Yamaha YZF-R1 2007 Service Manual Download

Page: 169 / 442

REAR BRAKE

4-40

EAS22590

REMOVING THE REAR BRAKE CALIPER

NOTE:

Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.

1. Remove:

• Union bolt “1”
• Copper washers “2”
• Brake hose “3”
• Brake caliper “4”

NOTE:

Put the end of the brake hose into a container
and pump out the brake fluid carefully.

EAS22600

DISASSEMBLING THE REAR BRAKE CALI-
PER
1. Remove:

• Brake caliper piston “1”
• Brake caliper piston seals “2”

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Secure the brake caliper piston with a

piece of wood “a”

b. Blow compressed air into the brake hose

joint opening “b” to force out the piston from
the brake caliper.

WARNING

EWA13550

• Cover the brake caliper piston with a rag.

Be careful not to get injured when the pis-
ton is expelled from the brake caliper.

• Never try to pry out the brake caliper pis-

ton.

c. Remove the brake caliper piston seals.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS22640

CHECKING THE REAR BRAKE CALIPER

1. Check:

• Brake caliper pistons “1”

Rust/scratches/wear

→

Replace the brake

caliper pistons.

• Brake caliper cylinders “2”

Scratches/wear

→

Replace the brake cali-

per assembly.

• Brake caliper body “3”

Cracks/damage

→

Replace the brake cali-

per assembly.

• Brake fluid delivery passages

(brake caliper body)
Obstruction

→

Blow out with compressed

air.

Recommended brake component
replacement schedule
Brake pads

If necessary

Piston seals

Every two years

Brake hoses

Every four years

Brake fluid

Every two years and
whenever the brake is
disassembled

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

email: [email protected]

Summary of Contents for YZF-R1 2007

Page 1: ...2007 YZF R1 W 4C8 28197 E0 SERVICE MANUAL Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 2: ...dition October 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: ...rom his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and will appear in future editions of this manual where applicable NOTE This Service Manual contains information regarding pe...

Page 4: ... section title 2 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 3 Numbers are given in the order of the jobs in the exploded diagram A number indicates a disas sembly step 4 Symbols indicate parts to be lubricated or replaced 5 Refer to SYMBOLS A job instruction chart accompanies the exploded diagram providing the...

Page 5: ...ening 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 G M E B LS M 9 10 11 12 13 14 15 16 LT New T R 1 2 3 4 5 6 7 8 16 Replace the part Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Code...

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

Page 7: ...AL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING 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: ...Intake 1 4 IMPORTANT INFORMATION 1 12 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 12 REPLACEMENT PARTS 1 12 GASKETS OIL SEALS AND O RINGS 1 12 LOCK WASHERS PLATES AND COTTER PINS 1 12 BEARINGS AND OIL SEALS 1 13 CIRCLIPS 1 13 CHECKING THE CONNECTIONS 1 14 SPECIAL TOOLS 1 15 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

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

Page 11: ... precise and finely tuned man ner To accommodate 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 detected by various...

Page 12: ...ition sensor intake air pressure sensor intake air temperature sensor coolant temper ature sensor atmospheric pressure sensor cylinder identification sensor lean angle sensor speed sensor and O2 sensor enable the ECU to determine 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 e...

Page 13: ...C I system calculates the value from the engine revolution number and throttle opening rate activates the intake air funnel with the electronic control motor drive to control the intake pipe length in order to gain the high power output in all revolution ranges from low speeds to high speeds Aims and advantages of using YCC T system Increased engine power By shortening the air intake path higher e...

Page 14: ...using the motor The intake pipe length switching operation in a minute time is now available by means of the motor drive using the electronic control The smooth power characteristic is provided which does not let an operator feel the switching action by the optimization of its switching revolution number and the most suitable application of engine at the time of changing the revolution A Down posi...

Page 15: ... motor driver operation sens ing shut off circuit 10 Throttle servo motor driver operation sensing feedback emergency stop 11 Emergency stop 12 Engine revolution pulse signal 13 Sensor input 14 Neutral switch 15 Crankshaft position sensor 16 Speed sensor 17 Coolant temperature sensor 18 Atmospheric pressure sensor 19 Intake funnel servo motor driver 20 Intake funnel servo motor Manuals by Motomatr...

Page 16: ...sition two signals 9 Throttle position two signals 10 Engine revolution 11 Vehicle speed 12 Coolant temperature 13 Neutral In gear 14 Atmospheric pressure 15 Throttle servo motor 16 ECU engine control unit 17 Base map 18 Idle speed control 19 Calculated throttle valve opening angle 20 Base map 21 Air funnel position Calculation value 22 Intake funnel servo motor Manuals by Motomatrix www motomatri...

Page 17: ...s the SELECT button for at least one second Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to ON the tachome ter needle will sweep once across the r min range and then return to zero r min in order to test the electrical circuit CAUTION ECA4C81017 Do not operate the engine in the tachome ter red zone R...

Page 18: ...digits will start flashing Release the SELECT button and then push it again for a few seconds until the stopwatch digits stop flashing Standard measurement 1 Push the RESET button to start the stop watch 2 Push the SELECT button to stop the stop watch 3 Push the SELECT button again to reset the stopwatch Split time measurement 1 Push the RESET button to start the stop watch 2 Push the RESET button...

Page 19: ...ror code NOTE If the display indicates error code 52 this could be caused by transponder interference If this error code appears try the following 1 Use the code re registering key to start the engine NOTE Make sure there are no other immobilizer keys close to the main switch and do not keep more than one immobilizer key on the same key ring Immobilizer system keys may cause signal interference wh...

Page 20: ...eactivated in other words it will not come on or flash This setting is selected when the indicator light flashes once every two seconds 2 Push the SELECT button to confirm the selected indicator light activity The control mode changes to the shift timing indicator light activation function ry two seconds To set the shift timing indicator light activation function NOTE The shift timing indicator li...

Page 21: ...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 sur faces oil seal lips and O rings...

Page 22: ...ate CAUTION ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfaces EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always 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 23: ...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 24: ...part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 71 Radiator cap tester 90890 01325 Radiator pressure tester YU 24460 01 6 3 Radiator cap tester adapter 90890 01352 Radiator pressure tester adapter YU 33984 6 3 Steering nut wrench 90890 01403 Spanner wr...

Page 25: ... 56 4 57 Fork spring compressor 90890 01441 YM 01441 4 52 4 57 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 55 Vacuum gauge 90890 03094 Carburetor synchronizer YU 44456 3 7 Compression gauge 90890 03081 Engine compression tester YU 33223 3 11 Extension 90890 04136 3 11 Tool name Tool No Illustration Reference pages Manuals by Motomatrix www motomatrix co uk The Solu...

Page 26: ...078 Water pump seal installer YM 33221 A 6 11 Universal clutch holder 90890 04086 YM 91042 5 47 5 51 Valve guide remover ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 5 25 Valve guide remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 5 25 Valve guide installer ø5 90890 04098 Valve guide installer 5 0 mm YM 04098 5 25 Tool name Tool No Illustration Reference pages Manuals by Motomat...

Page 27: ...amer 4 5mm YM 04118 5 25 Ignition checker 90890 06754 Opama pet 4000 spark checker YU 34487 8 95 Yamaha bond No 1215 Three Bond No 1215 90890 85505 5 67 6 11 Pivot shaft wrench 90890 01471 Frame spanner socket YM 01471 5 7 Pivot shaft wrench adapter 90890 01476 5 7 Tool name Tool No Illustration Reference pages Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys ...

Page 28: ... 14 Valve lapper 90890 04101 Valve lapping tool YM A8998 3 5 Fuel pressure adapter 90890 03176 YM 03176 7 6 Pressure gauge 90890 03153 YU 03153 3 14 7 6 Camshaft wrench 90890 04143 YM 04143 5 11 5 16 Ring nut wrench 90890 01507 YM 01507 4 68 4 70 Tool name Tool No Illustration Reference pages Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatr...

Page 29: ...S 1 20 Damper rod holder 22 mm 90890 01365 4 69 4 70 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 30: ...SPECIAL TOOLS 1 21 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 31: ... ENGINE TIGHTENING TORQUES 2 14 CHASSIS TIGHTENING TORQUES 2 18 LUBRICATION POINTS AND LUBRICANT TYPES 2 21 ENGINE 2 21 CHASSIS 2 22 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 ENGINE OIL LUBRICATION CHART 2 23 LUBRICATION DIAGRAMS 2 25 COOLING SYSTEM DIAGRAMS 2 35 CABLE ROUTING 2 39 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 32: ...dth 720 mm 28 3 in Overall height 1110 mm 43 7 in Seat height 835 mm 32 9 in Wheelbase 1415 mm 55 7 in Ground clearance 135 mm 5 31 in Minimum turning radius 3400 mm 133 9 in Weight With oil and fuel 200 kg 441 lb Maximum load 195 kg 430 lb Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 33: ...0 L 3 28 US qt 2 73 Imp qt Oil filter Oil filter type Formed Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance 0 010 0 100 mm 0 0004 0 0039 in Limit 0 18 mm 0 0071 in Outer rotor to oil pump housing clearance 0 090 0 190 mm 0 0035 0 0074 in Limit 0 26 mm 0 0102 in Oil pump housing to inner and outer rotor clearance 0 06 0 13 mm 0 0024 0 0051 in Limit 0 20 mm 0 0079 in Bypass...

Page 34: ...450 34 550 mm 1 3563 1 3602 in Limit 34 350 mm 1 3524 in Intake B 25 170 25 270 mm 0 9909 0 9949 in Limit 25 070 mm 0 9870 in Exhaust A 33 550 33 650 mm 1 3209 1 3248 in Limit 33 450 mm 1 3169 in Exhaust B 25 192 25 292 mm 0 9918 0 9957 in Limit 25 092 mm 0 9879 in Camshaft runout limit 0 030 mm 0 0012 in Timing chain Model number of links RH2020 124 Tensioning system Automatic Valve clearance col...

Page 35: ... 4 425 mm 0 1742 in Valve guide inside diameter intake 5 000 5 012 mm 0 1969 0 1973 in Limit 5 050 mm 0 1988 in Valve guide inside diameter exhaust 4 500 4 512 mm 0 1772 0 1776 in Limit 4 550 mm 0 1791 in Valve stem to valve guide clearance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clearance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 00...

Page 36: ...gf at 33 00 mm 1 299 in Spring tilt intake 2 5 1 7 mm Spring tilt exhaust 2 5 1 7 mm Winding direction intake Clockwise Winding direction exhaust Clockwise Cylinder Bore 77 000 77 010 mm 3 0315 3 0319 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in Piston Piston to cylinder clearance 0 010 0 035 mm 0 0004 0 0014 in Limit 0 12 mm 0 0047 in Diameter D 76 975 76 990 mm 3 0305 ...

Page 37: ...06 0 09 in End gap installed 0 10 0 40 mm 0 0039 0 0157 in Connecting rod Oil clearance using plastigauge 0 034 0 058 mm 0 0013 0 0023 in Bearing color code 1 Blue 2 Black 3 Brown 4 Green Crankshaft Width A 55 20 56 60 mm 2 173 2 228 in Width B 298 75 300 65 mm 11 76 11 84 in Runout limit C 0 030 mm 0 0012 in Big end side clearance D 0 160 0 262 mm 0 0063 0 0103 in Journal oil clearance using plas...

Page 38: ... 1 90 2 10 mm 0 075 0 083 in Plate quantity 8 pcs Warpage limit 0 10 mm 0 0039 in Clutch spring free length 43 80 mm 1 72 in Spring quantity 6 pcs Transmission Transmission type Constant mesh 6 speed Primary reduction system Spur gear Primary reduction ratio 65 43 1 512 Secondary reduction system Chain drive Secondary reduction ratio 45 17 2 647 Operation Left foot operation Manuals by Motomatrix ...

Page 39: ...turer 4C8 DENSO Maximum consumption amperage 6 0 A Output pressure 324 0 kPa 46 1 psi 3 24 kgf cm Fuel injector Model quantity 297500 1110 4 Manufacturer DENSO Throttle body Type quantity 45EIDW 1 Manufacturer MIKUNI ID mark 4C81 00 Throttle valve size 50 Throttle position sensor Resistance 2 0 3 0 kΩ Output voltage at idle 0 63 0 73 V Idling condition Engine idling speed 1150 1250 r min Intake va...

Page 40: ...er model PIRELLI DIABLO CORSA L Wear limit rear 0 8 mm 0 03 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 2 50 bar Rear 290 kPa 42 psi 2 90 kgf cm 2 90 bar Loading condition 90 195 kg 198 430 lb Front 250 kPa 36 psi 2 50 kgf cm 2 50 bar Rear 290 kPa 42 psi 2 90 kgf cm 2 90 bar High speed riding Front 250 kPa 36 psi 2 50 kgf cm 2 50 ...

Page 41: ...72 in Fork spring free length 237 5 mm 9 35 in Limit 232 8 mm 9 17 in Collar length 100 0 mm 3 94 in Installed length 223 0 mm 8 78 in Spring rate K1 9 07 N mm 51 79 lb in 0 92 kgf mm Spring stroke K1 0 0 120 0 mm 0 00 4 72 in Inner tube outer diameter 43 0 mm 1 69 in Inner tube bending limit 0 2 mm 0 01 in Optional spring available No Recommended oil Suspension oil 01 or equivalent Quantity 513 0...

Page 42: ...A SHINDENGEN Regulated voltage DC 14 2 14 8 V Rectifier capacity 50 0 A Withstand voltage 40 0 V Battery Model YTZ10S Voltage capacity 12 V 8 6 Ah Specific gravity 1 310 Manufacturer GYM Ten hour rate amperage 0 90 A Headlight Bulb type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 55 0 W 4 Auxiliary light 12 V 5 0 W 2 Tail brake light LED Front turn signal light 12 V 10 0 W 2 Rear tur...

Page 43: ...12 NIKKO Maximum amperage 3 0 A Coil resistance 1 15 1 25 Ω Performance 105 113 dB 2m Turn signal hazard relay Relay type Full transistor Model manufacturer FE218BM DENSO Built in self canceling device No Turn signal blinking frequency 75 0 95 0 cycles min Wattage 10 W 2 0 3 4 W Oil level gauge Model manufacturer 5VY SOMIC ISHIKAWA Servo motor Model manufacturer 5VY YAMAHA Fuses Main fuse 50 0 A H...

Page 44: ...a crisscross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Com ponents 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 45: ...ump inlet pipe bolt front side M6 1 10 Nm 1 0 m kg 7 2 ft lb Oil water pump drive sprocket bolt M6 1 15 Nm 1 5 m kg 11 ft lb Water pump bolt M6 2 12 Nm 1 2 m kg 8 7 ft lb Thermostat cover nut M6 2 10 Nm 1 0 m kg 7 2 ft lb Thermostat inlet pipe bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Oil cooler bolt M20 1 63 Nm 6 3 m kg 46 ft lb Engine oil drain bolt M14 1 43 Nm 4 3 m kg 31 ft lb Oil pipe bolt M6 2 10 N...

Page 46: ...case bolt main journal M9 10 See NOTE Crankcase bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Crankcase bolt M6 8 10 Nm 1 0 m kg 7 2 ft lb Crankcase bolt M8 1 24 Nm 2 4 m kg 17 ft lb Crankcase bolt M8 5 24 Nm 2 4 m kg 17 ft lb Generator rotor cover bolt M6 4 12 Nm 1 2 m kg 8 7 ft lb Generator rotor cover bolt M8 3 22 Nm 2 2 m kg 16 ft lb Drive sprocket cover bolt M6 3 12 Nm 1 2 m kg 8 7 ft lb Crankcase cover...

