Yamaha XT660R 2004 Service Manual
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Yamaha XT660R 2004 Service Manual

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Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys
2004
XT660R(S)
XT660X(S)
5VK1-AE1
SERVICE MANUAL
email: info@motomatrix.co.uk

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Summary of Contents for Yamaha XT660R 2004

  • Page 1 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 2004 XT660R(S) XT660X(S) 5VK1-AE1 SERVICE MANUAL email: info@motomatrix.co.uk...
  • Page 2 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
  • Page 3 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS00000 XT660R(S)/XT660X(S) 2004 SERVICE MANUAL ©2003 by MBK Industrie First edition, December 2003 All rights reserved. Any reproduction or unauthorized use without the written permission of MBK Industrie is expressly prohibited.

  • Page 4: Important Manual Information

    EAS00002 NOTICE This manual was produced by MBK Industrie primarily for use by Yamaha dealers and their quali- fied mechanics. It is not possible to include all the knowledge of a mechanic in one manual. There- fore, 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 5: How To Use This Manual

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS00007 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 6: General Information

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS00008 SYMBOLS The following symbols are not relevant to SPEC every vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information CHAS 2 Specifications 3 Periodic checks and adjustments 4 Chassis...

  • Page 7: Table Of Contents

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS00010 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE COOLING SYSTEM COOL FUEL INJECTION SYSTEM – ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG 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 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys INFO email: info@motomatrix.co.uk...
  • Page 10 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys INFO CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION..............1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE ....................1-2 FI SYSTEM....................1-3 IMPORTANT INFORMATION ................. 1-4 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-4 REPLACEMENT PARTS................1-4 GASKETS, OIL SEALS AND O-RINGS ............
  • Page 11 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys INFO email: info@motomatrix.co.uk...

  • Page 12: General Information

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys MOTORCYCLE IDENTIFICATION INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe.

  • Page 13: Features

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES INFO EAS00019 FEATURES EAS00896 OUTLINE The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.

  • Page 14: Fi System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES INFO EAS00897 FI SYSTEM The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the injector at 324 kPa (3.24 kg/cm , 46.1 psi) higher than the intake manifold pressure.

  • Page 15: Important Information

    5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 16: Lock Washers/Plates And Cotter Pins

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut.

  • Page 17: Checking The Connections

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2.

  • Page 18: Special Tools

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques.
  • Page 19 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration T-handle Damper rod holder T-handle 90890-01326 Holder These tools are used to hold the damper 90890-01460 rod holder when removing or installing the damper rod.
  • Page 20 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Thickness gauge 90890-03079 This tool is used to measure the valve clearance. Compression gauge 90890-03081 These tools are used to measure the engine compression.
  • Page 21 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Valve guide remover (ø 6) 90890-04064 This tool is needed to remove and install the valve guides. Valve guide installer (ø 6) 90890-04065 This tool is needed to install the valve guides.
  • Page 22 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Yamaha bond No. 1215 90890-85505 This bond is used to seal two mating sur- faces (e.g., crankcase mating surfaces). 1 - 11 email: info@motomatrix.co.uk...
  • Page 23 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...

  • Page 24: Spec

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC email: info@motomatrix.co.uk...
  • Page 25 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-11 ELECTRICAL SPECIFICATIONS ..............2-16 CONVERSION TABLE .................. 2-19 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-19 TIGHTENING TORQUE................. 2-20 ENGINE TIGHTENING TORQUE ............
  • Page 26 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC email: info@motomatrix.co.uk...

  • Page 27: Specifications

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code XT660R: 5VK1 (Europe) ---- 5VK2 (AUS) ---- 5VK3 (GB) ---- XT660X: 1D21 (Europe) ---- 1D22 (AUS) ---- 1D23 (GB) ----...

