Page 1 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 2012 SERVICE MANUAL YZF-R1(B) 1KB-28197-E0 email: info@motomatrix.co.uk...
Page 2 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS20040 YZF-R1(B) SERVICE MANUAL ©2011 by Yamaha Motor Co., Ltd. First edition, July 2011 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
Page 3 EAS20071 IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Page 4: How To Use This Manual
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order.
Page 5: Symbols
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS20100 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine Gear oil mounted Filling fluid...
Page 6 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
Page 7: Table Of Contents
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING 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: General Information
FEATURES ....................1-2 OUTLINE OF THE FI SYSTEM ..............1-2 FI SYSTEM .....................1-3 YCC-T (Yamaha Chip Controlled Throttle) YCC-I (Yamaha Chip Controlled Intake) ..........1-4 OUTLINE OF THE TCS (Traction Control System) ........1-8 INSTRUMENT FUNCTIONS ..............1-12 IMPORTANT INFORMATION ..............1-20 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-20 REPLACEMENT PARTS...............1-20...
Page 10: Identification
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the seat rail reinforcement under the passenger seat.
Page 11: Features
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES EAS20170 FEATURES EAS30340 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.
Page 12: Fi System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES EAS14B1017 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at a certain level. Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
Page 13: Ycc-T (Yamaha Chip Controlled Throttle) Ycc-I (Yamaha Chip Controlled Intake)
YCC-T (Yamaha Chip Controlled Throttle) YCC-I (Yamaha Chip Controlled Intake) Mechanism characteristics Yamaha developed the YCC-T and YCC-I system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles, but Yamaha has developed a faster, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed system has a high-speed calculating capacity that produces computations of running conditions every 1/1000th of a second.
Page 14 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES Aims and advantages of using YCC-I system • Improved power band By using a dual intake funnel system, YCC-I optimizes the effectiveness of the fuel injection sys- tem to deliver an incredibly precise air/fuel mixture to the combustion chamber.
Page 15 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES YCC-T/YCC-I system outline 1. Throttle position sensor 2. Throttle servo motor 3. Accelerator position sensor 4. ECU (engine control unit) 5. ETV main CPU (32 bit) 6.
Page 16 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES YCC-T/YCC-I control outline 17.ECU (engine control unit) 1. Accelerator position sensor 18.Base map 2. Throttle position sensor 19.Idle speed control 3. Crankshaft position sensor 20.Calculated throttle valve opening angle 4.
Page 17: Outline Of The Tcs (Traction Control System)
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES EAS1KB8101 OUTLINE OF THE TCS (Traction Control System) The traction control system controls excessive spinning (slipping) of the rear wheel when accelerat- ing. The ECU monitors the front and rear wheel speeds using the signals from the front and rear speed sensors, and detects rear wheel slipping according to the difference between the wheel speeds.
Page 18 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES TCS (Traction control system) block diagram The signals from the front and rear speed sensors are sent to the ECU, and the ECU calculates the amount of slip according to the difference between the detected front and rear wheel speeds. If the amount of slip exceeds the preset value, the ECU controls the ignition timing, fuel cut-off, and throttle valve opening of the YCC-T system so that the amount of slip is less than the preset value.
Page 19 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES There are six traction control system modes and an off mode. Display Mode 1 Mode 2 Mode 3 Mode 4 Mode 5 Mode 6 • “TCS” mode 1 provides for the least traction control system assist. •...
Page 20 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES 2. Traction control system mode display 1. Traction control system switch Resetting The traction control system may be disabled in the following conditions: • Either the front wheel or rear wheel comes off the ground while riding •...
Page 21: Instrument Functions
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES EAS1KB8102 • A fuel consumption display (instantaneous INSTRUMENT FUNCTIONS and average consumption functions) • A traction control system mode display Multi-function meter unit (which shows the selected traction control system mode) •...
Page 22 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES Clock and stopwatch modes Split time history 1. Clock/stopwatch 1. Coolant temperature display/air intake tem- perature display To set the clock 2. Stopwatch 1. Push the “SELECT” button and “RESET” The split time history displays up to 20 stored button together for at least two seconds.
Page 23 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES • To reset all the recorded times for the the distance traveled from that point. In that selected split time history, push the “RESET” case, push the “SELECT” button to switch the button for at least one second.
Page 24 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES Transmission gear display If traveling at speeds under 10 km/h (6.0 mi/h), “_ _._” is displayed. Average fuel consumption mode 1. Neutral indicator light “ ” 2.
Page 25 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES Traction control system mode display When the coolant temperature display is selected, “C” is displayed for one second, and then the coolant temperature is displayed. ECA14B1016 Do not continue to operate the engine if it is overheating.
Page 26 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES 1. Use the code re-registering key to start the b. Shift timing indicator light activity: engine. This function allows you to choose whether or not the indicator light should be activated and whether it should flash Make sure there are no other immobilizer keys or stay on when activated.
Page 27 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES 2. Push the “SELECT” button to confirm the 2. Push the “SELECT” button to confirm the selected indicator light activity. The control selected indicator light brightness level. mode changes to the shift timing indicator The display returns to the odometer or light activation function.
Page 28 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES Using this switch changes the drive mode to “STD”, “A”, or “B” in the following order: STD → A → B → STD The throttle grip must be completely closed in order to change the drive mode.
Page 29: Important Information
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.
Page 30: Bearings And Oil Seals
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu- facturer’s marks or numbers are visible. When installing oil seals “1”, lubricate the oil seal lips with a light coat of lithium-soap-based grease.
Page 31: Checking The Connections
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE CONNECTIONS EAS20250 5. Check: CHECKING THE CONNECTIONS • Continuity Check the leads, couplers, and connectors for (with the pocket tester) stains, rust, moisture, etc. Pocket tester 1.
Page 32: Handling The Electronic Parts
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLING THE ELECTRONIC PARTS EAS14B1120 HANDLING THE ELECTRONIC PARTS Electronic parts is very sensitive. Handle with care and do not give impact. Mankind has static electricity and it’s voltage is very high and electronic parts is very sensitive.
Page 33: Special Tools
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques.
Page 34 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Steering nut wrench 3-23, 4-74 90890-01403 Exhaust flange nut wrench YU-A9472 Damper rod holder 4-65, 4-67 90890-01506 YM-01506 Oil filter wrench 3-29 90890-01426 YU-38411...
Page 35 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod puller attachment (M10) 4-68, 4-69 90890-01436 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Fork spring compressor 4-64, 4-69 90890-01441 YM-01441 Fork seal driver...
Page 36 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Thickness gauge 3-7, 3-8, 4-24 90890-03180 Feeler gauge set YU-26900-9 Valve spring compressor 5-29, 5-35 90890-04019 YM-04019 Valve spring compressor attachment 5-29, 5-35 90890-04108 Valve spring compressor adapter 22 mm...
Page 37 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide remover (ø5) 5-31 90890-04097 Valve guide remover (5.0 mm) YM-04097 Valve guide remover (ø4.5) 5-31 90890-04116 Valve guide remover (4.5 mm) YM-04116 Valve guide installer (ø5) 5-31...
Page 38 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pivot shaft wrench adapter 5-10 90890-01476 Valve lapper 90890-04101 Valve lapping tool YM-A8998 Oil pressure adapter H 3-30 90890-03139 Pressure gauge 3-30, 7-18 90890-03153...
Page 39 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Damper rod holder (22 mm) 4-83, 4-84 90890-01365 Drive chain cut & rivet tool 4-86, 4-87 90890-01550 YM-01550 Piston installing tool 5-82 90890-04161 YM-04161...
Page 40 Test harness-speed sensor (3P) 8-141, 8-146 90890-03208 YU-03208 Test harness-lean angle sensor (6P) 8-138 90890-03209 YU-03209 Test harness S-pressure sensor (3P) 8-145, 8-146 90890-03207 YU-03207 Yamaha bond No. 1215 5-23, 5-38, 5- (Three bond No. 1215®) 44, 5-72 90890-85505 1-31 email: info@motomatrix.co.uk...
Page 41: Specifications
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-9 ELECTRICAL SPECIFICATIONS...............2-12 TIGHTENING TORQUES................2-15 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-15 ENGINE TIGHTENING TORQUES ............2-16 CHASSIS TIGHTENING TORQUES ............2-20 LUBRICATION POINTS AND LUBRICANT TYPES ........2-24 ENGINE ....................2-24 CHASSIS ....................2-26 LUBRICATION SYSTEM CHART AND DIAGRAMS .........2-27...
Page 42: General Specifications
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 1KB8, 1KBJ (AUT, BEL, CHE, CZE, DEU, DNK, ESP, FIN, GBR, GRC, HUN, IRL, ITA, NLD, NOR, POL, PRT, SVN, SWE, ZAF) 1KB9, 1KBK (BEL, FRA) 1KBH, 1KBP (AUS) Dimensions...
Page 43: Engine Specifications
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 998.0 cm³ Cylinder arrangement Inline 4-cylinder Bore × stroke 78.0 × 52.2 mm (3.07 × 2.06 in) Compression ratio 12.70 : 1 Standard compression pressure (at sea level)
Page 44 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Thermostat 71 °C (159.8 °F) Valve opening temperature 85 °C (185.0 °F) Valve full open temperature Valve lift (full open) More than 8 mm (0.31 in) Radiator core Width 383.0 mm (15.08 in)
Page 45 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Timing chain Tensioning system Automatic Valve, valve seat, valve guide Valve clearance (cold) Intake 0.11–0.20 mm (0.0043–0.0079 in) Exhaust 0.23–0.27 mm (0.0091–0.0106 in) Valve dimensions Valve head diameter A (intake) 30.90–31.10 mm (1.2165–1.2244 in) Valve head diameter A (exhaust)
Page 46 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Valve spring Inner spring Free length (intake) 39.33 mm (1.55 in) Limit 37.36 mm (1.47 in) Free length (exhaust) 37.96 mm (1.49 in) Limit 36.06 mm (1.42 in) Installed length (intake) 34.50 mm (1.36 in) Installed length (exhaust)
Page 47 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS End gap (installed) 0.15–0.25 mm (0.0059–0.0098 in) Limit 0.50 mm (0.0197 in) Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) Limit 0.115 mm (0.0045 in) 2nd ring Ring type Taper Dimensions (B ×...
Page 48 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Clutch Clutch type Wet, multiple-disc Clutch release method Outer pull, rack and pinion pull Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) Friction plate thickness 2.92–3.08 mm (0.115–0.121 in) Wear limit 2.82 mm (0.111 in)
Page 49 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Throttle position sensor Throttle position sensor resistance 1.2–2.8 kΩ Accelerator position sensor resistance 1.2–2.8 kΩ Output voltage (at idle) 0.63–0.73 V Fuel injection sensor 248–372 Ω at 20 °C (68 °F) Crankshaft position sensor resistance Cylinder identification sensor output voltage (ON)
Page 50: Chassis Specifications
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 24.0° Trail 102.0 mm (4.02 in) Front wheel Wheel type Cast wheel 17M/C × MT3.50 Rim size Rim material Aluminum Wheel travel...
Page 51 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS SPECIFICATIONS Front disc brake Disc outside diameter × thickness 310.0 × 5.0 mm (12.20 × 0.20 in) Brake disc thickness limit 4.5 mm (0.18 in) Brake disc deflection limit 0.10 mm (0.0039 in) Brake pad lining thickness (inner) 4.5 mm (0.18 in)
Page 52 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS SPECIFICATIONS Compression damping adjusting positions Minimum Standard Maximum Rear suspension Type Swingarm (link suspension) Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel 60.0 mm (2.36 in) Spring free length 161.0 mm (6.34 in) Installed length...
Page 53: Electrical Specifications
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Ignition timing (B.T.D.C.) 5.0°/1200 r/min Engine control unit Model/manufacturer TBDFE9/DENSO (1KB8, 1KBH, 1KBJ, 1KBP) TBDFF0/DENSO (1KB9, 1KBK) Ignition coil Minimum ignition spark gap...
Page 54 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SPECIFICATIONS Fuel level warning light Coolant temperature warning light Engine trouble warning light Immobilizer system indicator light Shift timing indicator light Traction control system indicator/warning light Electric starting system System type Constant mesh...
Page 55 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SPECIFICATIONS Ignition fuse 15.0 A 10.0 A × 2 Radiator fan fuse Turn signal light fuse 7.5 A Fuel injection system fuse 15.0 A Steering damper fuse 7.5 A Backup fuse 7.5 A...
Page 56: Tightening Torques
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFI- CATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual.
Page 57: Engine Tightening Torques
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Spark plugs 13 Nm (1.3 m·kgf, 9.4 ft·lbf) Cylinder head nut See TIP. Cylinder head nut See TIP.
Page 58 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Throttle body and throttle body 3 Nm (0.3 m·kgf, 2.2 ft·lbf) joint clamp Throttle position sensor screw 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) Accelerator position sensor screw 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) Secondary injector assembly bolt...
Page 59 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Generator rotor cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Drive sprocket cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Clutch cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Clutch cover bolt...
Page 60 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Starter motor bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Rear speed sensor bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Cylinder head nut Use new nuts and washers.
Page 61: Chassis Tightening Torques
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (front side) 70 Nm (7.0 m·kgf, 50 ft·lbf) Engine mounting nut (rear side) 51 Nm (5.1 m·kgf, 37 ft·lbf) Engine mount adjusting bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Page 62 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Handlebar end grip bolt 4 Nm (0.4 m·kgf, 2.9 ft·lbf) Front brake hose joint bracket bolt 11 Nm (1.1 m·kgf, 8.0 ft·lbf) Coolant reservoir bolt 5 Nm (0.5 m·kgf, 3.6 ft·lbf) Air chamber bracket bolt...
