Yamaha XT1200Z 2010 Service Manual
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Yamaha XT1200Z 2010 Service Manual

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Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys
2010
SERVICE MANUAL
XT1200Z(Z)
23P-28197-E0
email: info@motomatrix.co.uk

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  • Page 1 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 2010 SERVICE MANUAL XT1200Z(Z) 23P-28197-E0 email: info@motomatrix.co.uk...
  • Page 2 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS20040 XT1200Z(Z) 2010 SERVICE MANUAL ©2010 by Yamaha Motor Co., Ltd. First edition, March 2010 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
  • Page 3 EAS20071 IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha 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 EAS20091 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 EAS20101 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil...
  • 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

    MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 YCC-T (Yamaha Chip Controlled Throttle)..........1-4 OUTLINE OF THE UBS ................1-6 OUTLINE OF THE ABS................1-10 ABS COMPONENT FUNCTIONS ............1-15 UBS AND ABS OPERATION ..............1-20 ABS SELF-DIAGNOSIS FUNCTION............

  • 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 frame. EAS20150 MODEL LABEL The model label “1” is affixed to the frame under the rider seat.

  • Page 11: Features

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES EAS20170 FEATURES EAS30340 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the 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 EAS23P1100 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 324 kPa (3.24 kgf/cm², 47.0 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: Ycc-T (Yamaha Chip Controlled Throttle)

    Yamaha developed the YCC-T system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles, but Yamaha has developed a fast- er, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed system has a high-speed calculating capacity that produces computations of running conditions every 1/1000th of a second.
  • Page 14 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES YCC-T system outline 1. Throttle position sensor 2. Throttle servo motor 3. Accelerator position sensor 4. ECU (engine control unit) 5. YCC-T CPU 6. FI CPU 7.

  • Page 15: Outline Of The Ubs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES EAS23P1060 OUTLINE OF THE UBS This model is equipped with a unified brake system (UBS) that operates the rear brake when the brake lever is squeezed. When the brake lever is squeezed, the rear brake force is controlled electronically according to the brake lever input (hydraulic pressure) and vehicle speed (deceleration).
  • Page 16 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES • Brake lever input and brake pedal input: Front braking and rear braking (with and without UBS oper- ation) Brake lever and brake pedal both operated A.
  • Page 17 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES When the brake lever is squeezed, the front brake master cylinder pressure sensor in the hydraulic unit detects the hydraulic pressure. The ABS ECU calculates the appropriate rear brake force according to the detected hydraulic pressure and sends a signal to the rear brake hydraulic pump.
  • Page 18 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES a. Hydraulic pressure distribution b. Rear brake output (bars) c. Front brake input (bars) d. Rider only e. When carrying the maximum load f. Vehicle speed coefficient g.

  • Page 19: Outline Of The Abs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES EAS23P1061 OUTLINE OF THE ABS 1. This model is equipped with the latest, advanced type of ABS, which has improved feeling during operation and smoother braking than previous ABS brakes. The ABS ECU detects the hydraulic pressure using the pressure sensors and controls the pressure linearly using continuously variable adjustments to obtain the appropriate pressure when the wheels have a tendency to lock or accord- ing to the operation input (hydraulic pressure) from the brake lever or brake pedal.
  • Page 20 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES Useful terms • Wheel speed: The rotation speed of the front and rear wheels. • Chassis speed: The speed of the chassis. When the brakes are applied, wheel speed and chassis speed are reduced. However, the chassis travels forward by its inertia even though the wheel speed is reduced.
  • Page 21 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES a. Friction force between the tire and road e. Less slippery road surface surface f. Controlling zone b. Brake force g. Slippery road surface c. Side force d.
  • Page 22 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES a. Chassis speed d. Depressurizing phase b. Wheel speed e. Pressurizing phase c. Brake force ABS operation and vehicle control If the ABS starts operating, there is a tendency of the wheel to lock, and the vehicle is approaching the limit of control.
  • Page 23 Slip ratio (%) b. Brake force Electronic ABS features The Yamaha ABS (anti-lock brake system) has been developed with the most advanced electronic technology. The ABS also includes a highly developed self-diagnosis function. The ABS has been designed to op- erate as a conventional brake system if the ABS malfunctions.

  • Page 24: Abs Component Functions

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES ABS block diagram 1. Front brake master cylinder 10. Front brake master cylinder pressure sensor 2. Rear brake master cylinder 11. Check valve 3. Hydraulic unit assembly 12.
  • Page 25 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES 3. At low speed 7. Voltage 4. At high speed 8. Time 5. Wheel sensor 6. Wheel sensor rotor ABS warning light The ABS warning light “1” comes on to warn the rider if a malfunction in the ABS occurs. When the main switch is set to “ON”, the ABS warning light comes on for 2 seconds, then goes off, so that the rider can check if the ABS warning light is disconnected and check if the ABS is operating prop- erly.
  • Page 26 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES Hydraulic unit assembly The hydraulic unit assembly “1” is composed of hydraulic control valves (outlet solenoid valves, inlet solenoid valves, a shuttle solenoid valve, and a separation solenoid valve), buffer chambers, damping chambers, hydraulic pumps, an ABS motor, hydraulic pressure sensors (front brake master cylinder pressure sensor, rear brake master cylinder pressure sensor, and rear brake caliper pressure sensor), and an ABS ECU.
  • Page 27 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES 4 5 6 18 19 20 21 1. Battery 18. Rear brake inlet solenoid 2. AC magneto 19. Rear brake outlet solenoid 3. Rectifier/regulator 20. Separation solenoid valve 4.
  • Page 28 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES • The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was set to “ON”. During this test, a “clicking” noise can be heard from under the seat, and if the brake lever or brake pedal is even slightly operated, a vibration can be felt at the lever and pedal, but these do not indicate a malfunction.

  • Page 29: Ubs And Abs Operation

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES EAS23P1063 UBS AND ABS OPERATION The ABS hydraulic circuit consists of two systems: one for the front wheel and one for the rear wheel. Normal braking (ABS not activated and UBS not activated) Front brakes: When the ABS is not activated, the inlet solenoid valve is open and the outlet solenoid valve is closed because a control signal has not been transmitted from the ABS ECU.
  • Page 30 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES Emergency braking (ABS activated and UBS not activated) Depressurizing phase: When the front wheel (or the rear wheel) is about to lock, the outlet solenoid valve is opened by the “depressurization”...
  • Page 31 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES UBS (ABS not activated and UBS activated) Brake lever input only Front brakes: When the ABS is not activated, the inlet solenoid valve is open and the outlet solenoid valve is closed because a control signal has not been transmitted from the ABS ECU.
  • Page 32 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES UBS (ABS activated and UBS activated) Brake lever input only Front brakes: Refer to “Emergency braking (ABS activated and UBS not activated)”. Rear brake: When the rear wheel is about to lock, the outlet solenoid valve is opened by the “depressurization” sig- nal transmitted from the ABS ECU.

  • Page 33: Abs Self-Diagnosis Function

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES EAS23P1064 ABS SELF-DIAGNOSIS FUNCTION ABS warning light The ABS warning light “1” comes on when a malfunction is detected by the ABS self-diagnosis. The ABS warning light is located on the meter assembly. Instances when the ABS warning light comes on 1.
  • Page 34 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES 3. The ABS warning light comes on while riding. If the ABS warning light comes on while riding, a malfunction has been detected in the ABS or UBS. The ABS hydraulic control will not be performed.

  • Page 35: Abs Warning Light And Operation

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES The ABS warning light comes on or flashes if the vehicle is ridden with the test coupler adapter con- nected to the ABS test coupler. EAS23P1065 ABS WARNING LIGHT AND OPERATION ABS warning light •...
  • Page 36 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES ABS and UBS function EWA23P1038 WARNING • When hydraulic control is performed by the ABS, the brake system alerts the rider that the wheels have a tendency to lock by generating a reaction-force pulsating action in the brake lever or brake pedal.

  • Page 37: Outline Of The Tcs (Traction Control System)

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES EAS23P1099 OUTLINE OF THE TCS (Traction Control System) The traction control system controls excessive spinning (slipping) of the rear wheel when accelerating on slippery surfaces, such as unpaved or wet roads. The ECU monitors the front and rear wheel speeds using the signals from the front and rear wheel sen- sors, and detects rear wheel slipping according to the difference between the wheel speeds.
  • Page 38 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES 1. Front wheel sensor D. Actuator control 2. Rear wheel sensor E. Fuel cut-off 3. ABS ECU (electronic control unit) F. Ignition timing (retarded) 4. Traction control system switch G.
  • Page 39 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES • “TCS” “Off”: The traction control system is turned off. The system may also be automatically disabled in some riding conditions (Refer to “Resetting”). When the key is turned to “ON”, the traction control system is enabled and “TCS” “1” displays in the multi-function meter.

  • Page 40: Instrument Functions

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES EAS23P1106 • a traction control system mode display (which INSTRUMENT FUNCTIONS shows the selected traction control system mode) Multi-function meter unit • a self-diagnosis device EWA23P1041 •...
  • Page 41 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES Odometer and tripmeter modes Clock 1. Odometer/tripmeter/fuel reserve tripmeter 1. Clock 2. Left set button 2. Right set button 3. Left set button Pushing the left button switches the display be- tween the odometer mode “ODO”...
  • Page 42 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES Air intake temperature mode This fuel meter is equipped with a self-diagnosis system. If a problem is detected in the electrical circuit, all display segments start flashing. If this occurs, check the electrical circuit.
  • Page 43 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES Instantaneous fuel consumption mode • The “AVE_ _._ km/L” display shows the aver- age distance that can be traveled on 1.0 L of fuel. • The “AVE_ _._ L/100 km” display shows the average amount of fuel necessary to travel 100 •...
  • Page 44 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES This display indicates which traction control sys- EWA23P1042 NOTICE tem mode has been selected: “1”, “2” or “Off”. If the display indicates a fault code, the vehi- For more details on the modes and on how to cle should be checked as soon as possible select them, refer to “TCS (Traction Control Sys-...
  • Page 45 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES 1. Drive mode switch “MODE” Before using D-mode, make sure you under- stand its operation along with the operation of the drive mode switch. Touring mode “T” The touring mode “T”...

  • Page 46: 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 47: Bearings And Oil Seals

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMPORTANT INFORMATION EAS20231 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease.

  • Page 48: Basic Service Information

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys BASIC SERVICE INFORMATION EAS30380 BASIC SERVICE INFORMATION EAS30390 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out.

  • Page 49: Electrical System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys BASIC SERVICE INFORMATION ECA16760 EAS30402 NOTICE ELECTRICAL SYSTEM Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- Electrical parts handling tery lead connections could damage the ECA16600 NOTICE electrical components.
  • Page 50 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys BASIC SERVICE INFORMATION ECA16620 Checking the electrical system NOTICE Handle electrical components with special Before checking the electrical system, make care, and do not subject them to strong sure that the battery voltage is at least 12 V.
  • Page 51 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys BASIC SERVICE INFORMATION 2. Check: Checking the connections • Lead Check the leads, couplers, and connectors for • Coupler stains, rust, moisture, etc. • Connector 1. Disconnect: Moisture →...
  • Page 52 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys BASIC SERVICE INFORMATION • As a quick remedy, use a contact revitalizer available at most part stores. 4. Connect: • Lead • Coupler • Connector • When connecting a coupler or connector, push both sections of the coupler or connector to- gether until they are connected securely.

  • Page 53: 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 54 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Steering nut wrench 3-20, 4-94 90890-01403 Exhaust flange nut wrench YU-A9472 Oil filter wrench 3-25, 5-87 90890-01426 YU-38411 Oil pressure gauge set 3-26 90890-03120 Oil pressure adapter B...
  • Page 55 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod puller attachment (M10) 4-89 90890-01436 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Ring gear fix bolt (M14) 4-110 90890-01548 YM-01548...
  • Page 56 Pivot shaft wrench 90890-01485 Frame mount insert wrench YM-01485 Rotor holding tool 5-17, 5-20 90890-01235 Universal magneto & rotor holder YU-01235 Yamaha bond No. 1215 5-23, 5-47, 90890-85505 5-88 (Three Bond No.1215®) Valve spring compressor 5-30, 5-35 90890-04019 YM-04019 Valve spring compressor attachment...
  • Page 57 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide remover & installer set (ø5.5) 5-32 90890-04016 Valve guide remover (5.5 mm) YM-01122 Valve guide installer (ø5.5) 5-32 90890-04015 Valve guide installer (5.5 mm)
  • Page 58 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Universal clutch holder 5-60, 5-63 90890-04086 YM-91042 Slide hammer bolt 5-109 90890-01083 Slide hammer bolt 6 mm YU-01083-1 Weight 5-109 90890-01084 YU-01083-3...
  • Page 59 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Middle drive shaft nut wrench (55 mm) 5-118 90890-04054 Offset wrench 55 mm YM-04054 YM-04054 Middle gear backlash tool 5-121 90890-04080 Middle drive gear holder...
  • Page 60 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Middle driven shaft bearing driver 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 Pressure gauge 7-11 90890-03153 YU-03153 Fuel injector pressure adapter 7-11...

  • Page 61: 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 ................ 2-10 ELECTRICAL SPECIFICATIONS ..............2-13 TIGHTENING TORQUES ................2-16 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-16 ENGINE TIGHTENING TORQUES............2-17 CHASSIS TIGHTENING TORQUES............

