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Yamaha XVS1300A 2007 Service Manual

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Table of Contents
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys
2007
XVS1300A(W)
SERVICE MANUAL
11C-28197-E0
email: info@motomatrix.co.uk

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  Summary of Contents for Yamaha XVS1300A 2007

  • Page 1 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 2007 XVS1300A(W) SERVICE MANUAL 11C-28197-E0 email: info@motomatrix.co.uk...
  • Page 2 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS20040 XVS1300A(W) 2007 SERVICE MANUAL ©2006 by Yamaha Motor Co., Ltd. First edition, September 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
  • Page 3 EAS20070 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. 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 1. Serviceable with engine mounted SYMBOLS 2. Filling fluid The following symbols are used in this manual 3. Lubricant for easier understanding. 4. Special tool NOTE: 5.
  • 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

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER ............. 1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 INSTRUMENT FUNCTIONS ..............1-4 IMPORTANT INFORMATION .................
  • 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 frame. This information will be needed to order spare parts.
  • Page 11: Features

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES EAS20170 FEATURES EAS3D81037 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature.
  • Page 12: Fi System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES EAS3D81038 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 only 324 kPa (3.24 kg/cm², 46.1 psi). 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: Instrument Functions

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES EAS3D81033 Speedometer INSTRUMENT FUNCTIONS Multi-function meter unit EWA3D81011 WARNING Be sure to stop the vehicle before making any setting changes to the multi-function meter unit. 1. Speedometer The speedometer shows the riding speed.
  • Page 14 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES If the odometer/tripmeter/clock display indicates NOTE: any error codes, note the code number, and Push the “ ” side of the “SELECT” switch to then check the vehicle. Refer to “FUEL INJEC- switch the display in the reverse order.
  • Page 15: Important Information

    5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
  • Page 16: 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 17: Checking The Connections

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: •...
  • Page 18: 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 inappropriate tools or improvised techniques.
  • Page 19 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Compression gauge 3-10 90890-03081 Engine compression tester YU-33223 Oil filter wrench 3-11 90890-01469 YM-01469 66.8 Belt tension gauge 3-24 90890-03170 Rear drive belt tension gauge YM-03170...
  • Page 20 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Weight 5-15 90890-01084 YU-01083-3 YU-01083-3 Valve spring compressor 5-27, 5-32 90890-04019 YM-04019 Valve spring compressor attachment 5-27, 5-32 90890-01243 Valve spring compressor adapter (26 mm) YM-01253-1 Valve guide remover (ø6)
  • Page 21 Sheave holder 5-42, 5-43, 90890-01701 5-50, 5-53 Primary clutch holder YS-01880-A Flywheel puller 5-42 90890-01362 Heavy duty puller YU-33270-B Yamaha bond No. 1215 5-44, 5-70, 90890-85505 6-10 (Three Bond No.1215®) Universal clutch holder 5-50, 5-54 90890-04086 YM-91042 1-12 email: info@motomatrix.co.uk...
  • Page 22 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01 YU-24460-01 Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984 YU-33984 Mechanical seal installer 6-10...
  • Page 23 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Digital circuit tester 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Ignition checker 8-95 90890-06754 Opama pet-4000 spark checker YM-34487 1-14 email: info@motomatrix.co.uk...
  • Page 24 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS 1-15 email: info@motomatrix.co.uk...
  • Page 25: 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............
  • Page 26: General Specifications

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model XVS1300A 11C1 (Europe) XVS1300AW 12C1 (AUS) Dimensions Overall length 2490 mm (98.0 in) Overall width 980 mm (38.6 in) Overall height 1115 mm (43.9 in) Seat height 715 mm (28.1 in)
  • Page 27: 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, SOHC Displacement 1304.0 cm³ Cylinder arrangement V-type 2-cylinder Bore × stroke 100.0 × 83.0 mm (3.94 × 3.27 in) Compression ratio 9.50 :1 Standard compression pressure (at sea level)
  • Page 28 93.3–122.7 kPa (13.5–17.8 psi) (0.93–1.23 kgf/cm²) Valve relief pressure 4.9 kPa (0.7 psi) (0.05 kgf/cm²) Thermostat Model/manufacturer 1AE/YAMAHA Valve opening temperature 80.5–83.5 °C (176.90–182.30 °F) Valve full open temperature 95.0 °C (203.00 °F) Valve lift (full open) 8.0 mm (0.31 in)
  • Page 29 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Timing chain Model/number of links 98XRH2010–132M/132 Tensioning system Automatic Rocker arm/rocker arm shaft Rocker arm inside diameter 12.000–12.018 mm (0.4724–0.4731 in) Rocker arm shaft outside diameter 11.976–11.991 mm (0.4715–0.4721 in) Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.042 mm (0.0004–0.0017 in)
  • Page 30 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Valve stem runout 0.010 mm (0.0004 in) Cylinder head valve seat width (intake) 1.00–1.20 mm (0.0394–0.0472 in) Limit 1.6 mm (0.06 in) Cylinder head valve seat width (exhaust) 1.00–1.20 mm (0.0394–0.0472 in) Limit 1.6 mm (0.06 in)
  • Page 31 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Height H 8.0 mm (0.31 in) Offset 0.50 mm (0.0197 in) Piston pin bore inside diameter 23.004–23.015 mm (0.9057–0.9061 in) Limit 23.045 mm (0.9073 in) Piston pin outside diameter 22.991–23.000 mm (0.9052–0.9055 in) Limit...
  • Page 32 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Small end inside diameter 23.015–23.028 mm (0.9061–0.9066 in) Crankshaft Width A 97.95–98.00 mm (3.856–3.858 in) Runout limit C 0.020 mm (0.0008 in) Big end side clearance D 0.320–0.474 mm (0.0126–0.0187 in) Big end radial clearance E 0.022–0.046 mm (0.0009–0.0018 in)
  • Page 33 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS 24/25 (0.960) Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit 0.08 mm (0.0032 in) Shifting mechanism Shift mechanism type Guide bar Shift fork guide bar bending limit 0.025 mm (0.0010 in) Shift fork thickness...
  • Page 34: Chassis Specifications

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Double cradle Caster angle 32.70 ° Trail 145.0 mm (5.71 in) Front wheel Wheel type Cast wheel 16M/C × MT3.00 Rim size Rim material Aluminum...
  • Page 35 Spring stroke K1 0.0–135.0 mm (0.00–5.31 in) Inner tube outer diameter 41.0 mm (1.61 in) Optional spring available Recommended oil Yamaha fork oil 10WT Quantity 490.0 cm³ (16.57 US oz) (17.28 Imp.oz) Level 105.0 mm (4.13 in) Rear suspension Type...
  • Page 36 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS SPECIFICATIONS Spring stroke K1 0.0–48.0 mm (0.00–1.89 in) Optional spring available Enclosed gas/air pressure (STD) 1200 kPa (170.7 psi) (12.0 kgf/cm²) Spring preload adjusting positions Minimum Standard Maximum Swingarm...
  • Page 37: 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 Transistorized coil ignition (digital) Advancer type Electric Ignition timing (B.T.D.C.) 5.0 °/1000 r/min Engine control unit Model/manufacturer FUA0014/MITSUBISHI...
  • Page 38 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SPECIFICATIONS 12 V, 5.0 W/21.0 W × 1 Tail/brake light 12 V, 21.0 W × 2 Front turn signal light 12 V, 21.0 W × 2 Rear turn signal light 12 V, 5.0 W ×...
  • Page 39 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SPECIFICATIONS Oil level switch resistance (maximum level position)484–536 Ω Fuel sender Model/manufacturer 3D8/NIPPON SEIKI Starting circuit cut-off relay Model/manufacturer G8R-30Y-U3/OMRON 162.0–198.0 Ω Coil resistance Headlight relay Model/manufacturer ACM33211 M05/MATSUSHITA 86.40–105.60 Ω...
  • Page 40: 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 SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual.
  • Page 41: 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 Cylinder head stud bolt (exhaust 15 Nm (1.5 m·kg, 11 ft·lb) pipe) Oil check bolt 15 Nm (1.5 m·kg, 11 ft·lb) Cylinder head nut 65 Nm (6.5 m·kg, 47 ft·lb)
  • Page 42 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Drain cock bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Coolant delivery pipe bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Oil/water pump driven sprocket 15 Nm (1.5 m·kg, 11 ft·lb) bolt...
  • Page 43 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil baffle plate 2 bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Crankcase bearing retainer bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Primary drive gear bearing plate 10 Nm (1.0 m·kg, 7.2 ft·lb) bolt...
  • Page 44 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES NOTE: Connecting rod bolt Tighten the connecting rod bolts to 15 Nm (1.5 m·kg, 11 ft·lb), and then tighten them further to reach the specified angle 125–135°. NOTE: Exhaust pipe cover screw clamp Do not retighten the exhaust pipe cover screw clamps;...
  • Page 45: 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 bracket bolt (right front 48 Nm (4.8 m·kg, 35 ft·lb) upper side) Engine bracket bolt (left front up- 48 Nm (4.8 m·kg, 35 ft·lb) per side) Engine mounting bolt (front upper...
  • Page 46 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Lower bracket pinch bolt 23 Nm (2.3 m·kg, 17 ft·lb) Front fork cap bolt 23 Nm (2.3 m·kg, 17 ft·lb) Damper rod bolt 30 Nm (3.0 m·kg, 22 ft·lb) Lower front fork cover bolt...
  • Page 47 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front brake caliper bolt 27 Nm (2.7 m·kg, 19 ft·lb) Front brake disc bolt 23 Nm (2.3 m·kg, 17 ft·lb) Bleed screw (front brake caliper) 6 Nm (0.6 m·kg, 4.3 ft·lb) Rear wheel axle nut...
  • Page 48 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear brake master cylinder bolt 23 Nm (2.3 m·kg, 17 ft·lb) Rear brake master cylinder 23 Nm (2.3 m·kg, 17 ft·lb) bracket bolt Rider footrest assembly bolt (left 64 Nm (6.4 m·kg, 46 ft·lb)
  • Page 49: Lubrication Points And Lubricant Types