Page 63 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Bleed screw (master cylinder) 6 Nm (0.6 m·kgf, 4.3 ft·lbf) Front wheel axle pinch bolt 21 Nm (2.1 m·kgf, 15 ft·lbf) See TIP.
Page 64 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES If the end face of the axle is not parallel to the end face of the fork, align them so that one point of the axle circumference is positioned on the end face of the fork. At this stage, it can be accepted if the end face of the axle becomes partially concave to the end face of the fork.
Page 65: Lubrication Points And Lubricant Types
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Coolant hose insertion part Silicon fluid Bearings Camshaft lobes and journals (intake and exhaust) Valve stem seal (installed on valve guide) Silicon fluid...
Page 66 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Yamaha bond Cylinder head cover semicircular No.1215 (Three bond No.1215®) Yamaha bond Crankcase mating surface No.1215 (Three bond No.1215®)
Page 67: Chassis
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Throttle grip inner surface and throttle cable end Brake lever pivoting point and metal-to-metal moving parts Clutch lever pivoting point and metal-to-metal moving parts Clutch cable end Engine mounting bolts (rear upper and lower side)
Page 68: Lubrication System Chart And Diagrams
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-27 email: info@motomatrix.co.uk...
Page 69 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Sub gallery 6. Oil filter cartridge 7. Main gallery 8.
Page 70: Lubrication Diagrams
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-29 email: info@motomatrix.co.uk...
Page 71 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Crankshaft 4. Oil filter cartridge 5. Oil level switch 2-30 email: info@motomatrix.co.uk...
Page 72 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31 email: info@motomatrix.co.uk...
Page 73 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Timing chain tensioner 4. Crankshaft 5. Balancer shaft 6. Oil cooler 7. Relief valve 8. Oil pipe 9.
Page 74 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33 email: info@motomatrix.co.uk...
Page 75 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter cartridge 2. Oil level switch 3. Oil strainer 4. Oil pipe 5. Relief valve 6. Oil cooler 2-34 email: info@motomatrix.co.uk...
Page 76 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35 email: info@motomatrix.co.uk...
Page 77 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil/water pump assembly 2-36 email: info@motomatrix.co.uk...
Page 78 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37 email: info@motomatrix.co.uk...
Page 79 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil delivery pipe 2 3. Drive axle 2-38 email: info@motomatrix.co.uk...
Page 80 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 2-39 email: info@motomatrix.co.uk...
Page 81 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Shift fork guide bar 2. Shift fork-C 3. Shift drum assembly 4. Shift fork-R 5. Drive axle 6. Shift fork-L 2-40 email: info@motomatrix.co.uk...
Page 82 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 2-41 email: info@motomatrix.co.uk...
Page 83 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Exhaust camshaft 3. Intake camshaft 4. Oil nozzle 5. Crankshaft 2-42 email: info@motomatrix.co.uk...
Page 84 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 2-43 email: info@motomatrix.co.uk...
Page 85 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Balancer shaft 2. Crankshaft 2-44 email: info@motomatrix.co.uk...
Page 86: Cooling System Diagrams
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-45 email: info@motomatrix.co.uk...
Page 87 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM DIAGRAMS 1. Oil/water pump assembly 2. Radiator 3. Radiator fan 4. Thermostat 5. Oil cooler 2-46 email: info@motomatrix.co.uk...
Page 88 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM DIAGRAMS 2-47 email: info@motomatrix.co.uk...
Page 89 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator 3. Radiator fan 4. Oil cooler 2-48 email: info@motomatrix.co.uk...
Page 90: Cable Routing
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING EAS20430 CABLE ROUTING 2-49 email: info@motomatrix.co.uk...
Page 91 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Meter assembly 2. Meter lead 3. Meter bracket 4. Right auxiliary light lead 5. Headlight sub-wire harness 6. Headlight lead 7. Intake air temperature sensor 8.
Page 92 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-51 email: info@motomatrix.co.uk...
Page 93 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING P. Fasten the front wheel sensor lead on the 1. Clutch cable white tape. Face the end of the plastic 2. Main switch lead band to rear and to inside of the vehicle, 3.
Page 94 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-53 email: info@motomatrix.co.uk...
Page 95 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING Q. Fasten the clutch cable in front of the oil 1. Hazard switch lead cooler outlet hose. 2. Right auxiliary light lead 3. Headlight sub-wire harness 4.
Page 96 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-55 email: info@motomatrix.co.uk...
Page 97 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Ignition coil lead 2. Crankshaft position sensor lead 3. Rear brake light switch lead 4. O sensor lead A. Route the rear brake light switch lead out- side of the O sensor lead and push it to the occluding surface of the clutch cover.
Page 98 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-57 email: info@motomatrix.co.uk...
Page 99 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING P. When installing the exhaust chamber 1. Union bolt cover, route the rear brake light switch lead 2. Washer in front of the projection of the right footrest 3.
Page 100 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-59 email: info@motomatrix.co.uk...
Page 101 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Immobilizer unit lead 2. Left radiator fan motor lead 3. Radiator fan motor relay 4. ECU (engine control unit) 5. ECU (engine control unit) bracket 6.
Page 102 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-61 email: info@motomatrix.co.uk...
Page 103 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Oil level switch lead 2. Gear position sensor lead 3. Rear speed sensor lead 4. Sidestand switch lead 5. Fuel tank overflow hose 6. Fuel tank breather hose 7.
Page 104 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-63 email: info@motomatrix.co.uk...
Page 105 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING F. Route the coolant reservoir hose in front of 1. Right handlebar switch lead the crankcase breather hose and to the 2. Headlight sub-wire harness coolant reservoir tank.
Page 106 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-65 email: info@motomatrix.co.uk...
Page 107 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING Z. After connecting the main harness coupler and immobilizer unit coupler, insert them into the stay 1. AA.Main harness side AB.Fasten the secondary injector sub-wire harness and throttle sub-wire harness at the protector.
Page 108 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-67 email: info@motomatrix.co.uk...
Page 109 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING N. Insert the fuse box until back of the tab of 1. Rear frame the battery box 2. 2. Battery box 1 O. Black 3. License plate light lead P.
Page 110 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-69 email: info@motomatrix.co.uk...
Page 111 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Fuel tank upper cover 2. Fuel tank breather hose 3. Fuel tank overflow hose 4. Fuel tank 5. Fuel pump 6. Frame 7. Fuel hose connector cover 8.
Page 112 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-71 email: info@motomatrix.co.uk...
Page 113 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Upper air filter case 2. Fuel hose (secondary injector fuel rail side) 3. Fuel hose (primary injector fuel rail side) 4. Primary injector fuel rail 5.
Page 114 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-73 email: info@motomatrix.co.uk...
Page 115 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Cap case 2. Upper air filter case 3. Sub-wire harness 4. Secondary injector holder 5. Grommet 6. Plastic locking tie 7. Fuel rail A. Sub-wire harness should not be pinched under the bearing surface of the bolt.
Page 116 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-75 email: info@motomatrix.co.uk...
Page 117: Periodic Checks And Adjustments
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE .................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART.....3-2 CHECKING THE FUEL LINE (Primary injector) ........3-4 CHECKING THE FUEL LINE (Secondary injector) ........3-4 CHECKING THE SPARK PLUGS............3-4 ADJUSTING THE VALVE CLEARANCE ..........3-5...
Page 118 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE COOLANT LEVEL ............3-31 CHECKING THE COOLING SYSTEM ..........3-31 CHANGING THE COOLANT ..............3-32 CHECKING THE FRONT BRAKE LIGHT SWITCH ......3-33 ADJUSTING THE REAR BRAKE LIGHT SWITCH ......3-33 CHECKING AND LUBRICATING THE CABLES ........3-34 ADJUSTING THE THROTTLE CABLE FREE PLAY ......3-34 LUBRICATING THE REAR SUSPENSION ..........3-34...
Page 119 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
Page 120: Periodic Maintenance
UK, a mileage-based maintenance, is performed instead. • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
Page 121: General Maintenance And Lubrication Chart
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE EAS14B1034 GENERAL MAINTENANCE AND LUBRICATION CHART ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi)
Page 122 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) Rear suspension relay arm and con-...
Page 123: Checking The Fuel Line (Primary Injector)
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE EAS21030 4. Install: CHECKING THE FUEL LINE (Primary injec- • Fuel tank tor) Refer to “FUEL TANK” on page 7-1. The following procedure applies to all of the 5.
Page 124: Adjusting The Valve Clearance
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE 2. Remove: 10. Install: • Fuel tank • Spark plug Refer to “FUEL TANK” on page 7-1. Spark plug 3. Remove: 13 Nm (1.3 m·kgf, 9.4 ft·lbf) •...
Page 125 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE • Air cut-off valve Refer to “AIR INDUCTION SYSTEM” on page 7-21. • Radiator • Radiator fan motor Refer to “RADIATOR” on page 6-1. 2. Remove: •...
Page 126 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE b. Turn the crankshaft 105 degrees in clock- e. Measure the valve clearance #3 with a wise and align the pickup rotor T mark “a” thickness gauge.
Page 127 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE b. Calculate the difference between the speci- Thickness gauge fied valve clearance and the measured 90890-03180 valve clearance. Feeler gauge set Example: YU-26900-9 Specified valve clearance = 0.11–0.20 mm (0.0043–0.0079 in) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 128: Synchronizing The Throttle Bodies
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE i. If the valve clearance is still out of specifi- Valve pad range No. 160–240 cation, repeat all of the valve clearance 1.60–2.40 mm adjustment steps until the specified clear- Valve pad thickness (0.0630–0.0945 in) ance is obtained.
Page 129 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE 4. Install: Adjusting the throttle body synchronization • Vacuum gauge “1” 1. Adjust: • Digital tachometer • Throttle body synchronization (Use goods on the market) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 130: Checking The Throttle Body Joints
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE 3. Adjust: ECA13450 • Throttle cable free play Refer to “ADJUSTING THE THROTTLE Make sure the crankcase breather hose is CABLE FREE PLAY” on page 3-34. routed correctly.
Page 131: Adjusting The Exhaust Gas Volume
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE 11. Install: • Passenger seat Refer to “GENERAL CHASSIS” on page 4-1. 12. Install: • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. EAS20600 ADJUSTING THE EXHAUST GAS VOLUME Be sure to set the CO density level to stan- dard, and then adjust the exhaust gas volume.
Page 132: Checking The Air Induction System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE 5. Press the “SELECT” and “RESET” buttons 10. Turn the main switch to “OFF” to cancel the to select a cylinder. CO adjustment mode. EAS14B1099 CHECKING THE AIR INDUCTION SYSTEM Refer to “CHECKING THE AIR INDUCTION SYSTEM”...
Page 133: Adjusting The Clutch Cable Free Play
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE 2. Adjust: • Clutch cable free play 6. Install: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Air filter case cover Refer to “AIR FILTER CASE” on page 7- Handlebar side a.
Page 134: Checking The Brake Operation
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE c. Tighten the locknuts “1”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS14B1088 CHECKING THE BRAKE OPERATION 1. Check: • Brake operation Brake not working properly → Check the brake system. Refer to “FRONT BRAKE”...
Page 135: Adjusting The Front Disc Brake
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE EAS21160 EAS21250 ADJUSTING THE FRONT DISC BRAKE CHECKING THE FRONT BRAKE PADS 1. Adjust: The following procedure applies to all of the • Brake lever position brake pads.
Page 136: Checking The Rear Brake Pads
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE b. Turn the adjusting bolt “2” in direction “a” or 2. Check: “b” until the specified brake pedal position • Rear brake pad is obtained. Wear indicators “1”...
Page 137: Checking The Front Brake Hoses
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. h.
Page 138: Checking The Rear Brake Hose
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE 4. Check: EAS21650 CHECKING THE TIRES • Brake hose The following procedure applies to both of the Brake fluid leakage → Replace the dam- tires. aged hose.
Page 139 290 kPa (2.90 kgf/cm², 42 psi) concerning handling characteristics can be High-speed riding given if a tire combination other than one Front approved by Yamaha is used on this vehi- 250 kPa (2.50 kgf/cm², 36 psi) cle. Rear 290 kPa (2.90 kgf/cm², 42 psi)
Page 140: Checking The Wheel Bearings
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Move the rear wheel several times and find the tightest position of drive chain. 3.
Page 141: Lubricating The Drive Chain
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE EAS21500 CHECKING AND ADJUSTING THE STEER- ING HEAD 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over.
Page 142: Checking The Steering Damper
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE Steering nut wrench ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: 90890-01403 • Upper bracket Exhaust flange nut wrench Refer to “HANDLEBARS” on page 4-56. YU-A9472 EAS14B1092 Lower ring nut (initial tightening CHECKING THE STEERING DAMPER torque) Refer to “CHECKING THE STEERING...
Page 143: Adjusting The Shift Pedal
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE EAS21380 EAS14B1094 ADJUSTING THE SHIFT PEDAL CHECKING THE SIDESTAND 1. Stand the vehicle on a level surface. EWA13120 The shift pedal position is determined by the WARNING installed shift rod length “a”.
Page 144: Adjusting The Front Fork Legs
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE EAS21580 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. EWA14B1029 WARNING Securely support the motorcycle so that there is no danger of it falling over.
Page 145: Checking The Rear Shock Absorber Assembly