Page 47: ...assembly stay bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Starter clutch idler gear bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Clutch boss nut M20 1 115 Nm 11 5 m kg 83 ft lb Use a lock washer Clutch spring bolt M6 6 10 Nm 1 0 m kg 7 2 ft lb Drive sprocket nut M22 1 85 Nm 8 5 m kg 61 ft lb Use a lock washer Bearing plate bolt M6 3 12 Nm 1 2 m kg 8 7 ft lb Shift bar stopper plate bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb ...

Page 48: ...t lb with a torque wrench follow ing the tightening order 2 Loosen all the bolts one by one following the tightening order and then tighten them to 20 Nm 2 7 m kg 14 ft lb again 3 Retighten the bolts further to reach the specified angle 56 61 Cylinder head tightening sequence Crankcase tightening sequence Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email ...

Page 49: ... 0 Nm 0 5 m kg 3 6 ft lb Rear view mirror nut M6 4 7 0 Nm 0 7 m kg 5 1 ft lb Front cowling and intake air duct panel screw M5 2 1 3 Nm 0 13 m kg 0 9 ft lb Grip end bolt M6 2 4 0 Nm 0 4 m kg 2 9 ft lb Horn bracket bolt M6 2 11 Nm 1 1 m kg 8 0 ft lb Coolant reservoir bolt M6 2 5 0 Nm 0 5 m kg 3 6 ft lb Left front engine mounting bolt M10 1 45 Nm 4 5 m kg 33 ft lb Right front engine mounting bolt M10...

Page 50: ... ft lb Fuel tank bolt rear M6 4 7 0 Nm 0 7 m kg 5 1 ft lb Fuel tank side cover screw M5 2 4 0 Nm 0 4 m kg 2 9 ft lb Rider seat bolt M6 2 7 0 Nm 0 7 m kg 5 1 ft lb Seat lock assembly bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Upper tail cover bolt M5 1 4 0 Nm 0 4 m kg 2 9 ft lb Battery box bolt M6 2 7 0 Nm 0 7 m kg 5 1 ft lb Lean angle sensor bolt M4 2 2 0 Nm 0 2 m kg 1 4 ft lb Footrest bracket bolt M8 4 2...

Page 51: ...nd face of the axle becomes partially concave to the end face of the fork 4 In the order from the pinch bolt 4 pinch bolt 3 pinch bolt 4 tighten each bolt to 21 Nm 2 1 m kg 15 ft lb without performing temporary tightening Main frame and rear frame bolt 1 Check the clearance between rear frame and main frame by thickness gauge 1 Insert adjusting shim s to eliminate the gap according to the chart as...

Page 52: ...pull rod Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Transmission gears wheel and pinion Main axle and drive axle Shift drum Shift forks and shift fork guide bars Cylinder head cover mating surface Yamaha bond No 1215 Cylinder head cover semicircular Yamaha bond No 1215 Crankcase mating surface Yamaha bond No 1215 Crankcase cover mating surface Yamaha bond No...

Page 53: ...arm pivot bearing Swingarm head pipe end oil seal and bush Oil seal relay arm connecting arm and rear shock absorber Seat lock assembly moving parts Sidestand pivoting pint and metal to metal moving parts Link and sidestand switch contact point Sidestand hook and spring Shift shaft joint Front wheel oil seal right and left Front axle shaft Rear wheel oil seal Rear wheel drive hub oil seal Rear whe...

Page 54: ...HART AND DIAGRAMS 2 23 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 55: ...ain gallery 7 AC magneto drive gear shower 8 Shift fork upper 9 Main axle 10 Mission shower 11 Drive axle 12 AC magneto axle 13 Piston cooler 14 Chain tensioner 15 Intake camshaft 16 Exhaust camshaft 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 25 EAS20410 LUBRICATION DIAGRAMS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 57: ...M CHART AND DIAGRAMS 2 26 1 Intake camshaft 2 Exhaust camshaft 3 Oil filter cartridge 4 Oil level switch 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 27 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 59: ...MS 2 28 1 Intake camshaft 2 Exhaust camshaft 3 Crankshaft 4 Oil cooler 5 Relief valve 6 Oil pipe 7 Oil strainer 8 Oil pump 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 29 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 61: ... AND DIAGRAMS 2 30 1 Oil filter cartridge 2 Oil level switch 3 Oil pump 4 Oil strainer 5 Oil pipe 6 Oil cooler Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 A A A A Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 63: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Main axle 2 Oil delivery pipe 3 Drive axle Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 65: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Cylinder head 2 Crankshaft Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 66: ...COOLING SYSTEM DIAGRAMS 2 35 EAS20420 COOLING SYSTEM DIAGRAMS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 67: ...COOLING SYSTEM DIAGRAMS 2 36 1 Water pump 2 Radiator 3 Radiator fan Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 68: ...COOLING SYSTEM DIAGRAMS 2 37 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 69: ...COOLING SYSTEM DIAGRAMS 2 38 1 Radiator cap 2 Radiator 3 Oil cooler 4 Thermostat Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 70: ...CABLE ROUTING 2 39 EAS20430 CABLE ROUTING Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 71: ...speedometer lead should not be strained E To the headlight stay hole F Route by the rear side of the vehicle away from the right auxiliary light lead G Connect after passing over the upper side of the duct H To the turn signal light I Paste the latch of the clamp to be posi tioned toward the rear side of the vehicle J There should be no slack when clamping Point the tip of the clamp excessive part...

Page 72: ...CABLE ROUTING 2 41 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 73: ...nder bracket G Clamp the leads inside the front fork of the vehicle Point the exit of the horn lead to the left front fork side H Fit in the clamp from the inner side to the outer side of the vehicle so that the return side is positioned upper and the pull side is lower at the upper side of the vehicle above the brake hose I 0 to 30 mm 0 to 1 18 in J Route two throttle cables behind the brake hose...

Page 74: ...CABLE ROUTING 2 43 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 75: ... cable and coolant reser voir drain hose with a clamp G To the engine H Clamp the coolant reservoir drain hose to the lower side of the vehicle Fasten the clutch cable and coolant reser voir drain hose with a clamp I 80 to 100 mm 3 15 to 3 94 in J Cut the clamp tip leaving 2 to 4 mm 0 08 to 0 16 in K Route the rear brake light switch lead by the outer side of the vehicle than the O2 sensor lead an...

Page 76: ...CABLE ROUTING 2 45 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 77: ... the fuel tank drain hose and fuel tank breather hose through the hole of the cover from the outside of the water pipe after passing the water hose through first Any direction of the hose cut edge can be accepted I 40 to 60mm 1 57 to 2 36 in J Route the sidestand switch lead by the inside of the water hose and water pipe K Route the oil level switch lead by the inside of the water hose and water p...

Page 78: ...CABLE ROUTING 2 47 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 79: ...ds should be routed over the vehicle s upper side above the heat protector O To the fuel pump P To the speed sensor Q Clamp the wire harness winding in and insert it to the frame hole R Install the leads so that the engine ground lead is positioned lower and the battery negative lead to be upper Install the protrusion of each lead to be above the vehicle S It should not be positioned on the harnes...

Page 80: ...CABLE ROUTING 2 49 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 81: ...ten the battery negative lead wire har ness and starter motor lead with a clamp B Point the tip of the clamp excessive part to the inside of the vehicle Fasten the wire harness with a clamp C Hold down the clamp tips after passing each lead D Insert the leads to the rear frame hole E Insert the clamp from the vehicle front to the rear side and fasten each leads cou pler and onionhead to the tail b...

Page 82: ...CABLE ROUTING 2 51 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 83: ... does not come off Make sure that no foreign matter is caught in the sealing section It is prohibited to wear the cotton work gloves or equivalent coverings F After item E mentioned above is finished check that the clamp is inserted from the down side a b and c sections are per fectly equipped G This part works as a dropout stopper H Fuel piping connector attachment direc tions engine side Always ...

Page 84: ...CABLE ROUTING 2 53 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 85: ...ANT LEVEL 3 19 CHECKING THE COOLING SYSTEM 3 20 CHANGING THE COOLANT 3 20 CHASSIS 3 23 ADJUSTING THE FRONT DISC BRAKE 3 23 ADJUSTING THE REAR DISC BRAKE 3 23 CHECKING THE BRAKE FLUID LEVEL 3 24 CHECKING THE FRONT BRAKE PADS 3 24 CHECKING THE REAR BRAKE PADS 3 25 CHECKING THE FRONT BRAKE HOSES 3 25 CHECKING THE REAR BRAKE HOSE 3 25 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 25 BLEEDING THE HYDRAULIC B...

Page 86: ...M 3 37 CHECKING AND CHARGING THE BATTERY 3 37 CHECKING THE FUSES 3 37 REPLACING THE HEADLIGHT BULBS 3 37 ADJUSTING THE HEADLIGHT BEAMS 3 38 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 87: ...Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 88: ...formed by a Yamaha dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READ ING 1000 km Annual check 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or dam age 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 4 Air filter ele ment Replace 5 Clutch Check operation Adjust 6 Front brak...

Page 89: ... lithium soap based grease 18 Sidestand Check operation Lubricate 19 Sidestand switch Check operation 20 Front fork Check operation and for oil leakage 21 Shock absorber assembly Check operation and shock absorber for oil leakage 22 Rear suspen sion relay arm and connect ing arm pivot ing points Check operation 23 Fuel injection system Adjust synchronization 24 Engine oil Change Check oil level an...

Page 90: ...ry four years and if cracked or damaged 29 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 30 Air induction system Check the air cut off valve reed valve and hose for damage Replace any damaged parts if nec essary 31 Muffler and exhaust pipe Check the screw clamp for loose ness 32 EXUP syst...

Page 91: ... Refer to RADIATOR on page 6 1 2 Remove Ignition coils Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS on page 5 9 3 Remove Pickup rotor cover 1 4 Measure Valve clearance Out of specification Adjust a Turn the crankshaft counterclockwise b When piston 1 is at TDC on the compres sion stroke align the TDC mark a on the generator rotor with the mark b on the crankcase NO...

Page 92: ...ve pad from falling into the crankcase Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place b Select the proper valve pad from the follow ing table Valve clearance measuring sequence Cylinder 1 2 4 3 A Front A Degrees that the crankshaft is turned counterclockwise B Cylinder C Combustion cycle Cylinder 2 180 Cylinder 4 360 Cylinder 3...

Page 93: ...TE Lubricate the valve pad with molybdenum disulfide grease Lubricate the valve lifter with molybdenum disulfide oil The valve lifter must turn smoothly when rotated by hand Install the valve lifter and the valve pad in the correct place f Install the exhaust and intake camshafts timing chain and camshaft caps NOTE Refer to CAMSHAFTS on page 5 9 Lubricate the camshaft bearings camshaft lobes and c...

Page 94: ... Start the engine and let it warm up for sev eral minutes 7 Check Engine idling speed 8 Adjust Throttle body synchronization Basic procedure a Start the engine warm it up for several minutes and then let it run at the specified engine idling speed b Turn the bypass air screw 1 with a white paint mark out a little and then turn it in fully c Using the throttle body that has the bypass air screw wit...

Page 95: ...screw of the throttle body with the lowest vacuum pres sure After each step rev the engine two or three times each time for less than a second and check the synchronization again If an air screw was removed turn the screw 3 4 turn in and be sure to synchronize the throttle body NOTE The difference in vacuum pressure between two throttle bodies should not exceed 1 33 kPa 10 mmHg 9 Stop the engine a...

Page 96: ...CT and RESET but tons NOTE The CO adjustment volume appears on the tripmeter LCD To decrease the CO adjustment volume press the RESET button To increase the CO adjustment volume press the SELECT button 8 Release the switch to execute the selec tion 9 Simultaneously press the SELECT and RESET buttons to return to the cylinder selection step 5 10 Turn the main switch to OFF to cancel the mode EAS206...

Page 97: ...k Spark plug type Incorrect Change 6 Check Electrode 1 Damage wear Replace the spark plug Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 7 Clean Spark plugs with a spark plug cleaner or wire brush 8 Measure Spark plug gap a with a wire thickness gauge Out of specification Regap 9 Install Spark plugs Ignition coils NOTE Before installing the spark plug clean t...

Page 98: ...nking the engine NOTE The difference in compression pressure between cylinders should not exceed 100 kPa 1 kg cm 14 psi c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the minimum specification pour a teaspoonful of engine oil into the spark ...

Page 99: ...f CD a or higher and do not use oils labeled ENERGY CON SERVING II b Do not allow foreign materials to enter the crankcase 4 Start the engine warm it up for several minutes and then turn it off 5 Check the engine oil level again NOTE Before checking the engine oil level wait a few minutes until the oil has settled EAS20790 CHANGING THE ENGINE OIL 1 Start the engine warm it up for several minutes a...

Page 100: ...l Engine oil filler cap Lower cowlings Refer to GENERAL CHASSIS on page 4 1 11 Start the engine warm it up for several minutes and then turn it off 12 Check Engine for engine oil leaks 13 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 12 EAS20820 MEASURING THE ENGINE OIL PRESSURE 1 Check Engine oil level Below the minimum level mark a Add the recommended engine oil to the ...

Page 101: ...y bolt CAUTION ECA4C81014 Be careful to tighten too much EAS20870 ADJUSTING THE CLUTCH CABLE FREE PLAY 1 Check Clutch cable free play a Out of specification Adjust Oil pressure gauge set 90890 03153 YU 03153 Oil pressure adapter H 90890 03139 Engine oil pressure 230 kPa 2 3 psi 32 71 kgf cm Engine speed Approx 5000r min Oil temperature 80 0 90 0 C 176 00 194 00 F Engine oil pressure Possible cause...

Page 102: ...to GENERAL CHASSIS on page 4 1 Fuel tank side covers Fuel tank Refer to FUEL TANK on page 7 1 2 Remove Air filter case cover 1 Refer to GENERAL CHASSIS on page 4 1 3 Check Air filter element 1 Damage Replace NOTE Replace the air filter element every 40000 km 2400 mi of operation The air filter needs more frequent service if you are riding in unusually wet or dusty areas Clutch lever free play 10 0...

Page 103: ... make sure that the sealing surfaces are aligned to prevent any air leaks 6 Install Fuel tank Fuel tank side covers Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS21010 CHECKING THE THROTTLE BODY JOINTS The following procedure applies to all of the throttle body joints and intake manifolds 1 Remove Throttle bodies Refer to THROTTLE BODIES on page 7 4 2 Check Thro...

Page 104: ...CA13450 Make sure the crankcase breather hose is routed correctly 3 Install Fuel tank Fuel tank side covers Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 CAUTION ECA4C81016 To install the fuel tank check that the breather hose is not folded or pinched by the fuel tank EAS21080 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes a...

Page 105: ...to ON b Check the EXUP pulley position c Projection of the EXUP pulley position is between 1 and 2 d Loosen the both locknuts 3 e Turn the both adjusting nuts 4 in or out f Tighten the both locknuts Exhaust pipe nut 20 Nm 2 0 m kg 14 ft lb Exhaust pipe and exhaust valve pipe bolt 12 Nm 1 2 m kg 8 7 ft lb Exhaust valve pipe and catalyst pipe bolt 20 Nm 2 0 m kg 14 ft lb Catalyst pipe bolt 20 Nm 2 0...

Page 106: ...cle on a level surface NOTE Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Remove Lower cowlings Right side cowling Refer to GENERAL CHASSIS on page 4 1 3 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 CAUTION ECA13470 Adding water instea...

Page 107: ...Coolant reservoir cap 1 4 Drain Coolant from the coolant reservoir 5 Remove Radiator cap 2 WARNING EWA13030 A hot radiator is under pressure Therefore do not remove the radiator cap when the engine is hot Scalding hot fluid and steam may be blown out which could cause seri ous injury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radia tor cap and...

Page 108: ...freeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with water Do not mix different types of antifreeze 13 Install Radiator cap 14 Fill Coolant ...

