980 mm 0 8252 0 8260 in Camshaft lobe dimensions Intake A 42 988 43 088 mm 1 6924 1 6964 in Limit 42 888 mm 1 6885 in Int...

Page 29: ...394 0 0472 in Valve seat width C exhaust 1 00 1 20 mm 0 0394 0 0472 in Valve margin thickness D intake 1 15 1 45 mm 0 0453 0 0571 in Valve margin thickness D exhaust 1 15 1 45 mm 0 0453 0 0571 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 ...

Page 30: ...rate K1 exhaust 24 75 N mm 141 32 lb in 2 52 kgf mm Spring rate K2 exhaust 34 93 N mm 199 45 lb in 3 56 kgf mm Installed compression spring force intake 171 197 N 38 44 44 29 lbf 17 44 20 09 kgf Installed compression spring force exhaust 171 197 N 38 44 44 29 lbf 17 44 20 09 kgf Spring tilt intake 2 5 1 9 mm Spring tilt exhaust 2 5 1 9 mm Winding direction intake Clockwise Winding direction exhaus...

Page 31: ...imit 0 60 mm 0 0236 in Ring side clearance 0 030 0 080 mm 0 0012 0 0032 in Limit 0 130 mm 0 0051 in 2nd ring Ring type Taper Dimensions B T 1 20 4 00 mm 0 05 0 16 in End gap installed 0 45 0 60 mm 0 0177 0 0236 in Limit 0 95 mm 0 0374 in Ring side clearance 0 030 0 070 mm 0 0012 0 0028 in Limit 0 130 mm 0 0051 in Oil ring Dimensions B T 2 50 3 40 mm 0 10 0 13 in End gap installed 0 20 0 70 mm 0 00...

Page 32: ... thickness 2 92 3 08 mm 0 115 0 121 in Wear limit 2 82 mm 0 1110 in Plate quantity 7 pcs Clutch plate thickness 1 90 2 10 mm 0 075 0 083 in Plate quantity 8 pcs Warpage limit 0 20 mm 0 0079 in Clutch spring height 6 70 mm 0 26 in Minimum height 6 37 mm 0 25 in Spring quantity 1 pc Clutch housing thrust clearance 0 050 0 450 mm 0 0020 0 0177 in Clutch housing radial clearance 0 010 0 046 mm 0 0004 ...

Page 33: ...facturer MIKUNI ID mark 3D81 00 Throttle valve size 40 Fuel pressure 324 kPa 46 1 psi 3 24 kg cm Throttle position sensor Resistance 4 0 6 0 kΩ Output voltage at idle 0 63 0 73 V Fuel injection sensor Crankshaft position sensor resistance 248 372 Ω Intake air pressure sensor output voltage 3 75 4 25 V Coolant temperature sensor resistance 290 354 Ω at 80 C 176 F Idling condition Engine idling spee...

Page 34: ... model BRIDGESTONE EXEDRA G721 Wear limit front 1 6 mm 0 06 in Rear tire Type Tubeless Size 170 70B 16M C 75H Manufacturer model DUNLOP K555 Manufacturer model BRIDGESTONE EXEDRA G722 G Wear limit rear 1 6 mm 0 06 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 36 psi 2 50 kgf cm Rear 280 kPa 41 psi 2 80 kgf cm Loading condition 90 210 kg 198 463 lb Fro...

Page 35: ...3 in Recommended fluid DOT 4 Steering Steering bearing type Angular bearing Lock to lock angle left 35 0 Lock to lock angle right 35 0 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 135 0 mm 5 31 in Fork spring free length 345 5 mm 13 60 in Limit 339 4 mm 13 36 in Collar length 183 0 mm 7 20 in Installed length 339 4 mm 13 36 in Spring rat...

Page 36: ...d 4 Maximum 9 Swingarm Swingarm end free play limit radial 1 0 mm 0 04 in Swingarm end free play limit axial 1 0 mm 0 04 in Drive belt Model manufacturer UBD 0734 GATES CORPORATION Drive belt slack on the sidestand 5 0 7 0 mm 0 20 0 28 in Drive belt slack on a suitable stand 4 0 6 0 mm 0 16 0 24 in Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info mo...

Page 37: ...s than 65 0 4 1 4 V More than 65 3 7 4 4 V AC magneto Model manufacturer F3D8 MORIC Standard output 14 0 V 32 9 A 5000 r min Standard output 14 0 V 460 W 5000 r min Stator coil resistance 0 112 0 168 Ω Rectifier regulator Regulator type Semiconductor short circuit Model manufacturer FH012AA SHINDENGEN Regulated voltage DC 14 2 14 8 V Rectifier capacity DC 50 0 A Withstand voltage 40 0 V Battery Mo...

Page 38: ...ngth 12 5 mm 0 49 in Limit 5 00 mm 0 20 in Brush spring force 7 65 10 01 N 27 54 36 03 oz 780 1021 gf Commutator diameter 28 0 mm 1 10 in Limit 27 0 mm 1 06 in Mica undercut depth 0 70 mm 0 03 in Starter relay Model manufacturer 2768115 A JIDECO Amperage 180 0 A Coil resistance 4 18 4 62 Ω Horn Horn type Plane Quantity 1 pc Model manufacturer HF 12 NIKKO Maximum amperage 3 0 A Coil resistance 1 01...

Page 39: ... U3 OMRON Coil resistance 162 198 Ω Fan motor relay Model manufacturer ACM33211 M05 MATSUSHITA Coil resistance 86 40 105 60 Ω Coolant temperature sensor Model manufacturer K003T20191 MITSUBISHI Fuses Main fuse 50 0 A Headlight fuse 20 0 A Signaling system fuse 10 0 A Ignition fuse 15 0 A Radiator fan fuse 20 0 A Parking lighting fuse 10 0 A Fuel injection system fuse 10 0 A Backup fuse 10 0 A Rese...

Page 40: ... crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 m...

Page 41: ...plug M10 2 13 Nm 1 3 m kg 9 4 ft lb Tappet cover bolt M6 8 10 Nm 1 0 m kg 7 2 ft lb Timing chain tensioner housing bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Timing chain tensioner bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Connecting rod bolt 1st M8 4 15 Nm 1 5 m kg 11 ft lb See NOTE Connecting rod bolt final M8 4 Specified angle 125 135 See NOTE Generator rotor bolt M12 1 90 Nm 9 0 m kg 65 ft lb Right balancer ...

Page 42: ... exhaust pipe bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Exhaust pipe band bolt M8 2 12 Nm 1 2 m kg 8 7 ft lb Muffler band bolt M8 1 12 Nm 1 2 m kg 8 7 ft lb O2 sensor M18 1 44 Nm 4 4 m kg 32 ft lb Muffler bracket and frame bolt M10 3 53 Nm 5 3 m kg 38 ft lb Muffler bracket and muffler bolt M10 2 35 Nm 3 5 m kg 25 ft lb Crankcase stud bolt M12 6 15 Nm 1 5 m kg 11 ft lb Left crankcase bolt M6 19 10 Nm 1 0 m...

Page 43: ... bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Starter motor lead nut M6 1 10 Nm 1 0 m kg 7 2 ft lb Radiator filler pipe bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Front cylinder thermostat inlet pipe 1 bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Front cylinder thermostat inlet pipe 2 bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Rear cylinder thermostat inlet pipe 1 bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Rear cylinder thermostat inlet pip...

Page 44: ... exhaust pipe cover screw clamps always replace them with new ones if they are loosened Camshaft assembly tightening sequence Cylinder head tightening sequence B A 1 2 3 4 3 2 1 4 A Front cylinder camshaft assembly B Rear cylinder camshaft assembly 6 5 1 3 2 4 B 3 2 4 6 5 1 A A Front cylinder head B Rear cylinder head Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Code...

Page 45: ...ck absorber assembly lower nut M10 1 48 Nm 4 8 m kg 35 ft lb Rear shock absorber assembly upper nut M10 1 48 Nm 4 8 m kg 35 ft lb Pivot shaft nut M16 1 85 Nm 8 5 m kg 61 ft lb Relay arm and frame nut M10 1 48 Nm 4 8 m kg 35 ft lb Connecting arm and relay arm nut M12 1 59 Nm 5 9 m kg 43 ft lb Connecting arm and swingarm nut M12 1 59 Nm 5 9 m kg 43 ft lb Drive belt upper guard bolt M6 3 7 Nm 0 7 m k...

Page 46: ...2 3 m kg 17 ft lb Front brake hose guide bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Headlight bracket bolt M8 2 23 Nm 2 3 m kg 17 ft lb Headlight body bolt M6 4 7 Nm 0 7 m kg 5 1 ft lb Front turn signal light bracket bolt M8 2 23 Nm 2 3 m kg 17 ft lb Front turn signal light nut M10 2 11 Nm 1 1 m kg 8 0 ft lb Air temperature sensor screw M5 1 7 Nm 0 7 m kg 5 1 ft lb Meter assembly bolt M8 2 23 Nm 2 3 m kg 1...

Page 47: ... lb Passenger seat bolt M8 2 16 Nm 1 6 m kg 11 ft lb License plate bracket and rear fender bolt M6 2 11 Nm 1 1 m kg 8 0 ft lb Rear turn signal light nut M10 2 11 Nm 1 1 m kg 8 0 ft lb Left side cover bolt M6 1 4 Nm 0 4 m kg 2 9 ft lb Relay cover bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Sub fuel tank cover bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Coolant reservoir cover bolt M6 4 7 Nm 0 7 m kg 5 1 ft lb Side pan...

Page 48: ... tube bolt M8 1 30 Nm 3 0 m kg 22 ft lb Coolant reservoir cover bracket bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Locknut rear brake master cylin der M8 1 16 Nm 1 6 m kg 11 ft lb Brake fluid reservoir bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Rectifier regulator cover bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Rectifier regulator bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Drive pulley nut M22 1 140 Nm 14 0 m kg 100 ft lb Stake Dri...

Page 49: ...head bolts Starter clutch idle gear shaft Starter clutch idle gear Starter clutch gear inner and outer surfaces Torque limiter Primary driven gear inner surface Clutch push rod Oil water pump drive sprocket inner surface Clutch thrust washers Clutch boss nut and washer Transmission gears wheel and pinion and collar Shift forks and shift fork guide bars Shift drum Shift shaft and shift shaft oil se...

Page 50: ...urface and throttle cables Brake lever pivoting point and metal to metal moving parts Brake master cylinder push rod contact surface Clutch lever pivoting point and metal to metal moving parts Swingarm pivot bearings inner surface Swingarm pivot oil seals lip Rear shock absorber assembly upper bolt Connecting arm and swingarm spacer outer surface Relay arm bearings inner surface Relay arm oil seal...

Page 51: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 26 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 52: ...7 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 16 13 14 15 12 10 9 8 7 5 6 4 3 2 1 11 13 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 53: ...e 8 Main gallery 9 Crankcase 10 Front cylinder piston oil nozzle 11 Rear cylinder piston oil nozzle 12 Rear cylinder timing chain tensioner 13 Valve stem end intake side 14 Rear cylinder camshaft 15 Front cylinder timing chain tensioner 16 Front cylinder camshaft Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 54: ...UBRICATION SYSTEM CHART AND DIAGRAMS 2 29 EAS20410 LUBRICATION DIAGRAMS A A 1 2 2 3 A A Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 55: ...SYSTEM CHART AND DIAGRAMS 2 30 1 Oil filter cartridge 2 Oil delivery pipe 3 3 Relief valve assembly Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 56: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 1 2 3 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 57: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Camshaft 2 Oil nozzle 3 Crankshaft Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 58: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 1 2 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 59: ...UBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Oil delivery pipe 1 2 Timing chain tensioner Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 60: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 1 2 3 4 5 6 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 61: ...RAMS 2 36 1 Drive axle 2 Oil delivery pipe 2 3 Main axle 4 Oil delivery pipe 3 5 Oil water pump assembly 6 Oil strainer Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 62: ...COOLING SYSTEM DIAGRAMS 2 37 EAS20420 COOLING SYSTEM DIAGRAMS A A A A 2 1 4 3 5 6 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 63: ...let pipe 1 2 Front cylinder thermostat inlet pipe 1 3 Coolant delivery cover 2 4 Coolant delivery cover 1 5 Drain cock 6 Oil water pump assembly Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 64: ...COOLING SYSTEM DIAGRAMS 2 39 A B B A 4 3 3 1 2 2 A A B B Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 65: ...RAMS 2 40 1 Radiator outlet hose 2 Radiator outlet pipe 3 Coolant delivery pipe 4 Oil water pump assembly Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 66: ...ING SYSTEM DIAGRAMS 2 41 10 13 4 7 3 1 10 9 6 B C A 12 11 C B A 1 8 9 10 10 12 3 2 4 5 6 7 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 67: ...t inlet hose 5 Coolant reservoir hose 6 Rear cylinder thermostat inlet pipe 2 7 Thermostat assembly 8 Thermostat cover inlet hose 9 Thermostat cover inlet pipe 10 Radiator inlet hose 11 Radiator 12 Radiator outlet hose 13 Front cylinder thermostat inlet pipe 2 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 68: ... LOWER D D A A B B E C E C A B B A D D A E B D F G H C 1 2 2 3 3 6 4 5 5 5 6 6 6 7 7 7 6 5 7 8 8 9 10 11 12 13 14 15 16 17 18 19 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 69: ...ble B Pass the throttle cables and right handlebar switch lead through the guide making sure to route the lead to the outside of the cables C Fasten the starter motor lead securely to the engine mounting boss with a plastic locking tie making sure that the tie does not contact the engine bracket on the frame D Pass the front brake hose through the guide E Fit the rubber strap end without the tab o...

Page 70: ... F F D D G G E E B C A F F G G E E D D B C A B C D E F G I 1 1 1 2 2 2 2 2 3 3 3 4 5 6 7 9 8 9 8 12 11 10 H Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 71: ...ight couplers and then wrap the protective covering around the lead and couplers C Fasten the wire harness front turn signal light leads meter assembly lead and air temperature sensor lead with the plastic band making sure to align the white tape on the wire harness front turn signal light leads and meter assembly lead with the band D Route the main switch lead behind the wire harness and meter as...

Page 72: ...2 4 4 4 2 2 2 11 12 A B C D E F G H J I K 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 A 20 20 23 24 L L M N O P Q R S U T V W X Y 1 2 4 20 21 10 22 25 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 73: ...e frame with the plastic locking tie making sure to face the end of the tie inward J Pass a plastic locking tie through the space between the frame and the frame support and then fasten the rear brake light switch lead and horn lead to the frame with the tie making sure to face the end of the tie inward K Fasten the rear brake light switch lead and horn lead with the holder Face the fastener of th...

Page 74: ... ROUTING 2 49 C D D C C A A F E B A C B D E F F G 1 2 3 4 4 4 5 6 6 6 6 7 8 F A A D D C B E Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 75: ... rear brake caliper making sure that the brake pipe touches the projection on the caliper C Face the ends of the hose clamp inward D Face the end of the hose clamp upward as shown in the illustration E Install the brake fluid reservoir hose onto the rear brake master cylinder making sure that the brake pipe touches the projection on the rear brake master cylinder bracket F Insert the projection on...

Page 76: ... G F F 1 26 26 21 22 27 27 A 1 2 3 S S T 2 2 13 22 22 22 23 23 24 24 25 D E F 4 5 6 7 8 9 10 11 12 13 15 14 16 17 B C G H I J K L M N O P Q R U U 18 19 20 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 77: ...itch lead and sidestand switch lead may be routed in any order in the area shown in the illustration K Fasten the starter motor lead at the positioning tape to the engine mounting boss with a plastic locking tie Position the buckle of the plastic locking tie in front of the boss with the end facing upward and then cut off the excess end of the tie to 15 mm 0 59 in or less L Fasten the starter moto...