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE EAS14B1096 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY Refer to “CHECKING THE REAR SHOCK ABSORBER ASSEMBLY” on page 4-77. EAS21610 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EWA13120 WARNING Securely support the vehicle so that there...
Page 146 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE a. Turn the adjusting bolt “1” in direction “a” or ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ “b”. Rebound damping Direction “a” ECA13590 Compression damping increased (suspension is harder). Never go beyond the maximum or minimum Direction “b”...
Page 147: Checking The Connecting Arm And Relay Arm
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting bolt “1” in direction “a” or “b”. Direction “a” Compression damping increased (suspension is harder). Direction “b” Compression damping decreased (suspension is softer).
Page 148: Changing The Engine Oil
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE EAS20790 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt.
Page 149: Measuring The Engine Oil Pressure
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE 3. Remove: Engine oil quantity • Main gallery bolt “1” Total amount 4.58 L (4.84 US qt, 4.03 Imp.qt) Without filter cartridge replacement 3.73 L (3.94 US qt, 3.28 Imp.qt) With oil filter cartridge replace- ment 3.93 L (4.15 US qt, 3.46 Imp.qt)
Page 150: Checking The Coolant Level
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE 4. Check: Engine oil pressure Possible causes • Coolant level • Leaking oil passage • Faulty oil filter Above specification Before checking the coolant level, wait a few •...
Page 151: Changing The Coolant
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE EAS21130 The following procedure applies to all of the CHANGING THE COOLANT coolant drain bolts and copper washers. 1. Remove: 5. Remove: • Lower cowlings •...
Page 152: Checking The Front Brake Light Switch
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE • If coolant splashes on your clothes, 15. Install: quickly wash it away with water and then • Side cowlings with soap and water. • Lower cowlings •...
Page 153: Checking And Lubricating The Cables
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE EAS21690 2. Adjust: CHECKING AND LUBRICATING THE • Throttle cable free play CABLES ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ The following procedure applies to all of the a. Loosen the locknut “1”. inner and outer cables.
Page 154: Replacing The Headlight Bulbs
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE EAS21790 4. Install: REPLACING THE HEADLIGHT BULBS • Headlight bulb The following procedure applies to both of the Secure the new headlight bulb with the headlight bulbs.
Page 155 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE Direction “a” Headlight beam moves to the right. Direction “b” Headlight beam moves to the left. Right headlight Direction “a” Headlight beam moves to the left. Direction “b”...
Page 156 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE 3-37 email: info@motomatrix.co.uk...
Page 157: Chassis
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE QUICK FASTENER (SCREW TYPE).......4-10 INSTALLING THE QUICK FASTENER (SCREW TYPE)......4-10 REMOVING THE QUICK FASTENER (PUSH TYPE) ......4-10 INSTALLING THE QUICK FASTENER (PUSH TYPE) ......4-10 REMOVING THE QUICK FASTENER (PULL TYPE) ......4-10 INSTALLING THE QUICK FASTENER (PULL TYPE) ......4-11 INSTALLING THE PASSENGER SEAT LOCK CYLINDER ....4-11...
Page 158 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE ..................4-31 INTRODUCTION ..................4-36 CHECKING THE FRONT BRAKE DISCS ..........4-36 REPLACING THE FRONT BRAKE PADS ..........4-37 REMOVING THE FRONT BRAKE CALIPERS ........4-39 DISASSEMBLING THE FRONT BRAKE CALIPERS ......4-39 CHECKING THE FRONT BRAKE CALIPERS ........4-40 ASSEMBLING THE FRONT BRAKE CALIPERS .........4-40 INSTALLING THE FRONT BRAKE CALIPERS........4-40...
Page 159 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR SHOCK ABSORBER ASSEMBLY ..........4-76 HANDLING THE REAR SHOCK ABSORBER ........4-77 DISPOSING OF A REAR SHOCK ABSORBER........4-77 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY....4-77 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....4-77 CHECKING THE CONNECTING ARM AND RELAY ARM ....4-78 INSTALLING THE RELAY ARM............4-78 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ....4-78...
Page 160 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seats and battery Order Job/Parts to remove Q’ty Remarks Fuel tank side cover Refer to “FUEL TANK” on page 7-1. Rider seat Passenger seat Battery negative lead...
Page 161 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the side cowlings Order Job/Parts to remove Q’ty Remarks Front cowling inner panel Side cowling Front turn signal light coupler Disconnect. Front turn signal light Lower cowling Side cowling inner panel For installation, reverse the removal proce-...
Page 162 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the ECU and rectifier/regulator Order Job/Parts to remove Q’ty Remarks Side cowling Refer to “GENERAL CHASSIS” on page 4-1. ECU coupler Disconnect. Radiator fan motor relay coupler Disconnect.
Page 163 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the air ducts Order Job/Parts to remove Q’ty Remarks Side cowling Refer to “GENERAL CHASSIS” on page 4-1. Air chamber cover Air chamber Air chamber bracket Air intake air duct cover Rear intake air duct upper Rear intake air duct lower...
Page 164: General Chassis
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the front cowling assembly Order Job/Parts to remove Q’ty Remarks Side cowling Refer to “GENERAL CHASSIS” on page 4-1. Air duct Refer to “GENERAL CHASSIS” on page 4-1. Intake air temperature sensor coupler Disconnect.
Page 165 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the meter and headlight Order Job/Parts to remove Q’ty Remarks Side cowling Refer to “GENERAL CHASSIS” on page 4-1. Air duct Refer to “GENERAL CHASSIS” on page 4-1. Front cowling assembly Refer to “GENERAL CHASSIS”...
Page 166 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the meter and headlight Order Job/Parts to remove Q’ty Remarks Windshield Windshield inner panel Intake air temperature sensor Headlight assembly Front cowling Headlight bulb cover Headlight bulb coupler Disconnect.
Page 167 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the rear fender Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Passenger seat Refer to “GENERAL CHASSIS” on page 4-1. Muffler Refer to “ENGINE REMOVAL”...
Page 168 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Disassembling the license plate/turn signal light assembly Order Job/Parts to remove Q’ty Remarks License plate/turn signal light stay License plate/turn signal light stay plate Cover Rear turn signal light License plate light Rear reflector...
Page 169 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS EAS14B1029 REMOVING THE QUICK FASTENER (SCREW TYPE) To remove the quick fastener, turn its center with a screwdriver counterclockwise, then pull the fastener out. EAS14B1032 INSTALLING THE QUICK FASTENER (PUSH TYPE) To install the quick fastener, push its pin so that...
Page 170 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS EAS14B1038 REMOVING THE FRONT TURN SIGNAL LIGHTS EAS14B1104 1. Remove: INSTALLING THE QUICK FASTENER (PULL • Stay “1” TYPE) • Front turn signal light “2” To install the quick fastener, pull the pin, then Remove the stay “1”...
Page 171 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS EAS14B1040 REMOVING THE LOWER COWLINGS 1. Remove: • Lower cowling “1” Slide the lower cowling to the forward and remove. EAS14B1043 INSTALLING THE SIDE COWLING INNER PANELS 1.
Page 172 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS EAS14B1045 INSTALLING THE AIR CHAMBER COVERS 1. Install: • Air chamber cover “1” Insert the air chamber cover tab “a” downward into the hole “b” of the air chamber “2”. EAS14B1048 INSTALLING THE AIR INTAKE DUCTS 1.
Page 173 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS EAS14B1051 INSTALLING THE MIRROR FITTING PLATES 1. Install: • Mirror fitting plate “1” (to meter bracket “2”) Face the mirror fitting plate concave “a” up and install it to the meter bracket.
Page 174 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS d. Slide the upper tail cover forward and 2. Install: remove. • Passenger seat Refer to “GENERAL CHASSIS” on page 4-1. • Rider seat Refer to “GENERAL CHASSIS” on page 4-1.
Page 175 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS b. When adjusting the right rider footrest, change the position of the hole “a” of the exhaust chamber cover “2”. Exhaust chamber cover bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) e.
Page 176 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs Order Job/Parts to remove Q’ty Remarks Front cowling assembly Refer to “GENERAL CHASSIS” on page 4-1. Front speed sensor coupler Disconnect.
Page 177 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal (left and right) Wheel bearing Spacer Wheel bearing For assembly, reverse the disassembly pro- cedure.
Page 178 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL EAS21900 EAS21920 REMOVING THE FRONT WHEEL CHECKING THE FRONT WHEEL ECA1KB8401 1. Check: • Wheel axle Roll the wheel axle on a flat surface. • Keep any type of magnets (including Bends →...
Page 179 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL Use a socket “4” that matches the diameter of the wheel bearing outer race. 5. Replace: • Wheel bearings • Oil seals ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ e. Install the spacer. a.
Page 180 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL • The front speed sensor cannot be disas- sembled. Do not attempt to disassemble it. If faulty, replace with a new one. 1. Check: • Front speed sensor “1” Cracks/bends/distortion →...
Page 181 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL f. If the front speed sensor rotor deflection cannot be brought within specification, replace the front speed sensor rotor. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21970 ADJUSTING THE FRONT WHEEL STATIC BALANCE •...
Page 182 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL 4. Check: • Front wheel static balance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the front wheel and make sure it stays at each position shown. b. If the front wheel does not remain station- ary at all of the positions, rebalance it.
Page 183 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL 6. Lower the front wheel so that it is on the ground. • Before measuring the distance between the 7. Tighten: front speed sensor rotor and front speed •...
Page 184 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel Order Job/Parts to remove Q’ty Remarks Rear brake caliper Refer to “REAR BRAKE” on page 4-44. Locknut (left and right) Loosen.
Page 185 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL Removing the brake disc and rear wheel sprocket Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel sprocket Collar Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper Rear wheel For installation, reverse the removal proce-...
Page 186 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Collar Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly pro- cedure. 4-27 email: info@motomatrix.co.uk...
Page 187 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL EAS22040 REMOVING THE REAR WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated.
Page 188 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL EAS1KB8402 EAS22110 ASSEMBLING THE REAR WHEEL CHECKING THE REAR WHEEL DRIVE HUB 1. Install: 1. Check: • Rear wheel drive hub “1” • Wheel bearings Cracks/damage →...
Page 189 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL 3. Tighten: • Rear wheel axle nut Tighten the self-locking nuts in stages and in a • Rear brake caliper bolts crisscross pattern. Rear wheel axle nut 150 Nm (15 m·kgf, 110 ft·lbf) Rear brake caliper bolt (front side)
Page 190 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Front speed sensor Refer to “FRONT WHEEL”...
Page 191 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Removing the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-17. Stopper Brake fluid reservoir cap Brake fluid reservoir diaphragm holder...
Page 192: Front Brake
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Bleed screw Brake master cylinder body For installation, reverse the removal proce- dure.
Page 193 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Removing the front brake calipers Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Front speed sensor Refer to “FRONT WHEEL”...
Page 194 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Disassembling the front brake calipers Order Job/Parts to remove Q’ty Remarks Brake pad clip Brake pad pin Brake pad spring Brake pad kit Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw...
Page 195 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE EAS22220 INTRODUCTION EWA14100 WARNING Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. •...
Page 196 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE ECA1CW1401 EAS14B1004 REPLACING THE FRONT BRAKE PADS Replace the brake disc bolts with new • When replacing the brake pads, it is not nec- ones. essary to disconnect the brake hose or dis- assemble the brake caliper.
Page 197 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE 4. Measure: c. Tighten the bleed screw. • Brake pad wear limit “a” Out of specification → Replace the brake Bleed screw 5 Nm (0.5 m·kgf, 3.6 ft·lbf) pads as a set.
Page 198 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE 8. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-17. EAS22300 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the...
Page 199 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE EAS22390 • Whenever a brake caliper is disassem- CHECKING THE FRONT BRAKE CALIPERS bled, replace the brake caliper piston dust Recommended brake component replace- seals and brake caliper piston seals. ment schedule Recommended fluid Brake pads...
Page 200 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE “a” touches the projection “b” on the brake caliper. 6. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake 3. Fill: system.
Page 201 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE EAS22510 EAS22520 CHECKING THE FRONT BRAKE MASTER ASSEMBLING THE FRONT BRAKE MAS- CYLINDER TER CYLINDER 1. Check: EWA13520 WARNING • Brake master cylinder Damage/scratches/wear → Replace. •...
Page 202 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE EWA13530 ECA13540 WARNING Proper brake hose routing is essential to Brake fluid may damage painted surfaces insure safe vehicle operation. Refer to and plastic parts. Therefore, always clean “CABLE ROUTING”...
Page 203 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Rear brake caliper Brake pad shim Brake pad kit Bleed screw Brake pad spring...
Page 204 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-17. Footrest plate Brake fluid reservoir cap Rear brake fluid reservoir diaphragm holder...
Page 205 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder yoke Adjusting nut Brake master cylinder kit Dust cover Circlip Hose joint O-ring Brake master cylinder body...
Page 206 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Removing the rear brake calipers Order Job/Parts to remove Q’ty Remarks Union bolt Washer Brake hose Brake caliper For installation, reverse the removal proce- dure. 4-47 email: info@motomatrix.co.uk...
Page 207 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Brake pad kit Brake pad shim Brake pad spring Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal...
Page 208: Rear Brake
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14100 4.5 mm (0.18 in) WARNING 5. Adjust: Disc brake components rarely require dis- • Brake disc deflection assembly. Therefore, always follow these Refer to “CHECKING THE FRONT preventive measures: BRAKE DISCS”...