  • Page 28: Engine Specifications

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, SOHC ---- Displacement 660 cm (40.27 cu · in) ---- Cylinder arrangement Forward-inclined single cylinder ---- Bore ×...
  • Page 29 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil pump Oil pump type Trochoid ---- Inner-rotor-to-outer-rotor-tip clear- 0.07 ~ 0.12 mm (0.0028 ~ 0.0047 in) 0.2 mm ance (0.008 in) Outer-rotor-to-oil-pump-housing 0.03 ~ 0.08 mm (0.0012 ~ 0.0031 in) 0.15 mm...
  • Page 30 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshaft Drive system Chain drive (left) ---- Intake camshaft lobe dimensions Measurement A 43.488 ~ 43.588 mm (1.7121 ~ 1.7161 in) 43.338 mm (1.7062 in) Measurement B 36.959 ~ 37.059 mm (1.4551 ~ 1.4590 in) 36.840 mm...
  • Page 31 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ENGINE SPECIFICATIONS Item Standard Limit Rocker arm/rocker arm shaft Rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) 12.036 mm (0.4739 in) Shaft outside diameter 11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in) 11.955 mm (0.4707 in) Arm-to-shaft clearance...
  • Page 32 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve-stem-to-valve-guide clearance Intake 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.08 mm (0.0031 in) Exhaust 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) 0.10 mm (0.0039 in) Valve stem runout...
  • Page 33 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ENGINE SPECIFICATIONS Item Standard Limit Cylinder Cylinder arrangement Forward-inclined single cylinder ---- Bore × stroke 100.0 × 84.0 mm (3.94 × 3.31 in) ---- Compression ratio 10 : 1 ---- Bore...
  • Page 34 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ENGINE SPECIFICATIONS Item Standard Limit 2nd ring Ring type Taper ---- Dimensions (B × T) 1.20 × 4.00 mm (0.047 × 0.157 in) ---- End gap (installed) 0.35 ~ 0.50 mm (0.0138 ~ 0.0197 in) 0.85 mm (0.0335 in)
  • Page 35 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ENGINE SPECIFICATIONS Item Standard Limit Clutch Clutch type Wet, multiple disc ---- Clutch release method Outer pull, rack and pinion pull ---- Operation Left-hand operation ---- Clutch cable free play 10.0 ~ 15.0 mm (0.39 ~ 0.59 in) ----...
  • Page 36 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ENGINE SPECIFICATIONS Item Standard Limit Maximum main axle runout ---- 0.08 mm (0.0031 in) Maximum drive axle runout ---- 0.08 mm (0.0031 in) Shifting mechanism Shift mechanism type Shift drum and guide bar ---- Decompression device...

  • Page 37: Chassis Specifications

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Diamond ---- Caster angle 27.25° (XT660R) ---- 26° (XT660X) ---- Trail 107 mm (4.21 in) (XT660R) ---- 94 mm (3.70 in) (XT660X) ----...
  • Page 38 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front tire Tire type With tube ---- Size 90/90-21M/C 54S, 90/90-21M/C 54T ---- (XT660R) 120/70R 17M/C 58 H (XT660X) ---- Model/manufacturer TOURANCE FRONT/METZELER, ---- SIRAC/MICHELIN (XT660R)
  • Page 39 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front brakes Brake type Single-disc brake ---- Operation Right-hand operation ---- Recommended fluid DOT 4 ---- Brake discs Diameter × thickness 298.0 ×...
  • Page 40 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CHASSIS SPECIFICATIONS Item Standard Limit Steering Steering bearing type Taper roller bearing ---- Lock to lock angle (left) 44.0° ---- Lock to lock angle (right) 44.0° ---- Front suspension Suspension type...
  • Page 41 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear suspension Suspension type Swingarm (monocross) ---- Rear shock absorber assembly type Coil spring/gas-oil damper ---- Rear shock absorber assembly travel 65.0 mm (2.56 in) ---- Spring Free length...