Page 78: ...A 19 17 20 F F C E E C D D A B G H D E F I I J K L N M O P Q R S T U V 1 2 2 3 4 5 1 2 3 4 5 6 7 8 9 10 11 11 12 12 13 14 15 16 18 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 79: ...the projection on the wire harness holder completely into the hole in the sub fuel tank bracket L Fasten the speed sensor lead crankshaft position sensor stator assembly lead ground lead neutral switch lead starter motor lead and rectifier regulator lead with a plastic locking tie making sure to position the tie 10 mm 0 39 in or less to the front or rear of the front edge of the frame Face the end...

Page 80: ...6 7 8 9 9 10 11 14 13 12 13 15 14 16 16 11 17 17 18 18 19 21 20 22 23 24 25 26 27 29 29 29 28 34 35 30 31 32 33 B C D E F G H I J K L M N O P Q R S T U Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 81: ...area shown in the illustration F To fuel sender G Insert the projections on the wire harness holders completely into the holes in the frame H Route the fuel sender lead under the air vent hose I Fasten the starter relay lead neutral switch lead and speed sensor lead with a plastic locking tie making sure to position the tie to the inside of the starter relay Face the end of the plastic locking tie...

Page 82: ...CABLE ROUTING 2 57 3D8 3D8 A B B A A B C D 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 83: ...le position sensor 15 Crankcase breather hose 16 ISC idle speed control unit A Install the front cylinder intake air pressure sensor hose with its yellow paint mark facing outward B Install the rear cylinder intake air pressure sensor hose with its white paint mark facing outward C Route the front cylinder intake air pressure sensor hose and rear cylinder intake air pressure sensor hose over the r...

Page 84: ...CABLE ROUTING 2 59 A A A B B C D E F G H 1 2 3 4 5 6 7 8 9 10 11 12 13 14 B Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 85: ...r 14 Front cylinder intake air pressure sensor A Face the ends of the hose clamp inward B Face the ends of the hose clamp outward C Fasten the sub wire harness at the white tape with a plastic locking tie D Face the ends of the hose clamp rearward E Face the ends of the hose clamp forward F Install the front cylinder intake air pressure sensor hose with its white paint mark facing outward G Instal...

Page 86: ...D E E C B A 1 2 1 3 4 5 6 7 7 9 9 8 8 1 3 10 10 11 14 14 15 17 16 12 13 A K B C D 4 9 E F G H 9 7 I 18 D D L J E E Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 87: ...all the air vent hose to the fuel tank with its white paint mark facing downward D Face the crimped section of the hose clamp downward E Install the air vent hose with its paint mark facing upward F Face the ends of the hose clamp upward G Install the fuel cock hose with its yellow paint mark facing upward H Face the crimped section of the hose clamp upward I Face the crimped section of the hose c...

Page 88: ...CABLE ROUTING 2 63 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 89: ...16 CHANGING THE COOLANT 3 16 CHASSIS 3 19 ADJUSTING THE FRONT BRAKE LEVER FREE PLAY 3 19 ADJUSTING THE REAR DISC BRAKE 3 19 CHECKING THE BRAKE FLUID LEVEL 3 20 CHECKING THE FRONT BRAKE PADS 3 20 CHECKING THE REAR BRAKE PADS 3 20 CHECKING THE FRONT BRAKE HOSES 3 21 CHECKING THE REAR BRAKE HOSES 3 21 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 21 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 21 ADJUSTING THE SH...

Page 90: ...ND CHARGING THE BATTERY 3 30 CHECKING THE FUSES 3 30 REPLACING THE HEADLIGHT BULB 3 30 ADJUSTING THE HEADLIGHT BEAM 3 31 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 91: ...Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 92: ... Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 7 Rear brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 8 Brake hoses Check for cracks or damage Replace Every 4 years 9 Wheels Check runout and for damage 10 Tires Check tread depth and for damage Replace if necessary Check air press...

Page 93: ... Engine oil Change Check oil level and vehicle for oil leakage 23 Engine oil filter car tridge Replace 24 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years 25 Front and rear brake switches Check operation 26 Moving parts and ca bles Lubricate 27 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubr...

Page 94: ... 2 Remove Throttle body Intake manifold assembly Refer to THROTTLE BODIES on page 7 6 3 Drain Coolant Refer to CHANGING THE COOLANT on page 3 16 4 Remove Front cylinder thermostat inlet hose Rear cylinder thermostat inlet hose Refer to THERMOSTAT on page 6 4 5 Disconnect Spark plug caps Refer to ENGINE REMOVAL on page 5 1 6 Remove Spark plugs Refer to CAMSHAFTS on page 5 11 7 Remove Damper cover 1...

Page 95: ...ompression stroke align the TDC mark c on the generator rotor with the slot d in the generator cover NOTE When the piston is at TDC on the compression stroke there should be clearance between the valve stem tips and their respective rocker arm adjusting screws If there is no clearance rotate the crankshaft counterclockwise one turn c Measure the valve clearance with a thickness gauge 12 Adjust Val...

Page 96: ...ce and the engine idling speed should be properly adjusted and the ignition tim ing should be checked 1 Stand the vehicle on a level surface NOTE Place the vehicle on a suitable stand 2 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 3 Disconnect Front cylinder intake air pressure sensor hose 1 Rear cylinder intake air pressure sensor hose 2 Thicknes...

Page 97: ...on first and then syn chronize the throttle bodies NOTE After each step rev the engine two or three times each time for less than a second and check the synchronization again If the air screw was removed turn the screw in fully and then turn it out 1 1 4 turns Then syn chronize the throttle bodies CAUTION ECA14900 Do not use the throttle valve adjusting screws to adjust the throttle body synchroni...

Page 98: ...ANK on page 7 1 3 Adjust Throttle cable free play Throttle body side a Loosen the locknut 1 on the accelerator ca ble b Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained c Tighten the locknut NOTE If the specified throttle cable free play cannot be obtained on the throttle body side of the cable use the adjusting nut on the handlebar side Handleb...

Page 99: ...to light tan 6 Clean Spark plug with a spark plug cleaner or wire brush 7 Measure Spark plug gap a with a wire thickness gauge Out of specification Regap 8 Install Spark plug NOTE Before installing the spark plug clean the spark plug and gasket surface 9 Connect Spark plug cap 10 Install Rear cylinder right cover Front cylinder left cover Refer to ENGINE REMOVAL on page 5 1 EAS20700 CHECKING THE I...

Page 100: ...ult in a loss of performance 1 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 3 2 Start the engine warm it up for several min utes and then turn it off 3 Remove Front cylinder covers Rear cylinder covers Refer to ENGINE REMOVAL on page 5 1 4 Disconnect Spark plug caps 5 Remove Spark plug CAUTION ECA13340 Before removing the spark plugs use com...

Page 101: ...NE OIL LEVEL 1 Stand the vehicle on a level surface NOTE Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Check Engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended engine oil to the proper level Compression gauge 90890 03081 Engine compression tester YU 33223 Standard comp...

Page 102: ...l drain bolt 1 along with the gasket 4 Drain Engine oil completely from the crankcase 5 If the oil filter cartridge is also to be replaced perform the following procedure a Remove the oil filter cartridge 1 with an oil filter wrench 2 b Lubricate the O ring 3 of the new oil filter cartridge with a thin coat of engine oil CAUTION ECA13390 Make sure the O ring 3 is positioned cor rectly in the groov...

Page 103: ... engine oil pressure again e Tighten the oil check bolts to specification 13 Install Throttle body Refer to THROTTLE BODIES on page 7 6 Left side cover Refer to GENERAL CHASSIS on page 4 1 EAS20870 ADJUSTING THE CLUTCH LEVER FREE PLAY 1 Check Clutch lever free play a Out of specification Adjust 2 Adjust Clutch lever free play Handlebar side a Loosen the locknut 1 b Turn the adjusting bolt 2 in dir...

Page 104: ...ement Damage Replace NOTE The air filter needs more frequent service if you are riding in unusually wet or dusty areas 4 Install Air filter element Air filter case cover CAUTION ECA3D81015 Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affe...

Page 105: ...t hose 2 Fuel cock hose 3 Fuel tank breather hose 4 Fuel tank overflow hose 5 Cracks damage Replace Loose connection Connect properly CAUTION ECA3D81009 Make sure the fuel tank breather hose and fuel tank overflow hose are routed correctly 3 Install Fuel tank Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS21070 CHECKING THE CRANKCASE BREATHER HOSE 1 Remove Rider ...

Page 106: ... a suitable stand Make sure the vehicle is upright 2 Check Coolant level The coolant level should be between the maximum level mark a and minimum level mark b Below the minimum level mark Add the recommended coolant to the proper level NOTE To add coolant remove the coolant reservoir cap cover 1 and coolant reservoir cap 2 T R Exhaust pipe nut 20 Nm 2 0 m kg 14 ft lb Front cylinder exhaust pipe an...

Page 107: ...on page 5 1 EAS21130 CHANGING THE COOLANT 1 Remove Fuel tank Refer to FUEL TANK on page 7 1 Muffler Coolant reservoir cover Refer to ENGINE REMOVAL on page 5 1 2 Remove Radiator cap 1 WARNING EWA13030 A hot radiator is under pressure Therefore do not remove the radiator cap when the en gine is hot Scalding hot fluid and steam may be blown out which could cause serious in jury When the engine has c...

Page 108: ...ifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion 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 wa ter Do not mix different types of antifreeze 14 Install Radiator cap T R Coolant ...

Page 109: ... 18 Check Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 15 NOTE Before checking the coolant level wait a few minutes until the coolant has settled 19 Install Coolant reservoir cover Muffler Refer to ENGINE REMOVAL on page 5 1 Fuel tank Refer to FUEL TANK on page 7 1 a Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 110: ...ke pedal ad justing bolt is visible through the hole b Incorrect Adjust 2 Adjust Brake pedal adjusting bolt position a Loosen the locknut 1 b Adjust the brake pedal adjusting bolt 2 posi tion by turning the adjusting bolt in or out so that its end is visible through the hole c Tighten the locknut 1 to specification WARNING EWA3D81002 A soft or spongy feeling in the brake pedal can indicate the pre...

Page 111: ...icantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately NOTE In order to ensure a correct reading of the brake fluid level make sure the top of the brake fluid reservoir is horizontal EAS21250 CHECKING THE FRONT BRAKE PADS The following proced...

Page 112: ...E on page 4 32 EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear brake light switch is operated by move ment of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts 1 Check Rear brake light operation timing Incorrect Adjust 2 Adjust Rear brake light operation timing a Hold the main body 1 of the rear brake l...

Page 113: ...ke fluid reservoir to the proper level with the recommended brake fluid b Install the diaphragm brake master cylinder reservoir or brake fluid reservoir c Connect a clear plastic hose 1 tightly to the bleed screw 2 d Put the other end of the hose into an open container 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 ...

Page 114: ...e belt that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive belt slack within the specified lim its NOTE Measure the drive belt slack when the engine is cold and when the drive belt is dry 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that ...

Page 115: ...ack is ob tained NOTE Using the alignment marks on each side of the swingarm make sure that both belt pullers are in the same position for proper wheel alignment d Tighten the locknuts to specification e Tighten the rear wheel axle nut to specifica tion 5 Install Muffler Refer to ENGINE REMOVAL on page 5 1 Drive belt slack on the side stand 5 0 7 0 mm 0 20 0 28 in Drive belt slack on a suitable st...

Page 116: ...13140 Do not overtighten the lower ring nut d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD on page 4 56 e Install the rubber washer 3 f Install the upper ring nut 2 NOTE Install the upper ring nut and lower ring nut with their sh...

Page 117: ...is no danger of it falling over Spring preload CAUTION ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Remove Rear cylinder exhaust pipe Coolant reservoir cover Refer to ENGINE REMOVAL on page 5 1 2 Disconnect Fuel hose 1 from sub fuel tank Refer to FUEL TANK on page 7 1 3 Adjust Spring preload a Adjust the spring preload with the special wrench 1 and wrench handle 2 include...

Page 118: ... EWA13190 It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit re place the tire immediately 2 Check Tire surfaces Damage wear Replace the tire WARNING EWA14080 Do not use a tubeless tire on a wheel de signed only for tube tires to avoid tire fail ure and personal injury from sudden deflation 1 2 3 4 5 6 7 8 9 4 3 a b 1 3 2 Tire air pressure measured on cold tire...

Page 119: ...e approximately 100 km should be traveled at normal speed before any high speed riding is done NOTE For tires with a direction of rotation mark 1 Install the tire with the mark pointing in the di rection of wheel rotation Align the mark 2 with the valve installation point EAS21670 CHECKING THE WHEELS The following procedure applies to both of the wheels 1 Check Wheel Damage out of round Replace WA...

Page 120: ...LUBRICATING THE PEDAL Lubricate the pivoting point and metal to metal moving parts of the pedal EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting points and metal to metal moving parts of the rear suspension Recommended lubricant Engine oil or a suitable cable lu bricant R...

Page 121: ...ur hands away from the bulb until it has cooled down 7 Install Headlight bulb Secure the new headlight bulb with the head light bulb holder CAUTION ECA13690 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it w...

Page 122: ...ht beam horizontally a Turn the adjusting screw 1 with a screw driver in direction a or b Direction a Headlight beam is raised Direction b Headlight beam is lowered Direction a Headlight beam moves to the left Direction b Headlight beam moves to the right a b 1 b a 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 123: ...KE CALIPERS 4 27 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 27 CHECKING THE FRONT BRAKE CALIPERS 4 27 ASSEMBLING THE FRONT BRAKE CALIPERS 4 28 INSTALLING THE FRONT BRAKE CALIPERS 4 28 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 29 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 29 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 29 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 30 REAR BRAKE 4 32 INTRODUCTION 4...

Page 124: ...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 CHECKING THE CONNECTING ARM AND RELAY ARM 4 63 INSTALLING THE RELAY ARM 4 63 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 63 SWINGARM 4 65 REMOVING THE SWINGARM 4 67 CHECKING THE SWINGARM 4 67 INSTALLING THE SWINGARM 4 67 BELT ...

Page 125: ...Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 126: ...ay cover 1 5 Seat lock cable 1 Disconnect 6 Seat lock bracket 1 7 Left side cover 1 For installation reverse the removal proce dure 7 4 2 1 3 6 5 R 7 Nm 0 7 m kg 5 1 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib R 16 Nm 1 6 m kg 11 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 127: ...ignal light coupler 2 Disconnect 5 Meter assembly coupler 3 Disconnect 6 Main switch coupler 2 Disconnect 7 Plastic band bracket 1 8 Headlight body 1 For installation reverse the removal proce dure 3 4 2 7 1 8 5 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 6 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 128: ... Negative battery lead 1 Disconnect 6 Positive battery lead 1 Disconnect 7 Battery 1 8 Battery band 1 9 ECU coupler 2 Disconnect 10 ECU engine control unit 1 11 Fuse box 1 12 Main fuse 1 13 Relay unit 1 14 Rear brake fluid reservoir bolt 1 T R 7 Nm 0 7 m kg 5 1 ft Ib 2 1 3 4 10 9 9 5 6 7 8 15 14 11 12 13 4 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email...