  • Page 62: General Specifications

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 23P1 (Europe except (B) and (F)) (ZA) 23P2 (B) (F) 23P3 (AUS) Dimensions Overall length 2255 mm (88.8 in) Overall width 980 mm (38.6 in) Overall height 1410 mm (55.5 in)

  • Page 63: Engine Specifications

    9.4 psi/1100 r/min) at oil temperature of 65.0– 75.0 °C (149.00–167.00 °F) Final gear oil Type Yamaha genuine shaft drive gear oil SAE 80 API GL-5 or SAE 80 API GL-4 Hypoid gear oil Quantity 0.20 L (0.21 US qt, 0.18 Imp.qt)
  • Page 64 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Oil-pump-housing-to-inner-and-outer-rotor clearance (scavenging pump) 0.06–0.13 mm (0.0024–0.0051 in) Limit 0.20 mm (0.0079 in) Relief valve operating pressure 540.0–660.0 kPa (5.40–6.60 kgf/cm², 78.3–95.7 psi) Cooling system Radiator capacity (including all routes) 1.83 L (1.93 US qt, 1.61 Imp.qt) Coolant reservoir capacity (up to the maximum level...
  • Page 65 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Limit 29.850 mm (1.1752 in) Camshaft runout limit 0.030 mm (0.0012 in) Timing chain Tensioning system Automatic Valve, valve seat, valve guide Valve clearance (cold) Intake 0.10–0.16 mm (0.0039–0.0063 in) Exhaust...
  • Page 66 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Valve stem diameter (exhaust) 5.460–5.475 mm (0.2150–0.2156 in) Limit 5.430 mm (0.2138 in) Valve guide inside diameter (intake) 5.500–5.512 mm (0.2165–0.2170 in) Limit 5.550 mm (0.2185 in) Valve guide inside diameter (exhaust) 5.500–5.512 mm (0.2165–0.2170 in) Limit...
  • Page 67 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Diameter D 97.965–97.980 mm (3.8569–3.8575 in) Height H 8.0 mm (0.31 in) Offset 0.50 mm (0.0197 in) Offset direction Intake side Piston pin bore inside diameter 22.004–22.015 mm (0.8663–0.8667 in) Limit 22.045 mm (0.8679 in)
  • Page 68 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Crankshaft Width A 165.60–166.40 mm (6.520–6.551 in) Width B 67.75–68.25 mm (2.67–2.69 in) Runout limit C 0.020 mm (0.0008 in) Big end side clearance D 0.160–0.262 mm (0.0063–0.0103 in) Journal oil clearance 0.020–0.044 mm (0.0008–0.0017 in)
  • Page 69 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS 25/24 (1.042) 26/28 (0.929) 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 Shift drum and guide bar Shift fork guide bar bending limit 0.100 mm (0.0039 in)
  • Page 70 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Final gear backlash 0.20–0.40 mm (0.008–0.016 in) email: info@motomatrix.co.uk...

  • Page 71: Chassis Specifications

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Steel tube backbone Caster angle 28.00° Trail 126.0 mm (4.96 in) Front wheel Wheel type Spoke wheel 19M/C × MT2.50 Rim size Rim material Aluminum...
  • Page 72 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS SPECIFICATIONS Brake disc thickness limit 4.0 mm (0.16 in) Brake disc deflection limit 0.10 mm (0.0039 in) Brake pad lining thickness (inner) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Brake pad lining thickness (outer)
  • Page 73 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS SPECIFICATIONS Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions *With the adjusting screw fully turned in Minimum 10 click(s) out* Standard 8 click(s) out* Maximum 1 click(s) out* Compression damping adjusting positions...

  • Page 74: Electrical Specifications

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Ignition timing (B.T.D.C.) 5.0°/1100 r/min Engine control unit Model/manufacturer TBDF77/DENSO (Europe except (B) and (F)) (ZA) (AUS) TBDFD2/DENSO (B) (F) Ignition coil...
  • Page 75 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SPECIFICATIONS Engine trouble warning light ABS warning light Immobilizer system indicator light Traction control system indicator light Electric starting system System type Constant mesh Starter motor Power output 0.75 kW 0.0100–0.0200 Ω...
  • Page 76 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SPECIFICATIONS ABS solenoid fuse 20.0 A Backup fuse 7.5 A Electronic throttle valve fuse 7.5 A Accessory light fuse (OPTION) 20.0 A Spare fuse 30.0 A Spare fuse 20.0 A Spare fuse...

  • Page 77: Tightening Torques

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20331 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 78: 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 Exhaust pipe nut 20 Nm (2.0 m·kgf, 14 ft·lbf) Exhaust pipe bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) Exhaust pipe protector screw 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Exhaust pipe joint bolt...
  • Page 79 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Coolant drain bolt (water pump) 10 Nm (1.0 m·kgf, 7.2 ft·lbf) l=55 mm (2.17 in) Generator cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) l=25 mm Generator cover bolt...
  • Page 80 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 balancer holder bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) l=130 mm (5.12 in) Crankcase bolt See TIP. l=78 mm (3.07 in) Crankcase bolt...
  • Page 81 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 pipe bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Oil pump assembly bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Oil pump housing cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Oil strainer (oil pump) bolt...
  • Page 82 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES Crankcase bolt Tighten the crankcase bolts “1”–“6” to 10 Nm (1.0 m·kgf, 7.2 ft·lbf) in the proper tightening sequence. Then, retighten the bolts one at a time as follows: •...

  • Page 83: Chassis Tightening Torques

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (front right 75 Nm (7.5 m·kgf, 54 ft·lbf) side) Engine mounting bolt (front left 75 Nm (7.5 m·kgf, 54 ft·lbf) side) Engine mounting bolt (rear right...
  • Page 84 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine guard bracket bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Right side panel bolt 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) Right side inner panel bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Left side cowling bolt...
  • Page 85 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 master cylinder hold- 10 Nm (1.0 m·kgf, 7.2 ft·lbf) er bolt Brake master cylinder reservoir 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) cap bolt Brake lever pivot bolt 1.0 Nm (0.10 m·kgf, 0.72 ft·lbf)
  • Page 86 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 wheel sensor bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Rear wheel sensor rotor bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Rear brake disc bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) Spoke...
  • Page 87 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Swingarm pivot shaft end plate 6 Nm (0.6 m·kgf, 4.3 ft·lbf) bolt Rubber boot cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Rubber boot joint bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) Final drive assembly nut...
  • Page 88 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES 2-27 email: info@motomatrix.co.uk...

  • Page 89: Lubrication Points And Lubricant Types

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Camshaft lobes and camshaft journals Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Crankshaft big ends Piston surfaces...
  • Page 90 Lubrication point Lubricant Shift forks and shift fork guide bars Shift drum assembly Shift shaft washer Universal joint inner surface Yamaha genuine shaft drive oil SAE 80 Ring gear thrust washer API GL-5 or SAE 80 API GL-4 Hypoid gear oil...

  • Page 91: 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 Steering bearing oil seal lips Steering shaft and nut thread Front wheel oil seal lips (right and left) Rear wheel oil seal lip Rear wheel drive hub mating surface Rear brake pedal pivoting point and metal-to-metal moving parts...

  • Page 92: 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 2-31 email: info@motomatrix.co.uk...
  • Page 93 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pan (oil tank) 2. Oil strainer (oil pan) 3. Oil pump assembly 4. Oil pump (scavenging) 5. Oil pump (feed) 6.

  • Page 94: Lubrication Diagrams

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS Cylinder (right side view) and crankshaft (rear view) 2-33 email: info@motomatrix.co.uk...
  • Page 95 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil check bolt 2. Cylinder head 3. Cylinder 4. Upper crankcase 5. Timing chain tensioner 6. Intake camshaft 7. Exhaust camshaft 8.
  • Page 96 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS Crankcase (top view) and transmission (front view) 2-35 email: info@motomatrix.co.uk...
  • Page 97 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 passage cover 3. Front balancer shaft 4. Crankshaft 5. Drive axle 6. Middle driven pinion gear 7.
  • Page 98 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS Oil pump (right side view) 2-37 email: info@motomatrix.co.uk...
  • Page 99 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Shift fork-C 2. Shift fork-R 3. Shift fork-L 4. Oil pump assembly 5. Oil pan 6. Oil strainer (oil pump) 7. Shift fork upper guide bar 2-38 email: info@motomatrix.co.uk...
  • Page 100 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS Oil pump (left side view) 2-39 email: info@motomatrix.co.uk...
  • Page 101 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pump assembly 2. Oil filter cartridge 3. Oil strainer cover 4. Oil strainer (oil pan) 5. Oil pan 6. Lower crankcase 7.

  • Page 102: Cooling System Diagrams

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-41 email: info@motomatrix.co.uk...
  • Page 103 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator inlet hose 3. Radiator outlet hose 4. Radiator 5. Thermostat 6. Radiator outlet pipe 7. Water pump inlet hose 8.

  • Page 104: Cable Routing

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING EAS20430 CABLE ROUTING Headlight assembly (front and rear view) 2-43 email: info@motomatrix.co.uk...
  • Page 105 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Meter assembly lead 2. Front left turn signal light lead 3. Auxiliary DC jack 4. Front right turn signal light lead 5. Auxiliary DC jack lead 6.
  • Page 106 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING Handlebar (front view) 2-45 email: info@motomatrix.co.uk...
  • Page 107 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Right handlebar switch lead 2. Throttle cable (accelerator cable) 3. Throttle cable (decelerator cable) 4. Clutch hose 5. Left handlebar switch lead 6. Main switch lead 7.
  • Page 108 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING Front brake hose (left side view) 2-47 email: info@motomatrix.co.uk...
  • Page 109 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Clutch hose Q. Route the front wheel sensor lead, brake hose (hydraulic unit to left front brake caliper), and horn 2. Throttle cable (decelerator cable) lead in the order shown in the illustration.
  • Page 110 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING Front brake hose (left side view) 2-49 email: info@motomatrix.co.uk...
  • Page 111 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING AA.Route the immobilizer unit lead to the inside of the throttle cables. AB.Position the immobilizer unit coupler below the brake hose (front brake master cylinder to hydraulic unit).
  • Page 112 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING Fuel tank and throttle bodies (left side view) 2-51 email: info@motomatrix.co.uk...
  • Page 113 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Fuel tank overflow hose and fuel tank breather hose 2. Fuel tank 3. Fuel hose 4. Fuel pump 5. Air filter case 6. Cylinder head breather hose A.
  • Page 114 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING Coolant reservoir (rear and left side view) 2-53 email: info@motomatrix.co.uk...
  • Page 115 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Coolant reservoir hose 2. Coolant reservoir breather hose 3. Neutral switch lead 4. Coolant reservoir cap 5. Radiator 6. Radiator inlet hose 7. Clutch pipe 8.
  • Page 116 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING Engine (left side view) 2-55 email: info@motomatrix.co.uk...
  • Page 117 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Stator coil lead Q. Route the fuel tank overflow hose and fuel tank breather hose so that the hoses cross no more 2. Clutch hose than once between the fuel tank and the holder.
  • Page 118 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING Front brake hose (right side view) 2-57 email: info@motomatrix.co.uk...
  • Page 119 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Brake hose (front brake master cylinder to hydraulic unit) 2. Stator coil lead 3. Wire harness 4. Intake air temperature sensor lead 5. Negative battery lead 6.
  • Page 120 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING Electrical components tray (right side view) 2-59 email: info@motomatrix.co.uk...
  • Page 121 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Headlight relay J. Install the positive battery lead terminal and negative battery lead terminal to the starter relay 2. Turn signal/hazard relay so that the terminals are parallel to the relay as 3.
  • Page 122 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING Electrical components tray (right side view) 2-61 email: info@motomatrix.co.uk...
  • Page 123 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING AA.Route the stator coil lead over the wire harness. AB.Fasten the stator coil lead, wire harness, wire harness (starting circuit cut-off relay lead and starter relay lead), and wire harness (rectifier/regulator lead and stator coil lead) with the plastic band.
  • Page 124 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING Engine (right side view) 2-63 email: info@motomatrix.co.uk...
  • Page 125 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Brake hose (hydraulic unit to rear brake caliper) 2. Rear wheel sensor lead 3. O sensor #1 lead 4. O sensor #2 lead 5. Crankshaft position sensor lead 6.
  • Page 126 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING Rear brake hose (right side view) 2-65 email: info@motomatrix.co.uk...
  • Page 127 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Brake fluid reservoir hose 2. Brake hose (rear brake master cylinder to hydraulic unit) 3. Rear brake light switch lead 4. Brake hose (hydraulic unit to rear brake caliper) 5.
  • Page 128 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING Throttle bodies (top view) 2-67 email: info@motomatrix.co.uk...
  • Page 129 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Immobilizer unit lead 2. Cylinder-#1 left ignition coil lead 3. Accelerator position sensor lead 4. Cylinder-#1 right ignition coil lead (white tape) 5. Cylinder-#2 left ignition coil lead 6.
  • Page 130 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING Hydraulic unit assembly (top view) 13 12 2-69 email: info@motomatrix.co.uk...
  • Page 131 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Engine ground lead 2. Wire harness 3. ABS ECU lead 4. ABS test coupler 5. ABS test coupler lead 6. Hydraulic unit assembly 7. Coolant reservoir hose 8.
  • Page 132 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING Rear fender (top view) 2-71 email: info@motomatrix.co.uk...
  • Page 133 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. License plate light lead 2. Rear right turn signal light lead 3. Tail/brake light lead 4. Rear left turn signal light lead 5. Frame ground lead 6.
  • Page 134 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-73 email: info@motomatrix.co.uk...

  • Page 135: Periodic Checks And Adjustments

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ....... 3-1 CHECKING THE FUEL LINE ..............
  • Page 136 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE BRAKE LIGHT SWITCHES......... 3-30 ADJUSTING THE REAR BRAKE LIGHT SWITCH ......... 3-30 CHECKING AND LUBRICATING THE CABLES ........3-31 CHECKING THE THROTTLE GRIP OPERATION ......... 3-31 CHECKING THE SWITCHES, LIGHTS AND SIGNALS ......
  • Page 137 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...

  • Page 138: Periodic Maintenance

    UK, a mileage-based maintenance, is performed instead. • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 139 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) •...
  • Page 140 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE • The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas. • Hydraulic brake and clutch service •...

  • Page 141: Checking The Fuel Line

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE EAS21030 CHECKING THE FUEL LINE 1. Remove: • Rider seat • Left side cowling • Right side panel Refer to “GENERAL CHASSIS” on page 4-1. 2.

  • Page 142: Adjusting The Valve Clearance

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE 6. Clean: • Throttle bodies • Spark plug Refer to “THROTTLE BODIES” on page 7-5. (with a spark plug cleaner or wire brush) • Clutch cover 7.
  • Page 143 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE d. Turn the crankshaft clockwise 270 degrees so that the pickup rotor T mark “e” is pointing up as shown in the illustration. e. Measure the valve clearance #2 with a thick- ness gauge.
  • Page 144 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE d. Calculate the sum of the values obtained in steps (b) and (c) to determine the required valve pad thickness and the valve pad num- ber.

  • Page 145: Synchronizing The Throttle Bodies

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE g. Install the exhaust and intake camshafts, tim- ing chain and camshaft caps. Camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Refer to “CAMSHAFTS” on page 5-11. •...
  • Page 146 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE ECA23P1079 NOTICE Do not turn the bypass air screw of the throt- tle body that is the standard. Otherwise, the engine may run roughly at idle and the throttle bodies may not operate properly.