Page 109: ...evel Refer to CHECKING THE COOLANT LEVEL on page 3 19 NOTE Before checking the coolant level wait a few minutes until the coolant has settled 18 Install Side cowlings Lower cowlings Refer to GENERAL CHASSIS on page 4 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 110: ... brake system CAUTION ECA13490 After adjusting the brake lever position make sure there is no brake drag EAS21190 ADJUSTING THE REAR DISC BRAKE 1 Check Brake pedal position distance a from the center of the footrest bracket bolt to the center of the brake pedal Out of specification Adjust 2 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting bolt 2 in direction a or b until the...

Page 111: ...akage 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 perfor mance 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 flu...

Page 112: ...se Refer to FRONT BRAKE on page 4 20 EAS21290 CHECKING THE REAR BRAKE HOSE 1 Check Brake hose 1 Cracks damage wear Replace 2 Check Brake hose clamp 2 Loose Connection Tighten the clamp bolt 3 Hold the vehicle upright and apply the front brake several times 4 Check Brake hose Brake fluid leakage Replace the dam aged hose Refer to REAR BRAKE on page 4 33 EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITC...

Page 113: ... difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed Hydraulic brake system a Fill the brake fluid reservoir to the proper level with the recommended brake fluid b Install the brake fluid reservoir diaphragm c Connect a clear plastic hose 1 tightly to the bleed screw 2 NOTE Bleeding ord...

Page 114: ...ain slack must be checked at the tightest point on the chain CAUTION ECA13550 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swingarm or cause an accident Therefore keep the drive chain slack within the speci fied limits 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that ther...

Page 115: ... the O rings EAS21500 CHECKING AND ADJUSTING THE STEER ING HEAD 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 front wheel is elevated 2 Check Steering head Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the stee...

Page 116: ...ck washer tabs a sit correctly in the ring nut slots b 5 Install Upper bracket Refer to STEERING HEAD on page 4 59 6 Measure Steering head tension NOTE Make sure all of the cables and wires are prop erly routed a Point the front wheel straight ahead b Install a plastic locking tie 1 loosely around the end of the handlebar as shown c Hook a spring gauge 2 onto the plastic locking tie d Hold the spr...

Page 117: ...he vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK on page 4 50 EAS21580 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA13150 Always adjust both front fork legs evenly Uneven adjustment ...

Page 118: ...nd damping is increased suspension is harder Direction b Rebound damping is decreased suspension is softer Rebound damping adjust posi tions Minimum 26 click s out Standard 10 click s out Maximum 1 click s out With the adjusting screw fully turned in Direction a Compression damping is increased suspension is harder Direction b Compression damping is decreased suspension is softer Compression dampi...

Page 119: ...ON ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Rebound damping a Turn the adjusting knob 1 in direction a or b Direction a Spring preload is increased suspension is harder Direction b Spring preload is decreased suspension is softer Spring preload adjusting posi tions Minimum 1 Standard 5 Maximum 9 Direction a Rebound damping is increased suspension is harder Dire...

Page 120: ...ssure Out of specification Regulate Direction a Compression damping is increased suspension is harder Direction b Compression damping is decreased suspension is softer Compression damping fast com pression damping adjusting positions Minimum 4 turn s out Standard 3 turn s out Maximum 0 turn s out With the adjusting screw fully turned in Direction a Compression damping is increased suspension is ha...

Page 121: ...ew tube as a set To avoid pinching the tube make sure the wheel rim band and tube are centered in the wheel groove Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 36 psi 2 50 kgf cm 2 5...

Page 122: ...heel NOTE After a tire or wheel has been changed or replaced always balance the wheel EAS21690 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement Replace damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace ...

Page 123: ... parts of the sidestand EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease Recommended lubricant Molybdenum disulfide grease Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomat...

Page 124: ...headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down 6 Install Headlight bulb Secure the new headlight bulbs with the headlight 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 ...

Page 125: ...ng screw 1 in direction a or b 3 Adjust Headlight beam horizontally a Turn the adjusting knob 2 in direction a or b Left headlight Right headlight 4 Install Front cowling inner panels Refer to GENERAL CHASSIS on page 4 1 Direction a Headlight beam is raised Direction b Headlight beam is lowered Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left Direction a H...

Page 126: ...ELECTRICAL SYSTEM 3 39 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 127: ...IPERS 4 28 ASSEMBLING THE FRONT BRAKE CALIPERS 4 28 INSTALLING THE FRONT BRAKE CALIPERS 4 29 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 30 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 30 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 31 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 31 REAR BRAKE 4 33 INTRODUCTION 4 38 CHECKING THE REAR BRAKE DISC 4 38 REPLACING THE REAR BRAKE PADS 4 38 REMOVING THE REA...

Page 128: ...REAR SHOCK ABSORBER 4 64 DISPOSING OF A REAR SHOCK ABSORBER 4 64 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 64 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 64 CHECKING THE CONNECTING ARM AND RELAY ARM 4 65 INSTALLING THE RELAY ARM 4 65 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 65 SWINGARM 4 66 REMOVING THE SWINGARM 4 68 CHECKING THE SWINGARM 4 69 INSTALLING THE SWINGARM 4 69 CHAIN DRIVE 4 71 R...

Page 129: ...Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 130: ...eat 1 3 Battery negative lead 1 4 Battery positive lead 1 5 ECU engine control unit 1 6 ECU lead coupler 1 Disconnect 7 ECU cover 1 8 Battery band 1 9 Battery 1 10 Battery seat 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 131: ...ng 2 5 Lower cowling front cover 1 6 Intake air duct panel 2 7 Intake air temperature coupler 1 Disconnect 8 Meter assembly coupler 1 Disconnect 9 Front cowling 1 10 Rear intake air duct 2 11 Front intake air duct 2 12 Rear view mirror 2 13 Windshield 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info ...

Page 132: ...efer to ENGINE REMOVAL on page 5 1 1 Upper tail cover 1 2 Tail brake light lead coupler 1 Disconnect 3 Turn signal light licence plate light lead coupler 4 Disconnect 4 Mud guard assembly 1 5 Lower tail cover 1 6 Tail brake light 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 133: ...Air filter 1 3 Intake funnel servo motor rod assembly 1 4 Intake funnel joint 2 5 Intake funnel 2 6 Intake funnel rod 2 7 Bushing 2 5 8 Air induction system hose 1 9 Crankcase breather hose 1 10 Air filter case 1 11 Intake funnel servo motor 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix...

Page 134: ... moves to the contacting surface between upper stopper and lower seating position when it is moved by hand Make sure that the intake funnel smoothly strokes from the upper position to the seating position by its own weight Air filter case Intake funnel joint bolt 1 CAUTION ECA4C81022 Do not remove the bolts from the intake funnel joint Intake funnel joint bolt 2 Intake funnel servo motor rod assem...

Page 135: ...er to FUEL INJECTION SYSTEM on page 8 29 b Set the engine stop switch to c Check that the intake funnel operate smoothly strokes from the upper position to the lower seating position Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 136: ...LLING THE COVER 1 Install Rear fender Tail cover NOTE To install the quick fastener push its pin so that it protrudes from the fastener head then insert the fastener into the cover and push the pin a in with screwdriver Make sure that the pin is flush with the fastener s head Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 137: ... caliper 1 4 Right front brake caliper 1 5 Front wheel axle pinch bolt 4 6 Front wheel axle bolt 1 7 Front wheel axle 1 8 Collar left and right 2 9 Dust cover left and right 2 10 Front wheel 1 11 Front brake disc left and right 2 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 138: ...ts to remove Q ty Remarks 1 Oil seal left and right 2 2 Wheel bearing left and right 1 3 Spacer 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 139: ...flat surface Bends Replace WARNING EWA13460 Do not attempt to straighten a bent wheel axle 2 Check Tire Front wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 33 and CHECKING THE WHEELS on page 3 35 3 Measure Radial wheel runout 1 Lateral wheel runout 2 Over the specified limits Replace 4 Check Wheel bearings Front wheel turns roughly or is loose Replace the wheel bearings Oil seals...

Page 140: ... 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 the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps d t...

Page 141: ...p between the fork legs 3 Insert the wheel axle NOTE Install the tire and wheel with the mark 1 pointing in the direction of wheel rotation 4 Lower the front wheel so that it is on the ground 5 Tighten Front wheel axle bolt Front wheel axle pinch bolt CAUTION ECA4C81001 Before tightening the wheel axle push down hard on the handlebar s several times and check if the front fork rebounds smoothly 6 ...

Page 142: ...sure that there is enough space between the brake pads before installing the brake cali pers on to the brake discs Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 143: ... 3 Adjusting bolt left and right 2 Loosen 4 Rear wheel axle nut 1 5 Washer 1 6 Rear wheel axle 1 7 Left adjusting block 1 8 Right adjusting block 1 9 Rear wheel 1 10 Rear brake caliper bracket 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 144: ... disc 1 2 Rear wheel sprocket 1 3 Collar 2 4 Dust cover 2 5 Oil seal 1 6 Bearing 1 7 Rear wheel drive hub 1 8 Rear wheel drive hub damper 6 9 Rear wheel 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 145: ...ts to remove Q ty Remarks 1 Collar 1 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Circlip 1 6 Bearing 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 146: ... Push the rear wheel forward and remove the drive chain from the rear wheel sprocket 5 Remove Left collar 1 Rear wheel drive hub 2 Rear wheel drive hub damper Right collar EAS22090 CHECKING THE REAR WHEEL 1 Check Wheel axle Rear wheel Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 10 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 33 and CHEC...

Page 147: ...USTING THE REAR WHEEL STATIC BALANCE NOTE After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 11 EAS22160 INSTALLING THE REAR WHEEL 1 Lubricate Wheel axle Wheel bearings Oil sea...

Page 148: ... Rear wheel axle nut 150 Nm 15 0 m kg 108 ft lb Rear brake caliper bolt front side 27 Nm 2 7 m kg 20 ft lb Rear brake caliper bolt rear side 22 Nm 2 2 m kg 16 ft lb Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 149: ...marks 1 Brake hose holder 1 2 Front brake caliper 1 3 Brake pad clip 4 4 Brake pad pin 2 5 Brake pad spring 2 6 Brake pad 4 7 Bleed screw 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 150: ...e fluid reservoir diaphragm 1 5 Brake fluid reservoir tank 1 6 Brake fluid reservoir hose 1 7 Brake lever 1 8 Front brake light switch lead connector 1 Disconnect 9 Union bolt 1 10 Copper washer 2 11 Brake hose 1 12 Brake master cylinder holder 1 13 Brake master cylinder 1 14 Front brake light switch 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The S...

Page 151: ...ob Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Bleed screw 1 3 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 152: ...fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 26 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake caliper 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 153: ...ke pad clip 4 2 Brake pad pin 2 3 Brake pad spring 2 4 Brake pad 4 5 Brake caliper piston 6 6 Brake caliper piston seal 12 7 Bleed screw 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 154: ...Remove Front wheel Refer to FRONT WHEEL on page 4 8 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 deflection turn the handlebar to the left or right to ensure that the front w...

Page 155: ...onnect the brake hose or disas semble the brake caliper 1 Remove Brake hose holder 1 Brake caliper 2 2 Remove Brake pad clips 1 Brake pad pins 2 Brake pad springs 3 3 Remove Brake pads 1 4 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 5 Install Brake pads Brake pad spring Front brake disc bolt 18 Nm 1 8 m kg 13 ft lb LOCTITE Brake pad lining thickness inner 4 ...

Page 156: ...rk a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 24 8 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 26 EAS22300 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers NOTE Before removing the brake caliper drain the br...

Page 157: ...ons Brake caliper cylinders 2 Scratches wear Replace the brake cali per assembly Brake caliper body 3 Cracks damage Replace the brake cali per assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA13600 Whenever a brake caliper is disassembled replace the piston seals EAS22410 ASSEMBLING THE FRONT BRAKE CALI PERS WARNING EWA13620 Before insta...

Page 158: ...ke 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 perfor mance 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 pain...

Page 159: ...ntainer under the master cylinder and the end of the brake hose 3 Remove Brake master cylinder holder Brake master cylinder EAS22510 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder Damage scratches wear Replace Brake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage scratches wear Replace 3 Ch...

Page 160: ...earance between the right handlebar switch and the brake master cylinder holder 2 Install Copper washers Brake hose Union bolt WARNING EWA13530 Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING on page 2 39 NOTE While holding the brake hose tighten the union bolt as shown Turn the handlebar to the left and right to make sure the brake hose does not touc...

Page 161: ...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 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 26 5 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLU...

Page 162: ... Remarks 1 Screw plug 1 2 Brake pad pin 1 3 Rear brake caliper 1 4 Brake pad shim 4 5 Brake pad 2 6 Bleed screw 1 7 Brake pad spring 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 163: ...p 1 3 Rear brake fluid reservoir diaphragm holder 1 4 Rear brake fluid reservoir diaphragm 1 5 Brake fluid reservoir tank 1 6 Brake fluid reservoir hose 1 7 Hose joint 1 8 Bush 1 9 Union bolt 1 10 Copper washer 2 11 Brake hose 1 12 Brake master cylinder 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email inf...

Page 164: ...rts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Hose joint 1 3 Bush 1 4 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 165: ...luid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 26 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake caliper 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 166: ...1 2 Brake pad pin 1 3 Brake pad 2 4 Brake pad shim 4 5 Brake pad spring 1 6 Brake caliper piston 1 7 Brake caliper piston seal 2 8 Bleed screw 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 167: ...R WHEEL on page 4 14 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 25 4 Measure Brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4...

Page 168: ...ad 4 5 Install Brake pad pin Screw plug Brake caliper 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 24 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 26 Brake pad lining thickness inner 6 0 mm 0 24 in Li...

Page 169: ... careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton c Remove the brake caliper piston seals EAS22640 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper pistons 1 Rust scratches wear Replace the brake caliper pistons Brake caliper cylinders 2 Scratches wear Replace the brake cali per assembly Brake caliper body 3 Cracks d...

Page 170: ... 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 Brake caliper 3 Install Brake pad shims Brake pads Brake pad spring Brake pad pin Screw plug Brake caliper 4 Fill Brake fluid reservoir with the specified amount of the recom mended brake fluid WARNING EWA13090 Use only the designated brake fluid Other brake fl...

Page 171: ... the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 26 EAS22700 REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove Union bolt 1 Copper washers 2 Brake hose 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose 2 Remove Brake master cylinder EAS22720 CHECKING THE REAR BRAKE MASTER CYLINDER 1 Check Brake master cylind...

Page 172: ...e 2 39 CAUTION ECA14160 When installing the brake hose onto the brake master cylinder make sure the brake pipe touches the projection a as shown 2 Fill Brake fluid reservoir to the maximum level mark b WARNING EWA13090 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 ...

Page 173: ... Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 26 4 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 24 5 Adjust Brake pedal position Refer to ADJUSTING THE REAR DISC BRAKE on page 3 23 6 Adjust Rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT S...

Page 174: ...ar switch 1 5 Clutch cable 1 6 Clutch lever holder 1 7 Throttle cable housing 1 8 Throttle cable 2 9 Throttle grip 1 10 Front brake light switch lead connector 2 Disconnect 11 Right handlebar switch 1 12 Clutch cable holder 1 13 Brake fluid reservoir tank 1 14 Brake master cylinder holder 1 15 Brake master cylinder 1 16 Steering damper 1 17 Handlebar pinch bolt 2 Loosen Manuals by Motomatrix www m...

Page 175: ...m nut 1 Loosen 21 Upper bracket 1 22 Left handlebar 1 23 Right handlebar 1 For installation reverse the removal proce dure Removing the handlebars Order Job Parts to remove Q ty Remarks Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 176: ...THE HANDLEBARS 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Right handlebar switch 1 NOTE Align the projection a on the right handlebar switch with the hole b on the right handlebar 3 Install Brake master cylinder holder 1 CAUTION ECA14260 Install the brake master cylinder holder with the UP mark facing...