Page 129: ...he removal proce dure Removing the battery Order Job Parts to remove Q ty Remarks T R 7 Nm 0 7 m kg 5 1 ft Ib 2 1 3 4 10 9 9 5 6 7 8 15 14 11 12 13 4 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 130: ...ent 1 3 Air filter case bracket 1 4 Crankcase breather hose 1 Disconnect 5 Air filter case 1 For installation reverse the removal proce dure T R 4 Nm 0 4 m kg 2 9 ft Ib New New 1 2 3 5 4 4 T R 10 Nm 1 0 m kg 7 2 ft Ib Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 131: ...r relay 1 5 Crankshaft position sensor coupler 1 Disconnect 6 Tail brake light wire harness coupler 1 Disconnect 7 Stator coil coupler 1 Disconnect 8 Turn signal relay 1 9 Radiator fan motor relay 1 10 Headlight relay 1 11 Relay bracket 1 For installation reverse the removal proce dure 4 1 2 9 8 11 10 7 6 5 R 7 Nm 0 7 m kg 5 1 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib 3 Manuals by Motomatrix www motomatrix ...

Page 132: ... bolt 1 Loosen 3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Front brake disc 2 For installation reverse the removal proce dure T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 59 Nm 5 9 m kg 43 ft Ib 6 5 4 6 5 1 3 2 1 6 6 LT LT LT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Moto...

Page 133: ...Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 For assembly reverse the disassembly pro cedure 2 1 2 1 3 LS LS New New Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 134: ...driver NOTE To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a gener al bearing puller EAS21920 CHECKING THE FRONT WHEEL 1 Check Wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING EWA13460 Do not attempt to straighten a bent wheel ax le 2 Check Tire Front wheel Damage wear Replace Refer to CHECKING THE ...

Page 135: ... EAS21970 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE After replacing the tire wheel or both the front wheel static balance should be adjusted Adjust the front wheel static balance with the brake discs installed 1 Remove Balancing weight s 2 Find Front wheel s heavy spot NOTE Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at...

Page 136: ... Check Front wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it EAS22000 INSTALLING THE FRONT WHEEL FRONT BRAKE DISC The following procedure applies to both of the brake discs 1 Install Front brake disc NOTE Tighten the brake disc bolts in stages and in a crisscross pattern 2...

Page 137: ... the handlebar several times and check if the front fork rebounds smoothly 6 Install Front brake calipers WARNING EWA3D81008 Make sure the brake hoses are routed prop erly T R Front wheel axle 59 Nm 5 9 m kg 43 ft lb Front wheel axle pinch bolt 20 Nm 2 0 m kg 14 ft lb T R Front brake caliper bolt 40 Nm 4 0 m kg 29 ft lb Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Co...

Page 138: ...ght wire harness coupler 1 Disconnect 2 Rear fender bracket 2 3 Passenger seat bracket 1 4 Passenger seat guide 1 5 Rear fender assembly 1 6 Mudguard 1 For installation reverse the removal proce dure 1 2 2 5 4 3 6 T R T R T R 23 Nm 2 3 m kg 17 ft Ib 16 Nm 1 6 m kg 11 ft Ib 23 Nm 2 3 m kg 17 ft Ib Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info moto...

Page 139: ...belt adjusting bolt 2 Loosen 6 Rear wheel axle nut 1 7 Washer 1 8 Rear wheel axle 1 9 Right drive belt puller 1 10 Left drive belt puller 1 11 Rear brake caliper bracket 1 12 Collar 1 Black 13 Collar 1 Silver 3 1 2 LS LS T R 27 Nm 2 7 m kg 19 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib T R 150 Nm 15 0 m kg 110 ft lb LS T R 16 Nm 1 6 m kg 11 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib 11 8 3 12 14 6 7 13 4 5 9 4 5 10 ...

Page 140: ...remove Q ty Remarks 3 1 2 LS LS T R 27 Nm 2 7 m kg 19 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib T R 150 Nm 15 0 m kg 110 ft lb LS T R 16 Nm 1 6 m kg 11 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib 11 8 3 12 14 6 7 13 4 5 9 4 5 10 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 141: ...al 1 4 Circlip 1 5 Rear wheel drive hub 1 6 Circlip 1 7 Bearing 1 8 Collar 1 9 Bearing 1 10 Rear wheel drive hub damper 6 11 Rear wheel 1 For installation reverse the removal proce dure 1 11 2 3 4 9 8 7 6 10 5 LT T R 23 Nm 2 3 m kg 17 ft Ib 6 LS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 142: ...e Q ty Remarks 1 Collar 1 2 Bearing 1 3 Oil seal 1 4 Circlip 1 5 Bearing 1 6 Spacer 1 For assembly reverse the disassembly pro cedure 5 3 New New LS 4 6 2 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 143: ...heel Damage wear Replace Refer to CHECKING THE TIRES on page 3 27 and CHECKING THE WHEELS on page 3 28 3 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 9 EAS3D81016 CHECKING THE REAR BRAKE CALIPER BRACKET 1 Check Rear brake caliper bracket Cracks damage Replace EAS22110 CHECKING THE REAR WHEEL DRIVE HUB 1 Check Rear wheel drive hub Cracks damage Replac...

Page 144: ...gent LOCTITE to the threads of the brake disc bolts Tighten the brake disc bolts in stages and in a crisscross pattern 3 Check Rear brake disc Refer to CHECKING THE REAR BRAKE DISC on page 4 38 4 Install Rear wheel axle Washer Rear wheel axle nut NOTE Temporarily tighten the wheel axle nut 5 Adjust Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 23 6 Tighten Rear wheel axle nut ...

Page 145: ...taining bolt 2 2 Front brake caliper 1 3 Front brake pad 2 4 Brake pad shim 1 5 Front brake pad spring 1 6 Front brake pad support 2 For installation reverse the removal proce dure T R 6 Nm 0 6 m kg 4 3 ft Ib LS 2 1 1 3 4 3 5 6 6 T R 27 Nm 2 7 m kg 19 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk...

Page 146: ...r 1 6 Spring 1 7 Front brake light switch connector 2 Disconnect 8 Front brake hose union bolt 1 9 Copper washer 2 10 Front brake hose 1 11 Front brake master cylinder holder 1 12 Front brake master cylinder 1 13 Front brake light switch 1 For installation reverse the removal proce dure T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 1 5 6 7 8 10 9 2 3 4 11 12 13 New LS T R 10 Nm 1 0 m kg ...

Page 147: ...emove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure New New 1 2 3 4 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 148: ...YDRAULIC BRAKE SYSTEM on page 3 21 1 Front brake hose union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Front brake caliper bracket bolt 2 5 Front brake caliper 1 For installation reverse the removal proce dure 1 2 5 3 4 4 T R 30 Nm 3 0 m kg 22 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib New Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co u...

Page 149: ...ng 1 3 Brake pad 2 4 Brake pad shim 1 5 Brake pad support 2 6 Brake caliper bracket 1 7 Brake caliper piston seal 4 8 Brake caliper piston 2 9 Bleed screw 1 For assembly reverse the disassembly pro cedure 6 2 3 4 5 9 1 1 7 8 7 8 T R 27 Nm 2 7 m kg 19 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib New New LS LS LS LS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email in...

Page 150: ...r 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 a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflec tion turn the handlebar to the left or right to ensure that the front wheel is stationary c R...

Page 151: ...nd of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw to specification d Install a new brake pad shim new brake pads and a new brake pad spring 3 Lubricate Front brake caliper retaining bolts CAUTION ECA14150 Do not allow grease to contact the brake pads Remove any excess grease 4 Install ...

Page 152: ...ke caliper piston seals 2 a Blow compressed air into the brake hose joint opening a to force out the piston from the brake caliper WARNING EWA3D81009 Cover the brake caliper pistons with a rag Be careful not to get injured when the pis tons are expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston seals EAS22390 CHECKING THE FRONT BRAKE CA...

Page 153: ...t brake hose union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 43 CAUTION ECA14170 When installing the brake hose onto the brake caliper 1 make sure the brake pipe a touches the projection b on the brake caliper 2 Remove Front brake caliper 3 Install Brake pad supports Brake pads Brake pad spring Front brake cali...

Page 154: ...DER NOTE Before removing the front brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Front brake hose union bolt 1 Copper washers 2 Front brake hose 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS22500 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder Damage scratches wea...

Page 155: ...ING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder re...

Page 156: ... operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 21 LOWER a Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 157: ...aliper retaining bolt 2 2 Rear brake caliper 1 3 Rear brake pad 2 4 Brake pad spring 2 For installation reverse the removal proce dure 1 2 4 4 3 1 T R 6 Nm 0 6 m kg 4 3 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib LS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 158: ...ir 1 5 Brake fluid reservoir hose 1 6 Locknut rear brake master cylinder 1 Loosen 7 Brake pedal adjusting bolt 1 Loosen 8 Rear brake hose union bolt 1 9 Copper washer 2 10 Rear brake hose 1 11 Rear brake master cylinder bracket 1 12 Rear brake master cylinder cover 1 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 1...

Page 159: ...der Order Job Parts to remove Q ty Remarks T R 7 Nm 0 7 m kg 5 1 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib 3 4 2 5 1 6 7 13 8 10 11 12 9 New LT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 160: ...1 2 Circlip 1 3 Brake master cylinder kit 1 4 Circlip 1 5 Brake hose joint 1 6 O ring 1 7 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure 1 2 3 4 5 6 7 New New New New LS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 161: ... Rear brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Rear brake caliper retaining bolt 2 5 Rear brake caliper 1 For installation reverse the removal proce dure 4 5 2 3 4 1 T R 30 Nm 3 0 m kg 22 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib New LS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 162: ...y Remarks 1 Brake caliper piston 1 2 Brake caliper piston seal 2 3 Bleed screw 1 For assembly reverse the disassembly pro cedure 2 1 3 New T R 6 Nm 0 6 m kg 4 3 ft Ib LS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 163: ...cification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 25 NOTE Measure the deflection 1 5 mm 0 06 in below the edge of the brake disc 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 25 5 Adjust Brake disc defl...

Page 164: ...CALIPER NOTE Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Rear brake hose union bolt 1 Copper washers 2 Rear brake hose 3 NOTE Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22600 DISASSEMBLING THE REAR BRAKE CALIPER 1 Remove Brake caliper piston Brake caliper piston seals a Blow compressed air into the brak...

Page 165: ...caliper piston seals EAS22670 INSTALLING THE REAR BRAKE CALIPER 1 Install Rear brake caliper 1 temporarily Copper washers Rear brake hose 2 Rear brake hose union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 43 CAUTION ECA14170 When installing the brake hose onto the brake caliper 1 make sure the brake pipe a touch...

Page 166: ...level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 20 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 21 EAS22700 REMOVING THE REAR BRAKE MASTER CYLINDER NOTE Before removing the rear brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Rear brake hose union bolt 1 Copper washers ...

Page 167: ...that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up ...

Page 168: ...11 Left handlebar switch 1 12 Handlebar grip 1 13 Clutch cable 1 Disconnect 14 Clutch lever 1 15 Clutch switch 1 16 Meter assembly cover 1 LT LT LS LS LS T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 32 Nm 3 2 m kg 23 ft Ib T R 7 Nm 0 7 m kg 5 1...

Page 169: ...T LT LS LS LS T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 32 Nm 3 2 m kg 23 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 9 8 8 7 7 6 6 2 17 11 13 15 14 10 19 11 21 18 18 20 12 16 5 2 1 1 4 3 Manuals by Motomatrix www motomatrix co uk The Solution For Los...

Page 170: ...dlebar 1 Front handlebar holders 2 CAUTION ECA3D81006 First tighten the bolts on the lower side of the front handlebar holder and then on the upper side Turn the handlebar all the way to the left and right If there is any contact with the fuel tank adjust the handlebar position NOTE Align the punch mark a on the handlebar with the match mark b on the rear handlebar holder 3 Install Clutch lever 1 ...

Page 171: ...ion a on the right handlebar switch with the hole b in the handlebar 8 Install Front brake master cylinder 1 Front brake master cylinder holder 2 NOTE Install the front brake master cylinder holder with the UP mark facing up Align the end of the front brake master cylinder holder with the punch mark a on the handle bar First tighten the upper bolt then the lower bolt 9 Adjust Clutch lever free pla...

Page 172: ...4 43 1 Brake hose guide 2 2 Reflector bracket 2 3 Front fender 1 4 Main switch coupler 2 Disconnect 5 Upper bracket pinch bolt 2 Loosen 6 Cap bolt 1 Loosen 7 Steering stem nut 1 8 Upper bracket 1 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 18 N...

Page 173: ...ont fork legs Order Job Parts to remove Q ty Remarks T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 110 Nm 11 0 m kg 80 ft lb 1 2 1 2 3 5 8 7 5 4 9 10 11 12 13 6 14 Manuals by Motomatrix www motomatrix co uk The Solutio...

Page 174: ...7 Oil seal clip 1 8 Damper rod bolt 1 9 Copper washer 1 10 Damper rod 1 11 Rebound spring 1 12 Inner tube 1 13 Oil seal 1 14 Washer 1 15 Outer tube bushing 1 16 Inner tube bushing 1 6 7 13 14 12 16 17 18 9 8 19 15 5 10 11 1 2 3 4 T R 30 Nm 3 0 m kg 22 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib LS LT New New New New New New New Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Code...

Page 175: ...sembling the front fork legs Order Job Parts to remove Q ty Remarks 6 7 13 14 12 16 17 18 9 8 19 15 5 10 11 1 2 3 4 T R 30 Nm 3 0 m kg 22 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib LS LT New New New New New New New Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 176: ...with a flathead screwdriver CAUTION ECA14180 Do not scratch the inner tube 3 Remove Damper rod bolt 1 Copper washer NOTE While holding the damper rod with the damper rod holder 2 and T handle 3 loosen the damper rod bolt 4 Remove Inner tube a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the inner tube from the outer tube by pul...

Page 177: ...nter the front fork EAS23020 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA13660 Make sure the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability NOTE When assembling the front fork leg be sure to replace the following parts Inner tube bushing Outer tube bushing Oil seal Dust...

Page 178: ...talling the oil seal lubricate its lips with lithium soap based grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation 8 Install Oil seal clip 1 Recommended oil Yamaha fork oil 10WT T R Damper rod bolt 30 Nm 3 0 m kg 22 ft lb LOCTITE Damper rod holder 90890 ...

Page 179: ...along with the O ring NOTE Before installing the cap bolt lubricate its O ring with grease Temporarily tighten the cap bolt EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Lower front fork cover 1 Front fork leg 2 Upper bracket 3 Temporarily tighten the upper and lower bracket pinch bolts NOTE Make sure the inner tube end is flush wi...

Page 180: ... b in the upper front fork cover 2 with the lower front fork cover bolts 3 6 Tighten Steering stem nut Cap bolt Upper bracket pinch bolt WARNING EWA13680 Make sure the brake hoses are routed prop erly T R Lower bracket pinch bolt 23 Nm 2 3 m kg 17 ft lb T R Lower front fork cover bolt 18 Nm 1 8 m kg 13 ft lb T R Steering stem nut 110 Nm 11 0 m kg 80 ft lb T R Cap bolt 23 Nm 2 3 m kg 17 ft lb T R U...

Page 181: ...int 1 7 Lock washer 1 8 Upper ring nut 1 9 Rubber washer 1 10 Lower ring nut 1 11 Lower bracket 1 12 Upper bearing cover 1 13 Upper bearing inner race 1 14 Upper bearing 1 15 Washer 1 LT T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 18 Nm 1 8 m kg 13 ft lb T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LS LS LS T R 7 Nm 0 7 m kg 5 1 ft Ib 10 9 8 7 19 13 14 12 16 15 1...