    Clutch boss nut and washer Transmission gears (wheel and pinion) and collar Shift forks and shift fork guide bars Shift drum Shift shaft and shift shaft oil seal (lip) Yamaha bond Crankcase (mating surface) No.1215 (Three Bond No.1215®) Yamaha bond Stator coil assembly lead grommet No.1215 (Three Bond...
  • Page 50: 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 upper bearing dust cover (lip) Lower bearing dust seal (lip) Front wheel oil seals (lip) Rear wheel oil seal (lip) Rear wheel drive hub oil seal (lip) Rear wheel drive hub (mating surface)
  • Page 51 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION POINTS AND LUBRICANT TYPES 2-26 email: info@motomatrix.co.uk...
  • Page 52: 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 53 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil/water pump assembly 3. Oil delivery pipe 3 4. Relief valve assembly 5. Drive axle 6. Oil filter cartridge 7.
  • Page 54: 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 55 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 delivery pipe 3 3. Relief valve assembly 2-30 email: info@motomatrix.co.uk...
  • Page 56 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 57 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil nozzle 3. Crankshaft 2-32 email: info@motomatrix.co.uk...
  • Page 58 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 59 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil delivery pipe 1 2. Timing chain tensioner 2-34 email: info@motomatrix.co.uk...
  • Page 60 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 61 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Drive axle 2. Oil delivery pipe 2 3. Main axle 4. Oil delivery pipe 3 5. Oil/water pump assembly 6. Oil strainer 2-36 email: info@motomatrix.co.uk...
  • Page 62: Cooling System Diagrams

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-37 email: info@motomatrix.co.uk...
  • Page 63 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM DIAGRAMS 1. Rear cylinder thermostat inlet pipe 1 2. Front cylinder thermostat inlet pipe 1 3. Coolant delivery cover 2 4. Coolant delivery cover 1 5.
  • Page 64 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM DIAGRAMS 2-39 email: info@motomatrix.co.uk...
  • Page 65 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM DIAGRAMS 1. Radiator outlet hose 2. Radiator outlet pipe 3. Coolant delivery pipe 4. Oil/water pump assembly 2-40 email: info@motomatrix.co.uk...
  • Page 66 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM DIAGRAMS 2-41 email: info@motomatrix.co.uk...
  • Page 67 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM DIAGRAMS 1. Rear cylinder thermostat inlet pipe 1 2. Front cylinder thermostat inlet pipe 1 3. Rear cylinder thermostat inlet hose 4. Front cylinder thermostat inlet hose 5.
  • Page 68: Cable Routing

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING EAS20430 CABLE ROUTING 2-43 email: info@motomatrix.co.uk...
  • Page 69 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Clutch switch lead 2. Clutch cable 3. Left handlebar switch lead 4. Right handlebar switch lead 5. Front brake hose 6. Throttle cable (accelerator cable) 7.
  • Page 70 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-45 email: info@motomatrix.co.uk...
  • Page 71 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Wire harness 2. Front right turn signal light 3. Front left turn signal light 4. Main switch couplers 5. Front right turn signal light coupler 6.
  • Page 72 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 11 12 D E F 2-47 email: info@motomatrix.co.uk...
  • Page 73 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Wire harness L. Fasten the rear brake light switch lead and horn lead with a plastic locking tie, making sure to align 2. Coolant reservoir hose the tie with the frame weld.
  • Page 74 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-49 email: info@motomatrix.co.uk...
  • Page 75 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Horn 2. Rear brake light switch 3. Rear brake master cylinder 4. Brake fluid reservoir hose 5. Coolant reservoir breather hose 6. Rear brake hose 7.
  • Page 76 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 4 5 6 7 8 9 11 12 2-51 email: info@motomatrix.co.uk...
  • Page 77 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Left handlebar switch lead L. Fasten the starter motor lead and sidestand switch lead with a plastic locking tie. Face the end of the 2.
  • Page 78 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 9 10 2-53 email: info@motomatrix.co.uk...
  • Page 79 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Headlight relay N. Fasten the starter motor lead to the frame with a plastic locking tie. Face the end of the plastic 2. Stator coil coupler locking tie downward, and then cut off the excess 3.
  • Page 80 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-55 email: info@motomatrix.co.uk...
  • Page 81 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Wire harness K. Slide the boot over the neutral switch coupler and speed sensor coupler, making sure that they are 2. Coolant reservoir hose covered completely.
  • Page 82 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-57 email: info@motomatrix.co.uk...
  • Page 83 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Front cylinder intake air pressure sensor hose 2. Front cylinder intake air pressure sensor 3. Rear cylinder intake air pressure sensor hose 4. Rear cylinder intake air pressure sensor 5.
  • Page 84 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-59 email: info@motomatrix.co.uk...
  • Page 85 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Rear cylinder thermostat inlet hose 2. Right handlebar switch lead 3. Wire harness 4. Front cylinder resonator hose 5. Front cylinder intake air pressure sensor hose 6.
  • Page 86 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-61 email: info@motomatrix.co.uk...
  • Page 87 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Fuel tank overflow hose 2. Fuel tank 3. Fuel tank breather hose (fuel tank to hose joint) 4. Air vent hose 5. Sub-fuel tank 6.
  • Page 88 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-63 email: info@motomatrix.co.uk...
  • Page 89: 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 AND LUBRICATION CHART....... 3-1 ENGINE ......................3-3 ADJUSTING THE VALVE CLEARANCE ..........3-3 SYNCHRONIZING THE THROTTLE BODIES.......... 3-5 ADJUSTING THE THROTTLE CABLE FREE PLAY ........
  • Page 90 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SYSTEM................. 3-30 CHECKING AND CHARGING THE BATTERY........3-30 CHECKING THE FUSES ................ 3-30 REPLACING THE HEADLIGHT BULB............ 3-30 ADJUSTING THE HEADLIGHT BEAM ........... 3-31 email: info@motomatrix.co.uk...
  • Page 91 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
  • Page 92: Periodic Maintenance

    • From 50000 km, repeat the maintenance intervals starting from 10000 km. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1000 km)
  • Page 93 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE ODOMETER READING (× 1000 km) ANNU- ITEM CHECK OR MAINTENANCE JOB CHECK • Change. √ √ √ √ √ √ Engine oil • Check oil level and vehicle for oil leakage. Engine oil filter car- √...
  • Page 94: Engine

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE EAS20470 ENGINE EAS20530 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. •...
  • Page 95 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE M MMM M MMM M MMM M MMM M MMM Valve clearance (cold) Rear cylinder Intake a. Turn the crankshaft counterclockwise from 0.09–0.13 mm (0.0035–0.0051 in) the front cylinder piston TDC by 300 degrees.
  • Page 96: Synchronizing The Throttle Bodies

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE 15.Install: Thickness gauge • Crankshaft end screw 90890-03180 (along with the O-ring Feeler gauge set • Timing mark accessing screw YU-26900-9 (along with the O-ring c. Turn the adjusting screw “3” in direction “a” or •...
  • Page 97 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE 4. Install: • Vacuum gauge “1” • Digital tachometer Vacuum gauge 90890-03094 Carburetor synchronizer YU-44456 5. Install: • Fuel tank Refer to “FUEL TANK” on page 7-1. 6.
  • Page 98: Adjusting The Throttle Cable Free Play

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE Intake vacuum Throttle cable free play 32.0–37.3 kPa (9.4–11.0 inHg) 4.0–6.0 mm (0.16–0.24 in) (240–280 mmHg) 2. Remove: • Rider seat NOTE: Refer to “GENERAL CHASSIS” on page 4-1. The difference in vacuum pressure between two •...
  • Page 99: Checking The Spark Plugs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE d. Tighten the locknut. 7. Measure: e. Slide the throttle cable holder to its original • Spark plug gap “a” position. (with a wire thickness gauge) Out of specification →...
  • Page 100: Measuring The Compression Pressure

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE NOTE: The ignition timing is not adjustable. L LLL L LLL L LLL L LLL L LLL 5. Install: • Timing mark accessing screw (along with the O-ring •...
  • Page 101: Checking The Engine Oil Level

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE Compression pressure (with oil applied into Compression gauge the cylinder) 90890-03081 Reading Diagnosis Engine compression tester YU-33223 Higher than without Piston ring(s) wear or damage → Repair. Piston, valves or cyl- inder head gasket Same as without oil...
  • Page 102: Changing The Engine Oil

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE ECA11C1001 5. If the oil filter cartridge is also to be replaced, CAUTION: perform the following procedure. • Engine oil also lubricates the clutch and the M MMM M MMM M MMM...
  • Page 103: Adjusting The Clutch Lever Free Play

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE c. Check the engine oil passages, the oil filter Engine oil quantity cartridge and the oil pump for damage or Total amount leakage. Refer to “OIL PUMP” on page 5-71. 3.70 L (3.91 US qt) (3.26 Imp.qt) d.
  • Page 104: Replacing The Air Filter Element

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE EAS20960 REPLACING THE AIR FILTER ELEMENT 1. Remove: • Air filter case cover “1” NOTE: If the specified clutch lever free play cannot be obtained on the handlebar side of the cable, use the adjusting nut on the engine side.
  • Page 105: Checking The Intake Manifold Joints