Page 177: ...e end of the left handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rubber adhesive has fully dried 8 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY on page 3 14 9 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3 9 EAS4C81004 CHECKING THE STEERING DAMPER 1...

Page 178: ...HANDLEBARS 4 49 Bearing Damage pitting Replace It replace with the assembly Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 179: ...KE on page 4 20 Side cowling Refer to GENERAL CHASSIS on page 4 1 1 Front fender 1 2 Handlebar pinch bolt 1 Loosen 3 Upper bracket pinch bolt 1 Loosen 4 Cap bolt 1 Loosen 5 Lower bracket pinch bolt 1 Loosen 6 Front fork leg 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 180: ...t 1 5 Washer 1 6 Spacer 1 7 Fork spring 1 8 Dust seal 1 9 Oil seal clip 1 10 Oil seal 1 11 Washer 1 12 Damper rod assembly bolt 1 13 Copper washer 1 14 Damper rod assembly 1 15 Inner tube 1 16 Outer tube 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 181: ...t the front fork leg 4 Remove Front fork leg EAS22990 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove Cap bolt 1 from the damper adjusting rod Spacers 2 Nut 3 a Press down on the spacer with the fork spring compressor 4 b Install the rod holder 5 between the nut 3 and the spacer 2 NOTE Use the side of the rod holder that is marked A c Hold ...

Page 182: ...pring free length a Out of specification Replace 3 Check Damper rod assembly 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air Damper adjusting rod Bends damage Replace CAUTION ECA14200 The front fork leg has a built in damper adjusting rod and a very sophisticated internal construction which are particu larly sensitive to foreign material When disassembling a...

Page 183: ...Damper rod assembly bolt Cooper washer WARNING EWA4C81002 Always use new copper washer CAUTION ECA14210 Allow the damper rod assembly to slide slowly down the inner tube 2 until it pro trudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate Inner tube s outer surface 3 Tighten Damper rod assembly bolt 1 NOTE While holding the damper rod assembly with the damper...

Page 184: ... oil seal during installation 5 Install Washer Oil seal 1 with the fork seal driver 2 6 Install Oil seal clip 1 NOTE Adjust the oil seal clip so that it fits into the outer tube s groove 7 Install Dust seal 1 with the fork seal driver 2 8 Install Rod puller 1 Rod puller attachment 2 onto the damper rod 3 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 Fork seal driver 90...

Page 185: ...1 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed NOTE Be sure to bleed the front fork leg of any resid ual air 12 Measure Front fork leg oil level a Out of specification Correct 13 Install Damper adjusting rod locknut 1 Fork spring 2 Spacer 3 Damper adjusting rod 4 Cap bolt 5 Rod puller 90890 01437 Universal damping rod bleeding to...

Page 186: ...t the cap bolt distance c to specifica tion j Install the damper adjusting rod and cap bolt and then finger tighten the cap bolt k Hold the cap bolt and tighten the damper adjusting rod locknut to specification l Remove the rod holder and fork spring compressor Rod puller 90890 01437 Universal damping rod bleeding tool set YM A8703 Rod puller attachment M12 90890 01435 Universal damping rod bleedi...

Page 187: ...ap bolt 2 Handlebar pinch bolt 3 Upper bracket pinch bolt 4 WARNING EWA13680 Make sure the brake hoses are routed prop erly 3 Adjust Spring preload Rebound damping Compression damping Refer to ADJUSTING THE FRONT FORK LEGS on page 3 30 Lower bracket pinch bolt 23 Nm 2 3 m kg 17 ft lb Cap bolt 23 Nm 2 3 m kg 17 ft lb Handlebar pinch bolt 17 Nm 1 7 m kg 12 ft lb Upper bracket pinch bolt 26 Nm 2 6 m ...

Page 188: ...Refer to HANDLEBARS on page 4 45 1 Main switch lead coupler 2 Disconnect 2 Upper bracket bolt 2 3 Left handlebar assembly 1 4 Right handlebar assembly 1 5 Steering stem nut 1 6 Upper bracket 1 7 Front brake hose joint 1 8 Horn lead connector 1 Disconnect 9 Horn 1 10 Horn bracket 1 11 Lower bracket cover 1 12 Lock washer 1 13 Upper ring nut 1 14 Rubber washer 1 15 Lower ring nut 1 16 Lower bracket ...

Page 189: ... Lower bearing 1 21 Dust seal 1 22 Bearing outer race 2 For installation reverse the removal proce dure Removing the lower bracket Order Job Parts to remove Q ty Remarks Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 190: ...g rod 2 and hammer b Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer c Install a new dust seal and new bearing races 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 disassem bled replace the rubber seal 4 Check Upper brac...

Page 191: ...per bracket Steering stem nut NOTE Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to INSTALLING THE FRONT FORK LEGS on page 4 58 NOTE Temporarily tighten the upper and lower bracket pinch bolts Recommended lubricant Lithium soap based grease Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 192: ...on page 7 1 1 Self locking nut bolt 1 1 2 Self locking nut bolt 1 1 3 Self locking nut bolt 1 1 1 4 Self locking nut 1 5 Rear shock absorber assembly 1 6 Oil seal bearing collar 4 3 4 7 Collar self locking nut bolt 1 1 1 8 Connecting arm 1 9 Oil seal bearing collar 2 1 1 10 Catalytic converter pipe stay 1 11 Relay arm 1 For installation reverse the removal proce dure Manuals by Motomatrix www moto...

Page 193: ... its 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 Rear shock absorber a...

Page 194: ...Collars Bearings 2 Install Rear shock absorber assembly NOTE Install the connecting arm front bolt from the left 3 Tighten Rear shock absorber upper bracket nut Rear shock absorber assembly lower nut Relay arm to swingarm nut Recommended lubricant Lithium soap base grease Installed depth a 1 0 mm 0 04 in Installed depth b 4 0 mm 0 16 in A Left side B Right side Recommended lubricant Molybdenum dis...

Page 195: ... REMOVAL on page 5 1 1 Right footrest bracket 1 2 Drive chain adjusting bolt locknut 2 2 3 Drive chain guard 1 4 Rear fender 1 5 Brake hose holder 1 6 Pivot shaft nut washer 1 1 7 Pivot shaft ring nut washer 1 1 8 Pivot shaft 1 9 Swingarm 1 10 Drive chain 1 11 Dust cover 2 12 Washer 1 13 Drive chain guide 1 14 Spacer 1 15 Bearing 2 Manuals by Motomatrix www motomatrix co uk The Solution For Lost M...

Page 196: ...installation reverse the removal proce dure Removing the swingarm Order Job Parts to remove Q ty Remarks Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 197: ... side to side c If the swingarm side play is out of specifica tion check the spacers bearings washers and dust covers d Check the swingarm vertical movement B by moving the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the spacers bearings washers and dust cov ers 4 Remove Drive chain Refer to REMOVING THE DRIVE CHAIN on page 4 72 5 Remove Pivot shaf...

Page 198: ...r Washers Bearings 4 Check Dust covers 1 Spacer 2 Washer 3 Damage wear Replace Bearings 4 Damage pitting Replace EAS23380 INSTALLING THE SWINGARM 1 Lubricate Bearings Spacers Dust covers Pivot shaft 2 Install Bearing 1 Bearing 2 Washer 3 Damper rod holder 22 mm 90890 01365 Recommended cleaning solvent Kerosene Recommended lubricant Molybdenum disulfide grease Installed depth of bearing a 0 1 0 mm ...

Page 199: ...nut threads and mat ing surfaces with lithium soap based grease 6 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 27 5 Swingarm 6 Pivot shaft A Left side B Right side Pivot shaft 7 Nm 0 7 m kg 5 1 ft lb Damper rod holder 22 mm 90890 01365 Pivot shaft ring nut 65 Nm 6 5 m kg 47 ft lb Ring nut wrench 90890 01507 YM 01507 Pivot shaft nut 105 Nm 10 5 m kg 76 ft lb Drive cha...

Page 200: ...ob Parts to remove Q ty Remarks Swingarm Refer to SWINGARM on page 4 66 1 Drive chain guard 1 2 Drive chain 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 201: ...asurement at two or three dif ferent places 2 Check Drive chain Stiffness Clean and lubricate or replace 3 Clean Drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and remove any remaining dirt c Remove the drive chain from the kerosene and completely dry it CAUTION ECA4C81003 This vehicle has a drive chain with small rubber O rings 1 between the drive chain si...

Page 202: ...KET on page 4 18 EAS23480 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4 18 EAS23490 INSTALLING THE DRIVE CHAIN 1 Lubricate Drive chain 2 Install Drive chain 1 Drive sprocket 2 Washer Drive sprocket nut 3 NOTE While applying the rear brake tighten the drive sprocket nut Recommended lubricant Engine oil or chain lubricant suitable for O ring chains b Correct ...

Page 203: ...ACK on page 3 27 CAUTION ECA13550 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swingarm or cause an accident Therefore keep the drive chain slack within the speci fied limits Drive chain slack 30 0 40 0 mm 1 18 1 57 in Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info...

Page 204: ...CHAIN DRIVE 4 75 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 205: ...ING THE VALVE SPRINGS 5 27 CHECKING THE VALVE LIFTERS 5 28 INSTALLING THE VALVES 5 28 GENERATOR 5 30 REMOVING THE GENERATOR 5 32 INSTALLING THE GENERATOR 5 32 STARTER CLUTCH 5 34 REMOVING THE STARTER CLUTCH 5 35 CHECKING THE DAMPER 5 35 CHECKING THE STARTER CLUTCH 5 35 INSTALLING THE STARTER CLUTCH 5 36 CRANKSHAFT POSITION SENSOR 5 37 REMOVING THE CRANKSHAFT POSITION SENSOR 5 38 INSTALLING THE CRA...

Page 206: ...NSTALLING THE OIL WATER PUMP ASSEMBLY 5 62 INSTALLING THE OIL PAN 5 63 CRANKCASE 5 65 DISASSEMBLING THE CRANKCASE 5 67 CHECKING THE CRANKCASE 5 67 CHECKING THE BEARING AND OIL SEALS 5 67 ASSEMBLING THE CRANKCASE 5 67 CRANKSHAFT 5 69 REMOVING THE CONNECTING RODS AND PISTONS 5 71 REMOVING THE CRANKSHAFT ASSEMBLY 5 71 CHECKING THE CYLINDER AND PISTON 5 72 CHECKING THE PISTON RINGS 5 72 CHECKING THE P...

Page 207: ...CHECKING THE TRANSMISSION 5 90 INSTALLING THE TRANSMISSION 5 91 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 208: ...ive chain Loosen Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 27 1 Locknut 2 2 Shift rod 1 3 Sift arm 1 4 Drive sprocket cover 1 5 Drive sprocket nut 1 6 Lock washer 1 7 Drive sprocket 1 8 Plate 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 209: ...4 1 1 Right footrest bracket 1 2 Protector cover 1 3 Protector 1 4 EXUP valve pulley cover 1 5 EXUP cable 2 6 EXUP servo motor bracket 1 7 EXUP servo motor 1 8 O2 sensor 1 9 Muffler cover 2 10 Muffler 2 11 Gasket 2 12 Catalyst pipe assembly 1 13 Gasket 1 14 Exhaust valve pipe assembly 1 15 Exhaust valve pipe gasket 1 16 Exhaust pipe assembly 1 17 Exhaust pipe gasket 4 Manuals by Motomatrix www mot...

Page 210: ... installation reverse the removal proce dure Removing the exhaust pipe Order Job Parts to remove Q ty Remarks Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 211: ... 1 2 Pulley 1 3 Collar 1 4 Plate 1 5 Spring 1 6 EXUP pulley bracket 1 7 Housing 1 8 Gasket 1 9 Collar 1 10 Shaft arm 1 11 Exhaust valve pipe 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 212: ...EM on page 7 9 Starter motor Refer to ELECTRIC STARTER on page 5 39 1 Battery negative lead 1 2 Battery positive lead 1 3 Clutch cable 1 4 Engine ground lead 2 5 Stator coil assembly coupler 1 Disconnect 6 Crankshaft position sensor coupler 1 Disconnect 7 Oil level switch connector 1 Disconnect 8 Neutral switch connector 1 Disconnect 9 Speed sensor coupler 1 Disconnect 10 Cylinder identification s...

Page 213: ... Engine mount collar inner 1 5 Engine mounting bolt front left side 1 6 Locknut 1 7 Engine mounting bolt rear lower side 1 8 Locknut 1 9 Engine mounting bolt rear upper side 1 10 Engine mounting adjust bolt 2 11 Engine 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 214: ... 5 Install Engine mount collar inner 1 Engine mount collar center 2 Engine mount collar outer 3 Right front engine mount bolt 4 temporary tighten 6 Tighten Engine mounting adjust bolts NOTE Use the pivot shaft wrench 1 and pivot shaft wrench adapter 2 to tighten the engine mounting adjust bolts 7 Tighten Upper locknut 1 Lower locknut 2 Engine mounting adjust bolt 7 Nm 0 7 m kg 5 1 ft lb Pivot shaf...

Page 215: ...ight front engine mounting bolt 1 Upper locknut 51 Nm 5 1 m kg 37 ft lb Lower locknut 51 Nm 5 1 m kg 37 ft lb Engine mounting bolt front left side 45 Nm 4 5 m kg 33 ft lb Engine mounting bolt front right side 45 Nm 4 5 m kg 33 ft lb Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 216: ...r to THROTTLE BODIES on page 7 4 Radiator assembly Refer to RADIATOR on page 6 1 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 9 1 Ignition coil 4 2 Spark plug 4 3 Cylinder head cover 1 4 Cylinder head cover gasket 1 5 Timing chain guide top side 1 6 Cylinder identification sensor 1 7 O ring 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk Th...

Page 217: ...4 Loosen 2 Timing chain tensioner 1 3 Timing chain tensioner gasket 1 4 Intake camshaft cap 3 5 Dowel pin 6 6 Exhaust camshaft cap 3 7 Dowel pin 6 8 Intake camshaft 1 9 Exhaust camshaft 1 10 Camshaft sprocket 2 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 218: ...camshaft lobes are turned away from each other 3 Loosen Camshaft sprocket bolts 1 4 Remove Timing chain tensioner 1 Gasket 5 Remove Camshaft caps 1 Dowel pins CAUTION ECA13720 To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a criss cross pattern working from the outside in 6 Remove Intake camshaft 1 Exhaust camshaft 2 NOTE To prevent...

Page 219: ...s and in a crisscross pattern working from the inner caps out Do not turn the camshaft when measuring the camshaft journal to camshaft cap clear ance with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 2 Camshaft lobe dimension limit Intake A 34 450 34 550 mm 1 3563 1 3602 in Limit 34 350 mm 1 3524 in Intake B 25 170 25 270 mm 0 9909 0 9949 in Limit 25 07...

Page 220: ...3950 CHECKING THE TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides 1 Check Timing chain guide exhaust side 1 Timing chain guide intake side 2 Timing chain guide top side 3 Damage wear Replace the defective part s EAS23960 CHECKING THE TIMING CHAIN TEN SIONER 1 Remove Timing chain tensioner housing 1 Timing chain tensioner rod 2 Timing cha...

Page 221: ...g chain tensioner clip 2 and push the timing chain tensioner rod 3 NOTE When the timing chain tensioner rod 3 is pushed while holding the grip of the timing chain tensioner clip 2 make sure not to release the timing chain tensioner rod 3 before releasing the timing chain tensioner clip 2 Otherwise the timing chain tensioner rod 3 may run off c Hook the clip 4 to the timing chain ten sioner rod 3 N...