Page 182: ...b Parts to remove Q ty Remarks LT T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 18 Nm 1 8 m kg 13 ft lb T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LS LS LS T R 7 Nm 0 7 m kg 5 1 ft Ib 10 9 8 7 19 13 14 12 16 15 11 18 19 17 2 1 4 3 5 4 6 LT LT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 183: ... b Remove the bearing race from the lower bracket with a floor chisel 2 and hammer c Install a new dust seal and new bearing rac es CAUTION ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged NOTE Always replace the bearings and bearing races as a set Whenever the steering head is disassembled replace the dust seal 4 Check Upper bracket Lower bracket alon...

Page 184: ...re that the projection a on the lower bracket contacts the side b of the front brake hose joint 1 Align the projection c on the front brake hose holder with the hole d in the lower bracket 4 Install Front fork legs Upper bracket Refer to FRONT FORK on page 4 47 2 c d a 1 b Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 185: ...r to FUEL TANK on page 7 1 Rear wheel Refer to REAR WHEEL on page 4 13 1 Connecting arm nut Washer Bolt 2 2 2 2 Connecting arm 2 3 Rear shock absorber assembly lower nut Wash er Bolt Collar 1 1 1 1 4 Rear shock absorber assembly upper nut Bolt 1 1 5 Rear shock absorber assembly 1 6 Relay arm nut Bolt Spacer Collar 1 1 1 1 7 Relay arm 1 LS New New T R T R 9 10 11 9 1 1 2 7 2 1 8 10 12 6 6 6 3 3 3 5...

Page 186: ...oving the rear shock absorber assembly Order Job Parts to remove Q ty Remarks LS New New T R T R 9 10 11 9 1 1 2 7 2 1 8 10 12 6 6 6 3 3 3 5 4 4 6 T R 1 1 3 48 Nm 4 8 m kg 35 ft Ib 48 Nm 4 8 m kg 35 ft Ib 59 Nm 5 9 m kg 43 ft Ib LS LS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 187: ...end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23230 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Remove Connecting arm nuts 1 Conn...

Page 188: ...STALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate Spacer 2 Tighten Relay arm nut 3 Install Rear shock absorber assembly NOTE Raise the swingarm and then install the rear shock absorber assembly between the swing arm and relay arm 4 Tighten Rear shock absorber assembly upper nut Rear shock absorber assembly lower nut Recommended lubricant Lithium soap based grease Installed depth of bearing a 4...

Page 189: ...ing arms NOTE When installing the connecting arms lift up the swingarm T R Rear shock absorber assembly lower nut 48 Nm 4 8 m kg 35 ft lb Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 190: ...5 Drive belt adjusting locknut 2 6 Drive belt upper guard 1 7 Drive belt lower guard 1 8 Pivot shaft nut 1 9 Pivot shaft 1 10 Swingarm 1 11 Spacer 1 12 Bearing 2 13 Dust cover 2 14 Washer 2 LS LS LS LS LT LT T R 16 Nm 1 6 m kg 11 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 85 Nm 8 5 m kg 61 ft Ib 1 3 2 7 8 4 5 4 5 10 6 9 14 14 15 16 13 12 12 11 13 16 Manuals by Motomatrix www...

Page 191: ...s to remove Q ty Remarks LS LS LS LS LT LT T R 16 Nm 1 6 m kg 11 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 85 Nm 8 5 m kg 61 ft Ib 1 3 2 7 8 4 5 4 5 10 6 9 14 14 15 16 13 12 12 11 13 16 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 192: ...s binding check the spac ers bearings washers and dust covers EAS23360 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash Pivot shaft Dust covers Spacers Washers Bearings 4 Check Dust covers Spacer Washers Damage wear Replace 5 Check Beari...

Page 193: ...ust Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 23 2 Swingarm A Left side B Right side Installed depth a 0 1 0 mm 0 0 04 in T R Pivot shaft nut 85 Nm 8 5 m kg 61 ft lb T R Rectifier regulator bolt 7 Nm 0 7 m kg 5 1 ft lb a 1 1 2 A B a Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 194: ...e 4 65 1 Drive pulley cover 1 2 Drive belt 1 3 Drive pulley nut 1 4 Drive pulley 1 For installation reverse the removal proce dure New LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 140 Nm 14 0 m kg 100 ft lb 1 2 3 4 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 195: ...are The drive belt can not be bent smaller than 127 mm 5 in a The removed drive belt can not be twisted inside out 3 Check Drive pulley Rear wheel pulley Bent teeth Replace the drive belt and pul leys as a set EAS23540 INSTALLING THE DRIVE BELT AND DRIVE PULLEY 1 Install Drive belt CAUTION ECA14710 Install the drive belt facing the same way it was removed Do not twist the drive belt when installin...

Page 196: ...r plate bolts tempo rarily and then tighten them in proper tightening sequence as shown 5 Adjust Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 23 a 4 3 2 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 197: ...DS 5 24 CHECKING THE CYLINDER HEADS 5 24 INSTALLING THE CYLINDER HEADS 5 24 VALVES AND VALVE SPRINGS 5 26 REMOVING THE VALVES 5 27 CHECKING THE VALVES AND VALVE GUIDES 5 27 CHECKING THE VALVE SEATS 5 29 CHECKING THE VALVE SPRINGS 5 30 INSTALLING THE VALVES 5 31 CYLINDERS AND PISTONS 5 33 REMOVING THE PISTONS 5 34 CHECKING THE CYLINDERS AND PISTONS 5 34 CHECKING THE PISTON RINGS 5 35 CHECKING THE P...

Page 198: ...HE RIGHT BALANCER GEARS 5 60 CHECKING THE LEFT BALANCER GEARS 5 60 INSTALLING THE RIGHT BALANCER GEARS 5 60 INSTALLING THE LEFT BALANCER GEARS 5 60 ELECTRIC STARTER 5 61 CHECKING THE STARTER MOTOR 5 63 ASSEMBLING THE STARTER MOTOR 5 64 CRANKCASE 5 65 DISASSEMBLING THE CRANKCASE 5 69 CHECKING THE CRANKCASE 5 69 CHECKING THE BEARINGS AND OIL SEAL 5 69 CHECKING THE OIL DELIVERY PIPES AND COOLANT DELI...

Page 199: ...NKSHAFT ASSEMBLY 5 78 TRANSMISSION 5 79 CHECKING THE SHIFT FORKS 5 83 CHECKING THE SHIFT DRUM ASSEMBLY 5 83 CHECKING THE TRANSMISSION 5 83 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 84 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 5 84 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 200: ... installation reverse the removal proce dure 6 1 T R 4 Nm 0 4 m kg 2 9 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 44 Nm 4 4 m kg 32 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib New New T R 12 Nm 1 2 m kg 8 7 ft Ib 9 11 2 3 10 6 3 3 T R 6 Nm 0 6 m kg 4 3 ft Ib New New New New T R 6 Nm 0 6 m kg 4 3 ft Ib ...

Page 201: ...r screw clamps NOTE Do not retighten the exhaust pipe cover screw clamps always replace them with new ones if they are loosened T R Exhaust pipe cover screw clamp 6 Nm 0 6 m kg 4 3 ft lb New Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 202: ...nder right cover 1 10 Rear cylinder left cover 1 11 Rear cylinder right cover 1 12 Ground lead 1 Disconnect 13 Drive pulley housing 1 For installation reverse the removal proce dure T R 64 Nm 6 4 m kg 46 ft Ib T R 64 Nm 6 4 m kg 46 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 56 Nm 5 6 m kg 40 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LT T R 8 Nm 0 8 m kg 5 8 ft Ib LT T R 8 Nm 0 8 m kg 5 8 ft Ib T R 8 Nm 0 8...

Page 203: ...e rear bolt to spec ification EAS3D81018 INSTALLING THE SHIFT ARM 1 Install Shift arm 1 NOTE Align the I mark a in the shift shaft with the punch mark b in the shift arm 2 Adjust Shift rod length Refer to ADJUSTING THE SHIFT PEDAL on page 3 23 T R Cylinder cover bolt 8 Nm 0 8 m kg 5 8 ft lb T R Shift arm bolt 10 Nm 1 0 m kg 7 2 ft lb 2 1 4 3 a b 1 Manuals by Motomatrix www motomatrix co uk The Sol...

Page 204: ...r to ELECTRIC STARTER on page 5 61 1 Oil level switch coupler 1 Disconnect 2 Spark plug cap 2 Disconnect 3 Crankcase breather hose 1 4 Stator coil coupler 1 Disconnect 5 Crankshaft position sensor coupler 1 Disconnect 6 Speed sensor coupler 1 Disconnect 7 Neutral switch coupler 1 Disconnect 8 Neutral switch connector 1 Disconnect 9 Horn connector 2 Disconnect 10 Horn 1 1 9 10 2 3 4 5 7 6 8 11 9 Ma...

Page 205: ...ation reverse the removal proce dure Disconnecting the leads and hoses Order Job Parts to remove Q ty Remarks 1 9 10 2 3 4 5 7 6 8 11 9 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 206: ...r upper side 2 13 Engine bracket rear upper side 1 14 Engine bracket bolt rear lower side 2 15 Engine bracket rear lower side 1 16 Engine mounting bolt front left upper side 2 17 Engine mounting bolt front right upper side 2 T R 48 Nm 4 8 m kg 35 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 88 Nm 8 8 m kg 64 ft Ib T R 88 Nm 8 8 m kg 64 ft Ib T R 48 ...

Page 207: ... Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 88 Nm 8 8 m kg 64 ft Ib T R 88 Nm 8 8 m kg 64 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 88 Nm 8 8 m kg 64 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib LT LT LT LT LT LT LT LT LT LT 5 1 2 6 5 4 3 18 11 9 8 10 13 15 17 20 19 4 16 14 12 7 6 Manuals by Motomatrix www motomatrix co uk The Solution F...

Page 208: ...locking agent LOCTITE to the threads of the engine mounting bolts front right upper side engine bracket bolts rear lower side engine bracket bolts rear upper side down tube bolts front side and down tube bolts rear side Do not tighten the bolts and nuts 3 Tighten Engine bracket bolts rear lower side 7 Engine bracket bolts rear upper side 9 Down tube bolts front side 15 Down tube bolts rear side 16...

Page 209: ... mounting bolt front right upper side 48 Nm 4 8 m kg 35 ft lb LOCTITE Engine mounting bolt front left upper side 48 Nm 4 8 m kg 35 ft lb LOCTITE Engine mounting nut rear lower side 88 Nm 8 8 m kg 64 ft lb Engine mounting nut rear upper side 88 Nm 8 8 m kg 64 ft lb Engine mounting nut front lower side 88 Nm 8 8 m kg 64 ft lb 13 11 4 16 5 Manuals by Motomatrix www motomatrix co uk The Solution For L...

Page 210: ...17 in 8 Rear cylinder head cover bolt 2 l 30 mm 1 18 in 9 Rear cylinder head cover bracket 1 10 Front cylinder head cover 1 11 Rear cylinder head cover 1 12 Cylinder head cover gasket 2 13 Dowel pin 4 For installation reverse the removal proce dure 1 8 6 8 7 9 7 6 6 1 11 12 13 13 1 4 3 2 5 2 3 3 1 4 10 12 13 13 New New New New New New T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 1...

Page 211: ...1 9 Camshaft sprocket 2 10 Rear cylinder camshaft assembly 1 11 Front cylinder camshaft assembly 1 For installation reverse the removal proce dure FWD T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib E E T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 1 1 9 2 3 7 5 10 2 3 4 6 5 8 9 4 11 T R 13 N...

Page 212: ... 1 4 Exhaust rocker arm shaft 1 5 Intake rocker arm 1 6 Exhaust rocker arm 1 7 Circlip 1 8 Front cylinder camshaft 1 9 Rear cylinder camshaft 1 10 Camshaft carrier 1 For installation reverse the removal proce dure EX IN EX IN E E M T R 14 Nm 1 4 m kg 10 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib M New 1 1 2 2 3 5 8 9 7 4 6 2 10 1 2 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcyc...

Page 213: ...the front cylinder camshaft carrier 2 Remove Front cylinder timing chain tensioner 1 NOTE Never remove a timing chain tensioner when the engine is mounted 3 Remove Front cylinder camshaft sprocket NOTE While holding the camshaft sprocket with the rotor holding tool 1 loosen the camshaft sprocket bolts 2 To prevent the timing chain from falling into the crankcase fasten it with a wire 4 Remove Fron...

Page 214: ...mshaft assembly NOTE Never remove a timing chain tensioner when the engine is mounted Remove the parts using the same procedure as for the front cylinder camshaft assembly EAS3D81034 REMOVING THE ROCKER ARMS AND CAMSHAFTS The following procedure applies to all of the rocker arms and camshafts 1 Remove Intake rocker arm shaft Exhaust rocker arm shaft Intake rocker arm Exhaust rocker arm NOTE Remove...

Page 215: ...eck Rocker arm Rocker arm roller Damage wear Replace 2 Check Rocker arm shaft Blue discoloration excessive wear pit ting scratches Replace or check the lubri cation system 3 Measure Rocker arm inside diameter Out of specification Replace Camshaft lobe dimensions Intake A 42 988 43 088 mm 1 6924 1 6964 in Limit 42 888 mm 1 6885 in Intake B 37 045 37 145 mm 1 4585 1 4624 in Limit 36 945 mm 1 4545 in...

Page 216: ...ssemble Timing chain tensioner NOTE Prior to installing the timing chain tensioner rod drain the engine oil from the timing chain ten sioner housing a Install the timing chain tensioner outer spring timing chain tensioner clip 2 1 and clip 1 2 NOTE Be sure to face the ends of timing chain tension er clip 2 1 in the direction shown in the illustra tion and to fit timing chain tensioner clip 1 2 in ...

Page 217: ...ocedure applies to all of the rocker arms and camshafts 1 Lubricate Camshaft 2 Install Camshaft 1 Circlip 2 NOTE Position the camshaft as shown in the illustra tion so that the camshaft lobes will not catch on the camshaft carrier during installation Position the opening between the ends of the circlip in the 90 range a shown in the illustra tion The front cylinder camshaft is identified by the pu...

Page 218: ...e slot b in the generator cover c Install the timing chain 1 onto the front cylin der camshaft sprocket 2 then install the camshaft sprocket onto the camshaft and then finger tighten the camshaft sprocket bolts 3 CAUTION ECA13740 Do not turn the crankshaft when installing the camshaft s to avoid damage or improper valve timing NOTE To position the front cylinder piston at TDC on the compression st...

Page 219: ...ce up Push the end of the front cylinder timing chain guide intake side 3 to release the timing chain tensioner rod 6 Install Rear cylinder camshaft assembly 1 NOTE Be sure to install the camshaft assembly without a punch mark onto the rear cylinder 7 Tighten Rear cylinder camshaft assembly bolts NOTE Tighten the bolts in the proper sequence as shown Rotor holding tool 90890 01235 Universal magnet...

Page 220: ...e a punch mark Be sure to install the cam shaft assembly without a punch mark onto the rear cylinder When installing the rear cylinder camshaft sprocket be sure to keep the timing chain as tight as possible on the intake side d Remove the wire from the timing chain 9 Tighten Rear cylinder camshaft sprocket bolts 1 NOTE While holding the camshaft sprocket with the ro tor holding tool 2 tighten the ...