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE EAS3D81008 CHECKING THE INTAKE MANIFOLD JOINTS 1. Remove: • Left side cover Refer to “GENERAL CHASSIS” on page 4-1. • Fuel tank Refer to “FUEL TANK” on page 7-1. •...
  • Page 106: Checking The Exhaust System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE EAS21080 EAS21110 CHECKING THE EXHAUST SYSTEM CHECKING THE COOLANT LEVEL The following procedure applies to all of the ex- 1. Stand the vehicle on a level surface. haust pipes and gaskets.
  • Page 107: Checking The Cooling System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE ECA13470 • Muffler CAUTION: • Coolant reservoir cover • Adding water instead of coolant lowers the Refer to “ENGINE REMOVAL” on page 5-1. antifreeze content of the coolant. If water is 2.
  • Page 108 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE 12.Install: • Coolant drain bolt (radiator) (along with the copper washer Coolant drain bolt (radiator) 2 Nm (0.2 m·kg, 1.4 ft·lb) 13.Fill: • Cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol anti-...
  • Page 109 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE 15.Fill: • Coolant reservoir (with the recommended coolant to the maxi- mum level mark “a”) 16.Install: • Coolant reservoir cap 17.Start the engine, warm it up for several min- utes, and then stop it.
  • Page 110: Chassis

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS EAS21140 EAS21190 CHASSIS ADJUSTING THE REAR DISC BRAKE 1. Check: • Brake pedal adjusting bolt position EAS21150 ADJUSTING THE FRONT BRAKE LEVER Check that the end “a” of the brake pedal ad- FREE PLAY justing bolt is visible through the hole “b”.
  • Page 111: Checking The Brake Fluid Level

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS 3. Adjust: • When refilling, be careful that water does • Rear brake light switch not enter the front brake master cylinder Refer to “ADJUSTING THE REAR BRAKE reservoir and brake fluid reservoir.
  • Page 112: Checking The Front Brake Hoses

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS 2. Check: • Brake hose clamp Loose → Tighten the clamp bolt. 3. Hold the vehicle upright and apply the brake several times. 4. Check: • Brake hoses Brake fluid leakage →...
  • Page 113 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. • brake operation is faulty. 1. Remove: • Rider seat •...
  • Page 114: Adjusting The Shift Pedal

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS EWA13110 WARNING After bleeding the hydraulic brake system, check the brake operation. L LLL L LLL L LLL L LLL L LLL 5. Tighten: • Brake fluid reservoir bolt Brake fluid reservoir bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) LOCTITE®...
  • Page 115 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS b. Loosen both locknuts “2”. Drive belt slack (on the side- c. Turn both adjusting bolts “3” in direction “a” or stand) “b” until the specified drive belt slack is ob- 5.0–7.0 mm (0.20–0.28 in) tained.
  • Page 116: Checking And Adjusting The Steering Head

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS EAS21510 CHECKING AND ADJUSTING THE STEERING 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. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated.
  • Page 117: Checking The Front Fork

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS Spring preload ECA13590 CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Remove: • Rear cylinder exhaust pipe • Coolant reservoir cover Refer to “ENGINE REMOVAL” on page 5-1. 2.
  • Page 118: Checking The Tires

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS Tire air pressure (measured on cold tires) Loading condition 5 6 7 1 2 3 4 0–90 kg (0–198 lb) Front 250 kPa (36 psi) (2.50 kgf/cm²) Rear 280 kPa (41 psi) (2.80 kgf/cm²) Loading condition...
  • Page 119: Checking The Wheels

    The following procedure applies to both of the cerning handling characteristics can be giv- wheels. en if a tire combination other than one 1. Check: approved by Yamaha is used on this vehicle. • Wheel Damage/out-of-round → Replace. Front tire EWA13260...
  • Page 120: Lubricating The Levers

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS EWA13270 WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement. Re- place damaged outer cable and inner cables as soon as possible. 1.
  • Page 121 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SYSTEM EAS21750 6. Remove: ELECTRICAL SYSTEM • Headlight bulb “6” EAS21760 CHECKING AND CHARGING THE BATTERY Refer to “ELECTRICAL COMPONENTS” on page 8-79. EAS21770 CHECKING THE FUSES Refer to “ELECTRICAL COMPONENTS”...
  • Page 122 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SYSTEM EAS21810 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: • Headlight beam (vertically) M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting screw “1” with a screw driver in direction “a”...
  • Page 123 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS GENERAL CHASSIS..................4-1 FRONT WHEEL....................4-7 REMOVING THE FRONT WHEEL............4-9 DISASSEMBLING THE FRONT WHEEL..........4-9 CHECKING THE FRONT WHEEL ............4-9 ASSEMBLING THE FRONT WHEEL............4-10 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......
  • Page 124 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBAR ....................4-43 REMOVING THE HANDLEBAR.............. 4-45 CHECKING THE HANDLEBAR .............. 4-45 INSTALLING THE HANDLEBAR ............4-45 FRONT FORK....................4-47 REMOVING THE FRONT FORK LEGS..........4-51 DISASSEMBLING THE FRONT FORK LEGS ........4-51 CHECKING THE FRONT FORK LEGS ..........
  • Page 125 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
  • Page 126 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the rider seat and left side cover 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 127: General Chassis

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the headlight 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Turn signal light bracket cover...
  • Page 128 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the battery 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat/Sub-fuel tank cover 4-1.
  • Page 129 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the battery 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Battery box For installation, reverse the removal proce- dure.
  • Page 130 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the air filter case 4 Nm (0.4 m kg, 2.9 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Air filter case cover...
  • Page 131 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the relays 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
  • Page 132: Front Wheel

    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 40 Nm (4.0 m kg, 29 ft • • 59 Nm (5.9 m kg, 43 ft •...
  • Page 133 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 Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure. email: info@motomatrix.co.uk...
  • Page 134: Removing The Front Wheel

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL EAS21900 REMOVING THE FRONT 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. 2.
  • Page 135: Assembling The Front Wheel

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL 4. Check: L LLL L LLL L LLL L LLL L LLL • Wheel bearings EAS21970 Front wheel turns roughly or is loose → Re- ADJUSTING THE FRONT WHEEL STATIC place the wheel bearings.
  • Page 136: Installing The Front Wheel (Front Brake Disc)

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL M MMM M MMM M MMM M MMM M MMM a. Turn the front wheel and make sure it stays at each position shown. f. Repeat steps (c) through (e) several times until all the marks come to rest at the same spot.
  • Page 137 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL NOTE: Install the tire and wheel with the marks “1” pointing in the direction of wheel rotation. 5. Tighten: • Front wheel axle • Front wheel axle pinch bolt Front wheel axle 59 Nm (5.9 m·kg, 43 ft·lb) Front wheel axle pinch bolt...
  • Page 138: Rear Wheel

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL EAS22020 REAR WHEEL Removing the rear fender 16 Nm (1.6 m kg, 11 ft • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft •...
  • Page 139 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL Removing the rear wheel 27 Nm (2.7 m kg, 19 ft • • 16 Nm (1.6 m kg, 11 ft • • 150 Nm (15.0 m kg, 110 ft •...
  • Page 140 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL Removing the rear wheel 27 Nm (2.7 m kg, 19 ft • • 16 Nm (1.6 m kg, 11 ft • • 150 Nm (15.0 m kg, 110 ft •...
  • Page 141 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL Removing the rear brake disc and rear wheel drive hub 23 Nm (2.3 m kg, 17 ft • • Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel pulley Oil seal...
  • Page 142 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 Oil seal Circlip Bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-17 email: info@motomatrix.co.uk...
  • Page 143: Removing The Rear Wheel (Disc)

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL EAS28760 • Oil seals REMOVING THE REAR WHEEL (DISC) Refer to “CHECKING THE FRONT WHEEL” 1. Stand the vehicle on a level surface. on page 4-9. EWA13120 2.
  • Page 144: Assembling The Rear Wheel

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL Rear wheel pulley self-locking Rear brake disc bolt 23 Nm (2.3 m·kg, 17 ft·lb) 95 Nm (9.5 m·kg, 68 ft·lb) LOCTITE® NOTE: NOTE: Tighten the self-locking nuts in stages and in a •...
  • Page 145: Front Brake

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft • •...
  • Page 146 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Removing the front brake master cylinder 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 147 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 Dust boot Circlip Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure.
  • Page 148 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Removing the front brake calipers 40 Nm (4.0 m kg, 29 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of...
  • Page 149 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Disassembling the front brake calipers 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of...
  • Page 150: Introduction

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE EAS22220 INTRODUCTION Brake disc deflection limit EWA14100 0.12 mm (0.0047 in) WARNING Disc brake components rarely require disas- M MMM M MMM M MMM M MMM M MMM a.
  • Page 151: Replacing The Front Brake Pads

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE 2. Install: • Brake pads • Brake pad spring NOTE: Always install new brake pads and a new brake pad spring as a set. M MMM M MMM M MMM M MMM...
  • Page 152: Removing The Front Brake Calipers

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-20. LOWER M MMM M MMM M MMM M MMM M MMM a. Blow compressed air into the brake hose joint opening “a”...
  • Page 153: Assembling The Front Brake Calipers

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE • Brake caliper body “3” Cracks/damage → Replace the brake caliper Front brake hose union bolt 30 Nm (3.0 m·kg, 22 ft·lb) assembly. • Brake fluid delivery passages EWA13530 (brake caliper body) WARNING...
  • Page 154: Removing The Front Brake Master Cylinder

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE • Refill with the same type of brake fluid that NOTE: is already in the system. Mixing brake fluids To collect any remaining brake fluid, place a may result in a harmful chemical reaction, container under the master cylinder and the end leading to poor brake performance.
  • Page 155: Installing The Front Brake Master Cylinder

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE EAS22530 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • Brake master cylinder “1” 30–50˚ • Front brake master cylinder holder “2” Front brake master cylinder hold- er bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) 3.
  • Page 156 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE LOWER 6. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-21. 4-31 email: info@motomatrix.co.uk...
  • Page 157: Rear Brake