  • Page 42: Electrical Specifications

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V ---- Ignition system Ignition system type Transistorized coil ignition (digital) ---- Ignition timing 9.0° BTDC at 1,400 r/min ---- Advancer type Electric...
  • Page 43 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Bulbs (voltage/wattage × quantity) 12 V 55.0 W/60.0 W × 1 Headlight ---- 12 V 5.0 W × 1 Auxiliary light ---- 12 V 5.0 W/21.0 W ×...
  • Page 44 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Headlight relay Model/manufacturer ACM33211 M04/MATSUSHITA ---- Radiator fan Model/manufacturer 5VW/KTM ---- Fan motor relay Model/manufacturer ACM33211 M04/MATSUSHITA ---- Intake air pressure sensor Thermostat type/manufacturer 5PS1/DENSO ----...

  • Page 45: Conversion Table

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE All specification data in this manual are listed SPECIFICATIONS in SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC unit data to dard fasteners with a standard ISO thread...

  • Page 46: Tightening Torque

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC TIGHTENING TORQUE TIGHTENING TORQUE ENGINE TIGHTENING TORQUE Tightening torque Thread Part to be tightened Part name Q’ty Remarks size Nm m · kg ft · lb Cylinder head (exhaust pipe) Stud bolt Cylinder head (left side)
  • Page 47 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC TIGHTENING TORQUE Tightening torque Thread Part to be tightened Part name Q’ty Remarks size Nm m · kg ft · lb Oil strainer Bolt Oil pump Screw Oil baffle plate 2 Bolt...
  • Page 48 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC TIGHTENING TORQUE Tightening torque Thread Part to be tightened Part name Q’ty Remarks size Nm m · kg ft · lb Starter clutch Bolt Stator coil Bolt Crankshaft position sensor Bolt...

  • Page 49: Chassis Tightening Torques

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC TIGHTENING TORQUE CHASSIS TIGHTENING TORQUES Tightening torque Thread Part to be tightened Remarks size Nm m · kg ft · lb Engine mounting: Engine upper bracket and frame Engine upper bracket and engine Engine front bracket and frame Engine front bracket and engine...
  • Page 50 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC TIGHTENING TORQUE Tightening torque Thread Part to be tightened Remarks size Nm m · kg ft · lb Fuel tank and frame Fuel pump and fuel tank Rectifier/regulator and air filter case ECU and air filter case Horn bracket and frame...

  • Page 51: Lubrication Points And Lubricant Types

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point Symbol Oil seal lips O-rings Bearings Cylinder head tightening bolts Cylinder tightening bolts Crankshaft pin Timing chain sprocket inner surface Connecting rod big end thrust surface...
  • Page 52 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC LUBRICATION POINTS AND LUBRICANT TYPES Lubrication Point Symbol Yamaha bond Crankcase mating surface No.1215 Yamaha bond A.C. magnet lead grommet (A.C. magneto cover) No.1215 Yamaha bond Oil seal holder tightening bolt No.1215...

  • Page 53: Chassis

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication Point Symbol Front wheel oil seal lips (left and right) Rear wheel oil seal lips (left and right) Rear wheel drive hub contact surface Rear arm pivot shaft outer surface and bush outer surface and oil seal lip Dust cover thrust surface...

  • Page 54: Cooling System Diagrams

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC COOLING SYSTEM DIAGRAMS EAS00033 COOLING SYSTEM DIAGRAMS 1 Water jacket joint È From the radiator 2 Water pump outlet hose É To the cylinder 3 Water pump outlet pipe 4 Water pump È...
  • Page 55 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC COOLING SYSTEM DIAGRAMS 1 Fast idle plunger outlet hose È From the fast idle plunger 2 Coolant reservoir breather hose É To the cylinder 3 Coolant reservoir hose Ê...

  • Page 56: Lubrication Chart

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC LUBRICATION CHART LUBRICATION CHART : Pressure feed : Splashed scavenge Camshaft Cylinder head Oil tank Oil filter Drive axle Crankshaft Main axle Connecting Check ball Oil pump rotor 1 Oil pump rotor 2...