Page 221: ...5 mm 2 17 in 2 Install Front cylinder head cover Front cylinder head cover bracket 1 Bolts 2 l 30 mm 1 18 in Bolts 3 l 45 mm 1 77 in Bolts 4 l 55 mm 2 17 in T R Rear cylinder head cover bolt 10 Nm 1 0 m kg 7 2 ft lb A Intake side B Exhaust side 2 a 1 New 3 A B 4 3 2 1 3 4 2 3 T R Front cylinder head cover bolt 10 Nm 1 0 m kg 7 2 ft lb A Intake side B Exhaust side 3 3 2 3 4 2 4 1 A B Manuals by Mot...

Page 222: ...d 1 4 Cylinder head gasket 2 5 Dowel pin 4 For installation reverse the removal proce dure T R 15 Nm 1 5 m kg 11 ft Ib T R 15 Nm 1 5 m kg 11 ft Ib T R 65 Nm 6 5 m kg 47 ft Ib T R 65 Nm 6 5 m kg 47 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib FWD 2 1 4 4 3 5 1 5 New New 4 4 New E E New E E E E Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys ...

Page 223: ...ds Damage scratches Replace 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylinder head as follows d Place a 400 600 grit wet sandpaper on a sur face plate and resurface the cylinder head using a figure eight sanding pattern NOT...

Page 224: ...per tightening sequence as shown and torque them in two stages T R Cylinder head nut 65 Nm 6 5 m kg 47 ft lb Cylinder head bolt 13 Nm 1 3 m kg 9 4 ft lb A Front cylinder head B Rear cylinder head 3 2 4 6 5 1 A 6 5 1 3 2 4 B Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 225: ...INDER HEADS on page 5 23 1 Valve cotter 8 2 Upper spring seat 4 3 Valve spring 4 4 Intake valve 2 5 Exhaust valve 2 6 Valve stem seal 4 7 Lower spring seat 4 8 Valve guide 4 For installation reverse the removal proce dure New New New New M M M M M M E E 1 1 2 2 6 6 3 3 7 7 7 7 8 8 8 8 1 1 2 2 6 6 3 3 4 5 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email i...

Page 226: ...valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 3 Remove Upper spring seat 1 Valve spring 2 Valve 3 Valve stem seal 4 Lower spring seat 5 NOTE Identify the position of each part very carefully so that it can be reinstalled in its original place EAS24290 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve g...

Page 227: ...ve guide reface the valve seat 3 Eliminate Carbon deposits from the valve face and valve seat Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clear ance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 0039 in Valve guide position 14 5 14 9 mm 0 571 0 587 in a Valve guide position Valve guide remover ø6 90890 04...

Page 228: ... wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply Mechanic s blueing dye Dykem b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width NOTE Where the valve seat and valve face contacted one another th...

Page 229: ... the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b onto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear impres sion j Measure the valve seat width c again If the...

Page 230: ...t 3 Lubricate Valve stem end with the recommended lubricant 4 Install Lower spring seat 1 Installed compression spring force intake 171 197 N 38 44 44 29 lbf 17 44 20 09 kgf Installed compression spring force exhaust 171 197 N 38 44 44 29 lbf 17 44 20 09 kgf Installed length intake 35 00 mm 1 38 in Installed length exhaust 35 00 mm 1 38 in b Installed length Spring tilt intake 2 5 1 9 mm Spring ti...

Page 231: ... valve spring compressor 1 and the valve spring compressor attachment 2 6 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION ECA13800 Hitting the valve tip with excessive force could damage the valve b Smaller pitch Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attach ment 90890 01243 Valve spring compressor adapt er 26 ...

Page 232: ...inder 1 3 Rear cylinder 1 4 Front cylinder gasket 1 5 Rear cylinder gasket 1 6 Dowel pin 4 7 Circlip 4 8 Piston pin 2 9 Piston 2 10 Top ring 2 11 2nd ring 2 12 Oil ring 2 For installation reverse the removal proce dure New New New New New New E E E FWD 1 2 4 6 6 3 5 6 10 11 12 7 9 9 7 7 7 8 8 1 10 11 12 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email in...

Page 233: ...of the ring over the piston crown EAS24410 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cyl inders and pistons 1 Check Piston wall Cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure the cylinder bore C with the cylin der bore gauge NOTE Measure the cyli...

Page 234: ...and piston rings as a set NOTE Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder NOTE Level the piston ring in the cylinder with the pis ton crown Piston Diameter D 99 955 99 970 mm 3 9352 3 9358 in b 8 mm 0 31 in from the bottom edge of the piston Piston to cylinder clearance Cylinder...

Page 235: ...ston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set a 10 mm 0 39 in Piston ring Top ring End gap installed 0 20 0 35 mm 0 0079 0 0138 in Limit 0 60 mm 0 0236 in 2nd ring End gap installed 0 45 0 60 mm 0 0177 0 0236 in Limit 0 95 mm 0 0374 in Oil ring End gap installed 0 20 0 70 mm 0 0079 0 0276 in Piston pin outside diameter 22 991 23 000 mm 0 9052...

Page 236: ...pin clips cover the crankcase opening with a clean rag to prevent the clips from falling into the crankcase Install the piston pin clips so that the clip ends are 3 mm 0 12 in b or more from the cutout in the piston Reinstall each piston into its original cylinder 3 Lubricate Piston Piston rings Cylinder with the recommended lubricant 4 Offset Piston ring end gaps 5 Install Rear cylinder gasket 1 ...

Page 237: ...ing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide through the timing chain cavity 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 238: ... Stator coil coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Damper cover 1 4 Generator cover damper 1 5 Left side cover bracket 1 6 Generator cover 1 7 Generator cover gasket 1 8 Dowel pin 2 9 Crankshaft position sensor stator assembly lead holder 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib New New New New LS LS LS LT LT T R 10 N...

Page 239: ...ator coil Order Job Parts to remove Q ty Remarks T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib New New New New LS LS LS LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib LT 9 10 8 8 7 11 5 2 1 4 3 6 6 New E 12 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 240: ...druff key 1 4 Starter clutch gear 1 5 Torque limiter 1 6 Starter clutch idle gear shaft 1 7 Starter clutch idle gear 1 For installation reverse the removal proce dure 6 LT 1 6 7 5 4 3 2 T R 24 Nm 2 4 m kg 17 ft Ib T R 90 Nm 9 0 m kg 65 ft Ib E E E E E Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 241: ...red over the generator rotor EAS24560 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts Starter clutch NOTE While holding the generator rotor 1 with the sheave holder 2 loosen the starter clutch bolts EAS24570 CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers Damage wear Replace 2 Check Starter clutch idle gear Starter clutch gear Burrs chips roughness wear Replace the defective p...

Page 242: ...der 2 tighten the starter clutch bolts EAS24500 INSTALLING THE GENERATOR 1 Install Generator rotor Washer Generator rotor bolt NOTE Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure the woodruff key is properly seated in the key way of the crankshaft Lubricate the generator rotor bolt threads and washer mating surfaces with engine...

Page 243: ...ly Sealant onto the crankshaft position sensor stator assembly lead grommet Yamaha bond No 1215 90890 85505 Three Bond No 1215 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 244: ...tch cable holder 1 2 Clutch cable 1 Disconnect 3 Pull lever 1 4 Pull lever spring 1 5 Damper cover 1 6 Clutch cover damper 1 7 Clutch cover 1 8 Clutch cover gasket 1 9 Dowel pin 2 For installation reverse the removal proce dure New New T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 1 2 3 4 5 6 7 8 9 9 6 8 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded K...

Page 245: ... ty Remarks 1 Circlip 1 2 Pull lever shaft 1 3 Oil seal 1 4 Bearing 1 5 Bearing 1 For installation reverse the removal proce dure LS New E 4 5 2 New 1 3 LS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 246: ...ch boss nut 1 10 Conical spring washer 1 11 Wire circlip 1 12 Clutch plate 1 13 Friction plate 3 1 Inside diameter 135 mm 5 31 in 14 Clutch damper spring 1 15 Clutch damper spring seat 1 16 Clutch boss 1 17 Thrust washer 1 1 E 7 8 6 19 18 17 16 15 14 13 12 11 10 9 1 4 5 New New E LS 23 22 21 20 T R 8 Nm 0 8 m kg 5 8 ft Ib E E E LT LT 2 6 3 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 125 Nm 12 5 m kg 90 ft lb...

Page 247: ...on reverse the removal proce dure Removing the clutch Order Job Parts to remove Q ty Remarks E 7 8 6 19 18 17 16 15 14 13 12 11 10 9 1 4 5 New New E LS 23 22 21 20 T R 8 Nm 0 8 m kg 5 8 ft Ib E E E LT LT 2 6 3 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 125 Nm 12 5 m kg 90 ft lb E Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 248: ...ver Refer to GENERATOR AND STARTER CLUTCH on page 5 39 1 Primary drive gear cover 1 2 Primary drive gear cover gasket 1 3 Dowel pin 3 4 Primary drive gear nut 1 5 Lock washer 1 6 Spacer 1 7 Primary drive gear 1 For installation reverse the removal proce dure T R 10 Nm 1 0 m kg 7 2 ft Ib T R 100 Nm 10 0 m kg 72 ft lb New New New E T R 10 Nm 1 0 m kg 7 2 ft Ib LT New LS 7 5 2 12 1 4 3 3 6 LS 3 Manua...

Page 249: ...enerator rotor 3 with the sheave holder 4 loosen the primary drive gear nut Do not allow the sheave holder to touch the projection on the generator rotor EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replace the frict...

Page 250: ...LUTCH 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 2 Check Bearing Damage wear Replace the bearing and clutch housing EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss NOTE Pitting on the clutch ...

Page 251: ...E OIL WATER PUMP DRIVE SPROCKET AND OIL WATER PUMP DRIVE CHAIN 1 Check Oil water pump drive sprocket Cracks damage wear Replace the oil wa ter pump drive chain and oil water pump drive and driven sprockets as a set 2 Check Oil water pump drive chain Damage stiffness Replace the oil water pump drive chain and oil water pump drive and driven sprockets as a set EAS25230 INSTALLING THE PRIMARY DRIVE G...

Page 252: ...ary driven gear teeth and primary drive gear teeth mesh correctly After installing the clutch housing make sure that the primary drive gear 2 and clutch hous ing primary driven gear 3 are aligned as shown in the illustration 3 Install Clutch boss assembly 1 NOTE Install the clutch damper spring 2 with the OUTSIDE mark facing out If the wire circlip 3 has been removed care fully install a new one S...

Page 253: ...he clutch hous ing and align the cutout in the tab of friction plate 1 2 with the punch mark b on the hous ing 7 Install Clutch spring plate Clutch spring plate retainer NOTE Tighten the clutch spring plate retainer bolts in stages and in a crisscross pattern 8 Install Pull lever spring 1 Pull lever 2 Washer Circlip NOTE Make sure that the mark a on the pull lever is facing forward When installing...

Page 254: ... 55 9 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 12 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 255: ...5 1 Primary drive gear cover Refer to CLUTCH on page 5 45 1 Shift shaft 1 2 Stopper lever spring 1 3 Circlip 1 4 Stopper lever 1 5 Collar 1 6 Shift shaft spring 1 7 Shift shaft spring stopper 1 For installation reverse the removal proce dure LS New E 7 LT 1 6 5 4 3 2 New E T R 22 Nm 2 2 m kg 16 ft Ib Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info ...

Page 256: ...IFT SHAFT 1 Install Stopper lever 1 Stopper lever spring 2 Shift shaft 3 NOTE Lubricate the oil seal lips with lithium soap based grease Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss 4 Mesh the stopper lever with the shift drum seg ment assembly Hook the end of the shift shaft spring onto the shift shaft spring stopper 5 4 2 3 1 5 Manuals by Motomatrix www...

Page 257: ... Refer to CLUTCH on page 5 45 1 Straight key 1 2 Right balancer drive gear 1 3 Right balancer assembly 1 For installation reverse the removal proce dure R 12 Nm 1 2 m kg 8 7 ft Ib LT LT R 12 Nm 1 2 m kg 8 7 ft Ib LT E LT 2 1 3 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 258: ...Refer to GENERATOR AND STARTER CLUTCH on page 5 39 1 Left balancer drive gear 1 2 Left balancer assembly 1 For installation reverse the removal proce dure 1 2 T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib New E Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 259: ...OTE Align the punch mark a in the right balancer driven gear with the punch mark b in the right balancer drive gear EAS3D81027 INSTALLING THE LEFT BALANCER GEARS 1 Install Left balancer assembly 2 Install Left balancer drive gear 1 NOTE Align the punch mark a in the left balancer driven gear with the punch mark b in the left balancer drive gear Align the projection c on the left balancer drive gea...

Page 260: ...remove Q ty Remarks 1 Starter motor lead 1 Disconnect 2 Starter motor 1 For installation reverse the removal proce dure T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 2 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 261: ... Washer set 1 9 Starter motor rear cover 1 10 Gasket 2 11 Brush seat along with the brushes 1 12 Brush holder along with the brushes 1 13 Brush holder bracket 1 14 Starter motor yoke 1 For assembly reverse the disassembly pro cedure 2 6 5 4 7 10 10 14 9 8 13 12 11 New New New New New LS E 3 1 LS New Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info m...

Page 262: ...he starter motor a Measure the armature assembly resistances with the pocket tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Limit 27 0 mm 1 06 in Mica undercut depth 0 70 mm 0 03 in Pocket tester 90890 03112 A...

Page 263: ...b a on the brush seat with the slot b in the starter motor yoke 2 Install Starter motor yoke 1 Starter motor front cover 2 Starter motor rear cover 3 NOTE Align the match marks a on the starter motor yoke with the match marks b on the starter mo tor front and rear covers 1 a b a b 1 3 b 2 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix c...

Page 264: ... Spacer 1 10 Oil filter cartridge 1 11 Oil delivery pipe 2 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib T R 70 Nm 7 0 m kg 50 ft lb T R 15 Nm 1 5 m kg 11 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 20 Nm 2 0 m kg 14 ft ...

Page 265: ...m 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib T R 70 Nm 7 0 m kg 50 ft lb T R 15 Nm 1 5 m kg 11 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib New New New New New New New New New LS LT LT LS LS LT LT LS LT LT LT LT New LT LT LT LS LS LT N...

Page 266: ...case 1 For installation reverse the removal proce dure T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 36 Nm 3 6 m kg 25 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LT LT LT LT LT New New New New New LS LS LT LS LS 1 5 2 3 19 7 3 4 5 6 8 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email inf...

Page 267: ...nsmission Refer to TRANSMISSION on page 5 79 1 Bearing retainer 2 2 Oil seal 1 3 Bearing 7 4 Oil nozzle 2 For installation reverse the removal proce dure New LT LT LS LT LT E T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib LT E New LS E E New LS E 1 1 3 2 3 3 3 3 4 4 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 268: ...n rotate the inner race with your finger Rough movement Replace Oil seals Damage wear Replace EAS25600 CHECKING THE OIL DELIVERY PIPES AND COOLANT DELIVERY PIPE The following procedure applies to all of the oil delivery pipes and joint pipe 1 Check Oil delivery pipe Joint pipe Damage Replace Obstruction Wash and blow out with com pressed air 2 Check Coolant delivery pipe Cracks damage wear Replace...

Page 269: ... face hammer 4 Install Crankcase bolts M10 Crankcase bolts M6 NOTE Apply locking agent LOCTITE to the threads of the bolts 2 Tighten each bolt 1 4 of a turn at a time in stag es and in a crisscross pattern M10 110 mm bolts 1 M6 120 mm bolts 2 M6 80 mm bolts 3 5 Apply Engine oil onto the crankshaft pin bearings and oil de livery holes 6 Check Crankshaft and transmission operation Rough movement Rep...