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft • •...
  • Page 158 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Removing the rear brake master cylinder 16 Nm (1.6 m kg, 11 ft • • 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 159 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Removing the rear brake master cylinder 16 Nm (1.6 m kg, 11 ft • • 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 160 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 Dust boot Circlip Brake master cylinder kit Circlip Brake hose joint O-ring Brake master cylinder body For assembly, reverse the disassembly pro- cedure.
  • Page 161 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Removing the rear brake caliper 30 Nm (3.0 m kg, 22 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Parts to remove Q’ty Remarks Drain.
  • Page 162 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.
  • Page 163: Introduction

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE EAS22560 Refer to “CHECKING THE FRONT BRAKE INTRODUCTION DISCS” on page 4-25. EWA14100 WARNING Brake disc thickness limit Disc brake components rarely require disas- 5.5 mm (0.22 in) sembly.
  • Page 164: Removing The Rear Brake Caliper

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Refer to “BLEEDING THE HYDRAULIC NOTE: BRAKE SYSTEM” on page 3-21. Always install new brake pads and brake pad springs as a set. EAS22590 REMOVING THE REAR BRAKE CALIPER M MMM M MMM M MMM...
  • Page 165: Checking The Rear Brake Caliper

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE b. Remove the brake caliper piston seals. • Whenever a brake caliper is disassembled, replace the brake caliper piston seals. L LLL L LLL L LLL L LLL L LLL EAS22640...
  • Page 166: Removing The Rear Brake Master Cylinder

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE 4. Fill: EAS22700 REMOVING THE REAR BRAKE MASTER • Brake fluid reservoir CYLINDER (with the specified amount of the recom- NOTE: mended brake fluid) Before removing the rear brake master cylinder, Recommended fluid drain the brake fluid from the entire brake sys- DOT 4...
  • Page 167: Assembling The Rear Brake Master Cylinder

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE EAS22730 EWA13090 ASSEMBLING THE REAR BRAKE MASTER WARNING CYLINDER • Use only the designated brake fluid. Other EWA13520 brake fluids may cause the rubber seals to WARNING deteriorate, causing leakage and poor •...
  • Page 168 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • 28 Nm (2.8 m kg, 20 ft •...
  • Page 169 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBAR Removing the handlebar 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • 28 Nm (2.8 m kg, 20 ft •...
  • Page 170: Handlebar

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBAR EAS22860 • Turn the handlebar all the way to the left REMOVING THE HANDLEBAR and right. If there is any contact with the 1. Stand the vehicle on a level surface. fuel tank, adjust the handlebar position.
  • Page 171 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBAR 5. Install: • Handlebar grip “1” M MMM M MMM M MMM M MMM M MMM a. Apply a thin coat of rubber adhesive onto the left end of the handlebar.
  • Page 172: Front Fork

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 18 Nm (1.8 m kg, 13 ft 110 Nm (11.0 m kg, 80 ft • • • •...
  • Page 173 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK Removing the front fork legs 18 Nm (1.8 m kg, 13 ft 110 Nm (11.0 m kg, 80 ft • • • • 20 Nm (2.0 m kg, 14 ft •...
  • Page 174 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK Disassembling the front fork legs 23 Nm (2.3 m kg, 17 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of...
  • Page 175 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK Disassembling the front fork legs 23 Nm (2.3 m kg, 17 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Spring...
  • Page 176: Removing The Front Fork Legs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK EAS22960 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is...
  • Page 177: Checking The Front Fork Legs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK ECA14200 CAUTION: • The front fork leg has a built-in damper ad- justing rod and a very sophisticated inter- nal construction, which are particularly sensitive to foreign material. •...
  • Page 178 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK 2. Lubricate: • Inner tube’s outer surface Recommended oil Yamaha fork oil 10WT 3. Install: • Inner tube (in the outer tube) 4. Install: • Copper washer 7.
  • Page 179: Installing The Front Fork Legs

    490.0 cm³ (16.57 US oz) (17.28 Imp.oz) Recommended oil Yamaha fork oil 10WT 11.Measure: • Front fork leg oil level “a” (from the top of the inner tube, with the outer tube fully compressed and without the fork spring) Out of specification →...
  • Page 180 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK EWA13680 WARNING Lower bracket pinch bolt 23 Nm (2.3 m·kg, 17 ft·lb) Make sure the brake hoses are routed prop- erly. NOTE: Tighten the lower bracket pinch bolts to specifi- cation twice.
  • Page 181: Steering Head

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 1st 52 Nm (5.2 m kg, 37 ft • • 2nd 18 Nm (1.8 m kg, 13 ft •...
  • Page 182 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STEERING HEAD Removing the lower bracket 1st 52 Nm (5.2 m kg, 37 ft • • 2nd 18 Nm (1.8 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 183: Removing The Lower Bracket

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STEERING HEAD EAS23110 b. Remove the bearing race from the lower REMOVING THE LOWER BRACKET bracket with a floor chisel “2” and hammer. 1. Stand the vehicle on a level surface. c.
  • Page 184 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STEERING HEAD • Upper ring nut “3” • Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-25. 3. Install: • Front brake hose joint “1” •...
  • Page 185: Rear Shock Absorber Assembly

    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 48 Nm (4.8 m kg, 35 ft • • 48 Nm (4.8 m kg, 35 ft •...
  • Page 186 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 48 Nm (4.8 m kg, 35 ft • • 48 Nm (4.8 m kg, 35 ft • •...
  • Page 187: Handling The Rear Shock Absorber

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR SHOCK ABSORBER ASSEMBLY EAS23180 NOTE: HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that the EWA13740 WARNING rear wheel is elevated. This rear shock absorber contains highly 2.
  • Page 188: Checking The Connecting Arm And Relay Arm

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR SHOCK ABSORBER ASSEMBLY • Spring Damage/wear → Replace the rear shock ab- sorber assembly. • Bushing Damage/wear → Replace. • Spacer Damage/scratches → Replace. • Bolts Bends/damage/wear →...
  • Page 189 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR SHOCK ABSORBER ASSEMBLY Rear shock absorber assembly lower nut 48 Nm (4.8 m·kg, 35 ft·lb) 5. Install: • Connecting arms NOTE: When installing the connecting arms, lift up the swingarm.
  • Page 190: Swingarm

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SWINGARM EAS23330 SWINGARM Removing the swingarm 85 Nm (8.5 m kg, 61 ft • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 191 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SWINGARM Removing the swingarm 85 Nm (8.5 m kg, 61 ft • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 192: Removing The Swingarm

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SWINGARM Bends → Replace. EAS23350 REMOVING THE SWINGARM EWA13770 1. Stand the vehicle on a level surface. WARNING EWA13120 Do not attempt to straighten a bent pivot WARNING shaft.
  • Page 193 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SWINGARM 2. Swingarm A. Left side B. Right side Installed depth “a” 0–1.0 mm (0–0.04 in) 3. Install: • Pivot shaft nut Pivot shaft nut 85 Nm (8.5 m·kg, 61 ft·lb) 4.
  • Page 194: Belt Drive

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys BELT DRIVE EAS23510 BELT DRIVE Removing the drive belt 10 Nm (1.0 m kg, 7.2 ft • • 140 Nm (14.0 m kg, 100 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 195: Removing The Drive Belt And Drive Pulley

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys BELT DRIVE EAS23520 REMOVING THE DRIVE BELT AND DRIVE PULLEY NOTE: Loosen the drive pulley nut before removing the rear wheel. 1. Loosen: • Drive pulley nut NOTE: When loosening the drive pulley nut, press down 3.
  • Page 196 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys BELT DRIVE 4. Tighten: • Drive pulley cover plate bolt NOTE: Tighten the drive pulley cover plate bolts tempo- rarily, and then tighten them in proper tightening sequence as shown.
  • Page 197: Engine

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE EXHAUST PIPE COVER SCREW CLAMPS ....5-2 INSTALLING THE CYLINDER COVERS ..........5-4 INSTALLING THE SHIFT ARM ..............5-4 INSTALLING THE ENGINE............... 5-9 CAMSHAFTS....................
  • Page 198 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH ......................5-45 REMOVING THE CLUTCH ..............5-50 REMOVING THE PRIMARY DRIVE GEAR ..........5-50 CHECKING THE FRICTION PLATES............. 5-50 CHECKING THE CLUTCH PLATES ............5-51 CHECKING THE CLUTCH SPRING PLATE........... 5-51 CHECKING THE CLUTCH HOUSING ............
  • Page 199 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT ....................5-74 REMOVING THE CONNECTING RODS ..........5-75 CHECKING THE CRANKSHAFT AND CONNECTING RODS ....5-75 INSTALLING THE CONNECTING RODS..........5-77 INSTALLING THE CRANKSHAFT ASSEMBLY........5-78 TRANSMISSION....................
  • Page 200: Engine Removal

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the muffler and exhaust pipes 7 Nm (0.7 m kg, 5.1 ft • • 44 Nm (4.4 m kg, 32 ft •...
  • Page 201: Installing The Exhaust Pipe Cover Screw Clamps

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL EAS3D81019 INSTALLING THE EXHAUST PIPE COVER SCREW CLAMPS 1. Install: • Exhaust pipe cover screw clamps Exhaust pipe cover screw clamp 6 Nm (0.6 m·kg, 4.3 ft·lb) NOTE: Do not retighten the exhaust pipe cover screw clamps;...
  • Page 202 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Removing the sidestand and drive pulley housing 64 Nm (6.4 m kg, 46 ft 8 Nm (0.8 m kg, 5.8 ft • • • • 8 Nm (0.8 m kg, 5.8 ft •...
  • Page 203: Installing The Cylinder Covers