  • Page 147: Checking The Exhaust System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE 2. Stop the engine and remove the measuring equipment. 3. Install: • Cap • Intake air pressure sensor hose 4. Adjust: • Throttle cable free play Refer to “CHECKING THE THROTTLE GRIP OPERATION”...

  • Page 148: Checking The Cylinder Head Breather Hose

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE 3. Press the left set button to select the CO ad- justment mode “Co” “1” or the diagnostic The CO adjustment volume appears on the mode “dIAG”.

  • Page 149: Adjusting The Clutch Lever

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE 6. Install: • Air filter case cover After removing the fuel tank bolts, lift up the front • Cap of the fuel tank. Air filter case cover screw ECA23P1003 NOTICE 1.6 Nm (0.16 m·kgf, 1.2 ft·lbf)

  • Page 150: Checking The Clutch Fluid Level

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE • When refilling, be careful that water does not enter the clutch master cylinder reser- voir. Water will significantly lower the boil- ing point of the clutch fluid and could cause vapor lock.

  • Page 151: Adjusting The Front Disc Brake

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE b. Install the clutch master cylinder reservoir di- aphragm. Be sure to align the setting on the adjusting dial c. Connect a clear plastic hose “1” tightly to the with the arrow mark “2”...

  • Page 152: Bleeding The Hydraulic Brake System (Abs)

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE EAS23P1020 BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS) EWA14000 WARNING Always bleed the brake system when the brake related parts are removed. ECA23P1037 NOTICE • Bleed the brake system in the following or- der.

  • Page 153: Checking The Front Brake Pads

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE Refer to “HYDRAULIC UNIT OPERATION TESTS” on page 4-71. ECA23P1038 NOTICE Make sure that the main switch is turned to “OFF” before checking the operation of the hydraulic unit.

  • Page 154: Checking The Brake Hoses

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE 1. Operate the brake. EWA13260 WARNING 2. Check: Never attempt to make any repairs to the • Rear brake pad wear limit “a” Out of specification → Replace the brake wheel.

  • Page 155: Checking The Tires

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE Tire air pressure (measured on cold tires) Loading condition 0–90 kg (0–198 lb) Front 225 kPa (2.25 kgf/cm², 33 psi) Rear 250 kPa (2.50 kgf/cm², 36 psi) Loading condition 90–209 kg (198–461 lb) Front...

  • Page 156: Checking The Wheel Bearings

    1. Measure: en if a tire combination other than one • Swingarm side play approved by Yamaha is used on this vehicle. • Swingarm vertical movement Refer to “REMOVING THE SWINGARM” on Front tire page 4-102.

  • Page 157: Checking And Adjusting The Steering Head

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

  • Page 158: Lubricating The Steering Head

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE EAS23P1026 EAS21730 LUBRICATING THE STEERING HEAD LUBRICATING THE CENTERSTAND 1. Lubricate: Lubricate the pivoting point and metal-to-metal • Upper bearing moving parts of the centerstand. •...
  • Page 159 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE • Securely support the vehicle so that there is no danger of it falling over. Spring preload ECA13570 NOTICE • Grooves are provided to indicate the ad- justment position.

  • Page 160: Checking The Rear Suspension

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE Compression damping 3. Check: • Rear shock absorber assembly operation ECA13590 NOTICE • Rear suspension link pivots Never go beyond the maximum or minimum Push down seat on the vehicle several times adjustment positions.

  • Page 161: Checking The Engine Oil Level

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE EAS20731 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle on a level surface. S O F T • Place the vehicle on the centerstand. HA R D •...

  • Page 162: Changing The Engine Oil

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE ECA23P1072 NOTICE • Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of CD or higher and do not use oils la- beled “ENERGY CONSERVING II”.

  • Page 163: Measuring The Engine Oil Pressure

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE d. Tighten the new oil filter cartridge to specifi- 10.Start the engine, warm it up for several min- cation with an oil filter wrench. utes, and then turn it off. 11.Check: Oil filter cartridge •...

  • Page 164: Checking The Coolant Level

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE 6. Measure: ECA13470 NOTICE • Engine oil pressure • Adding water instead of coolant lowers the Oil pressure antifreeze content of the coolant. If water is 65.0 kPa/1100 r/min (0.65 used instead of coolant check, and if nec- kgf/cm²/1100 r/min, 9.4 psi/1100...

  • Page 165: Changing The Coolant

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE sidual pressure to escape. When the hissing sound has stopped, press down on the radi- ator cap and turn it counterclockwise to re- move. 3. Remove: •...

  • Page 166: Checking The Final Gear Oil Level

    10.Install: • Radiator cap Type 11.Fill: Yamaha genuine shaft drive • Coolant reservoir gear oil SAE 80 API GL-5 or SAE (with the recommended coolant to the maxi- 80 API GL-4 Hypoid gear oil mum level mark “a”)

  • Page 167: Changing The Final Gear Oil

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE ECA23P1039 NOTICE Take care not to allow foreign material to en- ter the final gear case. 6. Check: • Oil level Refer to “CHECKING THE FINAL GEAR OIL LEVEL”...

  • Page 168: Checking And Lubricating The Cables

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE With the engine stopped, turn the throttle grip slowly and release it. Make sure that the throttle grip turns smoothly and returns properly when released. Repeat this check with the handlebar turned all the way to the left and right.

  • Page 169: Checking The Switches, Lights And Signals

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE d. Tighten the locknut. e. Slide the rubber cover to its original position. Make sure that the adjusting nut is covered com- pletely by the rubber cover. L LLL L LLL L LLL...

  • Page 170: Replacing The Auxiliary Light Bulbs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE EWA13320 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 5. Install: •...

  • Page 171: Chassis

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS GENERAL CHASSIS..................4-1 INSTALLING THE SEATS................. 4-2 INSTALLING THE CARRIERS..............4-2 REMOVING THE ABS UNIT COVER ............4-7 INSTALLING THE ABS UNIT COVER ............4-7 REMOVING THE SIDE COWLINGS............4-9 INSTALLING THE SIDE COWLINGS ............
  • Page 172 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE ....................4-52 INTRODUCTION ..................4-59 CHECKING THE REAR BRAKE DISC............ 4-59 REPLACING THE REAR BRAKE PADS..........4-59 REMOVING THE REAR BRAKE CALIPER ..........4-60 DISASSEMBLING THE REAR BRAKE CALIPER ........4-60 CHECKING THE REAR BRAKE CALIPER..........
  • Page 173 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SWINGARM....................4-100 REMOVING THE SWINGARM..............4-102 CHECKING THE SWINGARM ..............4-102 INSTALLING THE SWINGARM ............4-102 SHAFT DRIVE .....................4-104 TROUBLESHOOTING ................4-108 CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND CHECKING THE SHAFT DRIVE FOR LEAKS........4-109 MEASURING THE FINAL GEAR BACKLASH ........4-109 ADJUSTING THE FINAL GEAR BACKLASH ........4-110 MEASURING THE RING-GEAR-TO-STOPPER-BOLT...

  • Page 174: General Chassis

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seats and carriers 20 Nm (2.0 m kgf, 14 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) 7 Nm (0.7 m 7 Nm (0.7 m...

  • Page 175: Installing The Seats

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS EAS23P1003 INSTALLING THE SEATS 1. Install: • Passenger seat “1” Insert the projection “a” on the rear of the pas- senger seat into the seat holder “b” in the addi- tional carrier.
  • Page 176 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Standard carrier 3. Tighten: Additional carrier • Seat bracket bolts “1” • Additional carrier bolts “2” Seat bracket bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Additional carrier bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Before tightening the bolts, make sure to align...
  • Page 177 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Align the slots “a” in the washer with the projec- tions “b” on the grab bar. 5. Remove: • Rubber plug “1” 6. Install: • Standard carrier “1” Standard carrier bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) Use the two standard carrier bracket bolts “2”...
  • Page 178 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the tail/brake light assembly 15 Nm (1.5 m kgf, 11 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 1.0 Nm (0.10 m kgf, 0.72 ft Ibf)
  • Page 179 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the tail/brake light assembly 15 Nm (1.5 m kgf, 11 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 1.0 Nm (0.10 m kgf, 0.72 ft Ibf)

  • Page 180: Removing The Abs Unit Cover

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS EAS23P1103 REMOVING THE ABS UNIT COVER 1. Remove: • ABS unit cover “1” Remove the quick fastener screw “2”, and then pull the ABS unit cover off as shown in the illus- tration.
  • Page 181 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the side cowlings, side panel, and engine guard 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) •...

  • Page 182: Removing The Side Cowlings

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS EAS23P1104 b. Install the left side cowling bolts and quick REMOVING THE SIDE COWLINGS fastener screws, and then tighten the bolts to 1. Remove: specification. •...
  • Page 183 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the electrical components tray 1/2 3.6 Nm (0.36 m kgf, 2.6 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “Removing the side cowlings, side Right side panel panel, and engine guard”.
  • Page 184 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the electrical components tray 1/2 3.6 Nm (0.36 m kgf, 2.6 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Turn signal/hazard relay Radiator fan motor relay Stator coil coupler Disconnect.
  • Page 185 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the electrical components tray 2/2 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • •...
  • Page 186 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the electrical components tray 2/2 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • •...

  • Page 187: Installing The Electrical Components Tray

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS EAS23P1069 INSTALLING THE ELECTRICAL COMPONENTS TRAY 1. Install: • Electrical components tray “1” Electrical components tray bolt “2” 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Electrical components tray bolt “3”...
  • Page 188 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the headlight assembly 0.5 Nm (0.05 m kgf, 0.36 ft Ibf) • • 1.3 Nm (0.13 m kgf, 0.94 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 189 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Disassembling the headlight Order Job/Parts to remove Q’ty Remarks Auxiliary light socket Auxiliary light bulb Headlight bulb cover Headlight coupler Disconnect. Headlight solenoid coupler Disconnect. Headlight bulb Headlight sub-wire harness For assembly, reverse the disassembly pro-...

  • Page 190: Assembling The Headlight

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS EAS23P1012 ASSEMBLING THE HEADLIGHT 1. Install: • Headlight sub-wire harness “1” Route the headlight sub-wire harness through the hole in the headlight, and then connect the headlight solenoid couplers “2”...
  • Page 191 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the air filter case 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 1.6 Nm (0.16 m kgf, 1.2 ft Ibf) • • 1.2 Nm (0.12 m kgf, 0.87 ft Ibf)

  • Page 192: Removing The Air Filter Case

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS EAS23P1013 REMOVING THE AIR FILTER CASE 1. Remove: • Fuel tank bolts “1” • Air filter case After removing the fuel tank bolts, lift up the front of the fuel tank.

  • Page 193: Front Wheel

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL EAS21880 FRONT WHEEL Removing the front wheel sensor, front wheel and brake discs 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) •...
  • Page 194 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL Removing the front wheel sensor, front wheel and brake discs 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) •...
  • Page 195 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL Disassembling the front wheel 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil seal Front wheel sensor rotor Oil seal Wheel bearing Spacer...

  • Page 196: Removing The Front Wheel

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL EAS21900 b. Remove the oil seals “1” with a flat-head REMOVING THE FRONT WHEEL screwdriver. ECA23P1004 NOTICE To prevent damaging the wheel, place a rag “2” Keep magnets (including magnetic pick-up between the screwdriver and the surface of the tools, magnetic screwdrivers, etc.) away...

  • Page 197: Maintenance Of The Front Wheel Sensor And Sensor Rotor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL • Front wheel EAS22010 MAINTENANCE OF THE FRONT WHEEL Damage/wear → Replace. SENSOR AND SENSOR ROTOR Refer to “CHECKING THE TIRES” on page ECA23P1006 3-18 and “CHECKING THE WHEELS” on NOTICE page 3-17.

  • Page 198: Assembling The Front Wheel

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL 3. Measure: d. If the deflection is still above specification, re- • Wheel sensor rotor deflection place the wheel sensor rotor. Out of specification → Clean the installation L LLL L LLL L LLL...

  • Page 199: Adjusting The Front Wheel Static Balance

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL b. When the front wheel stops, put an “X ” mark at the bottom of the wheel. L LLL L LLL L LLL L LLL L LLL 2.

  • Page 200: Installing The Front Wheel (Front Brake Discs)

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL c. If the heavy spot does not stay in that posi- 2. Check: tion, install a heavier weight. • Front brake discs d. Repeat steps (b) and (c) until the front wheel Refer to “CHECKING THE FRONT BRAKE is balanced.
  • Page 201 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. Insert the front wheel axle from the right side Front brake caliper bolt 40 Nm (4.0 m·kgf, 29 ft·lbf) and tighten it to 72 Nm (7.2 m·kgf, 52 ft·lbf).

  • Page 202: Rear Wheel

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL EAS22030 REAR WHEEL Removing the rear wheel sensor, rear wheel and brake disc 125 Nm (12.5 m kgf, 90 ft lbf) 25 Nm (2.5 m kgf, 18 ft Ibf) •...
  • Page 203 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL Removing the rear wheel sensor, rear wheel and brake disc 125 Nm (12.5 m kgf, 90 ft lbf) 25 Nm (2.5 m kgf, 18 ft Ibf) •...
  • Page 204 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL Disassembling the rear wheel 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Dust seal Rear wheel drive hub Wheel bearing Collar Rear wheel drive hub damper...

  • Page 205: Removing The Rear Wheel

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL EAS22050 EAS22080 REMOVING THE REAR WHEEL DISASSEMBLING THE REAR WHEEL ECA23P1013 ECA23P1015 NOTICE NOTICE Keep magnets (including magnetic pick-up • Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away tools, magnetic screwdrivers, etc.) away from the rear wheel hub “1”, otherwise the...

  • Page 206: Maintenance Of The Rear Wheel Sensor And Sensor Rotor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL • Oil seal 3. Measure: Refer to “CHECKING THE FRONT WHEEL” • Wheel sensor rotor deflection on page 4-23. Refer to “MAINTENANCE OF THE FRONT 2.

  • Page 207: Adjusting The Rear Wheel Static Balance

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL Rear brake disc bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) LOCTITE® Tighten the brake disc bolts in stages and in a crisscross pattern. L LLL L LLL L LLL L LLL...
  • Page 208 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL ECA23P1017 NOTICE To route the rear wheel sensor lead, refer to “CABLE ROUTING” on page 2-43. When installing the rear wheel sensor, check the rear wheel sensor lead for twists and the sensor electrode for foreign materials.