  • Page 57: Lubrication Diagrams

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC LUBRICATION DIAGRAMS EAS00034 LUBRICATION DIAGRAMS 1 Oil delivery hose 2 2 Oil strainer 3 Oil delivery hose 1 2 - 31 email: info@motomatrix.co.uk...
  • Page 58 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC LUBRICATION DIAGRAMS 1 Oil delivery pipe 2 2 Oil delivery pipe 1 3 Oil filter 4 Oil pump 2 - 32 email: info@motomatrix.co.uk...
  • Page 59 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC LUBRICATION DIAGRAMS 1 Oil delivery hose 2 È To oil tank 2 Oil delivery pipe 2 3 Oil filter 4 Oil pump rotor 1 5 Oil pump rotor 2 6 Main axle 7 Oil delivery pipe 3 È...
  • Page 60 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC LUBRICATION DIAGRAMS 1 Camshaft 2 Oil delivery pipe 1 3 Oil filter 4 Main axle 5 Drive axle 6 Crankshaft 2 - 34 email: info@motomatrix.co.uk...

  • Page 61: Cable Routing

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING EAS00035 CABLE ROUTING 1 Left handlebar switch lead 0 Immobilizer unit lead 2 Clutch switch lead 3 Clutch cable 4 Front brake light switch lead 5 Right handlebar switch lead 6 Throttle cable 7 Headlight lead...
  • Page 62 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING È When fastening the front brake light switch lead, Ì Route the throttle cables, left handlebar switch leave some slack in the lead at the area shown. lead, right handlebar switch lead, front brake É...
  • Page 63 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING 1 Front turn signal light lead (right) È Fasten the sub-wire harness and meter assem- 2 Meter assembly lead bly lead with a plastic band. Fasten the sub-wire 3 Auxiliary light lead harness at the white tape.
  • Page 64 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Ë Fasten the left and right front turn signal light Ï 0 ~ 5 mm (0 ~ 0.20 in) for both left and right leads to the headlight stay with a plastic locking sides tie.
  • Page 65 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING 1 Ignition coil lead B Fast idle plunger outlet hose 2 Main switch coupler 3 Immobilizer unit coupler È Fasten the fast idle plunger outlet hose and igni- 4 Air induction system lead tion coil leads with a hose holder.
  • Page 66 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Ê Fasten the main switch lead, immobilizer unit Ì Fasten the clutch cable to the horn bracket with lead, and horn switch lead with a plastic locking a cable holder.
  • Page 67 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING 1 Rear brake light switch lead È Fasten the wire harness, negative battery lead, 2 Negative battery lead and rear brake light switch lead to the frame with 3 Lean angle cut-off switch lead a plastic locking tie.
  • Page 68 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING 1 Neutral switch connector 0 A.C. magneto lead K Immobilizer unit lead 2 Crankshaft position sensor A Oil tank breather hose L Clutch cable B Oil delivery hose 2 M Main switch lead coupler...
  • Page 69 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING È Fasten the left handlebar switch lead, right han- É Fasten the left handlebar switch lead, right han- dlebar switch lead, headlight lead, meter assem- dlebar switch lead, headlight lead, meter assem- bly lead, front brake light switch lead, and clutch bly lead, front brake light switch lead, clutch...
  • Page 70 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Ë Fasten the wire harness to the frame at the Ï Fasten the neutral switch lead, crankshaft posi- white tape with a plastic locking tie. tion sensor lead, sidestand switch lead, speed Ì...
  • Page 71 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Ò Fasten the wire harness, air-filter-to-air-cut-off- valve hose, and oil delivery hose 2 with a plastic clamp. Ó Fasten the left handlebar switch lead, right han- dlebar switch lead, headlight lead, meter assem- bly lead, front brake light switch lead, and clutch switch lead with a plastic band.
  • Page 72 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING 1 Starter motor lead È Fasten the wire harness and starter motor lead 2 Fuse box 1 lead to the frame with a plastic locking tie. 3 Fuse box 2 lead É...
  • Page 73 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING 1 Immobilizer unit coupler È 0 ~ 10 mm (0 ~ 0.39 in) 2 Intake air temperature sensor É 30 ~ 40 mm (1.18 ~ 1.57 in) 3 Fuel injector lead Ê...
  • Page 74 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING 1 Battery È Fasten the tail/brake light lead with two plastic 2 Negative battery lead locking ties so that the coupler is positioned to 3 Tail/brake light coupler the inside of where the relays (turn signal/hazard 4 Rear turn signal light connector...
  • Page 75 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Ë Connect the couplers so that they are not pinched between the rear fender and rear fender cover. Ì Fasten the wire harness to the frame with a plas- tic locking tie.
  • Page 76 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING 1 Front brake hose È To install the brake hose holders, align the edge 2 Front brake master cylinder of each holder with the upper edge of the recess 3 Front mud guard in the brake hose.
  • Page 77 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Ì Route the front brake hose between the front fork and front mud guard and between the bosses on the front fork. Í When installing the brake hose onto the brake caliper, make sure that the brake pipe touches the brake caliper as shown.
  • Page 78 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING 1 Brake fluid reservoir È When installing the brake hose onto the brake 2 Brake fluid reservoir hose master cylinder, make sure that the brake pipe 3 Rear brake light switch touches the brake master cylinder as shown.