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL EAS3D81039 INSTALLING THE CYLINDER COVERS 1. Install: • Rear cylinder right cover “1” • Rear cylinder left cover “2” • Front cylinder right cover “3” •...
  • Page 204 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 Refer to “GENERAL CHASSIS” on page Sub-fuel tank cover 4-1. Radiator Refer to “RADIATOR” on page 6-1. Thermostat Refer to “THERMOSTAT”...
  • Page 205 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 Rubber cover For installation, reverse the removal proce- dure. email: info@motomatrix.co.uk...
  • Page 206 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Removing the down tube and engine 7 Nm (0.7 m kg, 5.1 ft 48 Nm (4.8 m kg, 35 ft • • • • 88 Nm (8.8 m kg, 64 ft •...
  • Page 207 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Removing the down tube and engine 7 Nm (0.7 m kg, 5.1 ft 48 Nm (4.8 m kg, 35 ft • • • • 88 Nm (8.8 m kg, 64 ft •...
  • Page 208: Installing The Engine

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE 1. Install: • Engine bracket (front upper side) “1” • Engine bracket bolts (front upper side) “2” Engine bracket bolt (front upper side) 30 Nm (3.0 m·kg, 22 ft·lb) 2.
  • Page 209 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL 4. Tighten: • Engine mounting bolts (front right upper side) “4” • Engine mounting bolts (front left upper side) “5” • Engine mounting nut (rear lower side) “11” •...
  • Page 210: Camshafts

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS EAS23740 CAMSHAFTS Removing the cylinder head covers 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 211 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS Removing the camshaft assemblies 10 Nm (1.0 m kg, 7.2 ft • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 212 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS Removing the rocker arms and camshafts 14 Nm (1.4 m kg, 10 ft • • 14 Nm (1.4 m kg, 10 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of...
  • Page 213: Removing The Camshaft Assemblies

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS EAS3D81020 REMOVING THE CAMSHAFT ASSEMBLIES 1. Align: • “I” mark on the front cylinder camshaft sprocket (with the arrow mark on the front cylinder camshaft carrier) M MMM M MMM M MMM...
  • Page 214: Removing The Rocker Arms And Camshafts

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS 5. Align: EAS3D81034 REMOVING THE ROCKER ARMS AND • “I” mark on the rear cylinder camshaft sprock- CAMSHAFTS The following procedure applies to all of the (with the arrow mark on the rear cylinder rocker arms and camshafts.
  • Page 215: Checking The Camshafts

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS EAS23840 EAS23870 CHECKING THE CAMSHAFTS CHECKING THE CAMSHAFT SPROCKETS 1. Check: 1. Check: • Camshaft lobes • Camshaft sprockets Blue discoloration/pitting/scratches → Re- More than 1/4 tooth wear “a” → Replace the place the camshaft.
  • Page 216: Checking The Timing Chain Tensioners

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS 4. Measure: • Rocker arm shaft outside diameter “a” Out of specification → Replace. Rocker arm shaft outside diame- 11.976–11.991 mm (0.4715– 0.4721 in) 1. Timing chain tensioner rod 2.
  • Page 217: Installing The Camshafts And Rocker Arms

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS b. Install the timing chain tensioner inner spring, EAS24040 INSTALLING THE CAMSHAFTS AND timing chain tensioner spring seat, and timing ROCKER ARMS chain tensioner rod. The following procedure applies to all of the c.
  • Page 218: Installing The Camshaft Assemblies

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS ECA3D81017 CAUTION: Make sure the cutouts in the rocker arm shafts face inward. A. Intake side B. Exhaust side 3. Install: • Front cylinder camshaft sprocket EAS3D81021 INSTALLING THE CAMSHAFT ASSEMBLIES M MMM...
  • Page 219 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS • When installing the front cylinder camshaft sprocket, be sure to keep the timing chain as tight as possible on the exhaust side. d. Remove the wire from the timing chain. L LLL L LLL L LLL...
  • Page 220 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS • When installing the rear cylinder camshaft sprocket, be sure to keep the timing chain as tight as possible on the intake side. A. Intake side B.
  • Page 221: Installing The Cylinder Head Covers

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS • Front cylinder head cover bracket “1” Front cylinder head cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Bolts “2”: l = 30 mm (1.18 in) Bolts “3”: l = 45 mm (1.77 in) Bolts “4”: l = 55 mm (2.17 in) A.
  • Page 222: Cylinder Heads

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEADS EAS24110 CYLINDER HEADS Removing the cylinder heads 13 Nm (1.3 m kg, 9.4 ft 13 Nm (1.3 m kg, 9.4 ft • • • • 15 Nm (1.5 m kg, 11 ft •...
  • Page 223: Removing The Cylinder Heads

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEADS EAS24150 REMOVING THE CYLINDER HEADS 1. Remove: • Cylinder head bolts • Cylinder head nuts NOTE: • Loosen the nuts and bolts in the proper se- quence as shown.
  • Page 224 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEADS Cylinder head nut 65 Nm (6.5 m·kg, 47 ft·lb) Cylinder head bolt 13 Nm (1.3 m·kg, 9.4 ft·lb) NOTE: • Lubricate the cylinder head nuts and washers with engine oil.
  • Page 225 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 The following procedure applies to both cyl- inders.
  • Page 226: Valves And Valve Springs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, and valve seats), make sure the valves properly seal.
  • Page 227 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS b. Install the new valve guide with the valve Valve-stem-to-valve-guide clear- guide installer “2” and valve guide remover ance (intake) “1”. 0.010–0.037 mm (0.0004–0.0015 Valve guide position Limit 14.5–14.9 mm (0.571–0.587 in)
  • Page 228: Checking The Valve Seats

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS 4. Check: 1. Eliminate: • Valve face • Carbon deposits Pitting/wear → Grind the valve face. (from the valve face and valve seat) •...
  • Page 229: Checking The Valve Springs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS e. Apply a fine lapping compound to the valve NOTE: face and repeat the above steps. After replacing the cylinder head or replacing the f.
  • Page 230: Installing The Valves

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS 2. Measure: EAS24340 INSTALLING THE VALVES • Compressed valve spring force “a” Out of specification → Replace the valve The following procedure applies to all of the valves and related components.
  • Page 231 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS • Valve stem seal “2” • Valve “3” • Valve spring “4” • Upper spring seat “5” (into the cylinder head) NOTE: • Make sure each valve is installed in its original place.
  • Page 232: Cylinders And Pistons

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDERS AND PISTONS EAS24360 CYLINDERS AND PISTONS Removing the cylinders and pistons Order Job/Parts to remove Q’ty Remarks Cylinder heads Refer to “CYLINDER HEADS” on page 5-23. Timing chain guide Front cylinder Rear cylinder...
  • Page 233: Removing The Pistons

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDERS AND PISTONS EAS24380 NOTE: REMOVING THE PISTONS When removing a piston ring, open the end gap The following procedure applies to all of the pis- with your fingers and lift the other side of the ring tons.
  • Page 234: Checking The Piston Rings

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDERS AND PISTONS EAS24430 CHECKING THE PISTON RINGS The following procedure applies to all of the pis- ton rings. 1. Measure: • Piston ring side clearance Out of specification → Replace the piston and piston rings as a set.
  • Page 235: Checking The Piston Pins

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDERS AND PISTONS Piston pin outside diameter 22.991–23.000 mm (0.9052– 0.9055 in) Limit 22.971 mm (0.9044 in) a. 10 mm (0.39 in) 3. Measure: • Piston ring end gap Out of specification →...
  • Page 236: Installing The Pistons And Cylinders

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDERS AND PISTONS EAS24460 INSTALLING THE PISTONS AND CYLINDERS The following procedure applies to all of the pis- tons and cylinders. 1. Install: • Top ring “1” •...
  • Page 237 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDERS AND PISTONS 6. Install: • Cylinder “1” NOTE: • While compressing the piston rings with one hand, install the cylinder with the other hand. • Pass the timing chain and timing chain guide through the timing chain cavity.
  • Page 238 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the stator coil 10 Nm (1.0 m kg, 7.2 ft • • (12) 6 Nm (0.6 m kg, 4.3 ft 10 Nm (1.0 m kg, 7.2 ft...
  • Page 239: Generator And Starter Clutch

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERATOR AND STARTER CLUTCH Removing the stator coil 10 Nm (1.0 m kg, 7.2 ft • • (12) 6 Nm (0.6 m kg, 4.3 ft 10 Nm (1.0 m kg, 7.2 ft 7 Nm (0.7 m kg, 5.1 ft...
  • Page 240 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch 90 Nm (9.0 m kg, 65 ft • • 24 Nm (2.4 m kg, 17 ft •...
  • Page 241: Removing The Generator

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERATOR AND STARTER CLUTCH EAS24490 REMOVING THE GENERATOR 1. Remove: • Generator rotor bolt “1” • Washer • Starter clutch bolts “2” NOTE: • While holding the generator rotor “3” with the sheave holder “4”, loosen the generator rotor bolt.
  • Page 242: Checking The Torque Limiter

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERATOR AND STARTER CLUTCH M MMM M MMM M MMM M MMM M MMM a. Install the starter clutch gear “1” onto the gen- erator rotor “2” and hold the generator rotor. b.
  • Page 243 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERATOR AND STARTER CLUTCH 3. Apply: • Sealant (onto the crankshaft position sensor/stator assembly lead grommet) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 5-44 email: info@motomatrix.co.uk...
  • Page 244: Clutch

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH EAS25060 CLUTCH Removing the clutch cover 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Muffler/Coolant reservoir cover...
  • Page 245 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 shaft Oil seal Bearing Bearing For installation, reverse the removal proce- dure. 5-46 email: info@motomatrix.co.uk...
  • Page 246 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH Removing the clutch 10 Nm (1.0 m kg, 7.2 ft • • 125 Nm (12.5 m kg, 90 ft • • 14 13 12 11 8 Nm (0.8 m kg, 5.8 ft •...
  • Page 247 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH Removing the clutch 10 Nm (1.0 m kg, 7.2 ft • • 125 Nm (12.5 m kg, 90 ft • • 14 13 12 11 8 Nm (0.8 m kg, 5.8 ft •...
  • Page 248 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH Removing the primary drive gear 100 Nm (10.0 m kg, 72 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (12) 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 249: Removing The Clutch