Page 209 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE 3. Measure: b. Loosen the bleed screw and push the • Brake pad wear limit “a” brake caliper pistons into the brake caliper Out of specification → Replace the brake with your finger.
Page 210 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE 7. Check: b. Blow compressed air into the brake hose • Brake pedal operation joint opening “b” to force out the piston from Soft or spongy feeling → Bleed the brake the brake caliper.
Page 211 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE EAS22670 INSTALLING THE REAR BRAKE CALIPER 1. Install: • Brake caliper “1” (temporarily) • Washers • Brake hose “2” • Union bolt “3” Rear brake hose union bolt 30 Nm (3.0 m·kgf, 22 ft·lbf) EWA14B1005 EWA13530...
Page 212 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE 4. Fill: 7. Check: • Brake fluid reservoir • Brake pedal operation Soft or spongy feeling → Bleed the brake (with the specified amount of the recom- mended brake fluid) system.
Page 213 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE 2. Check: EAS22740 INSTALLING THE REAR BRAKE MASTER • Brake fluid reservoir tank “1” CYLINDER Cracks/damage → Replace. 1. Install: • Brake fluid reservoir diaphragm “2” Cracks/damage →...
Page 214 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE 6. Adjust: Recommended fluid • Brake pedal position DOT 4 Refer to “ADJUSTING THE REAR DISC BRAKE” on page 3-16. EWA13090 WARNING Brake pedal position (from the •...
Page 215 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBARS EAS22850 HANDLEBARS Removing the handlebars Order Job/Parts to remove Q’ty Remarks Side cowling Refer to “GENERAL CHASSIS” on page 4-1. Air duct Refer to “GENERAL CHASSIS” on page 4-1. Front cowling Refer to “GENERAL CHASSIS”...
Page 216 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBARS Removing the handlebars Order Job/Parts to remove Q’ty Remarks Throttle grip Brake switch connector Disconnect. Right handlebar switch Handlebar pinch bolt Loosen. Handlebar bolt Loosen. Upper bracket pinch bolt Loosen.
Page 217 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBARS EAS22870 EWA13690 REMOVING THE HANDLEBAR WARNING 1. Stand the vehicle on a level surface. Do not attempt to straighten a bent handle- EWA13120 bar as this may dangerously weaken it. WARNING Securely support the vehicle so that there is no danger of it falling over.
Page 218 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBARS 6. Install: • Left handlebar switch “1” • Align the projection “a” on the left handlebar switch with the hole “b” on the left handlebar. • There should be 2.0–2.5 mm (0.08–0.10 in) of clearance between left handlebar switch and clutch lever holder.
Page 219 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBARS 9. Adjust: • Throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 3-34. Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) 4-60 email: info@motomatrix.co.uk...
Page 220 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies both of the front fork legs. Side cowling Refer to “GENERAL CHASSIS”...
Page 221 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Cap bolt O-ring Washer Spacer Upper spring seat...
Page 222 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks Damper rod assembly Damper adjusting rod Damper adjusting valve Damper adjusting valve spring Inner tube For installation, reverse the removal proce- dure.
Page 223: Front Fork
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK EAS14B1006 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. Each front fork leg is equipped with a spring preload adjusting bolt, the right fork leg is equipped with a rebound damping force adjusting screen and left front fork is equipped...
Page 224 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK Use the side of the rod holder that is marked “B”. 4. Remove: • Dust seal • Oil seal clip “1” (with a flat-head screwdriver) •...
Page 225 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK EAS23010 • When disassembling and assembling the CHECKING THE FRONT FORK LEGS front fork leg, do not allow any foreign The following procedure applies to both of the material to enter the front fork.
Page 226 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK • Before installing the oil seal, lubricate its lips with lithium-soap-based grease. • Lubricate the outer surface of the inner tube with fork oil. 2. Lubricate: •...
Page 227 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK 8. Install: 10. Fully compress the front fork leg. • Dust seal “1” 11. Fill: (with the fork seal driver weight “2”) • Front fork leg (with the specified amount of the recom- Fork seal driver mended fork oil)
Page 228 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK Be sure to bleed the front fork leg of any resid- Install the spring with the smaller diameter “a” ual air. facing up “A”. 14. Measure: •...
Page 229 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK j. Remove the rod puller and rod puller o. Remove the rod holder and fork spring attachment. compressor. k. Install the nut “1” all the way onto the ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 230 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK 5. Install: • Plastic band “1” Fasten the front brake hose to the right front fork leg with the plastic locking tie. 3. Tighten: • Cap bolt “1” Cap bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) •...
Page 231 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Side cowling Refer to “GENERAL CHASSIS” on page 4-1. Air duct Refer to “GENERAL CHASSIS” on page 4-1. Front speed sensor Refer to “FRONT WHEEL”...
Page 232 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Lower ring nut Lower bracket Upper bearing cover Upper bearing inner race Upper bearing Lower bearing Lower bearing inner race Lower bearing dust seal Upper bearing outer race...
Page 233 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STEERING HEAD EAS23110 3. Replace: REMOVING THE LOWER BRACKET • Bearings 1. Stand the vehicle on a level surface. • Bearing races EWA13120 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ WARNING a. Remove the bearing races “1” from the Securely support the vehicle so that there steering head pipe with a long rod “2”...
Page 234 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STEERING HEAD EAS23140 • Bearing INSTALLING THE STEERING HEAD Damage/pitting → Replace. 1. Lubricate: (It replace with the assembly.) • Upper bearing • Lower bearing • Bearing races Recommended lubricant Lithium-soap-based grease 2.
Page 235 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Passenger seat Refer to “GENERAL CHASSIS”...
Page 236 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR SHOCK ABSORBER ASSEMBLY EAS14B1010 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that EWA14B1013 the rear wheel is elevated. WARNING This rear shock absorber contains highly 2.
Page 237 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR SHOCK ABSORBER ASSEMBLY • Spring Installed depth of bearing “a” Damage/wear → Replace the rear shock 4.0 mm (0.16 in) absorber assembly. Installed depth of oil seal “b” •...
Page 238 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR SHOCK ABSORBER ASSEMBLY Rear shock absorber assembly bracket and frame nut 92 Nm (9.2 m·kgf, 66 ft·lbf) • Rear shock absorber assembly lower nut Rear shock absorber assembly lower nut 40 Nm (4.0 m·kgf, 29 ft·lbf) 4.
Page 239 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to “REAR WHEEL” on page 4-25. Refer to “REAR SHOCK ABSORBER Rear shock absorber assembly ASSEMBLY”...
Page 240 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Oil seal Circlip Bearing Bearing For installation, reverse the removal proce- dure. 4-81 email: info@motomatrix.co.uk...
Page 241 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SWINGARM EAS23350 REMOVING THE SWINGARM Swingarm side play (at the end 1. Stand the vehicle on a level surface. of the swingarm) EWA13120 1.0 mm (0.04 in) WARNING d.
Page 242 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SWINGARM 3. Wash: Damper rod holder (22 mm) • Pivot shaft 90890-01365 • Dust cover • Spacer • Washers • Bearings Recommended cleaning solvent Kerosene 4. Check: •...
Page 243 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SWINGARM Ring nut wrench 90890-01507 YM-01507 5. Dust cover 6. Collar 7. Swingarm 8. Pivot shaft A. Left side 5. Install: B. Right side • Pivot shaft nut “1” 3.
Page 244 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive sprocket and drive chain Order Job/Parts to remove Q’ty Remarks Refer to “ADJUSTING THE DRIVE CHAIN Drive chain SLACK” on page 3-21. Locknut Shift rod Shift arm...
Page 245 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAIN DRIVE EAS23410 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated.
Page 246 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAIN DRIVE use only kerosene to clean the drive EAS23460 CHECKING THE DRIVE SPROCKET chain. 1. Check: • Do not soak the drive chain in kerosene • Drive sprocket for more than ten minutes, otherwise the More than 1/4 tooth “a”...
Page 247 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAIN DRIVE • While applying the rear brake, tighten the drive sprocket nut. • Stake the drive sprocket nut at cutouts, “a” in the drive axle. b. After riveting, make sure the diameter between the edges “b”...
Page 248 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAIN DRIVE 4-89 email: info@motomatrix.co.uk...
Page 249: Engine
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE ENGINE INSPECTION..................5-1 MEASURING THE COMPRESSION PRESSURE .........5-1 ENGINE REMOVAL ..................5-3 INSTALLING THE ENGINE ..............5-10 INSTALLING THE EXHAUST PIPE AND MUFFLER......5-11 CAMSHAFTS....................5-13 REMOVING THE CAMSHAFTS ............5-16 CHECKING THE CAMSHAFTS ............5-17 CHECKING THE TIMING CHAIN AND SPROCKET......5-18 CHECKING THE TIMING CHAIN GUIDES ..........5-19 CHECKING THE TIMING CHAIN TENSIONER ........5-19...
Page 250 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP ....................5-50 REMOVING THE OIL PAN ..............5-53 CHECKING THE SPROCKET AND CHAIN .........5-53 CHECKING THE OIL PUMP ..............5-53 CHECKING THE RELIEF VALVE ............5-54 CHECKING THE OIL DELIVERY PIPES..........5-54 CHECKING THE OIL STRAINER............5-54 ASSEMBLING THE OIL PUMP ............5-55 INSTALLING THE OIL/WATER PUMP ASSEMBLY......5-55...
Page 251 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION..................5-91 REMOVING THE TRANSMISSION ............5-95 CHECKING THE SHIFT FORKS ............5-95 CHECKING THE SHIFT DRUM ASSEMBLY........5-96 CHECKING THE TRANSMISSION ............5-96 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ......5-97 INSTALLING THE TRANSMISSION.............5-97 email: info@motomatrix.co.uk...
Page 252: Engine Inspection
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE INSPECTION EAS14B1052 ENGINE INSPECTION EAS14B1053 MEASURING THE COMPRESSION PRES- SURE The following procedure applies to all of the cylinders. Insufficient compression pressure will result in a loss of performance. 6.
Page 253 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE INSPECTION Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without Piston ring(s) wear or damage → Replace. Same as without oil Piston, valves or cyl- inder head gasket possibly defective →...
Page 254: Engine Removal
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL EAS23711 ENGINE REMOVAL Removing the exhaust pipe and muffler Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Passenger seat Refer to “GENERAL CHASSIS”...
Page 255 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Removing the exhaust pipe and muffler Order Job/Parts to remove Q’ty Remarks Left muffler Left muffler gasket Right muffler clamp Loosen. Right muffler Right muffler gasket Rear brake light switch coupler Disconnect.
Page 256 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Removing the exhaust pipe and muffler Order Job/Parts to remove Q’ty Remarks Exhaust chamber protector Exhaust chamber pipe protector clamp Loosen. Exhaust chamber pipe protector Exhaust chamber bracket Exhaust pipe Exhaust pipe gasket...
Page 257 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Battery negative lead Refer to “GENERAL CHASSIS” on page 4-1. Battery positive lead Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK”...
Page 258 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Rear speed sensor lead coupler Disconnect. Oil level switch lead coupler Disconnect. Gear position sensor coupler Disconnect.
Page 259 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Left lower cowling bracket Right lower cowling bracket Left inner panel bracket Right inner panel bracket Sidestand assembly Sidestand switch Holder...
Page 260 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Engine mount nut (rear lower side) Engine mount bolt (rear upper side) Engine mount bolt (rear lower side) Engine Engine mount adjusting bolt For installation, reverse the removal proce-...
Page 261: Installing The Engine
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL EAS23720 5. Install: INSTALLING THE ENGINE • Engine mount collars (front right side) “1” ECA14B1021 • Engine mount collar (front right side) “2” • Engine mounting bolt (front right side) “3” Do not hold the radiator inlet pipe when (temporary tighten) removing the engine and moving the...
Page 262: Installing The Exhaust Pipe And Muffler
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL 8. Tighten: • Engine mounting bolt (front left side) “1” Engine mounting bolt (front left side) 70 Nm (7.0 m·kgf, 50 ft·lbf) 7. Tighten: • Engine mounting nut (rear lower side) “1” •...
Page 263 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Installed depth of gasket “c” 3.5 mm (0.14 in) 5-12 email: info@motomatrix.co.uk...
Page 264: Camshafts
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-5. Side cowling Refer to “GENERAL CHASSIS”...
Page 265 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Pickup coil cover 2 Refer to “PICKUP ROTOR” on page 5-42. Generator cover Refer to “GENERATOR” on page 5-36. Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap...
Page 266 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Crankshaft sprocket Collar Straight key For installation, reverse the removal proce- dure. 5-15 email: info@motomatrix.co.uk...
Page 267: Removing The Camshafts
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Remove: • Pickup rotor cover 2 Refer to “PICKUP ROTOR” on page 5-42. 2. Align: • “K” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ECA14B1034 When turning the crankshaft with a tool,...
Page 268: Checking The Camshafts
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS Camshaft lobe dimension limit Intake A 37.350–37.450 mm (1.4705– 1.4744 in) Limit 37.250 mm (1.4665 in) Intake B 28.034–28.134 mm (1.1037– 1.1076 in) Limit 7. Remove: 27.934 mm (1.0998 in) •...
Page 269: Checking The Timing Chain And Sprocket
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS 4. Measure: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Camshaft-journal-to-camshaft-cap clear- 5. Measure: ance • Camshaft journal diameter “a” Out of specification → Measure the cam- Out of specification → Replace the cam- shaft journal diameter.
Page 270: Checking The Timing Chain Guides
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS a. 1/4 tooth b. Correct 3. Hand press 1. Timing chain 4. Bearing 2. Camshaft sprocket or crankshaft sprocket b. Keep pressing the timing chain tensioner EAS23950 rod, mount clip “5”...
Page 271 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS b. When position #1 is at BTDC 105°, align the “K” mark “a” with the crankcase mating surface “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: • Intake camshaft sprocket “1” •...