Page 270: ... 7 Bearing 1 8 Pin 2 9 Oil pump outer rotor 1 10 Oil pump inner rotor 1 11 Pin 1 12 Water pump housing 1 For installation reverse the removal proce dure T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib LS 8 8 6 9 10 11 12 7 4 5 1 2 3 New New New New New LS LS LS New LS Manuals by Motomatrix www motomatrix...

Page 271: ...he defective part s EAS24970 CHECKING THE RELIEF VALVE 1 Check Relief valve body 1 Relief valve 2 Spring 3 Spring retainer 4 Damage wear Replace the defective part s Inner rotor to outer rotor tip clearance Less than 0 12 mm 0 0047 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump housing clearance 0 09 0 19 mm 0 0035 0 0075 in Limit 0 26 mm 0 0102 in Oil pump housing to inner and outer rotor cle...

Page 272: ...shaft with the grooves a in the in ner rotor 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 72 EAS25020 INSTALLING THE OIL WATER PUMP ASSEMBLY 1 Install Oil water pump assembly CAUTION ECA3D81020 After tightening the bolts make sure the oil water pump assembly turns smoothly Recommended lubricant Engine oil T R Oil pump housing bolt 10 Nm 1 0 m kg 7 2 ft lb 1 2 3 4 1 T R Oil w...

Page 273: ...t 1 2 Connecting rod cap 2 3 Big end lower bearing 2 4 Connecting rod 2 5 Big end upper bearing 2 For installation reverse the removal proce dure E E M M M M New New New E T R 1st 15 Nm 1 5 m kg 11 ft lb 2nd Specified angle 125 135 1 2 3 4 5 4 2 3 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 274: ...ot interchange the big end bearings and connecting rods To obtain the correct crankshaft pin to big end bearing clear ance and prevent engine damage the big end bearings must be installed in their origi nal positions a Clean the big end bearings crankshaft pin and the inside of the connecting rod halves b Install the big end upper bearing into the con necting rod and the big end lower bearing into...

Page 275: ...n to big end bearing clearance is out of specification select re placement big end bearings 4 Select Big end bearings P1 P2 NOTE The numbers a stamped into the crankshaft web and the numbers b on the connecting rods are used to determine the replacement big end bearing sizes P1 P2 refer to the bearings shown in the crank shaft illustration For example if the connecting rod P1 and the crankshaft we...

Page 276: ... Big end bearings Connecting rods Connecting rod caps onto the crankshaft pin NOTE Align the projections a on the big end bear ings with the notches b in the connecting rods and connecting rod caps Be sure to reinstall each big end bearing in its original place Make sure the projection c on each connect ing rod faces towards the left side of the crank shaft Make sure the characters d on both the c...

Page 277: ... not loosen and then retighten it Replace the bolt with a new one and perform the procedure again CAUTION ECA3D81012 Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angle EAS26210 INSTALLING THE CRANKSHAFT ASSEMBLY 1 Install Crankshaft assembly CAUTION ECA3D81013 To avoid scratching the crankshaft and to ease the installation proc...

Page 278: ...CASE on page 5 65 1 Long shift fork guide bar 1 2 Short shift fork guide bar 1 3 Shift drum assembly 1 4 Shift fork 1 2 5 Shift fork 2 1 6 Main axle assembly 1 7 Drive axle assembly 1 For installation reverse the removal proce dure New LS E E E 2 4 5 1 3 6 4 7 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 279: ...1 3 Circlip 1 4 3rd 4th pinion gear 1 5 Circlip 1 6 Toothed washer 1 7 5th pinion gear 1 8 Collar 1 9 Main axle 1st pinion gear 1 For assembly reverse the disassembly pro cedure New New New M M 1 2 3 4 5 6 7 8 9 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 280: ... gear 1 8 Toothed spacer 1 9 Toothed lock washer 1 10 Toothed lock washer retainer 1 11 3rd wheel gear 1 12 Toothed spacer 1 13 Toothed washer 1 14 Circlip 1 15 Dog clutch 1 16 Circlip 1 17 Toothed washer 1 New New New M M M M M M M 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 281: ... disassembly pro cedure Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks New New New M M M M M M M 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 282: ...r as a set EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum grooves Damage scratches wear Replace the shift drum assembly Shift drum segment 1 Damage wear Replace the shift drum as sembly Shift drum bearing 2 Damage pitting Replace the shift drum as sembly EAS26300 CHECKING THE TRANSMISSION 1 Measure Main axle runout with a centering device and dial gauge 1 Out of specification Replace...

Page 283: ...Toothed lock washer retainer 1 Toothed lock washer 2 NOTE With the toothed lock washer retainer 1 in the groove a in the drive axle align the projection c on the retainer with an axle spline b and then install the toothed lock washer 2 Be sure to align the projection on the toothed lock washer that is between the alignment marks e with the alignment mark d on the retainer EAS26320 INSTALLING THE S...

Page 284: ...ne oil to each gear and bearing thor oughly Before assembling the crankcase make sure that the transmission is in neutral and that the gears turn freely 4 1 2 3 5 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 285: ...AT 6 4 CHECKING THE THERMOSTAT 6 6 INSTALLING THE THERMOSTAT ASSEMBLY 6 6 WATER PUMP 6 7 DISASSEMBLING THE WATER PUMP 6 9 CHECKING THE WATER PUMP 6 9 ASSEMBLING THE WATER PUMP 6 9 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 286: ... hose holder 1 3 Plastic holder 1 4 Coolant reservoir breather hose 1 5 Coolant reservoir hose 1 6 Coolant reservoir cap 1 7 Coolant reservoir 1 8 Radiator cap 1 9 Radiator fan motor coupler 1 Disconnect 10 Radiator cover 1 LS T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib New New T R 2 Nm 0 2 m kg 1 4 ft...

Page 287: ...e Removing the radiator Order Job Parts to remove Q ty Remarks LS T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib New New T R 2 Nm 0 2 m kg 1 4 ft Ib LT LT 2 1 6 5 4 7 12 10 13 16 14 15 11 9 8 3 3 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix c...

Page 288: ... fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 29 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 16 2 Check Cooling system Leaks Repair or replace any faulty part 3 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer...

Page 289: ...nder thermostat inlet hose 1 4 Rear cylinder thermostat inlet pipe 1 1 5 Coolant temperature sensor coupler 1 Disconnect 6 Coolant temperature sensor 1 7 Radiator filler pipe 1 8 Thermostat cover inlet hose 1 9 Thermostat bracket 1 10 Thermostat cover assembly 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1...

Page 290: ...tallation reverse the removal proce dure Removing the thermostat Order Job Parts to remove Q ty Remarks T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib New New New New LT LT LT LT 5 1 2 3 6 4 7 12 10 13 16 17 18 14 15 11 9 8 Manuals by Motomatrix www motomatrix co uk The Solu...

Page 291: ...tat housing Thermostat pipes Thermostat hoses Radiator inlet hose Radiator filler pipe Cracks damage wear Replace EAS26480 INSTALLING THE THERMOSTAT ASSEMBLY 1 Install Thermostat NOTE Install the thermostat with its breather hole a facing up 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 16 3 Check Cooling system Leaks Repair or ...

Page 292: ...otors Refer to OIL PUMP on page 5 71 1 Water pump housing cover 1 2 Pin 2 3 O ring 1 4 Impeller shaft 1 5 Rubber damper holder 1 6 Rubber damper 1 7 Water pump seal 1 8 Oil seal 1 9 Bearing 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib LS 5 New New New New New LS LS LS New LS 3 1 2 2 10 6 7 8 9 4 Manuals by Motomatrix www motom...

Page 293: ... Parts to remove Q ty Remarks T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib LS 5 New New New New New LS LS LS New LS 3 1 2 2 10 6 7 8 9 4 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 294: ...acks damage wear Replace 2 Check Bearing Rough movement Replace EAS26560 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 into the oil water pump housing NOTE Before installing the oil seal apply tap water or coolant onto its outer surface Install the oil seal with a socket that matches its outside diameter 2 Install Water pump seal 1 CAUTION ECA14080 Never lubricate the water pump seal surface with...

Page 295: ...are flush with the impeller Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A Middle driven shaft bearing driv er 90890 04058 Bearing driver 40 mm YM 04058 Yamaha bond No 1215 90890 85505 Three Bond No 1215 A Push down 4 Mechanical seal installer 5 Middle driven shaft bearing driver New New Impeller shaft tilt limit 0 15 mm 0 006 in 1 Straightedge 2 Impeller Manuals by Mot...

Page 296: ...WATER PUMP 6 11 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 297: ...LLOVER VALVE 7 4 INSTALLING THE FUEL PUMP 7 5 INSTALLING THE FUEL TANK HOSES 7 5 THROTTLE BODIES 7 6 CHECKING THE INJECTORS 7 9 CHECKING THE THROTTLE BODIES 7 9 CHECKING THE FUEL PRESSURE 7 9 ADJUSTING THE THROTTLE POSITION SENSOR 7 9 INSTALLING THE INTAKE MANIFOLD ASSEMBLY 7 10 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 298: ... hose turn the fuel cock to OFF 6 Air vent hose 1 7 Fuel tank overflow hose 1 8 Fuel tank breather hose fuel tank to hose joint 1 9 Fuel tank 1 10 Fuel sender 1 11 Fuel cock 1 For installation reverse the removal proce dure T R 23 Nm 2 3 m kg 17 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib New T R 7 Nm 0 7 m kg 5 1 ft Ib New 5 6 1 9 2 3 10 11 7 8 1 New New New New New 4 Manuals by...

Page 299: ... pump coupler 1 Disconnect 2 Fuel hose 1 Disconnect 3 Sub fuel tank 1 4 Fuel pump bracket 1 5 Fuel pump gasket 1 6 Fuel pump 1 For installation reverse the removal proce dure 4 5 6 3 1 2 New R 10 Nm 1 0 m kg 7 2 ft Ib 3 3 3 6 T R 6 Nm 0 6 m kg 4 3 ft Ib Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 300: ... 1 Front cylinder covers Refer to ENGINE REMOVAL on page 5 1 1 Fuel tank breather hose 1 2 Fuel tank breather hose hose joint to rollover valve 1 3 Rollover valve 1 For installation reverse the removal proce dure 1 2 3 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 301: ... the fuel pump or give it a strong shock EAS26650 CHECKING THE FUEL COCK 1 Check Fuel cock Cracks damage wear Replace 2 Check Fuel cock strainer Obstruction Clean Blow out the jets with compressed air Damage Replace EAS26660 CHECKING THE FUEL COCK OPERATION NOTE After installing the fuel cock check its operation 1 Check Fuel cock operation Out of specification Replace the fuel cock a Check that th...

Page 302: ...hose is in the correct position otherwise the fuel hose will not be properly installed NOTE Install the fuel hose securely onto the fuel pump until a distinct click is heard To install the fuel hose onto the fuel pump slide the fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown EAS3D81040 INSTALLING THE FUEL TANK HOSES 1 Install Fuel tank breather hose fuel tank...

Page 303: ...ssure sensor hose 1 3 Rear cylinder intake air pressure sensor hose 1 4 Throttle cable 2 Disconnect 5 ISC idle speed control unit coupler 1 Disconnect 6 Throttle body 1 CAUTION ECA3D81003 The throttle body should not be disas sembled 7 Gasket 1 8 ISC idle speed control unit 1 9 Throttle position sensor 1 For installation reverse the removal proce dure 3 2 7 8 5 4 1 6 9 4 New New LS T R 10 Nm 1 0 m...

Page 304: ...r hose 1 4 Rear cylinder resonator hose 1 5 Resonator hose joint 1 6 Fuel hose 1 Disconnect 7 Sub wire harness coupler 2 Disconnect 8 Intake manifold joint clamp screw 2 Loosen 9 Rear cylinder intake manifold joint 1 10 Intake manifold assembly 1 11 Front cylinder intake manifold joint 1 For installation reverse the removal proce dure T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7...

Page 305: ...t 2 Rear cylinder injector coupler 1 Disconnect 3 Sub wire harness 1 4 Injector 2 5 Fuel pipe 1 6 Intake manifold 1 For assembly reverse the disassembly pro cedure T R 10 Nm 1 0 m kg 7 2 ft Ib New New New New 4 6 4 4 2 1 3 5 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 306: ...n the fuel hose 1 and fuel pump 2 d Connect the pressure gauge 4 to the fuel pressure adapter 3 e Start the engine f Measure the fuel pressure Faulty Replace the fuel pump EAS27030 ADJUSTING THE THROTTLE POSITION SENSOR NOTE Before adjusting the throttle position sensor the engine idling speed should be properly adjusted 1 Check Throttle position sensor Refer to CHECKING THE THROTTLE PO SITION SEN...

Page 307: ...projection a facing up as shown in the illus tration b Install the rear cylinder intake manifold joint 2 to the intake manifold assembly NOTE Make sure that the projection b on the rear cyl inder intake manifold joint contacts the projec tion c on the intake manifold assembly c Install the intake manifold assembly NOTE Lubricate the rear cylinder intake manifold joint and rear cylinder head mating...

Page 308: ...THROTTLE BODIES 7 11 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 309: ...3 COOLING SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 TROUBLESHOOTING 8 31 FUEL INJECTION SYSTEM 8 33 CIRCUIT DIAGRAM 8 33 ECU SELF DIAGNOSTIC FUNCTION 8 35 SELF DIAGNOSTIC FUNCTION TABLE 8 36 TROUBLESHOOTING METHOD 8 38 DIAGNOSTIC MODE 8 39 TROUBLESHOOTING DETAILS 8 45 FUEL PUMP SYSTEM 8 65 CIRCUIT DIAGRAM 8 65 TROUBLESHOOTING 8 67 IMMOBILIZER SYSTEM 8 69 CIRCUIT DIAGRAM 8 69 GENERAL INFORMATION 8 71 PART R...

Page 310: ... THE STARTER MOTOR OPERATION 8 97 CHECKING THE STATOR COIL 8 97 CHECKING THE RECTIFIER REGULATOR 8 97 CHECKING THE HORN 8 98 CHECKING THE OIL LEVEL SWITCH 8 98 CHECKING THE FUEL SENDER 8 99 CHECKING THE FUEL LEVEL WARNING LIGHT 8 99 CHECKING THE OIL LEVEL WARNING LIGHT 8 99 CHECKING THE SPEED SENSOR 8 100 CHECKING THE RADIATOR FAN MOTOR 8 100 CHECKING THE COOLANT TEMPERATURE SENSOR 8 100 CHECKING ...

Page 311: ...Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 312: ...h G B Y B B Br W BLACK BLACK BLACK B L G W DARK GREEN B L W Gy W G DARK GRAY GRAY A WIRE HARNESS SUB WIREHARNESS B WIRE HARNESS SUB WIREHARNESS C WIRE HARNESS Gy R Br W Dg Dg Ch Ch ON OFF RESET Br Br Br Br R W R R Y Dg Dg B B C Ch Ch Dg Ch B B Ch Ch B B Y L B B B Y L R L R Br Br L Br Y Y Y B Br Y B G C C C B B C B R B R R Br W B R B R B R R L R W R L R W L W B L L W Y R W L B Gy W Y Gy R O Gy R B ...