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH EAS25080 • Do not allow the sheave holder to touch the REMOVING THE CLUTCH projection on the generator rotor. 1. Loosen: • Clutch boss nut “1” Sheave holder NOTE: 90890-01701...
  • Page 250: Checking The Clutch Plates

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH EAS25130 CHECKING THE CLUTCH SPRING PLATE 1. Check: • Clutch spring plate Damage → Replace. 2. Check: • Clutch spring plate seat Damage → Replace. EAS25150 CHECKING THE CLUTCH HOUSING 1.
  • Page 251: Checking The Pressure Plate

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH 2. Check: EAS25170 CHECKING THE PRESSURE PLATE • Pull rod bearing Damage/wear → Replace. 1. Check: • Pressure plate Cracks/damage → Replace. EAS3D81028 CHECKING THE OIL/WATER PUMP DRIVE •...
  • Page 252: Installing The Clutch

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH 2. Install: Sheave holder • Clutch housing “1” 90890-01701 NOTE: Primary clutch holder • Fit the projections “a” on the oil/water pump YS-01880-A drive sprocket into the grooves “b” in the clutch housing.
  • Page 253 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH 4. Install: • Align the cutout in the tab of each friction plate • Clutch boss “1” 2 “1” with the “ ” mark “a” on the clutch hous- •...
  • Page 254 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH 9. Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-12. 5-55 email: info@motomatrix.co.uk...
  • Page 255: 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 22 Nm (2.2 m kg, 16 ft • • Order Job/Parts to remove Q’ty Remarks Drive pulley cover Refer to “BELT DRIVE”...
  • Page 256: 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 Bends/damage/wear → Replace. • Shift shaft spring Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1.
  • Page 257: Balancer Gears

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys BALANCER GEARS EAS3D81023 BALANCER GEARS Removing the right balancer assembly 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • •...
  • Page 258 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys BALANCER GEARS Removing the left balancer assembly 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERATOR AND STARTER...
  • Page 259: Checking The Right Balancer Gears

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys BALANCER GEARS EAS3D81024 2. Install: CHECKING THE RIGHT BALANCER GEARS • Left balancer drive gear “1” 1. Check: NOTE: • Right balancer drive gear • Align the punch mark “a” in the left balancer •...
  • Page 260: 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 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty...
  • Page 261 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 Starter motor front cover Lock washer Washer set Oil seal Bearing Armature assembly Washer set Starter motor rear cover Gasket Brush seat (along with the brushes)
  • Page 262: 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 Pocket tester 1. Check: 90890-03112 • Commutator Analog pocket tester Dirt → Clean with 600 grit sandpaper. YU-03112-C 2. Measure: •...
  • Page 263: Assembling The Starter Motor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTER 7. Check: • Gear teeth Damage/wear → Replace the gear. 8. Check: • Bearing Damage/wear → Replace the defective part(s). EAS24800 ASSEMBLING THE STARTER MOTOR 1.
  • Page 264: Crankcase

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE EAS25540 CRANKCASE Removing the oil delivery pipes and timing chains 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • •...
  • Page 265 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE Removing the oil delivery pipes and timing chains 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 20 Nm (2.0 m kg, 14 ft •...
  • Page 266 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 36 Nm (3.6 m kg, 25 ft •...
  • Page 267 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE Removing the oil seal and bearings 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Oil/water pump assembly...
  • Page 268: Disassembling The Crankcase

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE EAS25560 • Oil delivery passages DISASSEMBLING THE CRANKCASE Obstruction → Blow out with compressed air. 1. Remove: • Crankcase bolts EAS3D81029 CHECKING THE BEARINGS AND OIL SEAL NOTE: 1.
  • Page 269: Installing The Bearing Retainers

    1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 2. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) NOTE: Do not allow any sealant to come into contact with the oil gallery.
  • Page 270: Oil Pump

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP EAS24910 OIL PUMP Removing the oil/water pump assembly 24 Nm (2.4 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • •...
  • Page 271: Checking The Oil Pump

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP EAS24960 CHECKING THE OIL PUMP 1. Check: • Oil pump housing • Water pump housing Cracks/damage/wear → Replace the defec- tive part(s). 2. Measure: • Inner-rotor-to-outer-rotor-tip clearance “a” •...
  • Page 272: Checking The Oil Strainer

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP 3. Check: EAS24990 CHECKING THE OIL STRAINER • Oil pump operation 1. Check: Refer to “CHECKING THE OIL PUMP” on • Oil strainer “1” page 5-72. Damage →...
  • Page 273: Crankshaft

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft 1st 15 Nm (1.5 m kg, 11 ft • • 2nd Specified angle 125–135˚ Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE”...
  • Page 274: Removing The Connecting Rods

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT EAS26010 REMOVING THE CONNECTING RODS Oil clearance (using plasti- 1. Remove: gauge®) • Connecting rod caps “1” 0.030–0.054 mm (0.0012–0.0021 • Connecting rods • Big end bearings The following procedure applies to all of the NOTE: connecting rods.
  • Page 275 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT • P –P refer to the bearings shown in the crank- NOTE: shaft illustration. • Do not move the connecting rod or crankshaft until the clearance measurement has been completed.
  • Page 276: Installing The Connecting Rods

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT EAS26150 INSTALLING THE CONNECTING RODS Crankshaft journal diameter 1. Lubricate: 49.968–49.980 mm (1.9672– • Bolt threads 1.9677 in) (with the recommended lubricant) Recommended lubricant Molybdenum disulfide grease 2.
  • Page 277: Installing The Crankshaft Assembly

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT EWA3D81006 4. Tighten: WARNING • Connecting rod nuts When a bolt is tightened more than the spec- M MMM M MMM M MMM M MMM M MMM ified angle, do not loosen and then retighten EWA3D81005 WARNING...
  • Page 278 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-65. Long shift fork guide bar Short shift fork guide bar Shift drum assembly Shift fork 1...
  • Page 279 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 Circlip 2nd pinion gear Circlip 3rd/4th pinion gear Circlip Toothed washer 5th pinion gear Collar Main axle/1st pinion gear For assembly, reverse the disassembly pro- cedure.
  • Page 280 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 Washer 1st wheel gear Collar 5th wheel gear Circlip Toothed washer 4th wheel gear Toothed spacer Toothed lock washer Toothed lock washer retainer 3rd wheel gear...
  • Page 281: Transmission

    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 2nd wheel gear Collar Drive axle For assembly, reverse the disassembly pro- cedure. 5-82 email: info@motomatrix.co.uk...
  • Page 282: Checking The Shift Forks

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION EAS26260 EAS26270 CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY The following procedure applies to all of the shift 1. Check: forks and shift fork guide bars. •...
  • Page 283: Assembling The Main Axle And Drive Axle

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION 3. Check: 2. Install: • Transmission gears • Toothed lock washer retainer “1” Blue discoloration/pitting/wear → Replace • Toothed lock washer “2” the defective gear(s). NOTE: •...
  • Page 284 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION 2. Check: • Transmission Rough movement → Repair. NOTE: • Apply engine oil to each gear and bearing thor- oughly. • Before assembling the crankcase, make sure that the transmission is in neutral and that the gears turn freely.
  • Page 285: 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 THERMOSTAT ....................6-4 CHECKING THE THERMOSTAT.............. 6-6 INSTALLING THE THERMOSTAT ASSEMBLY ........6-6 WATER PUMP....................6-7 DISASSEMBLING THE WATER PUMP............
  • Page 286: Radiator

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys RADIATOR EAS26380 RADIATOR Removing the radiator 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 287 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys RADIATOR Removing the radiator 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 288: 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 radia- tor. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flathead screwdriver.
  • Page 289: Thermostat

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 290 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THERMOSTAT Removing the thermostat 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 291: Checking The Thermostat

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THERMOSTAT EAS26450 2. Check: CHECKING THE THERMOSTAT • Thermostat housing cover 1. Check: • Thermostat housing • Thermostat • Thermostat pipes Does not open at 82–95 °C (179.6–203.0 °F) •...
  • Page 292: Water Pump

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys WATER PUMP EAS26500 WATER PUMP Removing the water pump 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 293 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys WATER PUMP Removing the water pump 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 294: Disassembling The Water Pump

    • Install the water pump seal with the special Remove the bearing and oil seal from the inside tools. of the water pump housing. • Before installing the water pump seal, apply Yamaha bond No.1215 (Three Bond No.1215®) “2” to the water pump housing “3”. email: info@motomatrix.co.uk...
  • Page 295 0.15 mm (0.006 in) Water pump seal installer YM-33221-A Middle driven shaft bearing driv- 90890-04058 Bearing driver 40 mm YM-04058 Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 1. Straightedge 2. Impeller A. Push down 4. Mechanical seal installer 5. Middle driven shaft bearing driver 3.
  • Page 296 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys WATER PUMP 6-11 email: info@motomatrix.co.uk...
  • Page 297: 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 ..............7-4 REMOVING THE FUEL PUMP ..............7-4 CHECKING THE FUEL COCK..............7-4 CHECKING THE FUEL COCK OPERATION..........7-4 CHECKING THE FUEL PUMP BODY............
  • Page 298 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 23 Nm (2.3 m kg, 17 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 299 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK Removing the sub-fuel tank 10 Nm (1.0 m kg, 7.2 ft • • ( 3 ) ( 3 ) ( 3 ) ( 6 ) 6 Nm (0.6 m kg, 4.3 ft •...
  • Page 300 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK Removing the rollover valve Order Job/Parts to remove Q’ty Remarks Fuel tank/Side panels Refer to “FUEL TANK” on page 7-1. Front cylinder covers Refer to “ENGINE REMOVAL” on page 5-1. Fuel tank breather hose Fuel tank breather hose (hose joint to rollover valve)
  • Page 301: Fuel Tank