  • Page 79: Chk Adj

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
  • Page 80 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION....................3-1 PERIODIC MAINTENANCE AND LUBRICATION CHART ......3-1 COWLING AND COVER ................. 3-3 COVER...................... 3-3 COWLING ....................3-4 FUEL TANK..................... 3-5 REMOVING THE FUEL TANK ..............3-6 REMOVING THE FUEL PUMP ..............3-6 INSTALLING THE FUEL PUMP..............3-7...
  • Page 81 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS ....................... 3-36 ADJUSTING THE REAR BRAKE PEDAL ..........3-36 CHECKING THE BRAKE FLUID LEVEL..........3-37 CHECKING THE FRONT AND REAR BRAKE PADS AND BRAKE PAD PINS .................3-38 ADJUSTING THE REAR BRAKE LIGHT SWITCH .........3-38 CHECKING THE FRONT AND REAR BRAKE HOSES......

  • Page 82: Periodic Checks And Adjustments

    • From 50,000 km, repeat the maintenance intervals starting from 10,000 km. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1,000 km)
  • Page 83 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE AND LUBRICATION CHART ODOMETER READING (× 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK Chassis fasteners • Make sure that all nuts, bolts and screws are √...

  • Page 84: Cowling And Cover

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COWLING AND COVER COWLING AND COVER COVER 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 85: Cowling

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COWLING AND COVER COWLING 8 Nm (0.8 m kg, 5.8 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the cowling Remove the parts in the order listed.

  • Page 86: Fuel Tank

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK EAS00040 FUEL TANK 10 Nm (1.0 m kg, 7.2 ft • • Q’ty Remarks Order Job/Part Removing the fuel tank Remove the parts in the order listed. Seat/side panels (left and right) Refer to “COWLING AND COVER”.

  • Page 87: Removing The Fuel Tank

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank filler tube with a pump. 2. Remove: • fuel hose CAUTION: Although the fuel has been removed from the fuel tank be careful when removing the...

  • Page 88: Installing The Fuel Pump

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK INSTALLING THE FUEL PUMP 1. Install: • fuel pump 4 Nm (0.4 m · kg, 2.9 ft · lb) NOTE: • Do not damage the installation surfaces of the fuel tank when installing the fuel pump.