  • Page 209: 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 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) •...
  • Page 210 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Removing the front brake pads 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf)
  • Page 211 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Removing the front brake master cylinder 17 Nm (1.7 m kgf, 12 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • •...
  • Page 212 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Removing the front brake master cylinder 17 Nm (1.7 m kgf, 12 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • •...
  • Page 213 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure.
  • Page 214 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Removing the front brake calipers 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf)
  • Page 215 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Removing the front brake calipers 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf)
  • Page 216 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Disassembling the front brake calipers 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • Order Job/Parts to remove Q’ty...

  • Page 217: Introduction

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE EAS22221 e. Measure the deflection 1.5 mm (0.06 in) be- INTRODUCTION low the edge of the brake disc. EWA14101 WARNING Disc brake components rarely require disas- sembly.

  • Page 218: Replacing The Front Brake Pads

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE d. Measure the brake disc deflection. 3. Measure: e. If out of specification, repeat the adjustment • Brake pad wear limit “a” Out of specification → Replace the brake steps until the brake disc deflection is within specification.

  • Page 219: Removing The Front Brake Calipers

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE c. Tighten the bleed screw. 8. Check: • Brake lever operation Front brake caliper bleed screw Soft or spongy feeling → Bleed the brake sys- 5 Nm (0.5 m·kgf, 3.6 ft·lbf) tem.

  • Page 220: Checking The Front Brake Calipers

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Recommended brake component replace- ment schedule Brake pads If necessary Piston seals Every two years Piston dust seals Every two years Brake hoses Every four years Every two years and Brake fluid whenever the brake...

  • Page 221: Installing The Front Brake Calipers

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE • Whenever a brake caliper is disassembled, replace the brake caliper piston dust seals and brake caliper piston seals. Recommended fluid DOT 4 EAS22440 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers.

  • Page 222: 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 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 223: Installing The Front Brake Master Cylinder

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE EAS22530 • Turn the handlebar to the left and right to make INSTALLING THE FRONT BRAKE MASTER sure the brake hose does not touch other parts CYLINDER (e.g., wire harness, cables, leads).
  • Page 224 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE 6. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-15. 4-51 email: info@motomatrix.co.uk...
  • Page 225 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 kgf, 4.3 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) •...
  • Page 226 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Removing the rear brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • •...
  • Page 227 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Removing the rear brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • •...
  • Page 228 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Disassembling the rear brake master cylinder 17 Nm (1.7 m kgf, 12 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rear brake master cylinder joint Brake master cylinder kit Circlip Brake hose joint...
  • Page 229 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Removing the rear brake caliper 125 Nm (12.5 m kgf, 90 ft lbf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf)
  • Page 230 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Removing the rear brake caliper 125 Nm (12.5 m kgf, 90 ft lbf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf)
  • Page 231 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 kgf, 4.3 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro-...

  • Page 232: Rear Brake

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE EAS22561 INTRODUCTION Brake disc thickness limit EWA14101 4.5 mm (0.18 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- •...

  • Page 233: Removing The Rear Brake Caliper

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE • Brake pads Always install new brake pads, brake pad shims and brake pad supports as a set. M MMM M MMM M MMM M MMM M MMM a.

  • Page 234: Checking The Rear Brake Caliper

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE • Brake caliper cylinder “2” Scratches/wear → Replace the brake caliper assembly. • Brake caliper body “3” Cracks/damage → Replace the brake caliper assembly. • Brake fluid delivery passages (brake caliper body) Obstruction →...
  • Page 235 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Brake hose union bolt Align the slot “a” of the rear wheel sensor hous- 30 Nm (3.0 m·kgf, 22 ft·lbf) ing “1” with the projection “b” of the rear brake caliper bracket “2”, and then assemble them.

  • Page 236: Removing The Rear Brake Master Cylinder

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE 6. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-15. 7. Check: • Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level.

  • Page 237: Assembling The Rear Brake Master Cylinder

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE EAS22730 • Install the rear brake light switch spring “2” as ASSEMBLING THE REAR BRAKE MASTER shown in the illustration. CYLINDER EWA13520 WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid.
  • Page 238 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE EWA13090 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. •...

  • Page 239: Abs (Anti-Lock Brake System)

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (Anti-Lock Brake System) EAS22760 ABS (Anti-Lock Brake System) Removing the rear fender assembly and brake hoses 30 Nm (3.0 m kgf, 22 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf)
  • Page 240 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (Anti-Lock Brake System) Removing the rear fender assembly and brake hoses 30 Nm (3.0 m kgf, 22 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 241 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (Anti-Lock Brake System) Removing the hydraulic unit assembly 16 Nm (1.6 m kgf, 12 ft Ibf) 16 Nm (1.6 m kgf, 12 ft Ibf) • • •...

  • Page 242: Removing The Hydraulic Unit Assembly

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (Anti-Lock Brake System) EAS23P1014 REMOVING THE HYDRAULIC UNIT ASSEMBLY ECA23P1023 NOTICE Unless necessary, avoid removing and in- stalling the brake pipes of the hydraulic unit assembly. EWA13930 WARNING Refill with the same type of brake fluid that is...

  • Page 243: Checking The Hydraulic Unit Assembly

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (Anti-Lock Brake System) ECA23P1027 NOTICE Do not remove the rubber plugs or bolts (M10 × 1.00) installed in the flare nut holes before installing the hydraulic unit assem- bly.

  • Page 244: Hydraulic Unit Operation Tests

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (Anti-Lock Brake System) EWA23P1007 WARNING Brake hose union bolt 30 Nm (3.0 m·kgf, 22 ft·lbf) • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to ECA23P1029 deteriorate, causing leakage and poor NOTICE...
  • Page 245 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (Anti-Lock Brake System) • Hydraulic unit operation test 2: this test gener- ates the same reaction-force pulsating action that is generated in the brake lever and brake pedal when the ABS is activated.
  • Page 246 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (Anti-Lock Brake System) • If the pulse is hardly felt in either the brake 5. Remove the protective cap and then connect lever or brake pedal, check that the brake the test coupler adapter “1”...
  • Page 247 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (Anti-Lock Brake System) 9. After releasing the start switch, operate the brake lever and the brake pedal simulta- neously. 12.After the pulsating action has stopped in the brake pedal, it is generated in the brake lever 0.5 second later and continues for approxi- 10.A reaction-force pulsating action is generated...

  • Page 248: Trial Run

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (Anti-Lock Brake System) EAS22820 TRIAL RUN After all checks and servicing are completed, al- ways ensure the vehicle has no problems by performing a trial run at a speed of faster than 30 km/h.

  • Page 249: Handlebar

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 17 Nm (1.7 m kgf, 12 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 4.5 Nm (0.45 m kgf, 3.3 ft Ibf) •...
  • Page 250 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBAR Removing the handlebar 17 Nm (1.7 m kgf, 12 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 4.5 Nm (0.45 m kgf, 3.3 ft Ibf) •...
  • Page 251 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBAR Removing the handlebar 17 Nm (1.7 m kgf, 12 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 4.5 Nm (0.45 m kgf, 3.3 ft Ibf) •...

  • Page 252: Removing The Handlebar

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBAR EAS22860 REMOVING THE HANDLEBAR • The upper handlebar holders should be in- 1. Stand the vehicle on a level surface. stalled with the punch marks “a” facing for- EWA13120 WARNING ward.
  • Page 253 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBAR 4. Install: Right grip end bolt • Right handlebar switch “1” 27 Nm (2.7 m·kgf, 20 ft·lbf) Right upper hand shield bolt Right handlebar switch screw 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) Right lower hand shield bolt...
  • Page 254 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBAR • Align the mating surfaces of the clutch master cylinder holder with the punch mark “b” on the There should be 1–3 mm (0.04–0.12 in) of clear- handlebar.

  • Page 255: 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 26 Nm (2.6 m kgf, 19 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...
  • Page 256 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK Disassembling the front fork legs 15 Nm (1.5 m kgf, 11 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • Order Job/Parts to remove Q’ty...
  • Page 257 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK Disassembling the front fork legs 15 Nm (1.5 m kgf, 11 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • Order Job/Parts to remove Q’ty...

  • Page 258: Removing The Front Fork Legs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK EAS22960 • Nut “4” REMOVING THE FRONT FORK LEGS • Collar “5” The following procedure applies to both of the M MMM M MMM M MMM M MMM M MMM front fork legs.

  • Page 259: Checking The Front Fork Legs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK Damper rod holder 90890-01423 Damping rod holder YM-01423 L LLL L LLL L LLL L LLL L LLL EAS23011 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.

  • Page 260: Assembling The Front Fork Legs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK ECA14200 NOTICE • Before installing the oil seal, lubricate its lips • The front fork leg has a built-in damper ad- with lithium-soap-based grease. justing rod and a very sophisticated inter- •...
  • Page 261 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK 5. Install: • Oil seal “1” (with the fork seal driver “2”) Fork seal driver 90890-01442 Adjustable fork seal driver (36–46 YM-01442 8. Install: • Damper rod assembly “1” •...
  • Page 262 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK • When disassembling and assembling the front fork leg, do not allow any foreign ma- terial to enter the front fork. 13.After filling the front fork leg, slowly stroke the damper rod “1”...
  • Page 263 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK • Collar “6” • Nut “7” • Cap bolt “8” g. Press down on the spacer with the fork spring compressor “9” and then secure the com- pressor with a suitable tool “10”.

  • Page 264: Installing The Front Fork Legs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK EWA13680 WARNING Make sure the brake hoses are routed prop- erly. k. Install the damper adjusting rod and cap bolt, and then finger tighten the cap bolt. EWA23P1008 WARNING Always use a new cap bolt O-ring.

  • Page 265: 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 130 Nm (13 m kgf, 94 ft lbf) • • 26 Nm (2.6 m kgf, 19 ft Ibf) •...
  • Page 266 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STEERING HEAD Removing the lower bracket 130 Nm (13 m kgf, 94 ft lbf) • • 26 Nm (2.6 m kgf, 19 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) •...

  • Page 267: Removing The Lower Bracket

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STEERING HEAD EAS23110 M MMM M MMM M MMM M MMM M MMM REMOVING THE LOWER BRACKET a. Remove the bearing races from the steering 1. Stand the vehicle on a level surface. head pipe “1”...
  • Page 268 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STEERING HEAD • Lower bracket cap Be sure to fit the hexagonal portion of the steer- Face the hole “a” in the lower bracket cap rear- ing stem nut “2” into the hexagonal recess in the ward.

  • Page 269: 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 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) •...
  • Page 270 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) •...

  • Page 271: Handling The Rear Shock Absorber

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR SHOCK ABSORBER ASSEMBLY EAS23180 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on the centerstand so that the EWA13740 WARNING rear wheel is elevated. This rear shock absorber contains highly 2.

  • Page 272: 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 • Spacer Damage/scratches → Replace. • Bolts Bends/damage/wear → Replace. EAS23261 CHECKING THE CONNECTING ARM AND RELAY ARM 1. Check: • Connecting arms •...

  • Page 273: Swingarm

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SWINGARM EAS23330 SWINGARM Removing the swingarm 120 Nm (12 m kgf, 87 ft lbf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) •...
  • Page 274 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SWINGARM Removing the swingarm 120 Nm (12 m kgf, 87 ft lbf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) •...

  • Page 275: Removing The Swingarm

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SWINGARM EAS23350 ECA23P1064 REMOVING THE SWINGARM NOTICE 1. Stand the vehicle on a level surface. Before loosening the pivot shaft, be sure to EWA13120 remove the pivot shaft end plate. WARNING Securely support the vehicle so that there is no danger of it falling over.
  • Page 276 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SWINGARM Make sure that the four projections “a” on the plate are securely fitted onto the frame. 3. Install: • Rubber boot “1” • Align the “ ”...

  • Page 277: Shaft Drive

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHAFT DRIVE EAS23551 SHAFT DRIVE Removing the final drive assembly and drive shaft 42 Nm (4.2 m kgf, 30 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...
  • Page 278 BACKLASH” on page 4-110 and “ALIGNING Thrust washer THE FINAL DRIVE PINION GEAR AND RING GEAR” on page 4-114. * Yamaha genuine shaft drive oil SAE 80 API GL-5 or SAE 80 API GL-4 Hypoid gear oil 4-105 email: info@motomatrix.co.uk...
  • Page 279 Final drive pinion gear shim PINION GEAR AND RING GEAR” on page 4-114. Bearing holder Dowel pin Final drive pinion gear bearing * Yamaha genuine shaft drive oil SAE 80 API GL-5 or SAE 80 API GL-4 Hypoid gear oil 4-106 email: info@motomatrix.co.uk...
  • Page 280 Job/Parts to remove Q’ty Remarks Ring gear bearing Oil seal Collar Final gear case For assembly, reverse the disassembly pro- cedure. * Yamaha genuine shaft drive oil SAE 80 API GL-5 or SAE 80 API GL-4 Hypoid gear oil 4-107 email: info@motomatrix.co.uk...

  • Page 281: Troubleshooting

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHAFT DRIVE EAS23560 TROUBLESHOOTING Symptom Possible cause 1. A pronounced hesitation or jerky movement A. Bearing damage during acceleration, deceleration or sus- B. Improper gear backlash tained speeds (not to be confused with en- C.

  • Page 282: Checking The Final Drive Oil For Contamination And Checking The Shaft Drive For Leaks

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHAFT DRIVE NO → 2. Place the vehicle on the center- Rear wheel bearings and shaft drive bear- stand so that the rear wheel is ele- ings are probably not damaged. Repeat vated and then spin the rear wheel.

  • Page 283: Adjusting The Final Gear Backlash

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHAFT DRIVE h. Reinstall the ring gear fix bolt, final gear back- Final gear backlash lash band, and dial gauge. 0.20–0.40 mm (0.008–0.016 in) i. Repeat steps (d) to (h) three more times (for a total of four measurements).

  • Page 284: Measuring The Ring-Gear-To-Stopper-Bolt Clearance

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHAFT DRIVE b. If it is necessary to increase the final gear backlash by more than 0.2 mm (0.008 in), re- duce the ring gear shim thickness by 0.2 mm (0.008 in) for every 0.2 mm (0.008 in) in- crease of thrust washer thickness.

  • Page 285: Disassembling The Final Drive Assembly

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHAFT DRIVE ECA14320 NOTICE • The stopper bolt has left-hand threads. To tighten the stopper bolt, turn it counter- clockwise. • Apply LOCTITE® onto the stopper bolt. 3.