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK EAS3D81001 2. Check: REMOVING THE FUEL TANK • Fuel cock strainer 1. Extract the fuel in the fuel tank through the Obstruction → Clean. fuel tank cap with a pump. Blow out the jets with compressed air.
  • Page 302: Installing The Fuel Pump

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK • To install the fuel hose onto the fuel pump, slide the fuel hose connector cover “1” on the end of the hose in the direction of the arrow shown.
  • Page 303 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle body and ISC (idle speed control) unit 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
  • Page 304: Throttle Bodies

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES Removing the intake manifold assembly 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 4 Nm (0.4 m kg, 2.9 ft •...
  • Page 305 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES Disassembling the intake manifold 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Front cylinder injector coupler Disconnect. Rear cylinder injector coupler Disconnect.
  • Page 306: Checking The Injectors

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES EAS26980 CHECKING THE INJECTORS Pressure gauge 1. Check: 90890-03153 • Injectors YU-03153 Damage → Replace. Fuel pressure adapter 90890-03176 EAS26990 YM-03176 CHECKING THE THROTTLE BODIES 1.
  • Page 307: Installing The Intake Manifold Assembly

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES c. Turn the main switch to “ON”. NOTE: d. Measure the throttle position sensor output Make sure that the projection “b” on the rear cyl- voltage.
  • Page 308 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES 7-11 email: info@motomatrix.co.uk...
  • Page 309: 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 ................8-4 ELECTRIC STARTING SYSTEM ..............8-7 CIRCUIT DIAGRAM .................. 8-7 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......
  • Page 310 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS..............8-79 CHECKING THE SWITCHES ..............8-83 CHECKING THE BULBS AND BULB SOCKETS ........8-86 CHECKING THE FUSES ................ 8-87 CHECKING AND CHARGING THE BATTERY........8-87 CHECKING THE RELAYS ..............
  • Page 311 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
  • Page 312: 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 313 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IGNITION SYSTEM 3. Main fuse 5. Main switch 6. Battery 13.Relay unit 17.Neutral switch 19.Sidestand switch 21.Crankshaft position sensor 25.Lean angle sensor 28.ECU (engine control unit) 29.Rear cylinder ignition coil 30.Front cylinder ignition coil 31.Spark plug 69.Engine stop switch...
  • Page 314: Engine Stopping Due To Sidestand Operation

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IGNITION SYSTEM EAS3D81009 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 315: Troubleshooting

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3.
  • Page 316 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IGNITION SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch/immobilizer unit. SWITCHES” on page 8-83. OK ↓ NG → 9. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch.
  • Page 317 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IGNITION SYSTEM email: info@motomatrix.co.uk...
  • Page 318: 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 Sb/W L/W R Sb/W L/W L R/L L/R L/G L/Y Sb B/R B/R (GRAY) (BLACK) B L/G (BLACK) (BLACK) R/L B...
  • Page 319 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTING SYSTEM 3. Main fuse 5. Main switch 6. Battery 8. Starter relay 9. Starter motor 10.Diode 1 13.Relay unit 14.Starting circuit cut-off relay 16.Diode 2 17.Neutral switch 19.Sidestand switch 55.Clutch switch...
  • Page 320: Starting Circuit Cut-Off System Operation

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTING SYSTEM EAS27180 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 321 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEUTRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2.
  • Page 322: Troubleshooting

    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. NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Fuel tank 4.
  • Page 323 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTING SYSTEM NG → 8. Check the diode 2. Refer to “CHECKING THE DI- Replace the diode 2. ODES” on page 8-93. OK ↓ NG → 9.
  • Page 324: Charging System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM Sb/W L/W R Sb/W B/R B/R (GRAY) (BLACK) (BLACK) (BLACK) R/L B (DARK GREEN) L W/Y P O/R (BLACK) Br/R Br/R (BLACK)
  • Page 325 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 3. Main fuse 6. Battery 8-14 email: info@motomatrix.co.uk...
  • Page 326: Troubleshooting

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Rectifier/regulator cover NG →...
  • Page 327 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHARGING SYSTEM 8-16 email: info@motomatrix.co.uk...
  • Page 328: 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 329 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LIGHTING SYSTEM 3. Main fuse 5. Main switch 6. Battery 28.ECU (engine control unit) 39.Multi-function meter 42.High beam indicator light 45.Meter light 51.Headlight relay 53.Pass switch 54.Dimmer switch 62.Headlight 63.Auxiliary light 64.Accessory light (OPTION)
  • Page 330: Troubleshooting

    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, license plate light, meter light, auxiliary light and accessory light (OPTION). NOTE: •...
  • Page 331 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LIGHTING SYSTEM NG → 8. Check the entire lighting system’s wiring. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM” on tem’s wiring. page 8-17. OK ↓...
  • Page 332: 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 333 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM 3. Main fuse 4. Backup fuse (odometer, clock and immobilizer system) 5. Main switch 6. Battery 13.Relay unit 17.Neutral switch 20.Speed sensor 26.Coolant temperature sensor 28.ECU (engine control unit) 36.Fuel level warning light 37.Oil level warning light...
  • Page 334: Troubleshooting

    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 335 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM NG → 3. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 8-21. OK ↓ This circuit is OK.
  • Page 336 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM NG → 3. Check the hazard switch. The hazard switch is faulty. Replace the Refer to “CHECKING THE right handlebar switch. SWITCHES” on page 8-83. OK ↓...
  • Page 337 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM NG → 2. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 8-21. OK ↓ Replace the meter assembly.
  • Page 338 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM NG → 2. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 8-21. OK ↓ Replace the ECU or meter assembly.
  • Page 339 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM 8-28 email: info@motomatrix.co.uk...
  • Page 340: Cooling System

    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 341 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM 3. Main fuse 5. Main switch 6. Battery 11.Radiator fan motor fuse 26.Coolant temperature sensor 28.ECU (engine control unit) 74.Radiator fan motor 76.Radiator fan motor relay 78.Ignition fuse 8-30 email: info@motomatrix.co.uk...
  • Page 342: Troubleshooting

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM EAS27320 TROUBLESHOOTING The radiator fan motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Fuel tank 4.
  • Page 343 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM 8-32 email: info@motomatrix.co.uk...
  • Page 344: 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 345 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM 3. Main fuse 5. Main switch 6. Battery 7. Fuel injection system fuse 13.Relay unit 15.Fuel pump relay 16.Diode 2 17.Neutral switch 18.Fuel pump 19.Sidestand switch 20.Speed sensor 21.Crankshaft position sensor...
  • Page 346: Ecu Self-Diagnostic Function

    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 en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
  • Page 347: Self-Diagnostic Function Table

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM a. Main switch “OFF” d. Engine trouble warning light on for 1.4 seconds b. Main switch “ON” c. Engine trouble warning light off EAS27380 SELF-DIAGNOSTIC FUNCTION TABLE If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that...
  • Page 348 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive Rear cylinder intake Rear cylinder intake air pressure air pressure sensor sensor: open or short circuit de- Able...
  • Page 349: Troubleshooting Method

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Communication error with the meter Able / un- Fault Able / un- Item Symptom able to code No. able to start drive ECU internal malfunc- No signals are received from the Er-1 tion...
  • Page 350: Diagnostic Mode

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS27420 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 351 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM 8. Turn the main switch to “OFF” to cancel the diagnostic mode. Diagnostic code table Fault Diagnostic code Symptom Probable cause of malfunction code No. •...
  • Page 352 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in wire harness. Malfunction detected in the • Malfunction in front cylinder ignition coil. primary wire of the front •...
  • Page 353 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in wire harness. • Malfunction in meter. No signals are received Er-1 •...
  • Page 354 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 Vehicle speed pulse 0–999 Check that the number in- creases when the rear wheel is rotated. The num- ber is cumulative and does not reset each time the wheel is stopped.
  • Page 355 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 Malfunction history code erasure • No history — • History exists Up to 25 fault codes To erase the history, set the engine stop switch to “...
  • Page 356: Troubleshooting Details

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the radiator fan mo- tor relay for five cycles of five seconds. (ON 2 seconds, Check the operating sound Radiator fan motor relay OFF 3 seconds) of the radiator fan motor re-...
  • Page 357 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the crankshaft posi- tion sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause...
  • Page 358 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Front cylinder intake air pressure sensor: open or short circuit detected. Diagnostic code No. Front cylinder intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement...
  • Page 359 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Front cylinder intake air pressure sensor: hose system malfunction (clogged or detached hose). Diagnostic code No. Front cylinder intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement...
  • Page 360 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor: open or short circuit detected. Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method...
  • Page 361 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom A break or disconnection of the blue/black lead of the ECU is detected. Diagnostic code No. Sidestand switch Order Item/components and probable Check or maintenance job Reinstatement cause...
  • Page 362 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Air temperature sensor: open or short circuit detected. Diagnostic code No. Air temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method...
  • Page 363 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom No normal signal is received from the O sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method...
  • Page 364 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Rear cylinder intake air pressure sensor: open or short circuit detected. Diagnostic code No. Rear cylinder intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement...
  • Page 365 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Rear cylinder intake air pressure sensor: hose system malfunction (clogged or detached hose). Diagnostic code No. Rear cylinder intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement...
  • Page 366 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the front cylin- der ignition coil. Diagnostic code No. 30, 32 Front cylinder ignition coil Order Item/components and probable Check or maintenance job Reinstatement...
  • Page 367 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the rear cylin- der ignition coil. Diagnostic code No. 31, 33 Rear cylinder ignition coil Order Item/components and probable Check or maintenance job Reinstatement...
  • Page 368 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Engine speed is high when the engine is idling. Diagnostic code No. ISC valve Order Item/components and probable Check or maintenance job Reinstatement cause method...
  • Page 369 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Lean angle sensor: open or short circuit detected. Diagnostic code No. Lean angle sensor Order Item/components and probable Check or maintenance job Reinstatement cause method...
  • Page 370 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. Diagnostic code No. Speed sensor Neutral switch Order Item/components and probable...
  • Page 371 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. Diagnostic code No. Speed sensor Neutral switch Order Item/components and probable...
  • Page 372 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom The ECU is unable to monitor the battery voltage (an open or short circuit in the line to the ECU). Diagnostic code No.
  • Page 373 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the fuel injection system is not normal. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method...
  • Page 374 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signals are received from the ECU. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method...
  • Page 375 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method...
  • Page 376: 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 8-65 email: info@motomatrix.co.uk...
  • Page 377 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL PUMP SYSTEM 3. Main fuse 5. Main switch 6. Battery 7. Fuel injection system fuse 15.Fuel pump relay 16.Diode 2 18.Fuel pump 28.ECU (engine control unit) 69.Engine stop switch 78.Ignition fuse 8-66...
  • Page 378: Troubleshooting