Page 222: ...ll Dowel pins Intake camshaft caps Exhaust camshaft caps NOTE Make sure each camshaft cap is installed in its original place Refer to the identification marks as follows I Intake side camshaft cap mark E Exhaust side camshaft cap mark IL Intake left side camshaft cap mark IR Intake right side camshaft cap mark EL Exhaust left side camshaft cap mark ER Exhaust right side camshaft cap mark Make sure...

Page 223: ... b 8 Install Gasket Timing chain tensioner 1 Timing chain tensioner bolts 2 CAUTION ECA4C81006 The arrow mark a on the timing chain ten sioner should face up WARNING EWA4C81004 Always use a new gasket 9 Turn Crankshaft several turns clockwise 10 Check T mark a Make sure the T mark on the pickup rotor is aligned with the crankcase mating sur face b Camshaft punch mark c Make sure the punch mark c o...

Page 224: ...fication Adjust Refer to ADJUSTING THE VALVE CLEARANCE on page 3 4 12 Install Pickup coil rotor cover CRANKSHAFT POSITION SENSOR on page 5 37 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 225: ...mshaft Refer to CAMSHAFTS on page 5 9 Exhaust camshaft Refer to CAMSHAFTS on page 5 9 1 Cylinder head 1 2 Cylinder head gasket 1 3 Dowel pin 2 4 Coolant pipe 1 5 O ring 1 6 Water pump breather hose 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 226: ...LVE SEATS on page 5 25 Cylinder head water jacket Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylin der head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface t...

Page 227: ...uts 7 10 to 55 Nm 5 5 m kg 40 ft lb with a torque wrench Lubricate the cylinder head nuts with engine oil Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in four stages 5 Install Exhaust camshaft Intake camshaft Refer to INSTALLING THE CAMSHAFTS on page 5 15 Cylinder head nut 1st 10 Nm 1 0 m kg 7 2 ft lb Cylinder head nut 2nd 25 Nm 2 5 m kg 18 ft lb Cylind...

Page 228: ...at 8 5 Intake valve spring 8 6 Intake valve oil seal 8 7 Intake valve lower spring seat 8 8 Intake valve 8 9 Intake valve guide 8 10 Exhaust valve lifter 8 11 Exhaust valve pad 8 12 Exhaust valve cotter 16 13 Exhaust valve upper spring seat 8 14 Exhaust valve spring 8 15 Exhaust valve oil seal 8 16 Exhaust valve lower spring seat 8 17 Exhaust valve 8 18 Exhaust valve guide 8 Manuals by Motomatrix ...

Page 229: ...installation reverse the removal proce dure Removing the valves and valve springs Order Job Parts to remove Q ty Remarks Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 230: ... ports b Check that the valves properly seal NOTE There should be no leakage at the valve seat 1 3 Remove Valve cotters 1 NOTE Remove the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attach ment 3 4 Remove Upper spring seat 1 Valve spring 2 Valve stem seal 3 Lower spring seat 4 Valve 5 NOTE Identify the position of each part very ...

Page 231: ...alling the valve guide bore the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide clearance NOTE After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 0...

Page 232: ...heck Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head Valve guide remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 Valve guide remover ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 Valve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 Valve guide installer ø5 90890 04098 Valve guide...

Page 233: ...d replace the valves without lapping the valve seats and valve faces When replacing the valves or valves guides use new valves to lap the valve seats and then replace them with new valves a Apply a coarse lapping compound a to the valve face CAUTION ECA13790 Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem...

Page 234: ...CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure Valve spring free length a Out of specification Replace the valve spring 2 Measure Compressed valve spring force a Out of specification Replace the valve spring Valve spring free length Free length intake 39 79 mm 1 57 in Limit 37 80 mm 1 49 in Free length exhaust 38 42 mm 1 51 in Limit 36 50 mm 1 44 i...

Page 235: ...2 Lubricate Valve stem 1 Valve stem seal 2 with the recommended lubricant 3 Install Valve 1 Lower spring seat 2 Valve stem seal 3 Valve spring 4 Upper spring seat 5 into the cylinder head NOTE Make sure each valve is installed in its origi nal place Refer to the following embossed marks Intake valve Pink paint mark Exhaust valve 4C8 Install the valve springs with the larger pitch a facing up Sprin...

Page 236: ... the valve 6 Lubricate Valve pad 1 Valve lifter 2 with the recommended lubricant 7 Install Valve pad Valve lifter NOTE The valve lifter must move smoothly when rotated with a finger Each valve lifter and valve pad must be rein stalled in its original position b Smaller pitch Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attachment 90890 04108 Valve spring compressor adapter ...

Page 237: ... Lower cowlings Refer to GENERAL CHASSIS on page 4 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 12 1 Stator coil assembly coupler 1 Disconnect 2 Plug 1 3 Generator rotor cover 1 4 Gasket 1 5 Dowel pin 2 6 Generator rotor assembly 1 7 Stator coil assembly 1 8 Dowel pin 2 9 Bearing housing 1 10 Collar 1 11 Bearing 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Mo...

Page 238: ...14 Idler gear shaft 1 15 Washer 1 16 Bearing 1 For installation reverse the removal proce dure Removing the generator Order Job Parts to remove Q ty Remarks Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 239: ...Idle gear shaft bolt 1 Idle shaft Idle gear 2 EAS24500 INSTALLING THE GENERATOR 1 Install Idle gear shaft Idle gear 1 Washer Idle gear shaft bolt 2 2 Install Generator rotor and starter clutch assem bly 1 3 Install Generator rotor cover gasket Generator rotor cover 1 Idle gear shaft bolt 10 Nm 1 0 m kg 7 2 ft lb LOCTITE Generator rotor cover bolt M6 12 Nm 1 2 m kg 8 7 ft lb Generator rotor cover b...

Page 240: ...the M8 bolts and then tighten the M6 bolts Tighten the generator rotor cover bolts in stages and in a crisscross pattern Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 241: ...ty Remarks 1 Generator rotor 1 2 Damper 3 3 Driven gear 1 4 Washer 1 5 Starter clutch drive gear 1 6 Collar 1 7 Washer 1 8 Spacer 1 9 O ring 1 For assembly reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 242: ...ck Starter clutch rollers 1 Damage wear Replace 2 Check Starter clutch idle gear 1 Starter clutch drive gear 2 Burrs chips roughness wear Replace the defective part s 3 Check Starter clutch gear s contacting surfaces Damage pitting wear Replace the starter clutch gear 4 Check Starter clutch operation a Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch Ma...

Page 243: ...h is faulty and must be replaced EAS24600 INSTALLING THE STARTER CLUTCH 1 Install Generator rotor 1 Damper 2 Driven gear 3 NOTE The hole side of the damper is installed to the generator side Lubricate the engine oil 4 2 Install Starter clutch drive gear 1 Collar 2 Washer 3 Refer to CHECKING THE STARTER CLUTCH on page 5 35 3 Install Washer 1 O ring 2 Spacer 3 NOTE Lubricate the engine oil to O ring...

Page 244: ...Lower cowlings Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 12 1 Crankshaft position sensor lead coupler 1 2 Crankshaft position sensor 1 3 O ring 1 4 Pickup rotor cover 1 5 Gasket 1 6 Cover 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost M...

Page 245: ...scross pattern After all of the bolts are fully loosened remove them EAS24540 INSTALLING THE CRANKSHAFT POSITION SENSOR 1 Install Gasket Pickup rotor cover 1 O ring Crankshaft position sensor 2 Connect Crankshaft position sensor lead coupler Pickup rotor cover 12 Nm 1 2 m kg 8 7 ft lb Crankshaft position sensor bolt 10 Nm 1 0 m kg 7 2 ft lb LOCTITE New New Manuals by Motomatrix www motomatrix co u...

Page 246: ...1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Throttle body Refer to THROTTLE BODIES on page 7 4 1 Starter motor lead 1 Disconnect 2 Starter motor 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 247: ... ring 1 2 Front cover 1 3 Lock washer 1 4 Washer 1 5 Starter motor yoke 1 6 Armature assembly 1 7 Gasket 2 8 Brush holder 1 9 Rear cover 1 For assembly reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 248: ...the starter motor a Measure the armature assembly resis tances with the pocket tester b If any resistance is out of specification replace 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 23 5 mm 0 93 in Mica undercut depth 1 50 mm 0 06 in Pocket tester 90890 03112 ...

Page 249: ...e armature 2 Install O rings Rear cover 1 NOTE Align the tab a on the brush holder 2 with the tab b in the starter motor rear cover 3 Install Nut 1 4 Install Starter motor yoke 1 Gasket 2 Starter motor rear cover 3 Starter motor assembling bolts 4 NOTE Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers New Nut 5 Nm 0 5 m kg 3 6 ft lb...

Page 250: ...arter motor 1 Starter motor bolts 2 2 Connect Starter motor lead 3 Starter motor bolt 10 Nm 1 0 m kg 7 2 ft lb Starter motor lead bolt 7 Nm 0 7 m kg 5 1 ft lb Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 251: ...r to GENERAL CHASSIS on page 4 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 12 1 Cover 1 2 Clutch cable 1 Disconnect 3 Clutch cover 1 4 Clutch cover gasket 1 5 Dowel pin 2 6 Oil filler cap 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 252: ...Q ty Remarks 1 Circlip 2 2 Pull lever 1 3 Pull lever spring 1 4 Pull lever shaft 1 5 Oil seal 1 6 Bearing 2 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 253: ...late 2 1 9 Clutch plate 3 6 10 Friction plate 3 1 11 Clutch damper spring 1 12 Clutch damper spring seat 1 13 Muffler 1 14 Spring 3 15 Clutch boss 1 16 Pressure plate 2 1 17 Conical spring washer 1 18 Thrust plate 2 1 19 Clutch housing 1 20 Bearing 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info mot...

Page 254: ...riction plate 1 1 4 Remove Clutch plate 1 1 Friction plate 2 Clutch plate 2 Clutch plate 3 Friction plate 3 Clutch damper spring Clutch damper spring seat 5 Straighten the clutch boss nut rib 1 6 Loosen Clutch boss nut 1 NOTE While holding the clutch boss 2 with the uni versal clutch holder 3 loosen the clutch boss nut 7 Remove Clutch boss nut Universal clutch holder 90890 04086 YM 91042 Manuals b...

Page 255: ...ate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clutch plates as a set 3 Measure assembly width a of the friction plates and clutch plates Out of specification Adjust NOTE Perform the thickness measurement without applying the oil a Assembly width adjusted by clutch plate 1 and 2 b Select the clutch plate from the following table Clutch plate 1 Friction plat...

Page 256: ... 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch hous ing NOTE Pitting on the clutch housing dogs will cause erratic 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 boss splines ...

Page 257: ... Replace the push rod and push lever shaft pinion gear as a set 2 Check Push rod bearing Damage wear Replace EAS25240 INSTALLING THE CLUTCH 1 Install Clutch housing 1 Conical spring washer Thrust plate 2 NOTE Align the projection of clutch housing a and hollow of the oil pump drive gear b 2 Install Pressure plate 2 1 Clutch boss 2 NOTE Fit the groove a of the pressure plate 2 to the projection b o...

Page 258: ...nt aligned with the groove in the axle 4 Install Clutch damper spring seat 1 Clutch damper spring 2 NOTE Install the clutch damper spring as shown in the illustration 5 Lubricate Friction plates Clutch plates with the recommended lubricant 6 Install Friction plate 3 Friction plate 2 Clutch plate 3 Clutch plate 2 Clutch plate 1 1 Clutch boss nut 115 Nm 11 5 m kg 83 ft lb Universal clutch holder 908...

Page 259: ... facing toward upper side 11 Install Clutch cover Clutch cover gasket NOTE Install the push rod so that the teeth a face towards the rear of the vehicle Then install the clutch cover Apply oil onto the bearing Apply molybdenum disulfide grease onto the push rod When installing the clutch cover push the push lever and check that the punch mark a on the push lever aligns with the mark b on the clutc...

Page 260: ...a crisscross pattern 13 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY on page 3 14 Clutch cover bolt 12 Nm 1 2 m kg 8 7 ft lb Clutch cover bolt 12 Nm 1 2 m kg 8 7 ft lb LOCTITE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 261: ...fer to CLUTCH on page 5 44 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4 Collar 1 5 Shift shaft spring 1 6 Washer 1 7 Stopper screw 1 8 Stopper lever 1 9 Washer 1 10 Oil seal 1 11 Bearing 1 12 Bearing 1 13 Stopper lever spring 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 262: ...2 Stopper lever 3 Washer EAS25420 CHECKING THE SHIFT SHAFT 1 Check Shift shaft 1 Bends damage wear Replace Shift lever spring 2 Collar 3 Damage wear Replace EAS25430 CHECKING THE STOPPER LEVER 1 Check Stopper lever 1 Bends damage Replace Roller turns roughly Replace the stopper lever EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Washer Stopper lever 1 Stopper screw 2 Stopper screw 22 Nm 2 2 m kg 1...

Page 263: ...eal lips with lithium soap base grease Install the end of the shift shaft spring onto the shift shaft spring stopper 3 Install Washer 1 Circlip 2 4 Install Shift rod Shift arm Refer to ENGINE REMOVAL on page 5 1 5 Install Clutch assembly Refer to CLUTCH on page 5 44 New Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 264: ...EMOVAL on page 5 1 Muffler Refer to ENGINE REMOVAL on page 5 1 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 1 Clutch assembly Refer to CLUTCH on page 5 44 Water pump inlet pipe Refer to OIL COOLER on page 6 4 Water pump outlet pipe Refer to OIL COOLER on page 6 4 1 Oil level switch lead coupler 1 Disconnect 2 Oil level switch 1 3 Oil level switch lead holder 1 4 Oil pan 1 5 Oil pan gask...

Page 265: ...r pump assembly drive sprocket 1 15 Washer 1 16 Oil water pump assembly drive chain 1 17 Dowel pin 1 18 Oil water pump assembly 1 For installation reverse the removal proce dure Removing the oil pan and oil pump Order Job Parts to remove Q ty Remarks Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 266: ...ump driven sprocket 1 2 Collar 1 3 Oil pump housing 1 4 Bearing 1 5 Pin 2 6 Oil pump outer rotor 1 7 Oil pump inner rotor 1 8 Pin 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 267: ...S24960 CHECKING THE OIL PUMP 1 Check Oil pump driven gear 1 Oil pump housing 2 Cracks damage wear Replace the defective part s 2 Measure Inner rotor to outer rotor tip clearance a Outer rotor to oil pump housing clearance b Oil pump housing to inner rotor and outer rotor clearance c Out of specification Replace the oil pump Inner rotor to outer rotor tip clearance 0 010 0 100 mm 0 0004 0 0039 in L...

Page 268: ... delivery pipes 1 Check Oil delivery pipe 1 Oil pipe 2 Damage Replace Obstruction Wash and blow out with compressed air EAS24990 CHECKING THE OIL STRAINER 1 Check Oil strainer 1 Damage Replace Contaminants Clean with solvent EAS4C81013 CHECKING THE OIL NOZZLES The following procedure applies to all of the oil nozzles 1 Check Oil nozzle 1 Damage wear Replace the oil nozzles 1 Inner rotor 2 Outer ro...

Page 269: ... pump driven gear is installed at oil pump side 4 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 60 EAS25030 INSTALLING THE OIL WATER PUMP ASSEMBLY 1 Install Oil ring Oil water pump assembly 1 Dowel pin Bolts 2 2 Install Washer Oil water pump assembly drive chain 1 Oil water pump assembly drive sprocket 2 Collar Recommended lubricant Engine oil Oil pump housing bolt 10 Nm 1 0 m ...