Page 313: ... 21 Crankshaft position sensor 25 Lean angle sensor 28 ECU engine control unit 29 Rear cylinder ignition coil 30 Front cylinder ignition coil 31 Spark plug 69 Engine stop switch 78 Ignition fuse Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 314: ...e engine continues to run under the following conditions The transmission is in gear the neutral switch is open and the sidestand is up the sidestand switch is closed The transmission is in neutral the neutral switch is closed and the sidestand is down the sidestand switch is open 1 4 5 10 11 9 7 2 6 3 8 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignition coil 7 Spa...

Page 315: ...the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 8 Regap or replace the spark plug s 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 94 Ignition system is OK 5 Check the spark plug caps Refer to CHECKING THE SPARK PLUG CAPS on page 8 95 Replace the spark plug cap s 6 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on ...

Page 316: ...11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 83 Replace the sidestand switch 12 Check the relay unit diode Refer to CHECKING THE DI ODES on page 8 93 Replace the relay unit 13 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 96 Replace the lean angle sensor 14 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 Prope...

Page 317: ...IGNITION SYSTEM 8 6 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 318: ...G B Y B B Br W BLACK BLACK BLACK B L G W DARK GREEN B L Br W Dg Dg Ch Ch ON OFF RESET Br Br Br Br R W R R Y B Ch Ch B B Y L B B B Y L R L R Br Br L Br Y Y Y B Br Y B G C C B B C B R B R R Br W B R B R B R R L R W R L R W L W B L L W Y R W L B Gy W Y L Y G L G L G L G L P W Y G B Y P B R W L W Br W B R Y B R Y Br B Y G Y B L P W L B L B L Br W G W B L B L Y G L P L B L Y L Y L P W Y G B Y P Br W G ...

Page 319: ...r 10 Diode 1 13 Relay unit 14 Starting circuit cut off relay 16 Diode 2 17 Neutral switch 19 Sidestand switch 55 Clutch switch 69 Engine stop switch 70 Start switch 78 Ignition fuse Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 320: ...d the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be...

Page 321: ...n fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Diode 2 7 Relay unit starting circuit cut off relay 8 Relay unit diode 9 Clutch switch 10 Sidestand switch 11 Neutral switch 12 Diode 1 13 Starter relay 14 Start switch 15 Starter motor Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 322: ... motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 97 The starter motor is OK Perform the elec tric starting system troubleshooting start ing with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 63 Repair or replace the starter motor 5 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RE LAYS on page 8 91 Replace the re...

Page 323: ...Check the neutral switch Refer to CHECKING THE SWITCHES on page 8 83 Replace the neutral switch 13 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 83 Replace the sidestand switch 14 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 83 Replace the clutch switch 15 Check the start switch Refer to CHECKING THE SWITCHES on page 8 83 Replace the right handlebar switch...

Page 324: ... Y P G L B R Y B G L B L B Y G L B L B B Br W BLACK BLACK BLACK G W DARK GREEN B L Dg Dg Ch Ch ON OFF RESET Br Br Br Br R W R R Y Ch B L B B B Y L R L R Br Br L Br Y Y Y B Br Y B C C B B C B R B R R Br W B R B R B R R L R W R L R W L W G L G L G L P W Y G B Y P B R W L W Br W B R Y B R Y Br B L P W L B L B L G W B L B L Y G L P L B L Y L B R B L L W B Y Sb Sb L Y L R R L L G R L B B Gy Gy B L L G ...

Page 325: ...CHARGING SYSTEM 8 14 1 AC magneto 2 Rectifier regulator 3 Main fuse 6 Battery Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 326: ...the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 97 Replace the crankshaft position sen sor stator assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 97 Replace the rectifier regulator 5 Check the entire charging system s wiring Refer to CIRCUIT DIAGRAM on page 8 13 Properly connect ...

Page 327: ...CHARGING SYSTEM 8 16 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 328: ...h G B Y B B Br W BLACK BLACK BLACK B L G W DARK GREEN B L W Gy W G DARK GRAY GRAY A WIRE HARNESS SUB WIREHARNESS B WIRE HARNESS SUB WIREHARNESS C WIRE HARNESS Gy R Br W Dg Dg Ch Ch ON OFF RESET Br Br Br Br R W R R Y Dg Dg B B C Ch Ch Dg Ch B B Ch Ch B B Y L B B B Y L R L R Br Br L Br Y Y Y B Br Y B G C C C B B C B R B R R Br W B R B R B R R L R W R L R W L W B L L W Y R W L B Gy W Y Gy R O Gy R B ...

Page 329: ... 51 Headlight relay 53 Pass switch 54 Dimmer switch 62 Headlight 63 Auxiliary light 64 Accessory light OPTION 72 License plate light 73 Tail brake light 77 Headlight fuse 78 Ignition fuse 79 Signaling system fuse 80 Parking lighting fuse Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 330: ...hting Refer to CHECKING THE FUS ES on page 8 87 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 87 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 83 Replace the main switch immobilizer unit 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 8 83 The dimmer switch ...

Page 331: ...ystem s wiring Refer to CIRCUIT DIAGRAM on page 8 17 Properly connect or repair the lighting sys tem s wiring Replace the ECU or meter assembly Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 332: ...Ch G B Y B B Br W BLACK BLACK BLACK B L G W DARK GREEN B L W Gy W G DARK GRAY GRAY A WIRE HARNESS SUB WIREHARNESS B WIRE HARNESS SUB WIREHARNESS C WIRE HARNESS Gy R Br W Dg Dg Ch Ch ON OFF RESET Br Br Br Br R W R R Y Dg Dg B B C Ch Ch Dg Ch B B Ch Ch B B Y L B B B Y L R L R Br Br L Br Y Y Y B Br Y B G C C C B B C B R B R R Br W B R B R B R R L R W R L R W L W B L L W Y R W L B Gy W Y Gy R O Gy R B...

Page 333: ...arning light 43 Turn signal indicator light 46 Oil level switch 47 Fuel sender 49 Horn 50 Turn signal relay 56 Turn signal switch 57 Horn switch 58 Rear right turn signal light 59 Rear left turn signal light 60 Front right turn signal light 61 Front left turn signal light 66 Front brake light switch 71 Hazard switch 73 Tail brake light 75 Rear brake light switch 78 Ignition fuse 79 Signaling syste...

Page 334: ...ARGING THE BATTERY on page 8 87 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 83 Replace the main switch immobilizer unit 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signaling system s wiring Check the condition of each of the sig naling system s circ...

Page 335: ...n page 8 83 Replace the front brake light switch 3 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 83 Replace the rear brake light switch 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signaling system s wiring This circuit is OK 1 Check the turn signal light bulbs and sockets Refer to CHECKING THE BULBS ...

Page 336: ...21 Properly connect or repair the signaling system s wiring Replace the meter assembly 1 Check the neutral switch Refer to CHECKING THE SWITCHES on page 8 83 Replace the neutral switch 2 Check the relay unit diode Refer to CHECKING THE DI ODES on page 8 93 Replace the relay unit 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signal...

Page 337: ...gnaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signaling system s wiring Replace the meter assembly 1 Check the coolant temperature sen sor Refer to CHECKING THE COOL ANT TEMPERATURE SENSOR on page 8 100 Replace the coolant temperature sensor 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair t...

Page 338: ...system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signaling system s wiring Replace the ECU or meter assembly Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 339: ...SIGNALING SYSTEM 8 28 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 340: ... G B Y B B Br W BLACK BLACK BLACK B L G W DARK GREEN B L W Gy W G DARK GRAY GRAY A WIRE HARNESS SUB WIREHARNESS B WIRE HARNESS SUB WIREHARNESS C WIRE HARNESS Gy R Br W Dg Dg Ch Ch ON OFF RESET Br Br Br Br R W R R Y Dg Dg B B C Ch Ch Dg Ch B B Ch Ch B B Y L B B B Y L R L R Br Br L Br Y Y Y B Br Y B G C C C B B C B R B R R Br W B R B R B R R L R W R L R W L W B L L W Y R W L B Gy W Y Gy R O Gy R B R...

Page 341: ...adiator fan motor fuse 26 Coolant temperature sensor 28 ECU engine control unit 74 Radiator fan motor 76 Radiator fan motor relay 78 Ignition fuse Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 342: ...r to CHECKING THE SWITCHES on page 8 83 Replace the main switch immobilizer unit 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 100 Replace the radiator fan motor 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 91 Replace the radiator fan motor relay 6 Check the coolant temperature sen sor Refer to CHECKING THE COOL ANT TEMPERATURE S...

Page 343: ...COOLING SYSTEM 8 32 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 344: ...B Ch Ch G B Y B B Br W BLACK BLACK BLACK B L G W DARK GREEN B L W Gy W G DARK GRAY GRAY A WIRE HARNESS SUB WIREHARNESS B WIRE HARNESS SUB WIREHARNESS C WIRE HARNESS Gy R Br W Dg Dg Ch Ch ON OFF RESET Br Br Br Br R W R R Y Dg Dg B B C Ch Ch Dg Ch B B Ch Ch B B Y L B B B Y L R L R Br Br L Br Y Y Y B Br Y B G C C C B B C B R B R R Br W B R B R B R R L R W R L R W L W B L L W Y R W L B Gy W Y Gy R O G...

Page 345: ... 26 Coolant temperature sensor 27 Air temperature sensor 28 ECU engine control unit 29 Rear cylinder ignition coil 30 Front cylinder ignition coil 31 Spark plug 32 ISC idle speed control unit 33 Front cylinder injector 34 Rear cylinder injector 39 Multi function meter 40 Engine trouble warning light 48 O2 sensor 51 Headlight relay 67 Select switch 68 Reset switch 69 Engine stop switch 76 Radiator ...

Page 346: ...a fault code has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation The warning light flashes when any one of the conditions listed below is present and the start switch is pushed Checking the engine trouble warning light The engine trouble warning light comes on for 1 4 seconds after the main sw...

Page 347: ...osition sensor No normal signals are received from the crankshaft position sen sor Unable Unable 13 Front cylinder intake air pressure sensor open or short circuit Front cylinder intake air pressure sensor open or short circuit de tected Able Able 14 Front cylinder intake air pressure sensor hose system Front cylinder intake air pressure sensor hose system malfunction clogged or detached hose Able...

Page 348: ...n angle sensor open or short circuit Lean angle sensor open or short circuit detected Unable Unable 42 Speed sensor No normal signals are received from the speed sensor Able Able Neutral switch Open or short circuit is detected in the neutral switch 43 Fuel system voltage monitoring voltage The ECU is unable to monitor the battery voltage an open or short circuit in the line to the ECU Able Able 4...

Page 349: ...Sensor operation table and Actuator op eration table If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in the sensors and actuators check and repair the inner parts of the engine Fault code No Item Symptom Able un able to start Able un able to drive Er 1 ECU internal malfunc tion output signal error No signals are received fro...

Page 350: ...tic code number corresponding to the fault code number by pressing the SE LECT and RESET switches NOTE To decrease the selected diagnostic code number press the side of the SELECT switch Press the side of the SELECT switch for 1 second or longer to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the side of the switch Press the side of the s...

Page 351: ...tion of the blue black lead of the ECU is detected Open circuit in wire harness ECU coupler Malfunction in ECU 20 21 Coolant temperature sen sor open or short circuit detected Open or short circuit in wire harness Defective coolant temperature sensor Malfunction in ECU Improperly installed coolant temperature sensor 06 22 Air temperature sensor open or short circuit detect ed Open or short circuit...

Page 352: ...n wire harness Defective lean angle sensor Malfunction in ECU 08 42 No normal signals are re ceived from the speed sen sor Open circuit is detected in the neutral switch Open circuit in wire harness Defective speed sensor Malfunction in speed sensor detected Defective neutral switch Malfunction in the engine side of the neutral switch Malfunction in ECU 07 21 43 The ECU is unable to moni tor the b...

Page 353: ...d position 12 22 Check with throttle fully closed Fully opened position 87 107 Check with throttle fully open 03 Pressure difference atmospheric pressure and front cylinder intake air pressure Displays the front cylinder in take air pressure Set the engine stop switch to and then push the start switch If the dis play value changes the performance is OK 04 Pressure difference atmospheric pressure a...

Page 354: ...stand switch with the transmis sion in gear Sidestand retracted ON Sidestand extended OFF 21 Neutral switch Shift the transmission Neutral ON In gear OFF 60 EEPROM fault code dis play No history 00 History exists 01 or 02 Cylinder fault code If both cylinders are defec tive the display alternates every two seconds 61 Malfunction history code display No history 00 History exists Fault codes 12 70 I...

Page 355: ...k five times Connect an ignition checker 36 Front cylinder injector Actuates the front cylinder in jector five times at one sec ond intervals Illuminates the engine trou ble warning light Check the operating sound of the front cylinder injector five times 37 Rear cylinder injector Actuates the rear cylinder in jector five times at one sec ond intervals Illuminates the engine trou ble warning light...

Page 356: ...o tor relay for five cycles of five seconds ON 2 seconds OFF 3 seconds Illuminates the engine trou ble warning light and rotates the radiator fan motor Check the operating sound of the radiator fan motor re lay five times 52 Headlight relay Actuates the headlight relay for five cycles of five sec onds ON 2 seconds OFF 3 seconds Illuminates the engine trou ble warning light and head light Check the...

Page 357: ... coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between the crankshaft position sensor coupler and ECU cou pler gray gray black blue black blue 4 Defective crankshaft position s...

Page 358: ...ocking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between front cylinder intake air pressure sensor coupler and ECU coupler black blue black blue pink pink blue blue 3 Defective front cylinder intake air pressure sensor Exe...

Page 359: ...inder intake air pressure sen sor malfunction at intermediate elec trical potential Check and repair the connec tion Replace it if there is a malfunc tion 3 Connections Front cylinder intake air pressure sensor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler...

Page 360: ...lfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit between throttle position sensor coupler and ECU coupler blue blue yellow yellow black blue black blue 4 Throttle position sensor lead open cir cuit output voltage check Check for open circuit and re place the throttle position sen sor black blue yell...

Page 361: ... No 21 Symptom Coolant temperature sensor open or short circuit detect ed Diagnostic code No 06 Coolant temperature sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of coolant tempera ture sensor Check for looseness or pinching Turning the main switch to ON 2 Connections Coolant temperature sensor coupler Wire harness ECU coupler C...

Page 362: ...the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit between air temperature sensor coupler and ECU coupler brown white brown white black blue black blue 4 Defective air temperature sensor Execute ...

Page 363: ...or any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between O2 sensor coupler and ECU coupler gray white gray white red white red white gray black gray black black blue black blue 4 Check fuel pressure Refer t...

Page 364: ...dition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit between rear cylinder intake air pres sure sensor coupler and ECU coupler black blue black blue pink white pink white blue blue 3 Defective rear cylinder intake air pres sure sensor E...

Page 365: ...e curely 4 Defective rear cylinder intake air pres sure sensor Execute the diagnostic mode Code No 04 Replace if defective Refer to CHECKING THE IN TAKE AIR PRESSURE SEN SORS on page 8 101 Fault code No 30 Symptom The vehicle has overturned Diagnostic code No 08 Lean angle sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 The vehicle has overturned Rai...

Page 366: ...is a malfunction repair it and connect the coupler se curely Starting the en gine and oper ating it at idle 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between front cylinder ignition coil connector and ECU cou pler orange orange Between front cylinder ignition coil connector and right handle bar switch coupler black red black red 3 Defective fron...

Page 367: ... a malfunction repair it and connect the coupler se curely Starting the en gine and oper ating it at idle 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between rear cylinder ignition coil connector and ECU cou pler gray red gray red Between rear cylinder ignition coil connector and right handle bar switch coupler black red black red 3 Defective rear...