Page 272 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS • When installing the camshaft cap, face the hole with the screw thread “b” on the cam- shaft cap to the left side of the engine. 6.
Page 273 When turning the crankshaft with a tool, der head cover gasket. remove all the spark plugs. • Apply bond Yamaha bond No.1215 (Three 11. Check: bond No.1215®) “2” onto the mating surfaces • “K” mark “a”...
Page 274 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS • Tighten the cylinder head cover bolts stages and in a crisscross pattern. Yamaha bond No.1215 (Three Bond No.1215®) 90890-85505 5-23 email: info@motomatrix.co.uk...
Page 275: Cylinder Head
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-3. Intake camshaft Refer to “CAMSHAFTS” on page 5-13. Exhaust camshaft Refer to “CAMSHAFTS”...
Page 276: Removing The Cylinder Head
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD EAS24120 REMOVING THE CYLINDER HEAD 1. Remove: • Intake camshaft • Exhaust camshaft Refer to “REMOVING THE CAM- SHAFTS” on page 5-16. 2. Remove: • Cylinder head nuts •...
Page 277 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD 5. Install: • Exhaust camshaft • Intake camshaft Refer to “INSTALLING THE CAM- SHAFTS” on page 5-19. 3. Install: • Cylinder head • Washers • Cylinder head nuts •...
Page 278 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-24. Intake valve lifter Intake valve pad Intake valve cotter...
Page 279 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve spring retainer Exhaust valve spring Exhaust valve Exhaust valve stem seal...
Page 280: Valves And Valve Springs
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS EAS24280 3. Remove: REMOVING THE VALVES • Valve cotters The following procedure applies to all of the valves and related components. Remove the valve cotters by compressing the valve spring with the valve spring compressor Before removing the internal parts of the cylin- “1”...
Page 281: Checking The Valves And Valve Guides
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS EAS24290 2. Replace: CHECKING THE VALVES AND VALVE • Valve guide GUIDES The following procedure applies to all of the To ease valve guide removal and installation, valves and valve guides.
Page 282: Checking The Valve Seats
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS After replacing the valve guide, reface the valve seat. 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) 6.
Page 283 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS 4. Lap: Valve seat width • Valve face Valve seat width (intake) • Valve seat 0.90–1.10 mm (0.0354–0.0433 After replacing the cylinder head or replacing Limit the valves and valve guides, the valve seat and 1.60 mm (0.06 in)
Page 284: Checking The Valve Springs
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS EAS24310 CHECKING THE VALVE SPRINGS For the best lapping results, lightly tap the The following procedure applies to all of the valve seat while rotating the valve back and valve springs.
Page 285: Checking The Valve Lifters
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS EAS24340 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: • Valve stem end (with an oil stone) b.
Page 286 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS • When installing the valve stem seal to the valve guide, apply silicon fluid to the valve stem seal. 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer.
Page 287: Generator
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERATOR EAS24480 GENERATOR Removing the generator Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-5. Side cowling Refer to “GENERAL CHASSIS”...
Page 288: Removing The Generator
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERATOR EAS24490 4. Remove: REMOVING THE GENERATOR • Stator coil lead holder “1” 1. Remove: • Stator coil assembly “2” • Generator cover • Generator cover gasket •...
Page 289 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERATOR 4. Apply: • Sealant (onto the stator coil lead grommet “1”) Yamaha bond No.1215 (Three Bond No.1215®) 90890-85505 5-38 email: info@motomatrix.co.uk...
Page 290: Starter Clutch
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STARTER CLUTCH EAS24550 STARTER CLUTCH Removing the starter clutch Order Job/Parts to remove Q’ty Remarks Clutch housing assembly Refer to “CLUTCH” on page 5-58. Starter clutch gear Bearing Starter clutch assembly Starter idle gear...
Page 291: Removing The Starter Clutch
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STARTER CLUTCH EAS24560 REMOVING THE STARTER CLUTCH 1. Remove: • Starter clutch bolt “1” • While holding the clutch housing assembly “2” with the sheave holder “3”, remove the starter clutch bolt.
Page 292 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STARTER CLUTCH • While holding the clutch housing assembly “1” with the sheave holder “2”, tighten the starter clutch holder bolt “3”. • Fix the flat surface of the clutch housing assembly with the sheave holder.
Page 293: Pickup Rotor
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PICKUP ROTOR EAS14B1058 PICKUP ROTOR Removing the pickup rotor Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Generator cover Refer to “GENERATOR” on page 5-36. Air filter case Refer to “AIR FILTER CASE”...
Page 294: Removing The Pickup Rotor
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PICKUP ROTOR EAS14B1059 REMOVING THE PICKUP ROTOR 1. Remove: • Pickup rotor bolt “1” • Washer • Pickup rotor While holding the generator rotor “2” with the sheave holder “3”, loosen the pickup rotor bolt.
Page 295 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PICKUP ROTOR Yamaha bond No.1215 (Three Bond No.1215®) 90890-85505 5-44 email: info@motomatrix.co.uk...
Page 296: Electric Starter
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Battery negative lead Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK”...
Page 297 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Front cover Lock washer Washer Starter motor yoke Armature assembly Gasket Brush holder O-ring Rear cover For installation, reverse the removal proce- dure.
Page 298: Checking The Starter Motor
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTER EAS24790 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ CHECKING THE STARTER MOTOR a. Measure the armature assembly resis- 1. Check: tances with the digital circuit tester. • Commutator Dirt → Clean with 600 grit sandpaper. Digital circuit tester 2.
Page 299: Assembling The Starter Motor
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTER 6. Measure: • Brush spring force Out of specification → Replace the brush holder. Brush spring force 5.28–7.92 (538–808 19.01–28.51 oz) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Install: • Rear cover “1” Align the tab “a”...
Page 300 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTER Align the match marks “a” on the starter motor yoke with the match marks “b” on the front and rear covers. 5-49 email: info@motomatrix.co.uk...
Page 301: Oil Pump
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP EAS24921 OIL PUMP Removing the oil pan and oil/water pump assembly Order Job/Parts to remove Q’ty Remarks Side cowling Refer to “GENERAL CHASSIS” on page 4-1. Lower cowling Refer to “GENERAL CHASSIS”...
Page 302 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP Removing the oil pan and oil/water pump assembly Order Job/Parts to remove Q’ty Remarks Dowel pin Drain pipe Oil strainer Oil pipe Oil delivery pipe 1 Relief valve assembly Oil/water pump assembly drive chain guide Collar...
Page 303 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil/water pump driven sprocket Circlip Oil pump housing Bearing Dowel pin Oil pump outer rotor Oil pump inner rotor For installation, reverse the removal proce- dure.
Page 304: Removing The Oil Pan
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP EAS24930 EAS24960 REMOVING THE OIL PAN CHECKING THE OIL PUMP 1. Remove: 1. Check: • Oil level switch “1” • Oil pump driven gear “1” Cracks/damage/wear →...
Page 305: Checking The Relief Valve
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP EAS24980 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes. 1. Check: • Oil delivery pipe 1 “1” •...
Page 306: Assembling The Oil Pump
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP EAS25010 ASSEMBLING THE OIL PUMP 1. Lubricate: • Inner rotor • Outer rotor • Oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2.
Page 307: Installing The Oil Pan
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP ECA14B1018 After installing the oil/water pump assem- bly drive chain and drive sprocket, make sure the oil/water pump turns smoothly. 5. Install: • Relief valve assembly “1” •...
Page 308 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP Oil pan bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Oil level switch bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Engine oil drain bolt • Gasket Engine oil drain bolt 43 Nm (4.3 m·kgf, 31 ft·lbf) Tighten the oil pan bolts in stages and in a...
Page 309: Clutch
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH EAS25061 CLUTCH Removing the clutch cover Order Job/Parts to remove Q’ty Remarks Engine oil Drain. Pull lever cover Clutch cable Disconnect. Clutch cover Clutch cover gasket Dowel pin Oil filler cap For installation, reverse the removal proce-...
Page 310 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Pull lever Pull lever spring Circlip Pull lever shaft Oil seal Bearing Bearing For installation, reverse the removal proce- dure.
Page 311 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Compression spring Pressure plate 1 Pull rod Bearing Friction plate 1 Clutch plate 1 Friction plate 2 Clutch plate 2 Clutch plate 3 Friction plate 1...
Page 312 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Thrust washer Clutch housing assembly Bearing Washer For installation, reverse the removal proce- dure. 5-61 email: info@motomatrix.co.uk...
Page 313: Removing The Clutch
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH EAS25080 4. Remove: REMOVING THE CLUTCH • Clutch plate 1 “1” 1. Remove: • Friction plate 2 • Pull lever cover “1” • Clutch plate 2 •...
Page 314: Checking The Friction Plates
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH 7. Remove: EAS25110 CHECKING THE CLUTCH PLATES • Clutch boss nut The following procedure applies to all of the • Springs clutch plates. • Clutch boss 1.
Page 315: Checking The Clutch Springs
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH EAS25140 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: • Clutch spring Damage → Replace the clutch springs as a set.
Page 316: Checking The Clutch Boss
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH EAS25160 CHECKING THE CLUTCH BOSS 1. Check: • Clutch boss splines Damage/pitting/wear → Replace the clutch boss. Pitting on the clutch boss splines will cause erratic clutch operation. EAS25220 CHECKING THE PULL LEVER SHAFT AND PULL ROD...
Page 317 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH • Stake the clutch boss nut at a cutout “a” in the main axle. Universal clutch holder 90890-04086 YM-91042 2. Install: • Pressure plate 2 “1” •...
Page 318 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH • Tighten the clutch cover bolts in stages and in a crisscross pattern. 6. Install: • Bearing (into the pressure plate 1) • Pull rod • Pressure plate 1 7.
Page 319: Shift Shaft
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Shift arm Refer to “CHAIN DRIVE” on page 4-85. Clutch assembly Refer to “CLUTCH”...
Page 320: Checking The Shift Shaft
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft “1” Bends/damage/wear → Replace. • Shift shaft spring “2” • Collar Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1.
Page 321: Crankcase
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE EAS25540 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-3. Cylinder head Refer to “CYLINDER HEAD” on page 5-24. Refer to “ELECTRIC STARTER”...
Page 322 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Crankcase breather cover Crankcase breather cover gasket Crankcase breather case Crankcase breather case gasket Lower crankcase Dowel pin Crankcase baffle plate For installation, reverse the removal proce- dure.
Page 323: Disassembling The Crankcase
• Sealant order (refer to the numbers in the illustration). (onto the crankcase mating surfaces) • The numbers embossed on the crankcase Yamaha bond No.1215 indicate the crankcase tightening sequence. (Three Bond No.1215®) 90890-85505 Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings.
Page 324 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE *Following the tightening order, loosen the bolt one by one and then retighten it to the specific torque. EWA14B1030 WARNING If the crankcase bolt is tightened more than the specified angle, do not loosen the bolt and then retighten it.
Page 325 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS EAS14B1024 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-70. Connecting rod cap Big end lower bearing Big end upper bearing...
Page 326: Connecting Rods And Pistons
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS EAS26030 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the connecting rods and pistons. 1. Remove: • Connecting rod cap “1” •...
Page 327: Checking The Piston Rings
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS 2. Measure: • Piston-to-cylinder clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure cylinder bore “C” with the cylinder bore gauge. Measure cylinder bore “C” by taking side-to- side and front-to-back measurements of the cylinder.
Page 328: Checking The Piston Pin
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS Piston ring side clearance Piston ring end gap Top ring Top ring 0.030–0.065 (0.0012– 0.15–0.25 mm (0.0059–0.0098 0.0026 in) Limit Limit 0.115 mm (0.0045 in) 0.50 mm (0.0197 in) 2nd ring 2nd ring...
Page 329: Checking The Connecting Rods
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS a. Clean the big end bearings, crankshaft pins, and the inside of the connecting rods halves. b. Install the big end upper bearing into the connecting rod and the big end lower bear- ing into the connecting rod cap.
Page 330 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS • After installing the big end bearing, assemble the connecting rod and connecting rod cap • Do not move the connecting rod or crank- without installing them onto the crankshaft.
Page 331 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS 2. Select: • Big end bearings (P1–P4) • The numbers “A” stamped into the crank- shaft web and the numbers “1” on the con- necting rods are used to determine the replacement big end bearings sizes.
Page 332: Installing The Connecting Rod And Piston
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS EAS26190 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ INSTALLING THE CONNECTING ROD AND a. Replace the connecting rod bolts with new PISTON ones. The following procedure applies to all of the b.
Page 333 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS Recommended lubricant Engine oil 6. Offset: • Piston ring end gaps 4. Install: • Piston “1” (onto the respective connecting rod “2”) • Piston pin “3” •...
Page 334 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS Fit the projection “a” of the piston installing tool “3” and blunt-edged part “b” of the cylinder, fix the position of the piston installing tool, and then push the piston down to the cylinder.
Page 335 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS EWA13400 WARNING If the connecting rod bolt is tightened more than the specified angle, do not loosen the bolt and then retighten it. Instead, replace the connecting rod bolt with a new one and perform the procedure again.
Page 336: Crankshaft
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-70. Refer to “REMOVING THE CONNECTING Connecting rod RODS AND PISTONS”...