Page 270: ...e 1 5 Install Relief valve 1 O ring Oil strainer 2 O ring Oil pipe 3 O ring Drain pipe 4 O ring EAS25050 INSTALLING THE OIL PAN 1 Install Dowel pins Gasket Oil pan 1 Oil level switch 2 Engine oil drain bolt Oil water pump assembly drive chain guide bolt 10 Nm 1 0 m kg 7 2 ft lb LOCTITE Oil delivery pipe bolt 10 Nm 1 0 m kg 7 2 ft lb LOCTITE Oil strainer bolt 10 Nm 1 0 m kg 7 2 ft lb LOCTITE Oil pa...

Page 271: ...en the oil pan bolts in stages and in a crisscross pattern Lubricate the oil level switch O ring with engine oil Engine oil drain bolt 43 Nm 4 3 m kg 31 ft lb Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 272: ... Starter clutch Refer to STARTER CLUTCH on page 5 34 Shift shaft Refer to SHIFT SHAFT on page 5 54 Crankshaft position sensor Refer to CRANKSHAFT POSITION SEN SOR on page 5 37 Clutch Refer to CLUTCH on page 5 44 Oil pump Refer to OIL PUMP on page 5 57 Starter motor Refer to ELECTRIC STARTER on page 5 39 1 Timing chain 1 2 Timing chain guide intake side 1 3 Pin 2 4 Timing chain guide exhaust side 1...

Page 273: ... pin 3 9 Damper 1 For installation reverse the removal proce dure Separating the crankcase Order Job Parts to remove Q ty Remarks Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 274: ... pins 5 Remove Crankshaft journal lower bearing from the lower crankcase NOTE Identify the position of each crankshaft journal lower bearing so that it can be reinstalled in its original place EAS25580 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil d...

Page 275: ...ence cast on the crankcase M9 x 105 mm 4 1 in bolts 1 10 M8 x 60 mm 2 4 in bolt 11 LOCTITE M8 x 60 mm 2 4 in bolts 12 16 M8 x 50 mm 2 0 in bolts 13 15 M6 x 65 mm 2 5 in bolts 17 18 M6 x 70 mm 2 8 in bolts 19 21 23 M6 x 50 mm 2 0 in bolts 20 26 M6 x 60 mm 2 4 in bolt and washer 22 M6 x 60 mm 2 4 in bolts 24 25 Following the tightening order loosen the bolt one by one and then retighten it to the sp...

Page 276: ...ecting rod cap 4 2 Big end lower bearing 4 3 Big end upper bearing 4 4 Piston pin clip 8 5 Piston pin 4 6 Piston 4 7 Connecting rod 4 8 Top ring 4 9 2nd ring 4 10 Oil ring 4 11 Cylinder 1 12 Cylinder gasket 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 277: ...r to REMOVING THE CONNECTING RODS AND PISTONS on page 5 71 1 Crankshaft 1 2 Crankshaft journal lower bearing 5 3 Crankshaft journal upper bearing 5 4 Washer 1 5 Crankshaft drive gear 1 6 Pin 1 7 Pickup rotor 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 278: ...ston pin out NOTE For reference during installation put identifi cation marks on the piston crown Before removing the piston pin deburr the piston pin clip groove and the piston pin bore area If both areas are debarred and the pis ton pin is still difficult to remove remove it with the piston pin puller set 4 4 Remove Top ring 2nd ring Oil ring NOTE When removing a piston ring open the end gap wit...

Page 279: ...h the following formula f If out of specification rebore or replace the cylinder and replace the piston and piston rings as a set EAS24430 CHECKING THE PISTON RINGS 1 Measure Piston ring side clearance Out of specification Replace the piston and piston rings as a set NOTE Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings Bo...

Page 280: ...he piston pin 3 Measure Piston pin bore diameter b Out of specification Replace the piston Piston ring side clearance Top ring 0 030 0 065 mm 0 0012 0 0026 in Limit 0 115 mm 0 0045 in 2nd ring 0 020 0 055 mm 0 0008 0 0022 in Limit 0 115 mm 0 0045 in a 5 mm 0 20 in Piston ring end gap Top ring 0 15 0 25 mm 0 0059 0 0098 in Limit 0 50 mm 0 0197 in 2nd ring 0 30 0 45 mm 0 0118 0 0177 in Limit 0 80 mm...

Page 281: ... rod cap NOTE Align the projections a on the big end bear ings with the notches b in the connecting rod and connecting rod cap c Put a piece of Plastigauge 1 on the crankshaft pin d Assemble the connecting rod halves NOTE Do not move the connecting rod or crank shaft until the clearance measurement has been completed Lubricate the bolt threads with molybdenum disulfide grease Make sure that the Y ...

Page 282: ... b NOTE To install the big end bearing care should be taken not to install it at an angle and the posi tion should not be out of alignment j Loosen the connecting rod bolt remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in the current condi tion k Tighten the connecting rod bolts CAUTION EC2D1082 Tighten the connecting rod bo...

Page 283: ...ecting rod and big end bearings Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 71 r Measure the compressed Plastigauge width on the crankshaft pin If the crankshaft pin to big end bearing clearance is out of specification select replacement big end bearings 2 Select Big end bearings P1 P4 NOTE The numbers A stamped into the crank shaft wed and the numbers 1 on the con necting rods are...

Page 284: ...k b on the piston is pointing up as shown Reinstall each piston into its original cylinder numbering order starting from the left 1 to 4 3 Lubricate Piston Piston rings Cylinder with the recommended lubricant 4 Offset Piston ring end gaps 5 Lubricate Crankshaft pins Big end bearings Connecting rod big end inner surface with the recommended lubricant 6 Check Cylinder stud bolts 1 7 Install Cylinder...

Page 285: ...e the connecting rod and connecting rod cap once using a single unit of the connect ing rod d Tighten the connecting rod bolt while checking that the sections shown a and b are flush with each other by touching the surface NOTE To install the big end bearing care should be taken not to install it at an angle and the posi tion should not be out of alignment e Loosen the connecting rod bolt remove t...

Page 286: ...ten the connecting rod bolts c Put a mark 1 on the connecting rod bolt 2 and the connecting rod cap 3 d Tighten the bolt further to reach the speci fied angle 150 e After the installation check that the section shown a is flush with each other by touch ing the surface WARNING EWA13990 When the bolt is tightened more than the specified angle do not loosen the bolt and then retighten it Replace the ...

Page 287: ...t journal bearing clearance Out of specification Replace the crank shaft journal bearings CAUTION ECA4C81011 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crankshaft journal bearings must be installed in their original positions a Clean the crankshaft journal bearings crankshaft jou...

Page 288: ...s 17 18 M6 x 70 mm 2 8 in bolts 19 21 23 M6 x 50 mm 2 0 in bolts 20 26 M6 x 60 mm 2 4 in bolt and washer 22 M6 x 60 mm 2 4 in bolts 24 25 Following the tightening order loosen the bolt one by one and then retighten it to the specific torque NOTE Lubricate the crankcase bolt threads with engine oil Refer to CRANKCASE on page 5 65 g Remove the lower crankcase and the crankshaft journal lower bearing...

Page 289: ... that size is indicated Crankcase side only For example if the crankcase J1 and crankshaft web J1 numbers are 6 and 2 respectively then the bearing size for J1 is EAS26200 INSTALLING THE CRANKSHAFT 1 Install Crankshaft journal upper bearings 1 into the upper crankcase 2 Lubricate Crankshaft journal upper bearings with the recommended lubricant J1 crankcase J1 crankshaft web 1 6 2 1 3 brown CRANKSH...

Page 290: ...ll each crankshaft journal upper bearing in its original place 3 Install Crankshaft 4 Install Crankcase lower Refer to CRANKCASE on page 5 65 5 Install Pin Pickup rotor 1 Drive sprocket 2 Drive sprocket bolt 60 Nm 6 0 m kg 43 ft lb Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 291: ...sembly 1 2 Circlip 1 3 Oil seal 1 4 Bearing 1 5 Washer 1 6 Shift fork guide bar retainer 2 7 Spring 2 8 Shift fork guide bar 2 9 Shift fork L 1 10 Shift fork R 1 11 Shift drum assembly 1 12 Shift fork C 1 13 Main axle retainer 1 14 Main axle assembly 1 15 Oil pipe 1 16 O ring 2 17 Oil baffle plate 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info m...

Page 292: ...se the removal proce dure Removing the transmission shift drum assembly and shift forks Order Job Parts to remove Q ty Remarks Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 293: ...her retainer 1 4 6th pinion gear 1 5 Collar 1 6 Washer 1 7 Circlip 1 8 3rd pinion gear 1 9 Circlip 1 10 Washer 1 11 5th pinion gear 1 12 Collar 1 13 Main axle 1 14 Bearing housing 1 15 Bearing 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 294: ...wheel gear 1 8 Collar 1 9 Toothed lock washer 1 10 Toothed lock washer retainer 1 11 4th wheel gear 1 12 Collar 1 13 Washer 1 14 Circlip 1 15 6th wheel gear 1 16 Circlip 1 17 Washer 1 18 Collar 1 19 2nd wheel gear 1 20 Collar 1 21 Oil seal 1 22 Bearing 1 23 Drive axle 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 295: ...ly reverse the disassembly pro cedure Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 296: ...olts until the main axle assembly comes free from the upper crankcase 3 Remove Oil pipe 1 Bearing 2 EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat sur face Bends Replace WARNING EWA1284...

Page 297: ...easure Main axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle 2 Measure Drive axle runout with a centering device and dial gauge 1 Out of specification Replace the drive axle 3 Check Transmission gears Blue discoloration pitting wear Replace the defective gear s Transmission gear dogs Cracks damage rounded edges Replace the defective gear s Main axle r...

Page 298: ...ansmission gears Install shift fork C into the groove in the 3rd and 4th pinion gear on the main axle 3 Install Shift fork L 1 and R 2 Drive axle assembly 3 Shift fork guide bar Shift fork guide bar retainer 4 NOTE Install shift fork L into the groove in the 6th wheel gear and shift fork R into the groove in the 5th wheel gear on the drive axle Make sure that the drive axle bearing circlip a is in...

Page 299: ...N 5 92 4 Check Transmission Rough movement Repair NOTE Oil each gear shaft and bearing thoroughly Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 300: ...TRANSMISSION 5 93 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 301: ...ER 6 5 THERMOSTAT 6 6 CHECKING THE THERMOSTAT 6 8 ASSEMBLING THE THERMOSTAT ASSEMBLY 6 8 INSTALLING THE THERMOSTAT ASSEMBLY 6 8 WATER PUMP 6 9 DISASSEMBLING THE WATER PUMP 6 10 CHECKING THE WATER PUMP 6 10 ASSEMBLING THE WATER PUMP 6 10 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 302: ... Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 1 Radiator fan coupler 2 Disconnect 2 Fuse holder stay 1 3 Coolant reservoir tank 1 4 Coolant reservoir hose 1 5 Radiator inlet hose 1 6 Oil cooler outlet hose 1 7 Radiator outlet hose 1 8 Water pump inlet pipe 1 9 O ring 1 10 Radiator 1 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Mo...

Page 303: ...motor 2 For installation reverse the removal proce dure Removing the radiator Order Job Parts to remove Q ty Remarks Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 304: ...pply the specified pressure for ten sec onds and make sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to RADIATOR on page 6 1 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 20 2 Check Cooling system Leaks Repair or replace any faulty part Ra...

Page 305: ...ge 3 20 1 Oil cooler inlet hose 1 2 Oil cooler bolt 1 Loosen 3 Washer 1 Disconnect 4 Oil cooler 1 Disconnect 5 O ring 1 6 Water pump outlet pipe 1 7 O ring 1 8 Water jacket joint inlet hose 1 9 O ring 1 10 Water jacket joint 1 11 Stay 1 12 O ring 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motom...

Page 306: ...ooler bolt and O ring with a thin coat of engine oil Make sure the O ring is positioned properly Align the projection a on the oil cooler with the slot b in the crankcase 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 20 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 ...

Page 307: ...ilter case Refer to GENERAL CHASSIS on page 4 1 Coolant Refer to CHANGING THE COOLANT on page 3 20 1 Thermostat assembly outlet hose 1 2 Thermostat assembly breather hose 1 3 Thermostat assembly 1 4 Thermostat assembly inlet hose 1 5 Band 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co...

Page 308: ...rts to remove Q ty Remarks 1 Thermostat housing cover 1 2 Thermostat 1 3 Thermostat housing 1 4 O ring 1 For assembly reverse the disassembly pro cedure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 309: ...t housing cover 1 Thermostat housing 2 Cracks damage Replace EAS26460 ASSEMBLING THE THERMOSTAT ASSEM BLY 1 Install Thermostat housing 1 Thermostat 2 O ring 3 Thermostat housing cover 4 NOTE Install the thermostat with its breather hole a facing up EAS26480 INSTALLING THE THERMOSTAT ASSEM BLY 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT ...

Page 310: ... 5 57 Oil pump rotor Refer to OIL PUMP on page 5 57 1 Water pump cover 1 2 O ring 1 3 Pin 2 4 Impeller shaft along with the impeller 1 5 Water pump seal 1 6 Oil seal 1 7 Bearing 1 8 O ring 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 311: ... CHECKING THE WATER PUMP 1 Check Water pump housing cover 1 Water pump housing 2 Impeller shaft 3 Rubber damper 4 Rubber damper holder 5 Water pump seals Oil seal Cracks damage wear Replace 2 Check Bearing Rough movement Replace 3 Check Water pump outlet pipe Radiator outlet hose Cracks damage wear Replace EAS26560 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 into the water pump housing 2 NOTE B...

Page 312: ...ts outer surface 4 Measure Impeller shaft tilt Out of specification Repeat steps 3 and 4 CAUTION ECA14090 Make sure the rubber damper and rubber damper holder are flush with the impeller a 17 2 mm 0 68 in Mechanical seal installer 4 90890 04078 Water pump seal installer YM 33221 A Middle driven shaft bearing driver 5 90890 04058 Bearing driver 40 mm YM 04058 Yamaha bond No 1215 Three Bond No 1215 ...

Page 313: ...TLE BODIES 7 4 CHECKING THE INJECTORS 7 6 CHECKING THE THROTTLE BODIES 7 6 CHECKING THE FUEL PRESSURE 7 6 ADJUSTING THE THROTTLE POSITION SENSOR FOR THROTTLE VALVES 7 6 ADJUSTING THE THROTTLE POSITION SENSOR FOR THROTTLE CABLE PULLEY 7 7 AIR INDUCTION SYSTEM 7 9 CHECKING THE AIR INDUCTION SYSTEM 7 10 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info ...

Page 314: ... page 4 1 1 Fuel tank side cover 2 2 Fuel sender coupler 1 3 Fuel pump coupler 1 4 Fuel tank drain hose 1 5 Fuel tank breather hose 1 6 Fuel hose connector 1 7 Fuel hose 1 8 Fuel tank 1 9 Fuel tank top cover 1 10 Fuel pump 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 315: ... sure to lean the fuel tank in an upright position EAS26640 REMOVING THE FUEL PUMP 1 Remove Fuel pump CAUTION ECA14720 Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender EAS26670 CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Obstruction Clean Cracks damage Replace the fuel pump assembly 2 Check Diaphragms and gaskets Turn fatigue cracks Replac...

Page 316: ...o the fuel tank until a distinct click is heard and then make sure that it does not come loose To install the fuel hose from the fuel injection hose slide the cover a on the end of the hose in the direction of arrow shown 2 Install Fuel sender coupler Fuel pump coupler Fuel tank breather hose Fuel tank drain hose Fuel tank side cover NOTE There is white paint mark on the fuel tank breather hose Re...