  • Page 286: Removing And Installing The Bearings

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHAFT DRIVE ECA14340 NOTICE The final drive pinion gear should only be re- moved if ring gear replacement is necessary. M MMM M MMM M MMM M MMM M MMM a.

  • Page 287: Assembling The Final Drive Assembly

    (with an appropriate press tool “4” and press) replaced: • Final gear case The bearing can be reused, but Yamaha recom- • Ring gear bearing housing mends installing a new one. • Any bearing 1.
  • Page 288 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHAFT DRIVE b. To find final drive pinion gear shim thickness Where: “A”, use the following formula: c = a numeral on the final gear case, to be di- vided by 100 and added to “52”.
  • Page 289 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHAFT DRIVE In the example above, the calculated ring gear Install the washer with its “OUT” mark “a” facing shim thickness is 0.52 mm (0.0205 in). The chart outward.

  • Page 290: Checking The Drive Shaft

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHAFT DRIVE e. Measure the width of the flattened Plasti- gauge® “1”. 7. Install: • Ring gear bearing housing (along with the ring gear) Ring-gear-to-thrust-washer clear- 8. Adjust: ance •...
  • Page 291 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHAFT DRIVE Recommended lubricant Molybdenum disulfide grease 2. Lubricate: • Drive shaft spline (universal joint side) Recommended lubricant Lithium-soap-based grease 3. Install: • Oil seal “1” • Washer “2” (to the drive shaft with the fork seal driver weight “3”...
  • Page 292 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHAFT DRIVE 4-119 email: info@motomatrix.co.uk...

  • Page 293: Engine

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE ENGINE INSPECTION ..................5-1 MEASURING THE COMPRESSION PRESSURE........5-1 ENGINE REMOVAL ..................5-3 REMOVING THE ENGINE ................ 5-9 INSTALLING THE ENGINE............... 5-9 INSTALLING THE EXHAUST PIPE AND MUFFLER......5-10 CAMSHAFTS....................
  • Page 294 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTER ................... 5-48 CHECKING THE STARTER MOTOR ............. 5-50 ASSEMBLING THE STARTER MOTOR..........5-51 CLUTCH ......................5-52 REMOVING THE CLUTCH ..............5-60 CHECKING THE FRICTION PLATES............. 5-61 CHECKING THE CLUTCH PLATES ............
  • Page 295 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE ....................5-82 REMOVING THE REAR BALANCER ............. 5-87 DISASSEMBLING THE CRANKCASE............ 5-87 CHECKING THE CRANKCASE .............. 5-88 CHECKING THE REAR BALANCER ............5-88 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE (INTAKE SIDE) ..................

  • Page 296: Engine Inspection

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE INSPECTION EAS23P1087 ENGINE INSPECTION EAS20710 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cyl- inders. Insufficient compression pressure will result in a loss of performance.
  • Page 297 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE INSPECTION Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without Piston ring(s) wear or damage → Repair. Pistons, valves, cylin- der head gasket or Same as without oil piston ring(s) possi- bly defective →...

  • Page 298: Engine Removal

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL EAS23711 ENGINE REMOVAL Removing the exhaust pipe 28 Nm (2.8 m kgf, 20 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...
  • Page 299 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Removing the exhaust pipe 28 Nm (2.8 m kgf, 20 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 300 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Disconnecting the leads 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 63 Nm (6.3 m kgf, 46 ft Ibf) •...
  • Page 301 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Disconnecting the leads 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 63 Nm (6.3 m kgf, 46 ft Ibf) •...
  • Page 302 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Removing the engine 75 Nm (7.5 m kgf, 54 ft Ibf) 68 Nm (6.8 m kgf, 49 ft Ibf) • • • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...
  • Page 303 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Removing the engine 75 Nm (7.5 m kgf, 54 ft Ibf) 68 Nm (6.8 m kgf, 49 ft Ibf) • • • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...

  • Page 304: Removing The Engine

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL EAS23P1029 REMOVING THE ENGINE Pivot shaft wrench 1. Loosen: 90890-01485 • Engine positioning bolt Frame mount insert wrench YM-01485 Loosen the engine positioning bolt with the pivot shaft wrench “1”.

  • Page 305: Installing The Exhaust Pipe And Muffler

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Install the rubber damper to the frame so that the “O” mark “a” on the damper is facing inward. 3. Install: • Rubber cover “1” •...

  • Page 306: Camshafts

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • •...
  • Page 307 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS Removing the cylinder head cover 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 308 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS Removing the camshafts 10 Nm (1.0 m kgf, 7.2 ft Ibf) 24 Nm (2.4 m kgf, 17 ft Ibf) • • • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) 24 Nm (2.4 m...
  • Page 309 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS Removing the camshafts 24 Nm (2.4 m kgf, 17 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) 24 Nm (2.4 m...

  • Page 310: Removing The Cylinder Head Cover

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS EAS23P1089 REMOVING THE CYLINDER HEAD COVER 1. Remove: • Plastic band “1” • Wire harness holder “2” 5. Remove: • Brake hose joint bolt (hydraulic unit to left front brake caliper) “1”...

  • Page 311: Removing The Camshafts

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS • Brake pipe (hydraulic unit to left front brake caliper) “3” 9. Remove: • Cylinder head cover “1” • Cylinder head cover gasket Lift up the wire harness, brake pipes, clutch pipe, and clutch hose, and then pull the cylinder head cover rearward to remove it.

  • Page 312: Checking The Camshafts

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS ECA13720 NOTICE To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in. 4.

  • Page 313: Checking The Camshaft Sprocket

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS • Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. • Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance with the Plastigauge®.

  • Page 314: Checking The Timing Chain Tensioners

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS L LLL L LLL L LLL L LLL L LLL a. 1/4 tooth b. Correct EAS23980 CHECKING THE DECOMPRESSION SYSTEM 1. Timing chain roller 1. Check: 2.
  • Page 315 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS ECA23P1077 NOTICE Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine. •...
  • Page 316 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS ECA23P1073 NOTICE Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. • When installing the timing chain, start with the exhaust camshaft and be sure to keep the tim- ing chain as tight as possible on the exhaust side.
  • Page 317 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS d. Tighten the intake camshaft cap bolts. c. Install the timing chain tensioner in the cylin- der block. To prevent the timing chain from skipping a tooth Timing chain tensioner bolt on the intake camshaft sprocket, do not remove 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

  • Page 318: Installing The Cylinder Head Cover

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS Refer to the installation steps above. • Apply Yamaha bond No.1215 “4” onto the mat- • Intake camshaft hole ing surfaces of the cylinder head cover gasket Make sure the hole “e”...
  • Page 319 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS c. Check that the cylinder head cover gasket “2” 7. Install: is installed properly between the cylinder • Clutch hose holder bolt “1” head cover and the cylinder head. Clutch hose holder bolt 9 Nm (0.9 m·kgf, 6.5 ft·lbf) Insert the tab “a”...
  • Page 320 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS 9. Install: • Stator coil lead • Starter motor lead • Plastic bands • Wire harness holder 5-25 email: info@motomatrix.co.uk...

  • Page 321: Cylinder Head

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head 20 Nm (2.0 m kgf, 14 ft Ibf) • • 75 Nm (7.5 m kgf, 54 ft Ibf) •...

  • Page 322: Removing The Cylinder Head

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD EAS24120 • Cylinder head water jacket REMOVING THE CYLINDER HEAD Mineral deposits/rust → Eliminate. 1. Remove: 3. Measure: • Cylinder head bolts • Cylinder head warpage Out of specification →...
  • Page 323 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD 2. Tighten: • Cylinder head bolts EWA23P1013 WARNING Replace the bolts with new ones. Tighten the bolts using the following procedure. ×2 ×6 M MMM M MMM M MMM M MMM...

  • Page 324: Valves And Valve Springs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-26. Valve lifter Valve pad Valve cotter...

  • Page 325: Removing The Valves

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components.
  • Page 326 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide. • Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” - Valve stem diameter “b”...

  • Page 327: Checking The Valve Seats

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS Valve guide remover & installer Valve stem runout set (ø5.5) 0.010 mm (0.0004 in) 90890-04016 Valve guide remover (5.5 mm) YM-01122 Valve guide installer (ø5.5) 90890-04015 Valve guide installer (5.5 mm) YM-04015...
  • Page 328 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS For the best lapping results, lightly tap the valve seat while rotating the valve back and forth be- tween your hands. b. Install the valve into the cylinder head. c.

  • Page 329: Checking The Valve Springs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS EAS24310 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: • Valve spring free length “a” Out of specification →...
  • Page 330 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS 2. Lubricate: b. Smaller pitch • Valve stem “1” 4. Install: • Valve stem end • Valve cotters • Valve stem seal “2” (with the recommended lubricant) Install the valve cotters by compressing the Recommended lubricant...
  • Page 331 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS 6. Lubricate: • Valve pad (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil • Valve lifter (with the recommended lubricant) Recommended lubricant Engine oil 7.
  • Page 332 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER AND PISTONS EAS24370 CYLINDER AND PISTONS Removing the cylinder and pistons 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD”...

  • Page 333: Cylinder And Pistons

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER AND PISTONS EAS24380 • Oil ring REMOVING THE PISTONS The following procedure applies to both of the When removing a piston ring, open the end gap pistons.

  • Page 334: Checking The Piston Rings

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

  • Page 335: Checking The Piston Pins

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER AND PISTONS Piston pin outside diameter 21.991–22.000 mm (0.8658– 0.8661 in) Limit 21.971 mm (0.8650 in) a. 40.0 mm (1.57 in) 3. Measure: • Piston ring end gap Out of specification →...
  • Page 336 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER AND PISTONS 1. Install: • Oil ring expander “1” • Lower oil ring rail “2” • Upper oil ring rail “3” • 2nd ring “4” • Top ring “5” •...
  • Page 337 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER AND PISTONS 5-42 email: info@motomatrix.co.uk...

  • Page 338: Generator And Starter Clutch

    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, generator rotor and starter clutch 10 Nm (1.0 m kgf, 7.2 ft Ibf) • •...
  • Page 339 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...

  • Page 340: 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 While holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt.

  • Page 341: 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 342 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERATOR AND STARTER CLUTCH 3. Apply: • Sealant (onto the stator coil lead grommet) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 4. Install: • Generator cover gasket •...

  • Page 343: 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 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) •...
  • Page 344 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTER Disassembling the starter motor 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...

  • Page 345: 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 1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification → Cut the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator.

  • Page 346: Assembling The Starter Motor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTER 7. Check: • Bearing • Oil seal Damage/wear → Replace the starter motor front cover. EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Starter motor yoke “1” •...

  • Page 347: Clutch

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH EAS25061 CLUTCH Removing the clutch cover 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • (14) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • •...
  • Page 348 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH Removing the clutch 125 Nm (12.5 m kgf, 90 ft lbf) • • 9,11 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “Removing the clutch release cylin-...
  • Page 349 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH Removing the clutch 125 Nm (12.5 m kgf, 90 ft lbf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Clutch boss nut...
  • Page 350 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH Removing the clutch 125 Nm (12.5 m kgf, 90 ft lbf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Spacer...
  • Page 351 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH Removing the clutch master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) • • 1.0 Nm (0.10 m kgf, 0.72 ft Ibf) •...
  • Page 352 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH Removing the clutch master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) • • 1.0 Nm (0.10 m kgf, 0.72 ft Ibf) •...
  • Page 353 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH Disassembling the clutch master cylinder Order Job/Parts to remove Q’ty Remarks Clutch master cylinder push rod Clutch master cylinder kit Clutch master cylinder body For assembly, reverse the disassembly pro- cedure.
  • Page 354 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH Removing the clutch release cylinder 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...

  • Page 355: Removing The Clutch

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH EAS25070 4. Remove: REMOVING THE CLUTCH • Long clutch push rod “1” 1. Remove: • Clutch cover “1” Push the long clutch push rod into the clutch re- lease cylinder side of the engine, and remove it Loosen each bolt 1/4 of a turn at a time, in stag- from the clutch side of the engine.

  • Page 356: Checking The Friction Plates

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH There is a built-in damper between the clutch boss and the clutch plate. It is not necessary to remove the wire circlip “4” and disassemble the built-in damper unless there is serious clutch chattering.

  • Page 357: Checking The Clutch Housing

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH 2. Check: • Clutch spring plate seat Pitting on the clutch boss splines will cause er- Damage → Replace. ratic clutch operation. 3. Measure: • Clutch spring free height Out of specification →...

  • Page 358: Installing The Clutch

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH Excessive noise during operation → Replace • Clutch boss nut “3” the clutch housing and crankshaft as a set. Clutch boss nut 125 Nm (12.5 m·kgf, 90 ft·lbf) •...

  • Page 359: Disassembling The Clutch Master Cylinder

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH 8. Install: • Clutch cover “1” Clutch cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) LOCTITE® Tighten the clutch cover bolts in the proper tight- ening sequence as shown. 6.

  • Page 360: Checking The Clutch Master Cylinder

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH • Clutch fluid may damage painted surfaces 2. Check: and plastic parts. Therefore, always clean • Clutch master cylinder kit Rust/scratches/wear → Replace. up any spilt fluid immediately. •...

  • Page 361: Removing The Clutch Release Cylinder

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH EWA13370 WARNING • Use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance. • Refill with the same type of clutch fluid that is already in the system.

  • Page 362: Assembling The Clutch Release Cylinder

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH 2. Install: • Clutch release cylinder plate “1” Put the end of the clutch hose into a container • Dowel pins and pump out the clutch fluid carefully. •...
  • Page 363 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH 4. Fill: 7. Check: • Clutch master cylinder reservoir • Clutch lever operation Soft or spongy feeling → Bleed the clutch (with the specified amount of the recom- mended clutch fluid) system.

  • Page 364: Pickup Rotor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PICKUP ROTOR EAS24520 PICKUP ROTOR Removing the pickup rotor 65 Nm (6.5 m kgf, 47 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 365: Removing The Pickup Rotor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PICKUP ROTOR EAS24530 REMOVING THE PICKUP ROTOR 1. Remove: • Pickup rotor bolt “1” • Washer “2” • Pickup rotor “3” While holding the generator rotor “4” with the sheave holder “5”, loosen the pickup rotor bolt.
  • Page 366 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PICKUP ROTOR Crankshaft position sensor hold- er bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE® 4. Measure: • Gap (between the crankshaft position sensor “1” and pickup rotor “2”) “a” Out of specification →...