Page 337: Removing The Crankshaft And Balancer Shaft
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT EAS25980 REMOVING THE CRANKSHAFT AND BAL- ANCER SHAFT 1. Remove: • Balancer shaft “1” • Balancer shaft journal bearings • Crankshaft assembly “2” • Crankshaft journal bearings Identify the position of each balancer shaft journal bearings and crankshaft journal bear- ings so that it can be reinstalled in its original...
Page 338 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT g. Remove the lower crankcase and the crankshaft journal lower bearings. h. Measure the compressed Plastigauge® width “a” on each crankshaft journal. If the crankshaft-journal-to-crankshaft-jour- nal-bearing clearance is out of specifica- tion, select replacement crankshaft journal bearings.
Page 339: Checking The Balancer Shaft
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT ECA14B1020 Do not interchange the balancer shaft jour- nal bearings. To obtain the correct balancer shaft-journal-to-balancer shaft-journal- bearing clearance and prevent engine dam- age, the balancer shaft journal bearings must be installed in their original positions.
Page 340: Installing The Crankshaft
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT • If J –J are the same, use the same size for all of the bearings. • Align the projections “a” of the balancer shaft journal lower bearings with the notches “b” in For example, if the crankcase J and bal- the lower crankcase.
Page 341: Installing The Balancer Assembly
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT • Align the projections “a” on the crankshaft journal bearings “1” with the notches “b” in the crankcases. • Be sure to install each crankshaft journal bearing in its original place.
Page 342 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION EAS26241 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Lower crankcase Refer to “CRANKCASE” on page 5-70. Drive axle assembly Shift drum retainer Spring...
Page 343 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks When installing 2nd pinion gear, install the 2nd pinion gear gear with groove “a” facing to the toothed lock washer.
Page 344 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Circlip Bearing Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer...
Page 345 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Circlip 6th wheel gear Circlip Washer 2nd wheel gear Collar Collar Oil seal Circlip Bearing Drive axle For installation, reverse the removal proce- dure.
Page 346: Transmission
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Drive axle assembly “1” • Shift drum retainers “2” • Shift fork guide bars • Shift fork “L” and “R” •...
Page 347: Checking The Shift Drum Assembly
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION 3. Check: • Shift fork movement (along the shift fork guide bar) Rough movement → Replace the shift forks and shift fork guide bar as a set. 2.
Page 348: Assembling The Main Axle And Drive Axle
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION 4. Check: • Transmission gear engagement • With the toothed lock washer retainer “1” in (each pinion gear to its respective wheel the groove “a” in the axle, align the projection gear) “c”...
Page 349 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION • Install shift fork-R into the groove “a” in the 5th wheel gear and shift fork-L into the groove “b” in the 6th wheel gear on the drive axle.
Page 350 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION 5-99 email: info@motomatrix.co.uk...
Page 351: Cooling System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM RADIATOR....................6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR ..............6-3 OIL COOLER ....................6-5 CHECKING THE OIL COOLER..............6-7 INSTALLING THE OIL COOLER ............6-7 THERMOSTAT ....................6-8 CHECKING THE THERMOSTAT............6-10 ASSEMBLING THE THERMOSTAT ASSEMBLY .........6-10 INSTALLING THE THERMOSTAT ASSEMBLY ........6-11 WATER PUMP ....................6-12...
Page 352: Radiator
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys RADIATOR EAS26380 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-32. Refer to “GENERAL CHASSIS” on page 4-1. Side cowling Refer to “GENERAL CHASSIS”...
Page 353 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Radiator bracket Radiator fan Thermostat bypass hose 2 Disconnect. Thermostat bypass hose 3 Radiator inlet pipe Radiator inlet hose For installation, reverse the removal proce- dure.
Page 354: Checking The Radiator
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. Straighten any flattened fins with a thin, flat- head screwdriver.
Page 355 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys RADIATOR b. Apply 137.3 kPa (1.37 kgf/cm , 19.9 psi) of pressure. c. Measure the indicated pressure with the gauge. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Measure: • Radiator cap opening pressure Below the specified pressure →...
Page 356: Oil Cooler
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL COOLER EAS26410 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-32. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL”...
Page 357 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Water jacket joint O-ring Water pump outlet pipe O-ring O-ring For installation, reverse the removal proce- dure.
Page 358: Checking The Oil Cooler
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL COOLER EAS26420 3. Fill: CHECKING THE OIL COOLER • Cooling system 1. Check: (with the specified amount of the recom- • Oil cooler mended coolant) Cracks/damage → Replace. Refer to “CHANGING THE COOLANT”...
Page 359: Thermostat
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-32. Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE”...
Page 360 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THERMOSTAT Removing the thermostat Order Job/Parts to remove Q’ty Remarks Thermostat bypass hose 2 Water pump bypass hose Joint Thermostat bypass hose 1 Engine outlet pipe O-ring For installation, reverse the removal proce- dure.
Page 361: Checking The Thermostat
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THERMOSTAT EAS26450 CHECKING THE THERMOSTAT If the accuracy of the thermostat is in doubt, 1. Check: replace it. A faulty thermostat could cause seri- • Thermostat “1” ous overheating or overcooling.
Page 362: Installing The Thermostat Assembly
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THERMOSTAT EAS26480 INSTALLING THE THERMOSTAT ASSEM- 1. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-32. 2.
Page 363: Water Pump
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys WATER PUMP EAS26500 WATER PUMP Disassembling the water pump Order Job/Parts to removes Q’ty Remarks Oil/water pump assembly Refer to “OIL PUMP” on page 5-50. Oil pump rotor Refer to “OIL PUMP”...
Page 364: Disassembling The Water Pump
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys WATER PUMP EAS26520 EAS26540 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Water pump seal “1” • Water pump housing cover “1” •...
Page 365 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys WATER PUMP ECA14090 Mechanical seal installer 90890-04132 Make sure the rubber damper and rubber Water pump seal installer damper holder are flush with the impeller. YM-33221-A Middle driven shaft bearing Impeller shaft tilt limit driver 0.15 mm (0.006 in)
Page 366 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys WATER PUMP 6-15 email: info@motomatrix.co.uk...
Page 367: Fuel System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL SYSTEM FUEL TANK ....................7-1 REMOVING THE FUEL TANK SIDE COVERS ........7-3 REMOVING THE FUEL TANK ..............7-3 REMOVING THE FUEL PUMP...............7-3 CHECKING THE FUEL PUMP BODY ............7-3 CHECKING THE FUEL PUMP OPERATION .........7-3 INSTALLING THE FUEL PUMP..............7-3 INSTALLING THE FUEL TANK...............7-4...
Page 368 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK EAS26620 FUEL TANK Removing the fuel tank and fuel pump Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank side cover Bolt Bolt/collar/washer...
Page 369: Fuel Tank
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK Removing the fuel tank and fuel pump Order Job/Parts to remove Q’ty Remarks Fuel pump bracket Fuel pump Fuel pump gasket For installation, reverse the removal proce- dure.
Page 370 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK EAS14B1078 REMOVING THE FUEL TANK SIDE COVERS The following procedure applies to both of the fuel tank side covers. 1. Remove: • Fuel tank side cover “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 371 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK • Do not damage the installation surfaces of Install the fuel hose securely onto the fuel the fuel tank when installing the fuel pump. pump until a distinct “click” is heard. •...
Page 372 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR FILTER CASE EAS14B1062 AIR FILTER CASE Removing the air filter case and secondary injectors Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Crankcase breather hose Disconnect.
Page 373 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR FILTER CASE Removing the air filter case and secondary injectors Order Job/Parts to remove Q’ty Remarks Intake funnel servo motor rod assembly Intake funnel assembly Intake funnel servo motor For installation, reverse the removal proce- dure.
Page 374 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR FILTER CASE EAS14B1105 EAS14B1106 CHECKING THE SECONDARY INJECTORS REMOVING THE SECONDARY INJECTORS (BEFORE REMOVING) EWA14B1027 WARNING 1. Check: • Injectors • Check the injectors in a well-ventilated Use the diagnostic code number “D:40–...
Page 375 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR FILTER CASE 4. Remove: EAS14B1077 REMOVING THE INTAKE FUNNEL ASSEM- • Sub-wire harness • Secondary injectors 1. Remove: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Intake funnel servo motor rod assembly a.
Page 376 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR FILTER CASE 2. Check: EAS14B1067 INSTALLING THE INTAKE FUNNEL AND • Injector resistance LOWER AIR FILTER CASE Refer to “CHECKING THE FUEL INJEC- 1. Install: TORS” on page 8-148. •...
Page 377 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR FILTER CASE EAS14B1107 5. Install: INSTALLING THE SECONDARY INJEC- • Upper air filter case seal “1” TORS • Secondary injector assembly seal “2” ECA14B1046 • Always use new O-rings. •...
Page 378 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR FILTER CASE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS14B1069 INSTALLING THE FUEL HOSE (PRIMARY INJECTOR JOINT SIDE AND SECONDARY INJECTOR JOINT SIDE) 1. Connect: • Fuel hose (primary injector joint side and secondary injector joint side) ECA14B1033 When installing the fuel hose, make sure...
Page 379 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle body assembly Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE”...
Page 380 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES Removing the throttle body assembly Order Job/Parts to remove Q’ty Remarks Crankshaft position sensor coupler Disconnect. Heat protector Throttle body joint For installation, reverse the removal proce- dure.
Page 381 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES Removing the primary injectors Order Job/Parts to remove Q’ty Remarks Primary injector coupler #1 Disconnect. Primary injector coupler #2 Disconnect. Primary injector coupler #3 Disconnect. Primary injector coupler #4 Disconnect.
Page 382 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES EAS14B1108 CHECKING THE PRIMARY INJECTORS (BEFORE REMOVING) 1. Check: • Injectors Use the diagnostic code number “D:36– D:39”. Refer to “DIAGNOSTIC MODE” on page 8-38. EAS14B1109 REMOVING THE PRIMARY INJECTORS EAS14B1110...
Page 383 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES If the protector “a” is scratched or damaged, replace the throttle bodies as a set. c. Push the lever in the direction shown in the illustration to hold the throttle valves in the open position.
Page 384 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES ECA14B1029 • If an injector is subject to strong shocks or excessive force, replace it. • If installing the original fuel rails and • Do not use a tool, such as a wire brush, to bolts, remove the white paint marks using remove the carbon deposits;...
Page 385 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES EWA14B1001 Pressure gauge WARNING 90890-03153 Cover fuel hose connections with a cloth YU-03153 when disconnecting them. Residual pres- Fuel injector pressure adapter sure in the fuel lines could cause fuel to 90890-03210 spurt out when removing the hoses.
Page 386 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES EAS14B1073 ADJUSTING THE THROTTLE POSITION SENSOR EWA14B1023 WARNING • Handle the throttle position sensor with special care. • Never subject the throttle position sensor to strong shocks. If the throttle position sensor is dropped, replace it.
Page 387 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES “dIAG” appears on the odometer LCD. f. Diagnostic code number “D:14” is selected. g. Adjust the position of the accelerator posi- tion sensor angle so that 12–22 can appear in the meter.
Page 388: Air Induction System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM 7-21 email: info@motomatrix.co.uk...
Page 389 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR INDUCTION SYSTEM 1. Lower air filter case 2. Air induction system hose (air filter case to air cut-off valve) 3. Air cut-off valve 4. Air induction system hose (air cut-off valve to reed valve cover) 7-22 email: info@motomatrix.co.uk...
Page 390 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and hoses Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE”...
Page 391 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR INDUCTION SYSTEM Removing the reed valves Order Job/Parts to remove Q’ty Remarks Reed valve cover Reed valve assembly Reed valve plate For installation, reverse the removal proce- dure.
Page 392 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR INDUCTION SYSTEM EAS27060 CHECKING THE AIR INDUCTION SYSTEM Air injection The air induction system burns unburned exhaust gases by injecting fresh air (second- ary air) into the exhaust port, reducing the emission of hydrocarbons.
Page 393 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR INDUCTION SYSTEM 4. Check: A. Exhaust side • Air cut-off valve Cracks/damage → Replace. 3. Install: • Reed valve cover 5. Check: • Air induction system solenoid Reed valve cover bolt (air induc- Refer to “CHECKING THE AIR INDUC- tion system)
Page 394 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR INDUCTION SYSTEM 7-27 email: info@motomatrix.co.uk...
Page 395: Electrical System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SYSTEM IGNITION SYSTEM..................8-1 CIRCUIT DIAGRAM................8-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION .....8-3 TROUBLESHOOTING ................8-5 ELECTRIC STARTING SYSTEM..............8-7 CIRCUIT DIAGRAM................8-7 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION......8-9 TROUBLESHOOTING ................8-11 CHARGING SYSTEM .................8-13 CIRCUIT DIAGRAM................8-13 TROUBLESHOOTING ................8-15...
Page 396 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS..............8-121 CHECKING THE SWITCHES.............8-125 CHECKING THE BULBS AND BULB SOCKETS.......8-128 CHECKING THE FUSES..............8-129 CHECKING AND CHARGING THE BATTERY........8-129 CHECKING THE RELAYS..............8-133 CHECKING THE TURN SIGNAL/HAZARD RELAY ......8-134 CHECKING THE RELAY UNIT (DIODE) ..........8-135 CHECKING THE IGNITION COILS ............8-136 CHECKING THE CRANKSHAFT POSITION SENSOR .....8-137...
Page 397 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