Page 317: ...er 1 Disconnect 3 Throttle servo motor coupler 1 Disconnect 4 Throttle position sensor for throttle valves cou pler 1 Disconnect 5 Throttle position sensor for throttle cable pulley coupler 1 Disconnect 6 Throttle body joint clamp 4 Loosen 7 Throttle cables 2 Disconnect 8 Throttle bodies 1 9 Throttle body joint 3 10 Engine ground 2 11 Heat protector 1 12 Fuel hose 1 For installation reverse the re...

Page 318: ... Cylinder 4 injector coupler 1 Disconnect 6 Sub wire harness 1 7 Negative pressure hose 1 Disconnect 8 Intake air pressure sensor 1 9 Fuel distributor 1 10 Injector 4 11 Throttle position sensor for throttle valves 1 12 Throttle position sensor for throttle cable pulley 1 13 Throttle body assembly 1 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solu...

Page 319: ...l rail WARNING EWA4C81001 Cover fuel hose connections with a cloth when disconnecting them Residual pres sure in the fuel lines could cause fuel to spurt out when removing the hoses c Connect the pressure gauge 2 and adapter 3 to the fuel hose fuel tank to pri mary injector fuel rail d Start the engine e Measure the fuel pressure Faulty Replace fuel pump EAS27030 ADJUSTING THE THROTTLE POSITION SE...

Page 320: ... position sensor for throttle cable pulley Refer to ADJUSTING THE THROTTLE POSITION SENSOR FOR THROTTLE CABLE PULLEY on page 7 7 2 Adjust Throttle position sensor for throttle cable pulley angle a Temporary tighten the throttle position sen sor for throttle cable pulley b Check that the throttle valves are fully closed c Connect the throttle position sensor for throttle valves throttle position se...

Page 321: ...THROTTLE BODIES 7 8 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 322: ...r 1 Disconnect 2 Air cut off valve hose 1 1 Disconnect 3 Air cut off valve hose 2 1 Disconnect 4 Air cut off valve hose 3 1 Disconnect 5 Air cut off valve 1 6 Reed valve cap 2 7 Reed valve assembly 2 8 Plate 4 For installation reverse the removal proce dure Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 323: ...f the flow when the vehicle is being driven However if the coolant tempera ture is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value 1 Check Hoses Loose connections Connect properly Cracks damage Replace Pipes Cracks damage Replace 2 Check Reed valve 1 Reed valve stopper Reed v...

Page 324: ...AIR INDUCTION SYSTEM 7 11 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 325: ...25 TROUBLESHOOTING 8 27 FUEL INJECTION SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 ECU SELF DIAGNOSTIC FUNCTION 8 31 FAIL SAFE ACTIONS SUBSTITUTE CHARACTERISTICS OPERATION CONTROL 8 33 TROUBLESHOOTING METHOD 8 36 DIAGNOSTIC MODE 8 37 TROUBLESHOOTING DETAILS 8 45 FUEL PUMP SYSTEM 8 67 CIRCUIT DIAGRAM 8 67 TROUBLESHOOTING 8 69 IMMOBILIZER SYSTEM 8 71 CIRCUIT DIAGRAM 8 71 GENERAL INFORMATION 8 73 PART REPLACEME...

Page 326: ...CKING THE HORN 8 98 CHECKING THE OIL LEVEL SWITCH 8 98 CHECKING THE FUEL SENDER 8 99 CHECKING THE SPEED SENSOR 8 99 CHECKING THE RADIATOR FAN MOTORS 8 100 CHECKING THE COOLANT TEMPERATURE SENSOR 8 100 CHECKING THE THROTTLE POSITION SENSOR FOR THROTTLE CABLE PULLEY 8 101 CHECKING THE THROTTLE POSITION SENSOR FOR THROTTLE VALVES 8 101 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 8 102 CHECKING THE ATM...

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

Page 328: ...IGNITION SYSTEM 8 1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 329: ...unit 20 Ignition coil 1 21 Ignition coil 2 22 Ignition coil 3 23 Ignition coil 4 24 Spark plug 35 Crankshaft position sensor 40 Lean angle sensor 58 Engine stop switch 66 Clutch switch 81 Ignition fuse 91 Ground 92 Battery negative lead Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 330: ...attery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 10 Re gap or replace the spark plugs 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION COILS on page 8 95 Ignition system is OK 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 95 Replace the ignition coils 6 Check the crankshaft position sen sor Refer to CHECKING THE CRANKSHAFT POSITI...

Page 331: ...ch switch Refer to CHECKING THE SWITCHES on page 8 85 Replace the clutch switch 12 Check the starting circuit cut off relay Refer to CHECKING THE RELAYS on page 8 92 Replace the starting circuit cut off relay 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...

Page 332: ...ELECTRIC STARTING SYSTEM 8 5 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 333: ...tor 12 Starting circuit cut off relay 13 Neutral switch 14 Sidestand switch 58 Engine stop switch 59 Start switch 66 Clutch switch 81 Ignition fuse 91 Ground 92 Battery negative lead Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 334: ...h switch is closed and 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 con ditions 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 ...

Page 335: ... Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Starting circuit cut off relay 7 Diode 8 Clutch switch 9 Sidestand switch 10 Neutral switch 11 Start switch 12 Starter relay 13 Starter motor 14 Battery negative lead 15 Ground Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 336: ... the starter motor operation Refer to CHECKING THE STARTER MOTOR OPERATION on page 8 97 Repair or replace the starter motor 4 Check the starter motor Refer to CHECKING THE STARTER MOTOR on page 5 41 Repair or replace the starter motor 5 Check the starting circuit cut off relay Refer to CHECKING THE RELAYS on page 8 92 Replace the starting circuit cut off relay 6 Check the starter relay Refer to CH...

Page 337: ...n page 8 85 Replace the sidestand switch 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 85 Replace the clutch switch 12 Check the start switch Refer to CHECKING THE SWITCHES on page 8 85 Replace the right handlebar switch 13 Check the entire starting system s wiring Refer to ELECTRIC STARTING SYSTEM on page 8 5 Properly connect or repair the starting system s wiring The starti...

Page 338: ...CHARGING SYSTEM 8 11 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 339: ...EM 8 12 2 AC magneto 3 Rectifier regulator 4 Main fuse 8 Battery 91 Ground 92 Battery negative lead Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 340: ...8 89 Clean 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 stator coil 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 CHARGING SYSTEM on page 8 11 Properly connect or repair th...

Page 341: ...CHARGING SYSTEM 8 14 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 342: ...LIGHTING SYSTEM 8 15 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 343: ...tch 64 Dimmer switch 73 Headlight 74 Auxiliary light 76 License plate light 78 Tail brake light 79 Headlight relay on off 80 Headlight relay dimmer 82 Turn signal light fuse 84 Headlight fuse 91 Ground 92 Battery negative lead Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 344: ...he fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 89 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 85 Replace the immobilizer unit 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 8 85 The dimmer switch is faulty Replace the left handlebar switch 6 Check the pass switch R...

Page 345: ...light relay dimmer Refer to CHECKING THE RELAYS on page 8 92 Replace the headlight relay 10 Check the entire lighting system s wiring Refer to LIGHTING SYSTEM on page 8 15 Properly connect or repair the lighting system s wiring This circuit is OK Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 346: ...SIGNALING SYSTEM 8 19 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 347: ... light 52 Left turn signal indicator light 53 Right turn signal indicator light 57 Front brake light switch 60 Turn signal hazard relay 62 Hazard switch 65 Horn switch 67 Turn signal switch 68 Horn 69 Front left turn signal light 70 Front right turn signal light 71 Rear left turn signal light 72 Rear right turn signal light 77 Rear brake light switch 78 Tail brake light 81 Headlight fuse 82 Turn s...

Page 348: ...2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 89 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 85 Replace the main switch immobilizer assembly 4 Check the entire signaling system s wiring Refer to SIGNALING SYSTEM on page 8 19 Properly connect or repair the signal ing system s wiring This circ...

Page 349: ...HECKING THE SWITCHES on page 8 85 Replace the front brake light switch 3 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 85 Replace the rear brake light switch 4 Check the entire signaling system s wiring Refer to SIGNALING SYSTEM on page 8 19 Properly connect or repair the signal ing system s wiring This circuit is OK 1 Check the turn signal light bulb and socket Refer ...

Page 350: ...system s wiring Refer to SIGNALING SYSTEM on page 8 19 Properly connect or repair the signal ing system s wiring This circuit is OK 1 Check the neutral switch Refer to CHECKING THE SWITCHES on page 8 85 Replace the neutral switch 2 Check the entire signaling system s wiring Refer to SIGNALING SYSTEM on page 8 19 Properly connect or repair the signal ing system s wiring This circuit is OK 1 Check t...

Page 351: ...ace the fuel pump assembly 2 Check the entire signaling system s wiring Refer to SIGNALING SYSTEM on page 8 19 Properly connect or repair the signal ing system s wiring This circuit is OK 1 Check the speed sensor Refer to CHECKING THE SPEED SENSOR on page 8 99 Replace the speed sensor 2 Check the entire signaling system s wiring Refer to SIGNALING SYSTEM on page 8 19 Properly connect or repair the...

Page 352: ...COOLING SYSTEM 8 25 EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 353: ...81 Ignition fuse 86 Radiator fan motor relay 87 Right radiator fan motor fuse 88 Left radiator fan motor fuse 89 Right radiator fan motor 90 Left radiator fan motor 91 Ground 92 Battery negative lead Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 354: ... replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 85 Replace the immobilizer unit 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTORS on page 8 100 The radiator fan motor is faulty and must be replaced 5 Check the radiator fan motor relay Refer to CHECKING THE RELAYS on page 8 92 Replace the radiator fan motor relay 6 Check the coolant temp...

Page 355: ...ooling system s wiring Refer to COOLING SYSTEM on page 8 25 Properly connect or repair the cooling system s wiring This circuit is OK Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 356: ...FUEL INJECTION SYSTEM 8 29 EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 357: ...l 2 22 Ignition coil 3 23 Ignition coil 4 24 Spark plug 25 Injector 1 26 Injector 2 27 Injector 3 28 Injector 4 32 EXUP servo motor 33 Speed sensor 34 Intake air temperature sensor 35 Crankshaft position sensor 36 Coolant temperature sensor 37 Intake air pressure sensor 38 Atmospheric pressure sensor 39 Cylinder identification sensor 40 Lean angle sensor 48 Multi function meter 58 Engine stop swit...

Page 358: ...de has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and FI system operation The warning light flashes when any one of the conditions listed below is present and the start switch is pushed Checking engine trouble warning light The engine trouble warning light comes on for 1 4 seconds after the main switch has been turned to ON...

Page 359: ...ain switch OFF b Main switch ON c Engine trouble warning light off d Engine trouble warning light on for 1 4 sec onds Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 360: ...detected Able Able 14 Intake air pressure sensor pipe system Intake air pressure sensor pipe system malfunction clogged or detached hose Able Able 15 Throttle position sen sor for throttle valves open or short circuit loose connection Throttle position sensor for throttle valves open or short circuit detected Throttle position sensor for throttle valves coupler connection is loose Able Unable Able...

Page 361: ...ction detected in the pri mary wire of the ignition coil 4 Able depending on the num ber of faulty cylinders Able depending on the num ber of faulty cylinders 39 Injector open circuit Injector open circuit detected Able depending on the num ber of faulty cylinders Able depending on the num ber of faulty cylinders 41 Lean angle sensor open or short circuit Lean angle sensor open or short circuit de...

Page 362: ...d Motor is defective or ECU internal malfunction Able Unable Able Unable Fault code No Item Symptom Able unable to start Able unable to drive Er 1 ECU internal malfunc tion output signal error No signals are received from the ECU Unable Unable Er 2 ECU internal malfunc tion output signal error No signals are received from the ECU within the specified duration Unable Unable Er 3 ECU internal malfun...

Page 363: ...t come on 1 Check the operation of following sensors and actuators in the Diagnostic mode Refer to Sensor operation table and Actuator operation 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 inner parts of the engine Fault code No No fault code No Check and repair Refer t...

Page 364: ... meter stop watch LCD 6 Set the engine stop switch to OFF 7 Select the diagnostic code number corresponding to the fault code number by pressing the SELECT and RESET buttons NOTE The diagnostic code number appears on the odometer trip meter fuel reservoir trip meter stop watch LCD 01 70 To decrease the selected diagnostic code number press the RESET button Press the RESET button for 1 second or lo...

Page 365: ...or Malfunction in ECU 03 14 Intake air pressure sensor hose system malfunction clogged or detached hose Intake air pressure sensor hose is detached clogged kinked or pinched Malfunction in ECU 03 15 Throttle position sensor for throttle valves open or short circuit detected Throttle position sensor for throttle valves coupler con nection is loose Open or short circuit in wire harness Defective thr...

Page 366: ...ved from the O2 sen sor Open or short circuit in wire harness Defective O2 sensor Malfunction in ECU Improperly installed O2 sensor 30 Latch up detected No normal signal is received from the lean angle sensor The vehicle has overturned Defective lean angle sensor Malfunction in ECU Improperly installed lean angle sensor 08 33 Open circuit detected in the primary lead of the cylinder 1 ignition coi...

Page 367: ...em ory 59 Throttle position sensor for throttle cable pulley open or short circuit detected Throttle position sensor for throttle cable pulley cou pler connection is loose Open or short circuit in wire harness Defective throttle position sensor Improperly installed throttle position sensor Malfunction in ECU 14 15 60 Throttle servo motor open or short circuit detected Defective throttle servo moto...

Page 368: ...e air temperature Displays the intake air tem perature Compare the actually mea sured air temperature with the meter display value 06 Coolant temperature Displays the coolant tempera ture Compare the actually mea sured coolant temperature with the meter display value 07 Vehicle speed pulse 0 999 Check that the number increases when the rear wheel is rotated The num ber is cumulative and does not r...

Page 369: ...OFF the sidestand switch with the transmis sion in gear Stand retracted ON Stand extended OFF 21 Neutral switch Shift the transmission Neutral ON In gear OFF 60 EEPROM fault cylinder No No history History exists 00 01 04 fault cylinder No If more than one cylinder is defective the display changes every two seconds to show all the detected cyl inder numbers When all cylinder numbers are shown the d...

Page 370: ...the engine stop switch from to 70 Control number 00 Diag nostic code No Item Actuation Checking method 30 Cylinder 1 ignition coil Actuates the cylinder 1 igni tion coil five times at one sec ond intervals Illuminates the engine trou ble warning light Check the spark five times Connect an ignition checker 31 Cylinder 2 ignition coil Actuates the cylinder 2 igni tion coil five times at one sec ond ...

Page 371: ...r vals Illuminates the engine trou ble warning light Check the operating sound of the primary injector 3 five times 39 Injector 4 Actuates the injector 4 five times at one second inter vals Illuminates the engine trou ble warning light Check the operating sound of the primary injector 4 five times 48 Air induction system sole noid Actuates the air induction system solenoid five times at one second...

Page 372: ...fer to DIAGNOSTIC MODE on page 8 37 51 Radiator fan motor relay Actuates the radiator fan motor relay five times at one second intervals ON 2 sec onds OFF 3 seconds Illuminates the engine trou ble warning light Check the operating sound of the radiator fan motor relay five times 52 Headlight relay Actuates the headlight relay five times at one second intervals ON 2 seconds OFF 3 seconds Illuminate...

Page 373: ...in wire harness ECU coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between the cylinder identifica tion sensor coupler and ECU coupler Blue Blue White Black White Black Black B...

Page 374: ... POSITION SENSOR on page 8 96 Fault code No 13 Symptom Intake air pressure sensor open or short circuit detected Diagnostic code No 03 Intake air pressure sensor Orde r Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Intake air pressure sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking...

Page 375: ...eck or maintenance job Reinstatement method 1 Installed condition of throttle position sensor for throttle valves Check for looseness or pinch ing Check that the sensor is installed in the specified posi tion Turning the main switch to ON 2 Connections Throttle position sensor for throttle valves coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the ...