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING The fuel pump fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Fuel tank 4.
  • Page 379 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL PUMP SYSTEM NG → 8. Check the entire fuel pump sys- tem’s wiring. Properly connect or repair the fuel pump Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 8-65.
  • Page 380: Immobilizer System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 8-69 email: info@motomatrix.co.uk...
  • Page 381 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM 3. Main fuse 4. Backup fuse (odometer, clock and immobilizer system) 5. Main switch 6. Battery 12.Immobilizer unit 28.ECU (engine control unit) 39.Multi-function meter 44.Immobilizer system indicator light 78.Ignition fuse 8-70 email: info@motomatrix.co.uk...
  • Page 382: General Information

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM EAS27670 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 383 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM Parts to be replaced Main switch/immo- Key registration re- Accesso- bilizer unit Standard quirement ry lock* Main Immobiliz- and key switch er unit √ Standard key is lost New standard key All keys have been Code re-registering...
  • Page 384 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM Standby mode a. Main switch “ON” e. Standby mode on b. Main switch “OFF” f. Standby mode off c. LED on d. LED off 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 385 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM Standard key registration a. Main switch “ON” B. Immobilizer system indicator light stops flashing when the registration of the second b. Main switch “OFF” standard key is complete. c.
  • Page 386: Troubleshooting

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM EAS27700 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. NG → 1. Check the fuses. (Main, ignition, and backup) Replace the fuse(s).
  • Page 387 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code IMMOBILIZER Codes between the 1. Signal received from 1. Place the immo- UNIT key and immobilizer other transponder bilizer unit at unit do not match.
  • Page 388 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM a. Light on b. Light off 8-77 email: info@motomatrix.co.uk...
  • Page 389 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM 8-78 email: info@motomatrix.co.uk...
  • Page 390: Electrical Components

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 8-79 email: info@motomatrix.co.uk...
  • Page 391 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 1. Coolant temperature sensor 2. Front cylinder intake air pressure sensor 3. Rear cylinder intake air pressure sensor 4. Rear cylinder ignition coil 5. Front cylinder ignition coil 6.
  • Page 392 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 8-81 email: info@motomatrix.co.uk...
  • Page 393 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 1. Main switch 2. Rectifier/regulator 3. Fuse box 4. Headlight fuse 5. Backup fuse 6. Radiator fan motor fuse 7. Parking lighting fuse 8. Ignition fuse 9.
  • Page 394: Checking The Switches

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES Br/R Br/L Br/R (BLACK) Br/L L/Y B/Y (BLACK) (BLACK) Br/W Br/W Y/G B/Y (BLUE) RESET B/Y P P/W P/B Br/W Br/W 8-83 email: info@motomatrix.co.uk...
  • Page 395 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 1. Main switch 2. Rear brake light switch 3. Front brake light switch 4. Reset switch 5. Select switch 6. Engine stop switch 7. Start switch 8.
  • Page 396 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 CAUTION: Never insert the tester probes into the coupler terminal slots “a”.
  • Page 397: Checking The Bulbs And Bulb Sockets

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS EAS27990 EWA13320 CHECKING THE BULBS AND BULB WARNING SOCKETS Since the headlight bulb gets extremely hot, Check each bulb and bulb socket for damage or keep flammable products and your hands wear, proper connections, and also for continuity away from the bulb until it has cooled down.
  • Page 398: Checking The Fuses

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS Checking the condition of the bulb sockets 3. Replace: The following procedure applies to all of the bulb • Blown fuse sockets. M MMM M MMM M MMM M MMM M MMM...
  • Page 399 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS • Charge batteries in a well-ventilated area. ECA3D81022 CAUTION: • Keep batteries away from fire, sparks or First, disconnect the negative battery lead open flames (e.g., welding equipment, “1”, then the positive battery lead “2”.
  • Page 400 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS • To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery. • Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger.
  • Page 401 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS NOTE: NOTE: Set the charging voltage to 16–17 V. If the set- If the current is lower than the standard charging ting is lower, charging will be insufficient. If too current written on the battery, this type of battery high, the battery will be overcharged.
  • Page 402: Checking The Relays

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 10.Install: Relay unit (starting circuit cut-off relay) • Rider seat • Tool kit tray Refer to “GENERAL CHASSIS” on page 4-1. EAS28040 CHECKING THE RELAYS Check each relay for continuity with the pocket tester.
  • Page 403: Checking The Turn Signal Relay

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS Headlight relay M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (DC 20 V) to the turn signal relay terminal as shown. Pocket tester 90890-03112 Analog pocket tester...
  • Page 404: Checking The Diodes

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS Continuity Positive tester probe → sky blue “1” Negative tester probe → black/yellow “2” No continuity Positive tester probe → black/yellow “2” Negative tester probe → sky blue “1”...
  • Page 405: Checking The Ignition Spark Gap

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS c. Check the relay unit (diode) for continuity. Pocket tester d. Check the relay unit (diode) for no continuity. 90890-03112 L LLL L LLL L LLL L LLL L LLL Analog pocket tester...
  • Page 406: Checking The Spark Plug Caps

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM a. Disconnect the spark plug cap from the spark plug. b. Connect the ignition checker “1” as shown. Ignition checker 90890-06754 Opama pet-4000 spark checker...
  • Page 407: Checking The Crankshaft Position Sensor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS • Positive tester probe → Secondary coil resistance gray “1” 8.64–12.96 kΩ • Negative tester probe → black “2” M MMM M MMM M MMM M MMM M MMM a.
  • Page 408: Checking The Starter Motor Operation

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS EAS28150 CHECKING THE STATOR COIL 1. Disconnect: • Stator coil coupler (from the wire harness) 2. Check: • Stator coil resistance Out of specification → Replace the crank- shaft position sensor/stator assembly.
  • Page 409: Checking The Horn

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS • Positive tester probe → Charging voltage horn terminal “1” 14 V at 5000 r/min • Negative tester probe → horn terminal “2” M MMM M MMM M MMM M MMM...
  • Page 410: Checking The Fuel Sender

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (Ω × 100) to the oil Pocket tester 90890-03112 level switch terminal as shown. Analog pocket tester Pocket tester YU-03112-C...
  • Page 411: Checking The Speed Sensor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 1. Check: b. Set the main switch to “ON”. • Oil level warning light “1” c. Elevate the rear wheel and slowly rotate it. (Turn the main switch to “ON”.) d.
  • Page 412: Checking The Throttle Position Sensor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS • Positive tester probe → M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (Ω × 100) to the blue “1”...
  • Page 413: Checking The Air Temperature Sensor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS b. Immerse the air temperature sensor “1” in a container filled with water “2”. NOTE: Make sure that the air temperature sensor termi- nals do not get wet. c.
  • Page 414 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 8-103 email: info@motomatrix.co.uk...
  • Page 415: 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................
  • Page 416: Troubleshooting

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TROUBLESHOOTING EAS28450 4. Throttle body(-ies) TROUBLESHOOTING • Deteriorated or contaminated fuel • Sucked-in air EAS28460 GENERAL INFORMATION Electrical system NOTE: 1. Battery The following guide for troubleshooting does not •...
  • Page 417: Poor Medium-And-High-Speed Performance

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TROUBLESHOOTING Fuel system • Bent shift fork guide bar 1. Throttle body(-ies) Transmission • Damaged or loose throttle body joint • Seized transmission gear • Improperly synchronized throttle bodies •...
  • Page 418: Overheating

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TROUBLESHOOTING EAS28600 EAS28610 OVERHEATING OVERCOOLING Engine Cooling system 1. Clogged coolant passages 1. Thermostat • Cylinder head(s) and piston(s) • Thermostat stays open • Heavy carbon buildup EAS28620 2.
  • Page 419: Faulty Lighting Or Signaling System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TROUBLESHOOTING • Unevenly tensioned fork spring (both front • Faulty battery fork legs) • Incorrectly adjusted rear brake light switch • Broken fork spring • Tail/brake light bulb life expired •...
  • Page 420: Wiring Diagram

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS28740 53. Pass switch EAS28750 WIRING DIAGRAM COLOR CODE 54. Dimmer switch Black 55. Clutch switch XVS1300A(W) 2007 Brown 56. Turn signal switch 1. AC magneto Chocolate 57.
  • Page 421 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
  • Page 422 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN email: info@motomatrix.co.uk...
  • Page 423 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys XVS1300A(W) 2007 XVS1300A(W) 2007 XVS1300A(W) 2007 XVS1300A(W) 2007 XVS1300A(W) 2007 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO R/B R/G R/Y W/L Gy W W Gy Br/L Sb/W L/W R...
  • Page 424 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys XVS1300A(W) 2007 XVS1300A(W) 2007 XVS1300A(W) 2007 XVS1300A(W) 2007 XVS1300A(W) 2007 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO WIRE HARNESS SUB-WIREHARNESS WIRE HARNESS SUB-WIREHARNESS WIRE HARNESS TAIL BRAKE LIGHT WIRE HARNESS (GRAY) (BLACK)

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Xvs1300aw 2007