  • Page 89: Air Filter Case

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR FILTER CASE AIR FILTER CASE REAR MUD GUARD AND REAR FENDER 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 90 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR FILTER CASE 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 91 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR FILTER CASE EAS00043 AIR FILTER CASE 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 9 17 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 92 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR FILTER CASE 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 9 17 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 93: Installing The Air Filter Case Joint Clamp

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR FILTER CASE INSTALLING THE AIR FILTER CASE JOINT CLAMP 1. Install: • air filter case joint clamp 1 NOTE: To install the air filter case joint clamp, align its slot a with the projection b on the air filter case.

  • Page 94: Engine

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE VALVE CLEARANCE EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature.
  • Page 95 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE VALVE CLEARANCE 6. Measure: • valve clearance Out of specification → Adjust. Valve clearance (cold) Intake valve 0.09 ~ 0.13 mm (0.0035 ~ 0.0051 in) Exhaust valve 0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in)
  • Page 96 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE VALVE CLEARANCE d. Hold the adjusting screw to prevent it from moving and tighten the locknut to the speci- fied torque. Locknut 14 Nm (1.4 m · kg, 10 ft · lb) e.

  • Page 97: Adjusting The Exhaust Gas Volume

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE EXHAUST GAS VOLUME EAS00869 ADJUSTING THE EXHAUST GAS VOLUME NOTE: Be sure to set the CO density level to stan- dard, and then adjust the exhaust gas volume. 1.

  • Page 98: Adjusting The Engine Idling Speed

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00054 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air filter element should be cleaned, and the engine should have adequate compression.
  • Page 99 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE THROTTLE CABLE FREE PLAY 1. Check: • throttle cable free play a Out of specification → Adjust. Throttle cable free play (at the flange of the throttle grip) 3.0 ~ 5.0 mm (0.12 ~ 0.20 in) 2.

  • Page 100: Checking The Spark Plug

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUG c. Tighten the locknut. WARNING After adjusting the throttle cable free play, start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change.

  • Page 101: Checking The Ignition Timing

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE SPARK PLUG/ CHECKING THE IGNITION TIMING 7. Install: • spark plug 13 Nm (1.3 m · kg, 9.4 ft · lb) NOTE: Before installing the spark plug, clean the spark plug and gasket surface.

  • Page 102: Measuring The Compression Pressure

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE 4. Detach: • timing light 5. Install: • timing mark accessing screw EAS00067 MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance.
  • Page 103 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys MEASURING THE COMPRESSION PRESSURE 6. Measure: • compression pressure Out of specification → Refer to steps (c) and (d). Compression pressure (at sea level) Minimum 600 kPa (6.0 kg/cm , 85.3 psi) Standard 650 kPa (6.5 kg/cm...

  • Page 104: Checking The Engine Oil Level

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL 7. Install: • spark plug 13 Nm (1.3 m · kg, 9.4 ft · lb) 8. Connect: • spark plug cap EAS00069 CHECKING THE ENGINE OIL LEVEL 1.

  • Page 105: Changing The Engine Oil

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL 4. Start the engine, warm it up for several min- utes, and then turn it off. 5. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.
  • Page 106 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHANGING THE ENGINE OIL 9. If the oil filter element is also to be replaced, perform the following procedure. M MMM M MMM M MMM M MMM M MMM a.
  • Page 107 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHANGING THE ENGINE OIL 13.Install: • engine oil filler cap • camshaft sprocket cover 10 Nm (1.0 m · kg, 7.2 ft · lb) 14.Start the engine, warm it up for several min- utes, and then turn it off.

  • Page 108: Adjusting The Clutch Cable Free Play

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE CLUTCH CABLE FREE PLAY EAS00078 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: • clutch cable free play a Out of specification → Adjust. Clutch cable free play (at the end of the clutch lever) 10.0 ~ 15.0 mm (0.39 ~ 0.59 in) 2.