Page 398: Ignition System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM email: info@motomatrix.co.uk...
Page 399 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IGNITION SYSTEM 1. Main switch 4. Joint 5. Main fuse 9. Battery 10.Engine ground 14.Relay unit 17.Gear position sensor 18.Sidestand switch 21.Joint coupler 22.ECU (engine control unit) 23.Ignition coil #1 24.Ignition coil #2 25.Ignition coil #3...
Page 400 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IGNITION SYSTEM EAS14B1082 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down.
Page 401 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IGNITION SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Ignition coil 7. Spark plug 8. ECU (engine control unit) 9.
Page 402 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IGNITION SYSTEM EAS27150 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3.
Page 403 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IGNITION SYSTEM 8. Check the main switch. NG→ Replace the main switch/immobilizer Refer to “CHECKING THE unit assembly. SWITCHES” on page 8-125. OK↓ 9. Check the engine stop switch. NG→...
Page 404: Electric Starting System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM email: info@motomatrix.co.uk...
Page 405 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTING SYSTEM 1. Main switch 4. Joint 5. Main fuse 9. Battery 10.Engine ground 12.Starter relay 13.Starter motor 14.Relay unit 15.Starting circuit cut-off relay 17.Gear position sensor 18.Sidestand switch 21.Joint coupler 69.Right handlebar switch...
Page 406 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTING SYSTEM EAS14B1036 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
Page 407 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2.
Page 408 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Heat protector 4.
Page 409 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTING SYSTEM 8. Check the main switch. NG→ Replace the main switch/immobilizer Refer to “CHECKING THE unit. SWITCHES” on page 8-125. OK↓ 9. Check the engine stop switch. NG→...
Page 410: Charging System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-13 email: info@motomatrix.co.uk...
Page 411 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Joint 5. Main fuse 9. Battery 10.Engine ground 74.Engine ground 8-14 email: info@motomatrix.co.uk...
Page 412 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Right side cowling 1. Check the fuse. NG→...
Page 413 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHARGING SYSTEM 8-16 email: info@motomatrix.co.uk...
Page 414: Lighting System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-17 email: info@motomatrix.co.uk...
Page 415 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LIGHTING SYSTEM 1. Main switch 4. Joint 5. Main fuse 9. Battery 10.Engine ground 21.Joint coupler 22.ECU (engine control unit) 52.Meter assembly 64.High beam indicator light 67.Meter light 74.Engine ground 77.Left handlebar switch 79.Pass switch...
Page 416 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight or license plate light. • Before troubleshooting, remove the following part(s): 1.
Page 417 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LIGHTING SYSTEM 8. Check the entire lighting system’s NG→ wiring. Properly connect or repair the lighting Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 8-17. OK↓ Replace the ECU or meter assembly. 8-20 email: info@motomatrix.co.uk...
Page 418: Signaling System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-21 email: info@motomatrix.co.uk...
Page 419 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM 1. Main switch 4. Joint 5. Main fuse 9. Battery 10.Engine ground 14.Relay unit 17.Gear position sensor 19.Fuel sender 21.Joint coupler 22.ECU (engine control unit) 43.Coolant temperature sensor 47.Rear speed sensor 52.Meter assembly...
Page 420 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. •...
Page 421 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM 3. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring. page 8-21. OK↓ This circuit is OK.
Page 422 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM 4. Check the turn signal/hazard relay. NG→ Refer to “CHECKING THE TURN Replace the turn signal/hazard relay. SIGNAL/HAZARD RELAY” on page 8-134. OK↓ 5. Check the entire signaling system’s NG→...
Page 423 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM The fuel level warning light fails to come on. 1. Check the fuel sender. NG→ Refer to “CHECKING THE FUEL Replace the fuel pump assembly. SENDER”...
Page 424 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM The shift timing indicator light fails to come on. 1. Check that the shift timing indicator NG→ light is set to come on and that the brightness level of the light is Replace the meter assembly.
Page 425 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM 8-28 email: info@motomatrix.co.uk...
Page 426 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-29 email: info@motomatrix.co.uk...
Page 427 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM 1. Main switch 4. Joint 5. Main fuse 9. Battery 10.Engine ground 22.ECU (engine control unit) 43.Coolant temperature sensor 74.Engine ground 95.Left radiator fan motor 96.Right radiator fan motor 97.Left radiator fan motor fuse 98.Right radiator fan motor fuse...
Page 428 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM EAS27320 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Side cowlings 1. Check the fuses. NG→ (Main, ignition and radiator fan motor) Replace the fuse(s).
Page 429 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM 8-32 email: info@motomatrix.co.uk...
Page 430: Fuel Injection System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-33 email: info@motomatrix.co.uk...
Page 431 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM 101.Ignition fuse 1. Main switch 103.Headlight fuse 4. Joint 104.Steering damper fuse 5. Main fuse 6. ETV (Electronic Throttle Valve) fuse 9. Battery 10.Engine ground 11.Fuel injection system fuse 14.Relay unit 15.Starting circuit cut-off relay...
Page 432 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Page 433 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM ECU detects an abnormal signal from a sensor If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate for the type of malfunction.
Page 434 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS14B1115 The engine operation is not normal but the TROUBLESHOOTING METHOD engine trouble warning light does not come The engine operation is not normal and the 1.
Page 435 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS14B1084 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3.
Page 436 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM If the engine stop switch is set to “ ”, set it to “ ”, and then set it to “ ” again. 9. Turn the main switch to “OFF” to cancel the diagnostic mode. 8-39 email: info@motomatrix.co.uk...
Page 437 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Sensor operation table Diag- nostic Item Meter display Checking method code D:01 Throttle position sensor sig- nal 1 • Fully closed position 12–21 Check with throttle valves fully closed.
Page 438 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code D:13 Throttle position sensor sig- nal 2 • Fully closed position 9–23 Check with throttle valves fully closed.
Page 439 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code D:60 EEPROM fault code display — • No history • No malfunctions detected (If the self-diagnosis fault code 44 is indicated, the ECU is defective.) •...
Page 440 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code D:63 Malfunction code reinstate- ment (for fault code No. 24, 40 only) • No malfunction code —...
Page 441 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code D:36 Primary injector #1 Actuates the primary injector Check the operating sound #1 five times at one-second of the injector #1 five times.
Page 442 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code D:43 Secondary injector #4 Actuates the secondary injec- Check the operating sound tor #4 five times at one-sec- of the secondary injector #4 ond intervals.
Page 443 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS14B1085 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Check and ser- vice the items or components that are the probable cause of the malfunction following the order given.
Page 444 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Normal signals are not received from the cylinder identification sen- Symptom sor. Engine startup: Impossible Fail-safe action Riding: Possible Diagnostic monitor- —...
Page 445 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Normal signals are not received from the crankshaft position sen- Symptom sor. Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- —...
Page 446 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM If fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first. Fault code No. Symptom Open or short circuit of intake air pressure sensor lead Engine startup: Possible Fail-safe action Riding: Possible...
Page 447 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of intake air pressure sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:03 ing code No.
Page 448 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM If fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first. Fault code No. The intake air pressure sensor has failed (due to clogging of hose or Symptom sensor disconnection).
Page 449 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of throttle position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- D:01 ing code No.
Page 450 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of throttle position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- D:01 ing code No.
Page 451 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of throttle position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- D:01 ing code No.
Page 452 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of ECU input line (Blue/Yellow lead) Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- D:20 ing code No.
Page 453 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of ECU input line (Blue/Yellow lead) Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- D:20 ing code No.
Page 454 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. When the main switch is ON, there is a big difference in voltage Symptom value of the intake air pressure sensor and atmospheric pressure sensor Engine startup: Possible Fail-safe action...
Page 455 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. When the main switch is ON, there is a big difference in voltage Symptom value of the intake air pressure sensor and atmospheric pressure sensor Engine startup: Possible Fail-safe action...
Page 456 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of coolant temperature sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:06 ing code No. When engine is cold: Displays temperature closer to air temperature Meter display When engine is hot: Displays current coolant temperature...
Page 457 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of coolant temperature sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:06 ing code No. When engine is cold: Displays temperature closer to air temperature Meter display When engine is hot: Displays current coolant temperature...
Page 458 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of intake air temperature sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:05 ing code No.
Page 459 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of atmospheric pressure sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:02 ing code No. Meter display Displays the atmospheric pressure.
Page 460 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of atmospheric pressure sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:02 ing code No. Meter display Displays the atmospheric pressure.
Page 461 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. The O sensor does not operate. Symptom Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display —...
Page 462 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. The O sensor does not operate. Symptom Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display —...
Page 463 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Turnover of vehicle Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- D:08 ing code No. Lean angle sensor Meter display •...
Page 464 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil #1 primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- D:30 ing code No.
Page 465 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil #1 primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- D:30 ing code No.
Page 466 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil #2 primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- D:31 ing code No.
Page 467 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil #2 primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- D:31 ing code No.
Page 468 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil #3 primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- D:32 ing code No.
Page 469 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil #3 primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- D:32 ing code No.
Page 470 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil #4 primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- D:33 ing code No.
Page 471 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil #4 primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- D:33 ing code No.
Page 472 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of primary injector lead Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) D:36 Diagnostic monitor-...
Page 473 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of primary injector lead Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) D:36 Diagnostic monitor-...
Page 474 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of primary injector lead Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) D:36 Diagnostic monitor-...
Page 475 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of secondary injector lead Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) D:40 Diagnostic monitor-...
Page 476 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of secondary injector lead Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) D:40 Diagnostic monitor-...
Page 477 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of secondary injector lead Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) D:40 Diagnostic monitor-...
Page 478 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of secondary injector lead Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) D:40 Diagnostic monitor-...
Page 479 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of lean angle sensor lead Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- D:08 ing code No. Lean angle sensor Meter display •...
Page 480 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of lean angle sensor lead Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- D:08 ing code No. Lean angle sensor Meter display •...
Page 481 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. A. Normal signals are not received from the rear speed sen- sor. Symptom B. Open or short circuit of gear position sensor lead C.
Page 482 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM A. Rear speed sensor system malfunction Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Poor connection → Connect Connection of rear speed Start the engine, and check sensor (meter) coupler it securely, or repair/replace...
Page 483 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM B. Gear position sensor system malfunction Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Poor connection → Recon- Connection of gear position Start the engine, and check sensor coupler nect or repair the coupler.