  • Page 367: 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 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) •...
  • Page 368 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHIFT SHAFT Removing the shift shaft and stopper lever 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) •...

  • Page 369: 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 370 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHIFT SHAFT 2. Adjust: • Installed shift rod length M MMM M MMM M MMM M MMM M MMM a. Loosen both locknuts “1”. ECA23P1088 NOTICE The shift rod locknut (shift pedal side) has left-hand threads.

  • Page 371: Oil Pump

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP EAS24921 OIL PUMP Removing the oil pan and oil pump assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • (17) 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...
  • Page 372 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP Removing the oil pan and oil pump assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • (17) 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...
  • Page 373 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP Disassembling the oil pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...
  • Page 374 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP Disassembling the oil pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...

  • Page 375: Removing The Oil Pan And Oil Strainer Cover

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP EAS24930 3. Oil pump housing REMOVING THE OIL PAN AND OIL STRAINER COVER Inner-rotor-to-outer-rotor-tip 1. Remove: clearance • Oil strainer cover Less than 0.120 mm (0.0047 in) •...

  • Page 376: Checking The Oil Strainer

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP EAS24990 CHECKING THE OIL STRAINER Apply Three Bond No.1541C® “1” onto the mat- 1. Check: ing surfaces of the oil strainer cover and oil • Oil strainer (oil pan) Damage →...

  • Page 377: Crankcase

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE EAS25540 CRANKCASE Removing the rear balancer 12 Nm (1.2 m kgf, 8.7 ft Ibf) (10) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • •...
  • Page 378 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE Removing the rear balancer 12 Nm (1.2 m kgf, 8.7 ft Ibf) (10) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 379 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE Separating the crankcase 24 Nm (2.4 m kgf, 17 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) •...
  • Page 380 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE Separating the crankcase 24 Nm (2.4 m kgf, 17 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) •...
  • Page 381 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE Removing the oil nozzle 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 0.5 Nm (0.05 m kgf, 0.36 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) •...

  • Page 382: Removing The Rear Balancer

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE • M10 × 130 mm bolts: “1”–“6” EAS23P1092 REMOVING THE REAR BALANCER • M8 × 78 mm bolts: “7”–“12” 1. Remove: • M8 × 80 mm bolts: “13”–“19” •...

  • Page 383: Checking The Crankcase

    2. Apply: and make sure the crankcase halves sepa- • Sealant rate evenly. (onto the crankcase mating surfaces) EAS25580 Yamaha bond No. 1215 CHECKING THE CRANKCASE 90890-85505 1. Thoroughly wash the crankcase halves in a (Three Bond No.1215®) mild solvent.
  • Page 384 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE • Before installing the crankcase bolts “7”–“12”, install the O-rings onto the bolts, making sure that each O-ring contacts the bolt flange. • Lubricate the bolts “1”–“6” threads and wash- ers with engine oil.
  • Page 385 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE EWA23P1016 WARNING If the bolt is tightened more than the speci- fied angle, do not loosen the bolt and then re- tighten it. Instead, replace the bolt with a new ×3 one and perform the procedure again.
  • Page 386 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE Crankcase bolt “7”–“21”, “30”– “32” 24 Nm (2.4 m·kgf, 17 ft·lbf) Crankcase bolt “22”–“29” 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Tighten the crankcase bolts in the proper tight- ening sequence as shown.

  • Page 387: Installing The Rear Balancer

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE Rear balancer shaft retainer bolt Apply Three Bond No.1541C® “2” onto the mat- 12 Nm (1.2 m·kgf, 8.7 ft·lbf) ing surfaces of the oil delivery passage cover LOCTITE®...

  • Page 388: Crankshaft And Balancer

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT AND BALANCER EAS25950 CRANKSHAFT AND BALANCER Removing the crankshaft, connecting rods and front balancer 1st 20 Nm (2.0 m kgf, 14 ft Ibf) • • 2nd Specified angle 145–155˚ Order Job/Parts to remove Q’ty...
  • Page 389 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT AND BALANCER Removing the crankshaft, connecting rods and front balancer 1st 20 Nm (2.0 m kgf, 14 ft Ibf) • • 2nd Specified angle 145–155˚ Order Job/Parts to remove Q’ty Remarks...

  • Page 390: Removing The Front Balancer Shaft

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT AND BALANCER EAS23P1096 REMOVING THE FRONT BALANCER SHAFT Identify the position of each connecting rod cap, 1. Remove: connecting rod, and big end bearing so that it •...
  • Page 391 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT AND BALANCER b. Install the crankshaft journal lower bearings “1” and the crankshaft into the lower crank- case. Align the projections “a” on the crankshaft jour- nal lower bearings with the notches “b”...

  • Page 392: Checking The Connecting Rods

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT AND BALANCER M MMM M MMM M MMM M MMM M MMM The following procedure applies to all of the connecting rods. ECA13930 NOTICE Do not interchange the big end bearings and connecting rods.

  • Page 393: Checking The Front Balancer

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT AND BALANCER • Make sure the characters “d” on both the con- necting rod and connecting rod cap are aligned. • Make sure that the projection “e” on the con- necting rod cap faces the same direction as the “Y”...
  • Page 394 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT AND BALANCER 2. Measure: • Balancer shaft-journal-to-balancer shaft-jour- nal-bearing clearance Out of specification → Replace the balancer shaft journal bearings. Balancer shaft-journal-to-balanc- er shaft-journal-bearing clear- ance 0.016–0.040 mm (0.0006–0.0016 d.

  • Page 395: Installing The Connecting Rods

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT AND BALANCER 3. Select: Bearing color code • Front balancer shaft journal bearings (J –J 1.Blue 2.Black 3.Brown 4.Green • The numbers “A” stamped into the lower crank- EAS26150 INSTALLING THE CONNECTING RODS case and the numbers “B”...

  • Page 396: Installing The Crankshaft

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT AND BALANCER 30˚ 30˚ 145–155˚ 4. Tighten: EWA13400 WARNING • Connecting rod nuts M MMM M MMM M MMM M MMM M MMM If the connecting rod nut is tightened more EWA13390 than the specified angle, do not loosen the WARNING...

  • Page 397: Installing The Front Balancer Shaft

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT AND BALANCER c. Oil groove EAS26220 INSTALLING THE FRONT BALANCER SHAFT 1. Install: • Front balancer shaft journal upper bearings (into the upper crankcase) • Front balancer shaft journal lower bearings (into the lower crankcase) •...

  • Page 398: Transmission

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION EAS26241 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...
  • Page 399 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...
  • Page 400 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION Disassembling the main axle Order Job/Parts to remove Q’ty Remarks Circlip 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Toothed spacer Toothed washer Circlip 3rd/4th pinion gear...
  • Page 401 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION Disassembling the main axle Order Job/Parts to remove Q’ty Remarks Collar Bearing housing Spacer Bearing Main axle/1st pinion gear For assembly, reverse the disassembly pro- cedure. 5-106 email: info@motomatrix.co.uk...
  • Page 402 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION Disassembling the drive axle/middle drive pinion gear Order Job/Parts to remove Q’ty Remarks Middle drive pinion gear assembly Refer to “MIDDLE GEAR” on page 5-113. Bearing Washer 1st wheel gear Collar...
  • Page 403 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION Disassembling the drive axle/middle drive pinion gear Order Job/Parts to remove Q’ty Remarks 4th wheel gear Collar Toothed washer Circlip 6th wheel gear Circlip Toothed washer 2nd wheel gear Collar Drive axle...

  • Page 404: Removing The Transmission

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Main axle assembly “1” Remove the main axle assembly with the slide hammer bolts “2” and weight. Slide hammer bolt 90890-01083 3.

  • Page 405: Assembling The Main Axle And Drive Axle

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION Out of specification → Replace the main axle. Incorrect → Reassemble the transmission axle assemblies. Main axle runout limit 5. Check: 0.08 mm (0.0032 in) • Transmission gear movement Rough movement →...

  • Page 406: Installing The Transmission

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION 2. Install: • Main axle assembly “1” • Main axle bearing housing bolts Main axle bearing housing bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) LOCTITE® When installing the main axle assembly, use a pin “2”...
  • Page 407 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION • Install each shift drum retainer with its “OUT” mark “a” facing outward. • Align the projection “b” on the shift fork upper guide bar with the slot “c” in the shift drum up- per retainer.

  • Page 408: Middle Gear

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys MIDDLE GEAR EAS25711 MIDDLE GEAR Removing the middle driven pinion gear 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 33 Nm (3.3 m kgf, 24 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft...
  • Page 409 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys MIDDLE GEAR Removing the middle driven pinion gear 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 33 Nm (3.3 m kgf, 24 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 410 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys MIDDLE GEAR Removing the middle drive pinion gear 110 Nm (11 m kgf, 80 ft lbf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • •...
  • Page 411 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys MIDDLE GEAR Removing the middle drive pinion gear 110 Nm (11 m kgf, 80 ft lbf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • •...

  • Page 412: Removing The Middle Driven Pinion Gear Assembly

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys MIDDLE GEAR EAS23P1033 • While holding the universal joint yoke “2” with REMOVING THE MIDDLE DRIVEN PINION the universal joint holder “3” and the 20 mm GEAR ASSEMBLY (0.79 in) diameter attachment, loosen the uni- 1.

  • Page 413: Checking The Middle Driven Pinion Gear Assembly

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys MIDDLE GEAR b. Attach the middle drive shaft nut wrench (55 3. Check: mm) “1”. • Spring Cracks/damage → Replace. Middle drive shaft nut wrench (55 4. Check: •...

  • Page 414: Installing The Middle Drive Pinion Gear Assembly

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys MIDDLE GEAR EAS23P1040 INSTALLING THE MIDDLE DRIVE PINION GEAR ASSEMBLY 1. Install: • Washer • Spring retainers “1” While compressing the spring with the damper spring compressor “2”, install the washer and spring retainers.

  • Page 415: Installing The Middle Driven Pinion Gear Assembly

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys MIDDLE GEAR EAS23P1042 INSTALLING THE MIDDLE DRIVEN PINION GEAR ASSEMBLY 1. Install: • Middle driven pinion gear shim(s) “1” • Middle driven pinion gear assembly Middle driven pinion gear bearing housing bolt 33 Nm (3.3 m·kgf, 24 ft·lbf) LOCTITE®...

  • Page 416: Measuring The Middle Gear Backlash

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys MIDDLE GEAR 2. Measure: • Middle gear backlash Out of specification → Refer to “ADJUSTING THE MIDDLE GEAR BACKLASH” on page 5-121. Middle gear backlash 0.045–0.090 mm (0.002–0.004 in) M MMM M MMM M MMM...
  • Page 417 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys MIDDLE GEAR Middle driven pinion gear bearing housing bolt 33 Nm (3.3 m·kgf, 24 ft·lbf) ECA23P1047 NOTICE Do not overtighten the middle driven pinion gear bearing housing bolts or you may ob- tain too little middle gear backlash and dam- age the middle gears.

  • Page 418: Aligning The Middle Gear

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys MIDDLE GEAR 11.Measure: M MMM M MMM M MMM M MMM M MMM a. Position the middle gears with the appropri- • Middle gear backlash Out of specification → Refer to “MEASUR- ate shim(s) that has had its respective thick- ness calculated from information marked on ING THE MIDDLE GEAR BACKLASH”...
  • Page 419 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys MIDDLE GEAR Hundredths Rounded value 0, 1, 2 3, 4, 5, 6, 7 8, 9 Shims are supplied in the following thickness- Middle drive pinion gear shim Thickness (mm) “g”= a numeral on the upper crankcase, to be 0.10 0.15 0.20 0.30 0.40 0.50...
  • Page 420 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys MIDDLE GEAR Hundredths Rounded value 0, 1, 2 3, 4, 5, 6, 7 8, 9 Shims are supplied in the following thickness- Middle driven pinion gear shim Thickness (mm) 0.10 0.15 0.20 0.30 0.40 0.50 L LLL...

  • Page 421: 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.............. 6-5 INSTALLING THE THERMOSTAT............6-5 WATER PUMP....................6-6 DISASSEMBLING THE WATER PUMP............
  • Page 422 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 kgf, 5.1 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 423: Radiator

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys RADIATOR Removing the radiator 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 424: 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 inner side of the radiator. Damage → Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver.

  • Page 425: Thermostat

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) •...

  • Page 426: 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 cover 1. Check: Cracks/damage → Replace. • Thermostat Does not open at 69–73 °C (156.2–163.4 °F) EAS26480 → Replace. INSTALLING THE THERMOSTAT 1.

  • Page 427: 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 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) •...
  • Page 428 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys WATER PUMP Disassembling the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Water pump housing cover Gasket Circlip Impeller shaft Water pump seal...

  • Page 429: Disassembling The Water Pump

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys WATER PUMP EAS26510 EAS26541 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Water pump seal “1” • Water pump housing cover • Water pump housing •...
  • Page 430 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys WATER PUMP Mechanical seal installer 90890-04132 Water pump seal installer YM-33221-A Middle driven shaft bearing driv- 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 1. Straightedge 2.

  • Page 431: Installing The Water Pump

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys WATER PUMP EAS26590 INSTALLING THE WATER PUMP 1. Install: • Water pump assembly Align the projection “a” on the impeller shaft “1” with the slot “b” in the front balancer shaft “2”. 2.
  • Page 432 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys WATER PUMP 6-11 email: info@motomatrix.co.uk...

  • Page 433: 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 ..............7-3 REMOVING THE FUEL PUMP ..............7-3 CHECKING THE FUEL PUMP BODY............7-3 INSTALLING THE FUEL PUMP..............7-3 INSTALLING THE FUEL TANK..............

  • Page 434: Fuel Tank

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK EAS26620 FUEL TANK Removing the fuel tank and fuel pump 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 435 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK Removing the fuel tank and fuel pump 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 436: Removing The Fuel Tank

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK EAS26630 ECA14720 REMOVING THE FUEL TANK NOTICE 1. Extract the fuel in the fuel tank through the • Do not drop the fuel pump or give it a fuel tank cap with a pump.

  • Page 437: Installing The Fuel Tank

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK • Install the fuel hose connector securely onto the fuel tank until a distinct “click” is heard, and then make sure that it does not come loose. •...
  • Page 438 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies 4.5 Nm (0.45 m kgf, 3.3 ft Ibf) • • 4.5 Nm (0.45 m kgf, 3.3 ft Ibf) •...