Page 368: ...SC unit coupler High engine idling speed is detected with the ISC valve stuck fully open even though signals for the valve to close are continuously being transmitted by the ECU Check that the ISC unit coupler is not disconnected The ISC valve is stuck fully open if it does not operate when the main switch is turned to OFF Touch the ISC unit with your hand and check if it is vibrating to confirm i...

Page 369: ...tion of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to ON 2 Open or short circuit in lead Repair or replace if there is an open or short circuit between lean angle sensor coupler and ECU coupler blue blue yellow green yellow green black blue black blue 3 Defective lean angle sensor Execute the diagnostic mode Code No 08 Replace if defec...

Page 370: ... it and connect the coupler se curely Starting the en gine and acti vating the speed sensor by operating the vehicle at 20 to 30 km h A 2 Open or short circuit in speed sensor lead Repair or replace if there is an open or short circuit Between speed sensor coupler and ECU coupler blue blue white yellow white yellow black blue black blue A 3 Gear for detecting vehicle speed has broken Replace if de...

Page 371: ...elay unit coupler and main switch blue yellow blue yellow Between main switch and ECU coupler blue black blue black B 3 Faulty shift drum neutral detection ar ea Replace if defective Refer to TRANSMISSION on page 5 79 B 4 Defective neutral switch Execute the diagnostic mode Code No 21 Replace if defective Refer to CHECKING THE SWITCHES on page 8 83 Fault code No 42 Symptom A No normal signals are ...

Page 372: ...rter relay coupler red red Between relay unit coupler fuel pump relay and diode 2 cou pler blue white blue white Between diode 2 coupler and right handlebar switch coupler black red black red 3 Malfunction or open circuit in relay unit fuel pump relay Execute the diagnostic mode Code No 09 Replace if defective If there is no malfunction with the relay unit fuel pump relay replace the ECU Fault cod...

Page 373: ...to CHARGING SYS TEM on page 8 13 4 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between battery and main fuse red red Between main fuse and main switch coupler black red red Between main switch coupler and ignition fuse brown brown Between ignition fuse and ECU coupler red white red white Fault code No 50 Symptom Faulty ECU memory When this malfuncti...

Page 374: ...mbly 4 Malfunction in ECU Replace the ECU Fault code No Er 2 Symptom No signals are received from the ECU within the specified duration Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness ECU coupler Meter assembly coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler...

Page 375: ...e meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 4 Symptom Non registered data has been received from the meter Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness ECU coupler Meter assembly coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler I...

Page 376: ...Ch G B Y B B Br W BLACK BLACK BLACK B L G W DARK GREEN B L W Gy W G DARK GRAY GRAY A WIRE HARNESS SUB WIREHARNESS B WIRE HARNESS SUB WIREHARNESS C WIRE HARNESS Gy R Br W Dg Dg Ch Ch ON OFF RESET Br Br Br Br R W R R Y Dg Dg B B C Ch Ch Dg Ch B B Ch Ch B B Y L B B B Y L R L R Br Br L Br Y Y Y B Br Y B G C C C B B C B R B R R Br W B R B R B R R L R W R L R W L W B L L W Y R W L B Gy W Y Gy R O Gy R B...

Page 377: ...ery 7 Fuel injection system fuse 15 Fuel pump relay 16 Diode 2 18 Fuel pump 28 ECU engine control unit 69 Engine stop switch 78 Ignition fuse Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 378: ...echarge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 83 Replace the main switch immobilizer unit 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 83 The engine stop switch is faulty Replace the right handlebar switch 5 Check the relay unit fuel pump re lay Refer to CHECKING THE RE LAYS on page 8 91 Replace the relay unit 6 Check the...

Page 379: ...el pump sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 65 Properly connect or repair the fuel pump system s wiring Replace the ECU Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 380: ...h Ch G B Y B B Br W BLACK BLACK BLACK B L G W DARK GREEN B L W Gy W G DARK GRAY GRAY A WIRE HARNESS SUB WIREHARNESS B WIRE HARNESS SUB WIREHARNESS C WIRE HARNESS Gy R Br W Dg Dg Ch Ch ON OFF RESET Br Br Br Br R W R R Y Dg Dg B B C Ch Ch Dg Ch B B Ch Ch B B Y L B B B Y L R L R Br Br L Br Y Y Y B Br Y B G C C C B B C B R B R R Br W B R B R B R R L R W R L R W L W B L L W Y R W L B Gy W Y Gy R O Gy R...

Page 381: ...lizer system 5 Main switch 6 Battery 12 Immobilizer unit 28 ECU engine control unit 39 Multi function meter 44 Immobilizer system indicator light 78 Ignition fuse Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 382: ...s impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made or all keys are lost the entire immobilizer system must be replaced Therefore it is highly rec ommended to use either standard key for driving and to keep the code re registering key in a safe place Do not submerse the keys in water Do not expose the ke...

Page 383: ...ition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours After that time the indicator light will stop flashing but the immobilizer system is still enabled Parts to be replaced Key registration re quirement Main switch immo bilizer unit Standard key ECU Accesso ry lock and key Main switch Immobiliz er unit Standa...

Page 384: ... key registration mode NOTE The existing standard key code is erased from the memory when the key registration mode is activated When the key registration mode is activated the immobilizer system indicator light flashes rapidly 4 While the indicator light is flashing turn the main switch to OFF remove the key and within 5 sec onds insert the second standard key to be registered into the main switc...

Page 385: ...de re registering key g First standard key h Second standard key i Registration mode A Registration of the second standard key is complete B Immobilizer system indicator light stops flashing when the registration of the second standard key is complete a Main switch ON b Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g Remaining standard key h Registration mode A If ...

Page 386: ...3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 83 Replace the main switch immobilizer unit 4 Check the entire immobilizer sys tem wiring Refer to CIRCUIT DIAGRAM on page 8 69 Properly connect or repair the immobilizer system wiring Check the condition each of the im mobilizer system circuits Refer to SELF DIAGNOSIS FAULT CODE INDICATION on page 8 75 Fault code Part Symptom Cause ...

Page 387: ...s and connector 2 Replace the main switch im mobilizer unit 3 Replace the ECU 54 IMMOBILIZER UNIT Codes transmitted between the ECU and the immobilizer unit do not match Noise interference or disconnected lead ca ble 1 Interference due to radio wave noise 2 Disconnected com munication harness 3 Immobilizer unit mal function 4 ECU failure The ECU or immobi lizer unit was re placed with a used unit ...

Page 388: ...IMMOBILIZER SYSTEM 8 77 a Light on b Light off Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 389: ...IMMOBILIZER SYSTEM 8 78 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 390: ...ELECTRICAL COMPONENTS 8 79 EAS27970 ELECTRICAL COMPONENTS 1 4 5 6 7 8 9 10 11 12 13 2 3 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 391: ...e sensor 4 Rear cylinder ignition coil 5 Front cylinder ignition coil 6 Sub wire harness 7 ECU engine control unit 8 Turn signal relay 9 Speed sensor 10 Neutral switch 11 Oil level switch 12 Horn 13 Air temperature sensor Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 392: ...ELECTRICAL COMPONENTS 8 81 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 393: ... fuse 9 Signaling system fuse 10 Main fuse 11 Battery 12 Lean angle sensor 13 Starter relay 14 Fuel injection system fuse 15 Relay unit 16 Radiator fan motor relay 17 Headlight relay 18 Sidestand switch 19 Rear brake light switch 20 Radiator fan motor Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 394: ... 5 7 8 3 4 1 Br L Br R L B L Y B Y R W B W Br W Dg Ch L W P W Y G B Y N Br W Ch Dg P B B R B Y B B Y L Y Y B Dg Ch Br W BLUE BLACK B Y P G R Y L B B Y Y G B W B P W P B R W B R Br L W Br B Br R R Br L ON OFF Br W Dg Ch Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 395: ...ch 5 Select switch 6 Engine stop switch 7 Start switch 8 Hazard switch 9 Neutral switch 10 Pass switch 11 Dimmer switch 12 Turn signal switch 13 Horn switch 14 Clutch switch 15 Sidestand switch Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 396: ...en the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch position is indicated by There is continuity between the red brown b...

Page 397: ...lb WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down CAUTION ECA3D81021 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the t...

Page 398: ...rage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit WARNING EWA13310 Never use a fuse with an amperage rating other than that specified Improvising or us ing a fuse with the wrong amperage rating may cause extensive damage to the electri cal system cause the lighting and ignition systems to malfunct...

Page 399: ...ill drop considerably Therefore take special care when charging the bat tery NOTE Since MF batteries are sealed it is not possible to check the charge state of the battery by mea suring the specific gravity of the electrolyte Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals 1 Remove Rider seat Tool kit tray Refer to GENERAL CHASSIS on page 4 1...

Page 400: ... contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the battery charger and let the bat tery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of an MF battery stabi lizes about 30 minutes after charging has been completed Therefore wait ...

Page 401: ...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 charging current written on the battery this type of battery charger cannot charge the MF battery A vari able voltage charger is recommended d Charge the battery until the battery s charg ing voltage is 15 V NOTE Set the charging time to 20 hours maximum e Measu...

Page 402: ...ay Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 R B R 2 1 4 3 L R L 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative batt...

Page 403: ...al as shown 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 Turn signal relay input voltage DC 12 V R Y G L Br Y B 1 2 3 4 L 1 2 3 4 G Y R W Br W Pocket tester 90890 03112 ...

Page 404: ...ow 2 No continuity Positive tester probe black yellow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe blue yellow 3 No continuity Positive tester probe blue yellow 3 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe sky blue white 4 No continuity Positive tester probe sky blue white 4 Negative tes...

Page 405: ...for no continuity EAS3D81017 CHECKING THE IGNITION SPARK GAP 1 Check Ignition spark gap Out of specification Perform the ignition system troubleshooting starting with step 5 Refer to TROUBLESHOOTING on page 8 4 NOTE If the ignition spark gap is within specification the ignition system circuit is operating normally Pocket tester 90890 03112 Analog pocket tester YU 03112 C Continuity Positive tester...

Page 406: ...e EAS28100 CHECKING THE IGNITION COILS The following procedure applies to all of the igni tion coils 1 Check Primary coil resistance Out of specification Replace a Disconnect the ignition coil connectors from the ignition coil terminals b Connect the pocket tester Ω 1 to the igni tion coil as shown c Measure the primary coil resistance 2 Check Secondary coil resistance Out of specification Replace...

Page 407: ...nsor output voltage Out of specification Replace a Connect the lean angle sensor coupler to the wire harness b Connect the pocket tester DC 20 V to the lean angle sensor coupler as shown Secondary coil resistance 8 64 12 96 kΩ Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe black red 1 Negative tester probe spark plug lead 2 Crankshaft position sensor resis tance 24...

Page 408: ...the vicinity b Check the starter motor operation EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the crank shaft position sensor stator assembly a Connect the pocket tester Ω 1 to the stator coil coupler as shown b Measure the stator coil resistance EAS28170 CHECKING THE RECTIFIER REGULATOR 1 Check...

Page 409: ...ew in direction a or b until the specified horn sound is obtained EAS3D81012 CHECKING THE OIL LEVEL SWITCH 1 Drain Engine oil 2 Remove Oil level switch from the crankcase 3 Check Oil level switch resistance Out of specification Replace the oil level switch Charging voltage 14 V at 5000 r min Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe black red 1 Negative tester...

Page 410: ...ing light is OK Warning light does not come on Replace the meter assembly Warning light flashes eight times then goes off for three seconds in a repeated cycle mal function detected in fuel sender or thermistor Replace the fuel sender EAS3D81015 CHECKING THE OIL LEVEL WARNING LIGHT This model is equipped with a self diagnosis de vice for the oil level detection circuit Pocket tester 90890 03112 An...

Page 411: ... 1 Check Radiator fan motor Faulty rough movement Replace a Disconnect the radiator fan motor coupler from the wire harness b Connect a battery DC 12 V as shown c Check the radiator fan motor movement EAS28260 CHECKING THE COOLANT TEMPERATURE SENSOR 1 Remove Coolant temperature sensor Refer to THERMOSTAT on page 6 4 WARNING EWA14130 Handle the coolant temperature sensor with special care Never sub...

Page 412: ...3 Install Throttle position sensor NOTE When installing the throttle position sensor ad just its angle properly Refer to ADJUSTING THE THROTTLE POSITION SENSOR on page 7 9 EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSORS The following procedure applies to both of the in take air pressure sensors 1 Check Intake air pressure sensor output voltage Out of specification Replace a Connect the pocket te...

Page 413: ... a Connect the pocket tester Ω 100 to the air temperature sensor terminal as shown b Immerse the air temperature sensor 1 in a container filled with water 2 NOTE Make sure that the air temperature sensor termi nals do not get wet c Place a thermometer 3 in the water d Slowly heat the water and then let it cool down to the specified temperature e Measure the air temperature sensor resis tance Air t...

Page 414: ...ELECTRICAL COMPONENTS 8 103 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 415: ...2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 416: ...fuel 2 Fuel pump Faulty fuel pump Faulty relay unit fuel pump relay 3 Fuel cock Clogged or damaged fuel hose 4 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn...

Page 417: ...adjusted shift rod Bent shift shaft Shift drum 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 dru...

Page 418: ... brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper kit 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 EAS28650 FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged ...

Page 419: ...eadlight bulb life expired Tail brake light does not come on Wrong tail brake light bulb Too many electrical accessories Incorrect connection Burnt out tail brake light bulb Tail brake light bulb burnt out Wrong tail brake light bulb Faulty battery Incorrectly adjusted rear brake light switch Tail brake light bulb life expired Turn signal does not come on Faulty turn signal switch Faulty turn sign...

Page 420: ...ft handlebar switch 53 Pass switch 54 Dimmer switch 55 Clutch switch 56 Turn signal switch 57 Horn switch 58 Rear right turn signal light 59 Rear left turn signal light 60 Front right turn signal light 61 Front left turn signal light 62 Headlight 63 Auxiliary light 64 Accessory light OPTION 65 Right handlebar switch 66 Front brake light switch 67 Select switch 68 Reset switch 69 Engine stop switch...

Page 421: ...Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 422: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 423: ...GRAY BLACK BLACK GRAY GRAY BLACK BLACK B Ch Ch G B Y B B Br W BLACK BLACK BLACK B L G W DARK GREEN B L W Gy W G DARK GRAY GRAY A WIRE HARNESS SUB WIREHARNESS B WIRE HARNESS SUB WIREHARNESS C WIRE HARNESS Gy R Br W Dg Dg Ch Ch ON OFF RESET Br Br Br Br R W R R Y Dg Dg B B C Ch Ch Dg Ch B B Ch Ch B B Y L B B B Y L R L R Br Br L Br Y Y Y B Br Y B G C C C B B C B R B R R Br W B R B R B R R L R W R L R ...

Page 424: ...8 49 50 51 52 54 53 55 56 57 58 76 75 77 78 79 80 59 60 61 62 63 65 66 67 68 69 70 71 72 73 74 64 N BLACK BLACK BLACK A WIRE HARNESS SUB WIREHARNESS B WIRE HARNESS SUB WIREHARNESS C WIRE HARNESS GRAY BLACK BLACK DARK GREEN BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLUE BLUE BLACK BLACK BLACK BLUE BLUE GRAY GRAY BLACK BLACK GRAY GRAY BLACK BLACK BLACK BLACK BLACK DARK GREEN DARK GRAY GRAY TAI...

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