Page 376: ...de Code No 53 Replace if defective Fault code No 18 Symptom EXUP servo motor is stuck Diagnostic code No 53 EXUP servo motor Orde r Item components and probable cause Check or maintenance job Reinstatement method 1 Connections EXUP servo motor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the couplers If there is a malfun...

Page 377: ...w Blue Yellow Between relay unit coupler and sidestand switch coupler Blue Black Blue Black Between sidestand switch cou pler and engine ground Black Black 3 Defective sidestand switch Replace if defective Refer to CHECKING THE SWITCHES on page 8 85 Fault code No 20 Symptom When the main switch is turned to ON the atmospheric pressure sensor voltage and intake air pressure sensor voltage differ gr...

Page 378: ...ive Refer to CHECKING THE COOLANT TEMPERATURE SENSOR on page 8 100 Fault code No 22 Symptom Air temperature sensor open or short circuit detected Diagnostic code No 05 Air temperature sensor Orde r Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Air temperature sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may have p...

Page 379: ...c mode Code No 02 Replace if defective Refer to CHECKING THE ATMOSPHERIC PRESSURE SENSOR on page 8 102 Fault code No 24 Symptom No normal signal is received from the O2 sensor Diagnostic code No Orde r Item components and probable cause Check or maintenance job Reinstatement method 1 Installed state of O2 sensor Check for looseness or pinching Execute the diagnostic mode Code No 63 Set the engine ...

Page 380: ...code No 30 Cylinder 1 ignition coil Orde r Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Cylinder 1 ignition coil coupler Main wire harness ECU coupler Sub wire harness 1 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 coupler securely Cranking t...

Page 381: ...If there is a malfunction repair it and connect the coupler securely Cranking the engine Connect the cylinder 2 igni tion coil cou pler 2 Open or short circuit in wire harness and or sub wire harness 1 Repair or replace if there is an open or short circuit Between cylinder 2 ignition coil coupler and ECU coupler Red Black Red Black Gray Red Gray Red 3 Defective cylinder 2 ignition coil Execute the...

Page 382: ...there is a malfunction repair it and connect the coupler securely Cranking the engine Connect the cylinder 3 igni tion coil cou pler 2 Open or short circuit in wire harness and or sub wire harness 1 Repair or replace if there is an open or short circuit Between cylinder 3 ignition coil coupler and ECU coupler Red Black Red Black Orange Green Orange Green 3 Defective cylinder 3 ignition coil Execut...

Page 383: ...s a malfunction repair it and connect the coupler securely Cranking the engine Connect the cylinder 4 igni tion coil cou pler 2 Open or short circuit in wire harness and or sub wire harness 1 Repair or replace if there is an open or short circuit Between cylinder 4 ignition coil coupler and ECU coupler main wire harness Red Black Red Black Gray Green Gray Green 3 Defective cylinder 4 ignition coil...

Page 384: ...e is a malfunction repair it and connect the coupler securely Cranking the engine Connect the fuel injector couplers 2 Open or short circuit in wire harness and or sub wire harness 2 Repair or replace if there is an open or short circuit Between injector coupler and ECU coupler Red Blue Red Blue 1 Red Black Red Black 2 Green Black Green Black 3 Blue Black Blue Black 4 Orange Black Orange Black 3 D...

Page 385: ...coupler If there is a malfunction repair it and connect the coupler securely Reinstated automatically if a normal signal is received 2 Open or short circuit in lead wire 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 0...

Page 386: ...Yellow Black Blue Black Blue A 4 Defective speed sensor Execute the diagnostic mode Code No 07 Replace if defective Refer to CHECKING THE SPEED SENSOR on page 8 99 B 1 Installed state of neutral switch Check for looseness or pinching B 2 Connections Neutral switch coupler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check the locking condition of the coupler...

Page 387: ...securely Turning the main switch to ON when the engine stop switch is set to 2 Open or short circuit in the wire har ness Repair or replace if there is an open or short circuit Between relay unit coupler and ECU coupler Blue Yellow Blue Yellow Red Blue Red Blue Between relay unit coupler and starter relay coupler Red Red Between relay unit coupler and right handlebar switch coupler Red Black Red B...

Page 388: ...ume after it is reinstated Fault code No 46 Symptom Power supply is not normal Diagnostic code No Orde r Item components and probable cause Check or maintenance job Reinstatement method 1 Malfunction in rectifier regulator Replace if defective Refer to CHARGING SYS TEM on page 8 11 Starting the engine and operating it at idle 2 Open or short circuit in wire harness Repair or replace if there is an...

Page 389: ...to ON 2 Connections Throttle position sensor for throttle cable pulley coupler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between throttle position se...

Page 390: ...or short circuit Between throttle servo motor coupler and ECU coupler Yellow Red Yellow Red Light green Red Light green Red 4 Defective throttle servo motor Execute the diagnostic mode Code Nos 01 13 Replace the throttle body assembly if defective 5 Malfunction in ECU Replace the ECU Fault code No Er 1 Symptom No signals are received from the ECU Diagnostic code No Orde r Item components and proba...

Page 391: ...ly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 3 Symptom Data from the ECU cannot be received correctly Diagnostic code No Orde r Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Main wire harness ECU coupler Main wire harness meter assembly coupler Check the couplers for any pins that may be pulled out Check the lo...

Page 392: ...may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 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 meter assembly cou pler and ECU coupler Yellow Blue Yellow Blue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction ...

Page 393: ...FUEL INJECTION SYSTEM 8 66 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 394: ...FUEL PUMP SYSTEM 8 67 EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 395: ... 12 Starting circuit cut off relay 15 Fuel pump 19 ECU engine control unit 48 Multi function meter 58 Engine stop switch 81 Ignition fuse 91 Ground 92 Battery negative lead Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 396: ...on page 8 89 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 85 Replace the immobilizer unit 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 85 Replace the right handlebar switch 5 Check the starting circuit cut off relay Refer to CHECKING THE RELAYS on page 8 92 Replace the starting circuit cut of...

Page 397: ...el pump sys tem s wiring Refer to FUEL PUMP SYSTEM on page 8 67 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 398: ...IMMOBILIZER SYSTEM 8 71 EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 399: ... Immobilizer unit 8 Battery 19 ECU engine control unit 42 Immobilizer system indicator light 48 Multi function meter 91 Ground 92 Battery negative lead Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 400: ...e is not neces sary CAUTION ECA14971 DO NOT LOSE THE CODE RE REGISTERING KEY If the code re registering key is lost reg istering new codes in the standard keys is impossible The standard keys can still be used to start the 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 r...

Page 401: ...that the engine can be started 3 Register the standard key following the instructions in the section below Standby mode To enable the immobilizer system turn the ignition 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 e...

Page 402: ... key registration mode NOTE The existing standard key code is erased from the memory when the key registration mode is acti vated When the key registration mode is activated the immobilizer system indicator light flashes rapidly 4 While the indicator light is flashing turn the main switch to OFF remove the key and within 5 seconds insert the second standard key to be registered into the main switc...

Page 403: ...ode 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 404: ... 8 89 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 85 Replace the main switch immobilizer unit 4 Check the entire immobilizer sys tem wiring Refer to IMMOBILIZER SYSTEM on page 8 71 Properly connect or repair the immobi lizer system wiring Check the condition of the each immobilizer system circuits Refer to SELF DIAGNO...

Page 405: ...onder of other vehicles 2 Register the stan dard key 53 IMMOBILIZER UNIT Codes cannot be transmitted between the ECU and the immobilizer unit Noise interference or dis connected lead cable 1 Interference due to radio wave noise 2 Disconnected commu nication harness 3 Immobilizer unit mal function 4 ECU malfunction 1 Check the wire harness and con nector 2 Replace the main switch immobi lizer unit ...

Page 406: ...ample fault code 52 56 ECU Undefinition code is received Noise interference or dis connected lead cable 1 Check the wire harness and con nector 2 Replace the main switch immobi lizer unit 3 Replace the ECU Fault code Part Symptom Cause Action 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 407: ...IMMOBILIZER SYSTEM 8 80 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 408: ...ELECTRICAL COMPONENTS 8 81 EAS27970 ELECTRICAL COMPONENTS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 409: ...ear brake light switch 11 EXUP servo motor 12 Sidestand switch 13 O2 sensor 14 Speed sensor 15 Oil level switch 16 Ignition coil 17 Radiator fan motor 18 Rectifier regulator 19 Horn 20 Fuse box radiator fan motor signaling sys tem ignition ETV backup 21 Fuse box headlight turn Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 410: ...ELECTRICAL COMPONENTS 8 83 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 411: ...e sensor 9 Crankshaft position sensor 10 Intake air pressure sensor 11 Throttle servo motor 12 Throttle position sensor for throttle cable pulley 13 Throttle position sensor for throttle valves 14 Cylinder identification sensor 15 Radiator fan motor relay 16 Headlight relay dimmer 17 Headlight relay on off Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email...

Page 412: ...ELECTRICAL COMPONENTS 8 85 EAS27980 CHECKING THE SWITCHES Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 413: ...witch 6 Hazard switch 7 Clutch switch 8 Sidestand switch 9 Engine stop switch 10 Front brake light switch 11 Start switch 12 Oil level switch 13 Neutral switch 14 Rear brake light switch Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 414: ...ch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch position is indication by There is continuity...

Page 415: ...cooled down CAUTION ECA14380 Be sure to hold the socket firmly when removing the bulb Never pull the lead otherwise it may be pulled out of the ter minal in the coupler Avoid touching the glass part of the head light bulb to keep it free from oil other wise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thorough...

Page 416: ...3310 Never use a fuse with an amperage rating other than that specified Improvising or using a fuse with the wrong amperage rat ing may cause extensive damage to the electrical system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install Side cowlings Passenger seat Rider seat EAS28030 CHECKING AND CHARGING THE BATTERY WARNING EWA13290 Batteries generate ...

Page 417: ...he charge of the battery has to be checked by measuring the voltage at the battery terminals 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 2 Disconnect Battery leads from the battery terminals CAUTION ECA13640 First disconnect the negative battery lead 1 and then positive battery lead 2 3 Remove Battery 4 Check Battery charge a Connect a pocket tester to the battery ter minals NOTE The ...

Page 418: ...y and start charging NOTE Set the charging voltage at 16 17 V If the set ting is lower charging will be insufficient If too high the battery will be over charged c Make sure that the current is higher than the standard charging current written on the battery NOTE If the current is lower than the standard charg ing current written on the battery set the charging voltage adjust dial at 20 24 V and m...

Page 419: ... relay 1 Disconnect the relay from the wire harness 2 Connect the pocket tester Ω 1 and bat tery 12 V to the relay terminal as shown Check the relay operation Out of specification Replace Relay unit starting circuit cut off relay Relay unit fuel pump relay 12 8 V or more Charging is complete 12 7 V or less Recharging is required Under 12 0 V Replace the battery Recommended lubricant Dielectric gre...

Page 420: ...ification Replace 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity No continuity 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity No continuity 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result...

Page 421: ...tester probe Black Yellow 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 bl...

Page 422: ...coil b Connect the pocket tester Ω 1k to the ignition coil as shown c Measure the secondary coil resistance 3 Check Ignition spark gap Out of specification Replace a Disconnect the ignition coil from the spark plug b Connect the ignition checker dynamic spark tester 2 as shown Primary coil resistance 0 85 1 15 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester...

Page 423: ...move Lean angle sensor from the bracket 2 Check Lean angle sensor out put 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 c When turn the lean angle sensor to 65 1 Ignition coil Crankshaft position sensor resistance 336 504 Ω at 20 C 68 F Pocket tester 90890 03112 Analog p...

Page 424: ...l coupler from the rectifier regulator 2 Check Stator coil resistance Out of specification Replace the stator coil 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 Charging voltage Out of specification Replace the rectifier regulator a Set the engine tachometer to the ignition coil of cylinder...

Page 425: ...THE OIL LEVEL SWITCH 1 Drain Engine oil 2 Remove Oil level switch from the oil pan 3 Check Oil level switch resistance a Connect the pocket tester Ω 100 to the oil level switch terminal as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Red 1 Negative tester probe Black 2 Horn resistance 1 15 1 25 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester Y...

Page 426: ... ON c Elevate the rear wheel and slowly rotate it Pocket tester 90890 03112 Analog pocket tester YU 03112 C Maximum level position A Positive tester probe Connector white 1 Negative tester probe Body earth 2 Minimum level position B Positive tester probe Connector white 1 Negative tester probe Body earth 2 Fuel sender resistance 19 141Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester Y...

Page 427: ...r to strong shocks If the coolant temperature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 100 to the coolant temperature sensor 1 as shown b Immerse the coolant temperature sensor in a container filled with coolant 2 NOTE Make sure the coolant temperature sensor ter minals do not get wet c Place a thermometer...

Page 428: ...hrottle cable pulley adjust its angle properly Refer to ADJUSTING THE THROTTLE POSI TION SENSOR FOR THROTTLE CABLE PULLEY on page 7 7 EAS28300 CHECKING THE THROTTLE POSITION SENSOR FOR THROTTLE VALVES 1 Remove Throttle position sensor for throttle valves from the throttle body 2 Check Throttle position sensor for throttle valves maximum resistance Out of specification Replace the throttle position...

Page 429: ...heric pressure sensor coupler wire harness side as shown b Set the main switch to ON c Measure the atmospheric pressure sensor output voltage EAS28390 CHECKING THE CYLINDER IDENTIFICA TION SENSOR 1 Check Cylinder identification sensor output volt age Out of specification Replace a Connect the pocket tester DC 20 V to the cylinder identification sensor coupler wire harness side as shown Solenoid re...

Page 430: ...re sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it 2 Check Intake air temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 100 to the intake air temperature sensor terminal as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe W...

Page 431: ...air temperature sensor resistance 3 Install Intake air temperature sensor Intake air temperature sensor bolt 1 2 Nm 0 12 m kg 0 87 ft lb Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 432: ...ELECTRICAL COMPONENTS 8 105 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 433: ... FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 2 OVER COOLING 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 434: ... relay 3 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 or damaged electrode Worn or damaged insulator 4 Ignition coil s Cracked or broken ignition coil body...

Page 435: ...oreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS28560 FAULTY CLUTCH Clutch slips 1 Clutch Improperly assembled clutch Improperly adjusted clutch cable Loose...

Page 436: ...Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high Loose damper rod assembly bolt Damaged damper rod assembly bolt copper washer Cracked or damaged cap bolt O ring Malfunction Bent or damaged inner tube Bent or damaged outer tube Damaged fork spring Worn or damaged outer tube bushing Bent or damaged damper rod ...

Page 437: ...t connection Tail brake light bulb burnt out Faulty battery Incorrectly adjusted rear brake light switch Turn signal does not come on Faulty turn signal switch Faulty turn signal relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signal blinks slowly Faulty turn signal relay Faulty mai...

Page 438: ... Start switch 60 Turn signal hazard relay 61 Left handlebar switch 62 Hazard switch 63 Pass switch 64 Dimmer switch 65 Horn switch 66 Clutch switch 67 Turn signal switch 68 Horn 69 Front left turn signal light 70 Front right turn signal light 71 Rear left turn signal light 72 Rear right turn signal light 73 Headlight 74 Auxiliary light 75 Ground cord head light 76 License plate light 77 Rear brake...

Page 439: ...Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 440: ...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 441: ... W 2007 SCHEMA DE CABLAGE YZF R1 W 2007 SCHALTPLAN YZF R1 W 2007 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE YZF R1 W 2007 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 442: ... W 2007 SCHEMA DE CABLAGE YZF R1 W 2007 SCHALTPLAN YZF R1 W 2007 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE YZF R1 W 2007 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

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