Page 484 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Shift drum (that detects the Check the gear shift drum Start the engine, and check neutral position) malfunction (that detects the neutral posi- the secure connection of the...
Page 485 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Open short circuit → Replace Continuity of wire harness Start the engine, and check the wire harness.
Page 486 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Incorrect voltage supplied to the fuel injector and fuel pump Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:50 ing code No.
Page 487 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom An error is detected while reading or writing on EEP-ROM Engine startup: Under certain conditions Fail-safe action Riding: Under certain conditions Diagnostic monitor- D:60 ing code No.
Page 488 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom An error is detected while reading or writing on EEP-ROM Engine startup: Under certain conditions Fail-safe action Riding: Under certain conditions Diagnostic monitor- D:60 ing code No.
Page 489 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Incorrect voltage is supplied to the ECU. Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display —...
Page 490 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom ECU memory malfunction Engine startup: Under certain conditions Fail-safe action Riding: Under certain conditions Diagnostic monitor- — ing code No. Meter display —...
Page 491 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of accelerator position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- D:14 ing code No.
Page 492 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of accelerator position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- D:14 ing code No.
Page 493 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of accelerator position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- D:14 ing code No.
Page 494 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Defect Found in YCC-T Drive Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- —...
Page 495 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Defect Found in YCC-T Drive Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- —...
Page 496 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of steering damper solenoid lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:47 ing code No. Meter display The steering damper warning light lights up.
Page 497 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Item Normal signals are not received from the front speed sensor. Engine startup: Possible Fail-safe system Riding: Possible Diagnostic code No. D:16 Meter display Vehicle speed pulses: 0–999...
Page 498 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Item Normal signals are not received from the front speed sensor. Engine startup: Possible Fail-safe system Riding: Possible Diagnostic code No. D:16 Meter display Vehicle speed pulses: 0–999...
Page 499 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signal is received from the ECU. Engine startup: Possible, Impossible if ECU Failure Fail-safe action Riding: Possible, Impossible if ECU Failure Diagnostic monitor- —...
Page 500 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Er-2 Symptom No signal is sent from ECU. Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display —...
Page 501 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Er-3 Symptom Correct data cannot be received from the ECU. Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display —...
Page 502 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom No registration data can be received from the meter unit. Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- —...
Page 503 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM 8-106 email: info@motomatrix.co.uk...
Page 504: Fuel Pump System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-107 email: info@motomatrix.co.uk...
Page 505 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL PUMP SYSTEM 1. Main switch 4. Joint 5. Main fuse 9. Battery 10.Engine ground 11.Fuel injection system fuse 14.Relay unit 16.Fuel pump relay 20.Fuel pump 22.ECU (engine control unit) 69.Right handlebar switch 71.Engine stop switch 74.Engine ground...
Page 506 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Passenger seat 4.
Page 507 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL PUMP SYSTEM 7. Check the entire fuel pump sys- NG→ tem’s wiring. Properly connect or repair the fuel Refer to “CIRCUIT DIAGRAM” on pump system’s wiring. page 8-107.
Page 508: Immobilizer System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 8-111 email: info@motomatrix.co.uk...
Page 509 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM 1. Main switch 4. Joint 5. Main fuse 7. Backup fuse 8. Immobilizer unit 9. Battery 10.Engine ground 21.Joint coupler 22.ECU (engine control unit) 52.Meter assembly 53.Immobilizer system indicator light 59.Multi-function meter 74.Engine ground...
Page 510 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM EAS27671 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: •...
Page 511 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM EAS27691 PART REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS In the course of use, you may encounter the following cases where replacement of parts and regis- tration of code re-registering/standard keys are required.
Page 512 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM Standby mode d. LED off a. Main switch “ON” e. Standby mode on b. Main switch “OFF” f. Standby mode off c. LED on Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced.
Page 513 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM Standard key registration i. Registration mode a. Main switch “ON” b. Main switch “OFF” A. Registration of the second standard key is c. LED on complete.
Page 514 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM EAS27701 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. 1. Check the fuses. NG→...
Page 515 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM EAS27721 SELF-DIAGNOSIS FAULT CODE INDICATION When a system failure occurs, the error code number is indicated in the LCD display of meter and the immobilizer system indicator light blinks at the same time. The pattern of blinking also shows the error code.
Page 516 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code IMMOBILIZER Key code registra- Same standard key was Register another UNIT tion malfunction. attempted to be regis- standard key. tered two consecutive times.
Page 517 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM 8-120 email: info@motomatrix.co.uk...
Page 518 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS EAS27972 ELECTRICAL COMPONENTS 8-121 email: info@motomatrix.co.uk...
Page 519 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 1. Main switch 2. Immobilizer unit 3. Front brake light switch 4. Clutch switch 5. Ignition coil 6. Battery 7. Fuse box 8. Main fuse 9.
Page 520 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 8-123 email: info@motomatrix.co.uk...
Page 521 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. Headlight relay 3. Turn signal/hazard relay 4. Atmospheric pressure sensor 5. Intake air pressure sensor 6. Intake funnel servo motor 7.
Page 522 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 8-125 email: info@motomatrix.co.uk...
Page 523 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 1. Horn switch 2. Clutch switch 3. Main switch 4. Dimmer switch 5. Pass switch 6. Turn signal switch 7. Traction control system switch 8. Sidestand switch 9.
Page 524 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 Never insert the tester probes into the coupler terminal slots “a”.
Page 525 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS EAS27990 otherwise it may be pulled out of the ter- CHECKING THE BULBS AND BULB SOCK- minal in the coupler. • Avoid touching the glass part of the head- light bulb to keep it free from oil, other- Do not check any of the lights that use LEDs.
Page 526 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS d. If the fuse immediately blows again, check the electrical circuit. Check each bulb socket for continuity in the same manner as described in the bulb section; Amperage Fuses Q’ty...
Page 527 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS • Keep batteries away from fire, sparks or EWA1KB8801 WARNING open flames (e.g., welding equipment, lighted cigarettes). The battery cover material can conduct • DO NOT SMOKE when charging or han- electricity.
Page 528 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS b. Check the charge of the battery, as shown ECA13670 in the charts and the following example. • Never remove the VRLA (Valve Regulated Example Lead Acid) battery sealing caps.
Page 529 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS d. Adjust the voltage so that the current is at the standard charging level. e. Set the time according to the charging time suitable for the open-circuit voltage. f.
Page 530 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 2. Connect the pocket tester (Ω × 1) and bat- 6. Install: • Battery seat tery (12 V) to the relay terminal as shown. • Battery Check the relay operation.
Page 531 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS Relay unit (fuel pump relay) Radiator fan motor relay 1. Positive battery terminal 1. Positive battery terminal 2. Negative battery terminal 2. Negative battery terminal 3.
Page 532 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS EAS28050 CHECKING THE RELAY UNIT (DIODE) 1. Check: • Relay unit (diode) Out of specification → Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. Turn the main switch to “ON”. The pocket tester or the analog pocket tester c.
Page 533 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Continuity a. Disconnect the relay unit coupler from the Positive tester probe wire harness. Sky blue “1” b. Connect the pocket tester (Ω × 1) to the Negative tester probe relay unit terminal as shown.
Page 534 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 2. Check: • Secondary coil resistance Out of specification → Replace. Secondary coil resistance 8.50–11.50 kΩ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 1 k) to the ignition coil as shown.
Page 535 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS c. Set the main switch to “ON”. b. Measure the crankshaft position sensor d. Turn the lean angle sensor to 45°. resistance. e. Measure the lean angle sensor output volt- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 536 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS EAS28150 EAS28170 CHECKING THE STATOR COIL CHECKING THE RECTIFIER/REGULATOR 1. Disconnect: 1. Check: • Stator coil coupler • Rectifier/regulator input voltage Out of specification → Correct the stator (from the wire harness) 2.
Page 537 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS b. Connect the pocket tester (Ω × 1) to the 2. Check: • Rectifier/regulator output voltage horn terminals. Out of specification → Replace the recti- Pocket tester fier/regulator.
Page 538 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS Fuel pump is atmosphere “A” Pocket tester → Fuel level warning light is come on 90890-03112 Fuel pump is soaked in fuel “B” Analog pocket tester →...
Page 539 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS c. Turn the main switch to “ON”. d. Elevate the rear wheel and slowly rotate it. e. Measure the voltage. With each full rotation of the rear wheel, the voltage reading should cycle from 0.6 V to 4.8 V to 0.6 V to 4.8 V.
Page 540 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Throttle position sensor resis- a. Connect the pocket tester (Ω × 100) to the tance coolant temperature sensor as shown. 1.2–2.8 kΩ Pocket tester ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 541 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS b. Connect the digital circuit tester to the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 1 k) to the throttle servo motor coupler. accelerator position sensor terminal as Digital circuit tester shown.
Page 542 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS • Positive tester probe • Positive tester probe Orange “1” Pink (wire harness color) • Negative tester probe • Negative tester probe Green “2” Black/blue (wire harness color) c.
Page 543 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS b. Connect the digital circuit tester (DCV) to Pocket tester the test harness S-pressure sensor (3P). 90890-03112 Analog pocket tester Digital circuit tester YU-03112-C 90890-03174 Test harness-speed sensor (3P) Model 88 Multimeter with 90890-03208...
Page 544: Specifications
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 2. Check: Intake air temperature sensor • Steering damper solenoid resistance resistance Out of specification → Replace the steer- 5.4–6.6 kΩ at 0 °C (32 °F) ing damper assembly.
Page 545 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C Result Neutral position Continuity Positive tester probe EAS14B1101 Sky blue “1” CHECKING THE FUEL INJECTORS Negative tester probe 1.
Page 546 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 8-149 email: info@motomatrix.co.uk...
Page 547: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TROUBLESHOOTING TROUBLESHOOTING ..................9-1 GENERAL INFORMATION ..............9-1 STARTING FAILURES ................9-1 INCORRECT ENGINE IDLING SPEED ..........9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING ..............9-2 SHIFT PEDAL DOES NOT MOVE............9-2 JUMPS OUT OF GEAR ................9-2 FAULTY CLUTCH ...................9-2 OVERHEATING ..................9-2...
Page 548: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TROUBLESHOOTING EAS28451 Electrical system TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) • Blown, damaged or incorrect fuse The following guide for troubleshooting does •...
Page 549 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TROUBLESHOOTING Electrical system EAS28550 JUMPS OUT OF GEAR 1. Battery • Discharged battery Shift shaft • Faulty battery • Incorrect shift pedal position 2. Spark plug(s) • Improperly returned stopper lever •...
Page 550 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TROUBLESHOOTING 2. Engine oil • Faulty brake caliper kit • Incorrect oil level • Faulty brake caliper seal • Incorrect oil viscosity • Loose union bolt • Inferior oil quality •...
Page 551 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TROUBLESHOOTING 6. Tire(s) Turn signal blinks quickly • Uneven tire pressures (front and rear) • Incorrect turn signal bulb • Incorrect tire pressure • Faulty turn signal/hazard relay •...
Page 552 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS28740 55. Oil level warning light Gray WIRING DIAGRAM 56. Neutral indicator light Blue 57. Tachometer YZF-R1(B) Light green 58. Shift timing indicator light Orange 1. Main switch 59.
Page 553 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
Page 554 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
Page 555 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES YZF-R1(B) YZF-R1(B) YZF-R1(B) YZF-R1(B) DE YZF-R1(B) email: info@motomatrix.co.uk...
Page 556 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES YZF-R1(B) YZF-R1(B) YZF-R1(B) YZF-R1(B) DE YZF-R1(B) email: info@motomatrix.co.uk...

This manual is also suitable for:

Yzf-r1 2012

Yamaha YZF-R1B 2012 Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Engine

Engine Inspection

Engine Removal

Camshafts

Cylinder Head

Valves and Valve Springs

Generator

Starter Clutch

Pickup Rotor

Electric Starter

Oil Pump

Clutch

Shift Shaft

Crankcase

Connecting Rods and Pistons

Crankshaft

Transmission

Cooling System

Radiator

Oil Cooler

Thermostat

Water Pump

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Yamaha YZF-R1B 2012