  • Page 439: Throttle Bodies

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES Removing the throttle bodies 4.5 Nm (0.45 m kgf, 3.3 ft Ibf) • • 4.5 Nm (0.45 m kgf, 3.3 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 440 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES Removing the injectors 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) •...

  • Page 441: Checking The Injectors (Before Removing)

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES EAS23P1077 EAS23P1080 CHECKING THE INJECTORS (BEFORE CHECKING AND CLEANING THE THROTTLE REMOVING) BODIES 1. Check: • Injectors Clean the throttle bodies only if they cannot be Use the diagnostic code number “d:36–d:37”.
  • Page 442 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES • Do not apply cleaning solvent directly to any plastic parts, sensors, or seals. • Do not directly push the throttle valves to open them. •...

  • Page 443: Checking The Throttle Body Joints

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES • If an injector is subject to strong shocks or excessive force, replace it. • If installing the original fuel rail and screws, remove the white paint marks using a cleaning solvent.

  • Page 444: Checking The Fuel Pressure

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES ECA23P1003 NOTICE Pressure gauge 90890-03153 When lifting up the fuel tank, be careful not YU-03153 to pull the fuel tank overflow hose and fuel Fuel injector pressure adapter tank breather hose.

  • Page 445: Adjusting The Throttle Position Sensor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES d. Start the engine. e. Measure the fuel pressure. “dIAG” appears on the odometer LCD. Output pressure f. Diagnostic code number “d:01” is selected. 324.0 kPa (3.24 kgf/cm², 47.0 g.

  • Page 446: Installing The Throttle Body Joints

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES l. Check the meter display value. If the meter M MMM M MMM M MMM M MMM M MMM a. Temporary tighten the accelerator position display value is not 97–113, adjust the accel- sensor.

  • Page 447: 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 448 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM)............8-89 CIRCUIT DIAGRAM ................8-89 ABS COMPONENTS CHART ..............8-91 ABS COUPLER LOCATION CHART ............8-93 MAINTENANCE OF THE ABS ECU ............8-95 ABS TROUBLESHOOTING OUTLINE............
  • Page 449 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...

  • Page 450: 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 451 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IGNITION SYSTEM 3. Main fuse 4. Battery 5. Engine ground 9. Main switch 18.Ignition fuse 21.Relay unit 24.Neutral switch 25.Sidestand switch 28.Crankshaft position sensor 34.Lean angle sensor 39.ECU (engine control unit) 40.Cylinder-#1 left ignition coil 41.Cylinder-#1 right ignition coil...

  • Page 452: Engine Stopping Due To Sidestand Operation

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IGNITION SYSTEM EAS23P1071 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 453: 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). • Before troubleshooting, remove the following part(s): 1. Right side cowling 2. Right side panel 3.
  • Page 454 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IGNITION SYSTEM NG → 9. Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch. SWITCHES” on page 8-137. OK ↓ NG → 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch.
  • Page 455 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IGNITION SYSTEM email: info@motomatrix.co.uk...

  • Page 456: Electric Starting System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM email: info@motomatrix.co.uk...
  • Page 457 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTING SYSTEM 3. Main fuse 4. Battery 5. Engine ground 7. Starter relay 8. Starter motor 9. Main switch 18.Ignition fuse 21.Relay unit 22.Starting circuit cut-off relay 24.Neutral switch 25.Sidestand switch 54.Frame ground...

  • Page 458: 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 459: 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. • Before troubleshooting, remove the following part(s): 1. Right side cowling 2. Right side panel 3. Fuel tank NG →...
  • Page 460 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTING SYSTEM NG → 9. Check the engine stop switch. The engine stop switch is faulty. Replace Refer to “CHECKING THE the right handlebar switch. SWITCHES” on page 8-137. OK ↓...
  • Page 461 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTING SYSTEM 8-12 email: info@motomatrix.co.uk...

  • Page 462: Charging System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-13 email: info@motomatrix.co.uk...
  • Page 463 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 4. Battery 8-14 email: info@motomatrix.co.uk...

  • Page 464: 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. • Before troubleshooting, remove the following part(s): 1. Right side cowling 2. Right side panel NG → 1.
  • Page 465 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHARGING SYSTEM 8-16 email: info@motomatrix.co.uk...

  • Page 466: 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 467 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LIGHTING SYSTEM 3. Main fuse 4. Battery 5. Engine ground 9. Main switch 13.Headlight fuse 18.Ignition fuse 39.ECU (engine control unit) 54.Frame ground 60.Multi-function meter 63.High beam indicator light 67.Meter light 70.Headlight relay 73.Pass switch...

  • Page 468: 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 or meter light. • Before troubleshooting, remove the following part(s): 1.
  • Page 469 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LIGHTING SYSTEM NG → 8. Check the entire lighting system wiring. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM” on tem wiring. page 8-17. OK ↓...

  • Page 470: 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 471 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM 3. Main fuse 4. Battery 5. Engine ground 9. Main switch 17.ABS ECU fuse 18.Ignition fuse 21.Relay unit 24.Neutral switch 27.Fuel sender 32.Coolant temperature sensor 39.ECU (engine control unit) 49.Rear wheel sensor 51.Rear wheel sensor lead shield...

  • Page 472: 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 473 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 8-21. OK ↓ Replace the horn.
  • Page 474 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM NG → 5. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 8-21. OK ↓ Replace the meter assembly.
  • Page 475 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 8-21. OK ↓ Replace the meter assembly.

  • Page 476: Cooling System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-27 email: info@motomatrix.co.uk...
  • Page 477 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM 3. Main fuse 4. Battery 5. Engine ground 9. Main switch 16.Radiator fan motor fuse 18.Ignition fuse 32.Coolant temperature sensor 39.ECU (engine control unit) 54.Frame ground 90.Radiator fan motor 91.Radiator fan motor relay 8-28...

  • Page 478: 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. • Before troubleshooting, remove the following part(s): 1. Right side cowling 2. Right side panel 3. Fuel tank 4.
  • Page 479 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM NG → 7. Check the entire cooling system wiring. Properly connect or repair the cooling sys- Refer to “CIRCUIT DIAGRAM” on tem wiring. page 8-27. OK ↓...

  • Page 480: Fuel Injection System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS27331 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-31 email: info@motomatrix.co.uk...
  • Page 481 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM 3. Main fuse 4. Battery 5. Engine ground 7. Starter relay 9. Main switch 10.Fuel injection system fuse 11.Electric throttle valve fuse 13.Headlight fuse 17.ABS ECU fuse 18.Ignition fuse 21.Relay unit...

  • Page 482: Ecu Self-Diagnostic Function

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS27351 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 483: Troubleshooting Method

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS30580 4. Set the main switch to “OFF”, then to “ON” TROUBLESHOOTING METHOD again, and then check that no fault code num- ber is displayed. The engine operation is not normal and the engine trouble warning light comes on.
  • Page 484 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM • All displays on the meter disappear except the odometer displays. • “dIAG” appears on the odometer LCD. If “Co” appears on the odometer LCD, press the left set button to select “dIAG”.

  • Page 485: Troubleshooting Details

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM • If a diagnostic code No. does not have a corresponding fault code number, the information is shown in “DIAGNOSTIC CODE TABLE”. (Refer to “DIAGNOSTIC CODE TABLE” on page 8-73.) 8.
  • Page 486 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received Item from the crankshaft position sensor. Installed condition of crank- Improperly installed sensor Crank the engine.
  • Page 487 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Open or short circuit → Re- Wire harness continuity. Set the main switch to “ON”. place the wire harness.
  • Page 488 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged Item or detached hose). Set the engine stop switch to “ ”, and then operate the throttle Procedure while pushing the start switch “...
  • Page 489 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Throttle position sensor signal 2 Meter display • 7–23 (fully closed position) d:13 Procedure •...
  • Page 490 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Throttle position sensor out- Check for disconnected lead Set the main switch to “ON”. put voltage in the throttle position sensor Fault code number is not dis-...
  • Page 491 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the black/red Item lead of the ECU is detected. Improperly connected → Connection of wire harness Set the main switch to “ON”, ECU coupler.
  • Page 492 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Item Coolant temperature sensor: open or short circuit detected. Improperly connected → Connection of coolant tem- Set the main switch to “ON”. perature sensor coupler.
  • Page 493 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Improperly connected → Connection of intake air tem- Set the main switch to “ON”. perature sensor coupler.
  • Page 494 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. sensor #1: no normal signals are received from the O sen- Item sor #1. Probable cause of mal- Confirmation of service Item Maintenance job function and check...
  • Page 495 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. sensor #1: no normal signals are received from the O sen- Item sor #1. Defective O sensor. Replace the O sensor. Start the engine, warm it up, and then race it.
  • Page 496 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Cylinder-#1 left ignition coil: open or short circuit detected in Item the primary lead of the cylinder-#1 left ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
  • Page 497 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Cylinder-#1 left ignition coil: open or short circuit detected in Item the primary lead of the cylinder-#1 left ignition coil. Malfunction in ECU. Replace the ECU.
  • Page 498 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Cylinder-#1 right ignition coil: open or short circuit detected in Item the primary lead of the cylinder-#1 right ignition coil. Defective cylinder-#1 right ig- Execute the diagnostic Start the engine and let it idle nition coil.
  • Page 499 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Cylinder-#2 left ignition coil: open or short circuit detected in Item the primary lead of the cylinder-#2 left ignition coil. Open or short circuit → Re- Wire harness continuity.
  • Page 500 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Cylinder-#2 right ignition coil: open or short circuit detected in Item the primary lead of the cylinder-#2 right ignition coil. Improperly connected → Connection of wire harness Start the engine and let it idle ECU coupler.
  • Page 501 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Item Injector: open or short circuit detected. Probable cause of mal- Confirmation of service Item Maintenance job function and check completion Identify the malfunctioning Execute the diagnostic mode —...
  • Page 502 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. d:08 Lean angle sensor output voltage Meter display...
  • Page 503 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Malfunction in ECU. Replace the ECU. Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor.
  • Page 504 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected.
  • Page 505 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected.
  • Page 506 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected.
  • Page 507 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected.
  • Page 508 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected.
  • Page 509 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: the ECU is unable to monitor the battery Item voltage (an open or short circuit in the wire harness to the ECU).
  • Page 510 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. EEPROM cylinder fault code number: an error is detected Item while reading or writing on EEPROM (CO adjustment value). EEPROM fault code display •...
  • Page 511 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Item Charging voltage is abnormal. Meter display — Procedure — Probable cause of mal- Confirmation of service Item Maintenance job function and check completion Malfunction in charging sys- Check the charging system.
  • Page 512 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Item Accelerator position sensor: open or short circuit detected. Accelerator position sensor signal 2 Meter display • 9–25 (fully closed position) •...
  • Page 513 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Item Accelerator position sensor: open or short circuit detected. Accelerator position sensor Check for disconnected lead Set the main switch to “ON”. output voltage in the accelerator position Fault code number is not dis-...
  • Page 514 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Item YCC-T drive system: malfunction detected. Abnormality → Replace the Check the ETV (Electronic Set the main switch to “ON”. Throttle Valve) fuse. ETV (Electronic Throttle Fault code number is not dis- played →...
  • Page 515 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. sensor #2: no normal signals are received from the O sen- Item sor #2. Improperly connected → Connection of O sensor Start the engine, warm it up, Connect the coupler secure- and then race it.
  • Page 516 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Front wheel sensor: no normal signals are received from the Item rear wheel sensor. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 517 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Front wheel sensor: no normal signals are received from the Item rear wheel sensor. Improperly connected → Connection of ABS ECU Execute the diagnostic coupler.
  • Page 518 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Front wheel sensor: no normal signals are received from the Item rear wheel sensor. Defective rear wheel sensor. Improperly installed sensor Execute the diagnostic →...
  • Page 519 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Er-1 ECU internal malfunction (output signal error): no signals are Item received from the ECU. Improperly connected → Connection of multi-function Set the main switch to “ON”.
  • Page 520 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Er-2 ECU internal malfunction (output signal error): no signals are Item received from the ECU within the specified duration. Improperly connected → Connection of multi-function Set the main switch to “ON”.
  • Page 521 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Er-3 ECU internal malfunction (output signal error): data from the Item ECU cannot be received correctly. Improperly connected → Connection of multi-function Set the main switch to “ON”.

  • Page 522: Diagnostic Code Table

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Er-4 ECU internal malfunction (input signal error): non-registered Item data has been received from the meter. Improperly connected → Connection of multi-function Set the main switch to “ON”.
  • Page 523 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Diag- nostic Item Meter display/Actuation Procedure code d:57 Grip warmer relay Illuminates the engine trou- — ble warning light. d:61 Malfunction history code — display •...

  • Page 524: 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 8-75 email: info@motomatrix.co.uk...
  • Page 525 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL PUMP SYSTEM 3. Main fuse 4. Battery 5. Engine ground 9. Main switch 10.Fuel injection system fuse 18.Ignition fuse 21.Relay unit 23.Fuel pump relay 26.Fuel pump 39.ECU (engine control unit) 54.Frame ground 99.Engine stop switch...

  • Page 526: Troubleshooting

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Right side cowling 2. Right side panel 3.
  • Page 527 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL PUMP SYSTEM 8-78 email: info@motomatrix.co.uk...

  • Page 528: Immobilizer System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 8-79 email: info@motomatrix.co.uk...
  • Page 529 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM 3. Main fuse 4. Battery 5. Engine ground 9. Main switch 12.Backup fuse (odometer, clock, and immobilizer system) 18.Ignition fuse 20.Immobilizer unit 39.ECU (engine control unit) 54.Frame ground 56.Immobilizer system indicator light 60.Multi-function meter...

  • Page 530: General Information

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM EAS27671 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: •...
  • Page 531 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 532 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 533 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 534: Troubleshooting

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM EAS27701 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. NG → 1. Check the fuses. (Main, ignition, and backup) Replace the fuse(s).
  • Page 535 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 536 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM a. Light on b. Light off 8-87 email: info@motomatrix.co.uk...
  • Page 537 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM 8-88 email: info@motomatrix.co.uk...

  • Page 538: Abs (Anti-Lock Brake System)

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) EAS28790 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27730 CIRCUIT DIAGRAM 8-89 email: info@motomatrix.co.uk...
  • Page 539 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) 3. Main fuse 4. Battery 5. Engine ground 6. ABS motor fuse 7. Starter relay 9. Main switch 14.ABS solenoid fuse 17.ABS ECU fuse 18.Ignition fuse 21.Relay unit 22.Starting circuit cut-off relay...

  • Page 540: Abs Components Chart

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) EAS27740 ABS COMPONENTS CHART 12 13 1. ABS warning light 2. Front wheel sensor rotor 3. Front wheel sensor 4. Right front brake caliper 5.
  • Page 541 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) 8-92 email: info@motomatrix.co.uk...

  • Page 542: Abs Coupler Location Chart

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) EAS27750 ABS COUPLER LOCATION CHART Lg R/W G Dg Sb/W (GRAY) Y W/L R/W B Br L/B Dg Br/W 8-93 email: info@motomatrix.co.uk...
  • Page 543 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) 1. Right handlebar switch coupler 2. Starter relay coupler 3. Main fuse coupler 4. ABS ECU coupler 5. ABS test coupler 6. Rear wheel sensor coupler 7.

  • Page 544: Maintenance Of The Abs Ecu

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) EAS27770 MAINTENANCE OF THE ABS ECU If the ABS ECU coupler is clogged with mud or dirt, clean with compressed air. Checking the ABS ECU 1.

  • Page 545: Basic Instructions For Troubleshooting

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was set to “ON”. During this test, a “clicking” noise can be heard from under the rider seat, and if the brake lever or brake pedal are even slightly applied, a vibration can be felt at the lever and pedal, but these do not indicate a malfunction.

  • Page 546: Basic Process For Troubleshooting

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) EAS27810 BASIC PROCESS FOR TROUBLESHOOTING [A] Set the main switch to “ON” and check the ABS warning light. The ABS warning light (LED) is defective. •...

  • Page 547: [A] Checking The Abs Warning Light

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) EWA23P1019 WARNING When maintenance or checks have been performed on components related to the ABS, be sure to perform a final check before delivering the vehicle to the customer. (Refer to “[D-3] FINAL CHECK”...

  • Page 548: [B-5] Malfunctions Are Currently Detected

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) a. Light on e. Fault code 21 b. Light off f. 1 cycle c. Time (second) g. Repeats d. Fault code 12 2. The ABS warning light flashes every 0.5 second for more than 6 seconds. The ABS warning light flashes every 0.5 second if no fault code for a past malfunction is stored in the memory of the ABS ECU.

  • Page 549: [C-3] The Abs Warning Light Remains On

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) 2. Battery • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-142. • If the battery is defective, clean the battery terminals and recharge it, or replace the battery. 3.

  • Page 550: [C-4] The Abs Warning Light Flashes

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) • Set the main switch to “ON”, and then check the ABS warning light. • If the ABS warning light is on, the internal circuit of the meter assembly is defective. Replace the meter assembly.
  • Page 551 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Fault Symptom Check point code No. • Rear wheel sensor circuit • Wire harness (ABS circuit) Rear wheel sensor circuit is short-cir- • Connection of the rear wheel sensor cou- cuited.
  • Page 552 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Fault Symptom Check point code No. Solenoid valve data is abnormal. • Hydraulic unit assembly Hydraulic pressure sensor power is ab- • Hydraulic unit assembly normal.
  • Page 553 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Front wheel sensor signal is not received prop- erly. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel sensor.
  • Page 554 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Rear wheel sensor signal is not received proper- Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel sensor.
  • Page 555 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Incorrect signal from the front wheel sensor is detected. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel sensor.
  • Page 556 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Incorrect signal from the rear wheel sensor is detected. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel sensor.
  • Page 557 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Front wheel sensor circuit is short-circuited. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Connections •...
  • Page 558 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Front wheel sensor circuit is short-circuited. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Wire harness continuity. •...
  • Page 559 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Front wheel sensor circuit is short-circuited. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Defective wheel sensor. If the above items were per- formed and no malfunctions were found, connect the ABS ECU...
  • Page 560 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Rear wheel sensor circuit is short-circuited. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Wire harness continuity. •...
  • Page 561 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Rear wheel sensor circuit is short-circuited. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Defective wheel sensor. If the above items were per- formed and no malfunctions were found, connect the ABS ECU...
  • Page 562 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Missing pulses detected in the rear wheel sen- sor signal. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method...
  • Page 563 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Start switch signal is not received properly (start switch circuit or start switch monitor cir- cuit). Order Item/components and probable Check or maintenance job Reinstatement cause...
  • Page 564 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom ABS motor is defective. Power is not supplied to the ABS motor. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation...
  • Page 565 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Hydraulic unit ABS motor is short-circuited. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Short circuit in ABS motor relay. Replace the hydraulic unit as- •...
  • Page 566 Brake lines • Check the brake lines for kinks and deterioration. EWA23P1020 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • Check that the connections of the brake lines from the brake...
  • Page 567 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Front wheel will not recover from the locking tendency even though the signal is continuous- ly transmitted from the ABS ECU to release the hydraulic pressure (when the battery voltage is normal).
  • Page 568 (particularly between the hydraulic unit and the rear brake caliper). EWA23P1020 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • Check that the connections of the brake lines from the brake master cylinder to the hydraulic unit are correct.
  • Page 569 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Rear wheel will not recover from the locking ten- dency even though the signal is continuously transmitted from the ABS ECU to release the hy- draulic pressure (when the battery voltage is normal).
  • Page 570 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Power voltage is too high. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Battery voltage Replace the battery.
  • Page 571 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom ABS ECU has internal malfunction. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Hydraulic unit assembly internal mal- Replace the hydraulic unit as- •...
  • Page 572 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Hydraulic pressure sensor power is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Defective internal monitor circuit (hy- Replace the hydraulic unit as- •...
  • Page 573 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Rear brake master cylinder pressure sensor is defective. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Rear brake master cylinder pressure Replace the hydraulic unit as-...
  • Page 574 (particularly between the hydraulic unit and the rear brake caliper). EWA23P1020 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • Check that the connections of the brake lines from the brake master cylinder to the hydraulic unit are correct.
  • Page 575 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) EWA23P1022 WARNING The rear brake will not function properly if the connections are reversed. • Brake hose (rear brake master cylinder to hydraulic unit brake pipe joint) “1” inlet: from the rear brake master cylinder •...
  • Page 576 (particularly between the hydraulic unit and the rear brake caliper). EWA23P1020 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • Check that the connections of the brake lines from the brake master cylinder to the hydraulic unit are correct.
  • Page 577 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) EWA23P1022 WARNING The rear brake will not function properly if the connections are reversed. • Brake hose (rear brake master cylinder to hydraulic unit brake pipe joint) “1” inlet: from the rear brake master cylinder •...

  • Page 578: [D-1] Deleting The Fault Codes

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) EAS23P1056 8. Set the main switch to “OFF”. [D-1] DELETING THE FAULT CODES 9. Disconnect the test coupler adapter from the 1. Remove the protective cap, and then connect ABS test coupler, and then install the protec- the test coupler adapter “1”...
  • Page 579 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) L/B Dg Br/W b. Measure the ABS ECU voltage. 4. Connect the ABS ECU coupler (without cou- pler cover) “1”. L LLL L LLL L LLL L LLL L LLL...

  • Page 580: [D-3] Final Check

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) 11.If the above-mentioned checks are within M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (DC 20 V) to the specification, replace the hydraulic unit as- ABS ECU coupler.
  • Page 581 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) 8-132 email: info@motomatrix.co.uk...

  • Page 582: Electrical Components

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS EAS27973 ELECTRICAL COMPONENTS 8-133 email: info@motomatrix.co.uk...
  • Page 583 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 1. Main switch 2. Front brake light switch 3. Clutch switch 4. Intake air temperature sensor 5. Throttle servo motor 6. Throttle position sensor 7. Accelerator position sensor 8.
  • Page 584 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 8-135 email: info@motomatrix.co.uk...
  • Page 585 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 1. Rectifier/regulator 2. Relay unit 3. Main fuse 4. Radiator fan motor relay 5. Turn signal/hazard relay 6. Headlight relay 7. ECU (engine control unit) 8.

  • Page 586: Checking The Switches

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS EAS27981 CHECKING THE SWITCHES R/Y W/Y Br/W Br/W R Br/L Br/R R/Y Br/W W/Y Br/R Br B/W Br B/Y L/Y Ch (BLACK) ( BLACK ) Br/L R/W R/B L/W B...
  • Page 587 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 1. Pass switch 2. Dimmer switch 3. Hazard switch 4. Turn signal switch 5. Horn switch 6. Engine stop switch 7. Start switch 8. D-mode switch 9.
  • Page 588 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 NOTICE Never insert the tester probes into the coupler terminal slots “a”.

  • Page 589: 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, keep flammable products and your hands Do not check any of the lights that use LEDs. away from the bulb until it has cooled down.

  • Page 590: 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 b. If the pocket tester indicates “∞”, replace the The following procedure applies to all of the bulb fuse.

  • Page 591: Checking And Charging The Battery

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS cal system, cause the lighting and ignition be charged according to the appropriate systems to malfunction and could possibly charging method. If the battery is over- cause a fire.
  • Page 592 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS • No charging is necessary when the open-cir- • If it is impossible to regulate the charging cuit voltage equals or exceeds 12.8 V. current on the battery charger, be careful not to overcharge the battery.
  • Page 593 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS c. Make sure that the current is higher than the standard charging current written on the bat- Voltage should be measured 30 minutes after tery. the engine is stopped.

  • Page 594: Checking The Relays

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 10.Install: 3. Positive tester probe • Right side cowling 4. Negative tester probe Refer to “GENERAL CHASSIS” on page 4-1. Result EAS28040 Continuity CHECKING THE RELAYS (between “3”and “4”) Check each switch for continuity with the pocket tester.

  • Page 595: Checking The Turn Signal/Hazard Relay

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS Radiator fan motor relay Br/L b. Turn the main switch to “ON”. 1. Positive battery terminal c. Measure the turn signal/hazard relay input 2. Negative battery terminal voltage.

  • Page 596: Checking The Relay Unit (Diode)

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS EAS28050 CHECKING THE RELAY UNIT (DIODE) 1. Check: • Relay unit (diode) Out of specification → Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C M MMM M MMM M MMM M MMM...

  • Page 597: Checking The Ignition Spark Gap

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS Minimum ignition spark gap 6.0 mm (0.24 in) If the ignition spark gap is within specification, the ignition system circuit is operating normally. M MMM M MMM M MMM M MMM...

  • Page 598: Checking The Lean Angle Sensor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS • Positive tester probe → Pocket tester yellow/green “1” 90890-03112 • Negative tester probe → Analog pocket tester black/blue “2” YU-03112-C • Positive tester probe → black “1”...

  • Page 599: Checking The Stator Coil

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS b. Check the starter motor operation. EAS28170 CHECKING THE RECTIFIER/REGULATOR L LLL L LLL L LLL L LLL L LLL 1. Check: EAS28150 • Charging voltage CHECKING THE STATOR COIL Out of specification →...

  • Page 600: Checking The Fuel Sender

    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 en- green “1”...

  • Page 601: Checking The Oil Level Warning Light

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS c. Measure the radiator fan motor movement. EAS29050 CHECKING THE OIL LEVEL WARNING L LLL L LLL L LLL L LLL L LLL LIGHT EAS28261 This model is equipped with a self-diagnosis de- CHECKING THE COOLANT TEMPERATURE vice for the oil level detection circuit.

  • Page 602: Checking The Throttle Position Sensor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS • Positive tester probe → blue “1” • Negative tester probe → black/blue “2” d. Heat the coolant or let it cool down to the specified temperatures.

  • Page 603: Checking The Intake Air Pressure Sensor

    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 Pocket tester a. Connect the test harness S-pressure sensor 90890-03112 (3P) between the intake air pressure sensor Analog pocket tester and wire harness.

  • Page 604: Checking The Intake Air Temperature Sensor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS EAS28421 3. Install: CHECKING THE INTAKE AIR • Intake air temperature sensor TEMPERATURE SENSOR 1. Remove: Intake air temperature sensor • Intake air temperature sensor screw (from the air filter case.) 1.2 Nm (0.12 m·kgf, 0.87 ft·lbf)
  • Page 605 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 2. Disconnect: • Throttle servo motor coupler 3. Check: • Throttle servo motor resistance Out of specification → Replace the throttle bodies. Resistance 0–100 Ω ECA23P1083 NOTICE Do not disassemble the throttle servo motor.
  • Page 606 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 8-157 email: info@motomatrix.co.uk...

  • Page 607: 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 608: Troubleshooting

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TROUBLESHOOTING EAS28451 Electrical system TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) • Blown, damaged or incorrect fuse The following guide for troubleshooting does not •...

  • Page 609: Poor Medium-And-High-Speed Performance

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TROUBLESHOOTING Electrical system EAS28550 JUMPS OUT OF GEAR 1. Battery • Discharged battery Shift shaft • Faulty battery • Incorrect shift pedal position 2. Spark plug(s) • Improperly returned stopper lever •...

  • Page 610: Overheating

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TROUBLESHOOTING EAS30480 EAS28620 OVERHEATING POOR BRAKING PERFORMANCE • Worn brake pad Engine • Worn brake disc 1. Clogged coolant passages • Air in hydraulic brake system • Cylinder head and piston(s) •...

  • Page 611: Faulty Lighting Or Signaling System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TROUBLESHOOTING 4. Swingarm Turn signal does not come on • Worn bearing or bushing • Faulty turn signal switch • Bent or damaged swingarm • Faulty turn signal/hazard relay 5.

  • Page 612: Wiring Diagram

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS28740 54. Frame ground EAS28750 WIRING DIAGRAM COLOR CODE 55. Meter assembly Black 56. Immobilizer system indicator XT1200Z(Z) 2010 Brown light 1. AC magneto Chocolate 57. Oil level warning light 2.
  • Page 613 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
  • Page 614 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 615: Wiring Diagram

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys XT1200Z(Z) 2010 XT1200Z(Z) 2010 XT1200Z(Z) 2010 XT1200Z(Z) 2010 XT1200Z(Z) 2010 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO Br/G W3 W2 (BLACK) (GRAY) R/W2 LEAN ANGLE SENSOR NEUTRAL SWITCH WIRE HARNESS WIRE HARNESS...
  • Page 616 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys XT1200Z(Z) 2010 XT1200Z(Z) 2010 XT1200Z(Z) 2010 XT1200Z(Z) 2010 XT1200Z(Z) 2010 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO (BLACK) (GRAY) LEAN ANGLE SENSOR NEUTRAL SWITCH WIRE HARNESS WIRE HARNESS SUB-WIRE HARNESS...

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