  • Page 109: Checking The Air Filter Element

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE AIR FILTER ELEMENT EAS00086 CHECKING THE AIR FILTER ELEMENT NOTE: There is a check hose 1 at the bottom of the air filter case. If dust and/or water collects in this hose, clean the air filter element and air fil- ter case.

  • Page 110: Checking The Throttle Body Joint

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE AIR FILTER ELEMENT/ CHECKING THE THROTTLE BODY JOINT/ CHECKING THE FUEL HOSE 6. Install: • right side panel • seat Refer to “COWLING AND COVER”. EAS00094 CHECKING THE THROTTLE BODY JOINT 1.

  • Page 111: Checking The Breather Hose

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM EAS00098 CHECKING THE BREATHER HOSE 1. Check: • crankcase-to-crankcase-breather-chamber hose 1 • air-filter-to-crankcase-breather-chamber hose 2 Cracks/damage → Replace. Loose connection → Connect properly. CAUTION: Make sure the breather hoses are routed correctly.

  • Page 112: Checking The Coolant Level

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE COOLANT LEVEL/ CHECKING THE COOLING SYSTEM EAS00102 CHECKING THE COOLANT LEVEL 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. •...

  • Page 113: Changing The Coolant

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE COOLING SYSTEM/ CHANGING THE COOLANT 2. Check: • radiator 1 • radiator outlet hose 2 • radiator inlet hose 3 • water pump assembly 4 •...
  • Page 114 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHANGING THE COOLANT 2. Remove: • radiator cap retainer 1 • radiator cap 2 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot.
  • Page 115 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHANGING THE COOLANT 10.Fill: • cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity...
  • Page 116 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHANGING THE COOLANT 11.Install: • radiator cap • radiator cap retainer 7 Nm (0.7 m · kg, 5.1 ft · lb) 12.Fill: • coolant reservoir (with the recommended coolant to the maxi- mum level mark a) 13.Install: •...

  • Page 117: Chassis

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE REAR BRAKE PEDAL EAS00110 CHASSIS ADJUSTING THE REAR BRAKE PEDAL 1. Check: • brake pedal position (distance a from the top of the rider foot- rest to the top of the brake pedal) Out of specification →...

  • Page 118: Checking The Brake Fluid Level

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE REAR BRAKE PEDAL/ CHECKING THE BRAKE FLUID LEVEL 3. Adjust: • rear brake light switch Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”. EAS00115 CHECKING THE BRAKE FLUID LEVEL 1.

  • Page 119: Checking The Front And Rear Brake Pads And Brake Pad Pins

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE FRONT AND REAR BRAKE PADS AND BRAKE PAD PINS/ADJUSTING THE REAR BRAKE LIGHT SWITCH EAS00118 È CHECKING THE FRONT AND REAR BRAKE PADS AND BRAKE PAD PINS The following procedure applies to all of the brake pads.

  • Page 120: Adjusting The Rear Brake Light Switch

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE FRONT AND REAR BRAKE HOSES 1. Check: • rear brake light operation timing Incorrect → Adjust. 2. Adjust: • rear brake light operation timing M MMM M MMM M MMM...

  • Page 121: Bleeding The Hydraulic Brake System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00134 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the hydraulic brake system when- ever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced.

  • Page 122: Adjusting The Shift Pedal

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SHIFT PEDAL g. Loosen the bleed screw. NOTE: Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend.

  • Page 123: Adjusting The Drive Chain Slack

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK 2. Adjust: • shift pedal position M MMM M MMM M MMM M MMM M MMM a. Remove the bolt 1. b.
  • Page 124 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE DRIVE CHAIN SLACK 3. Check: • drive chain slack a Out of specification → Adjust. Drive chain slack 40.0 ~ 55.0 mm (1.57 ~ 2.17 in) 4.

  • Page 125: Lubricating The Drive Chain

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATING THE DRIVE CHAIN/ CHECKING AND ADJUSTING THE STEERING HEAD EAS00142 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained prop- erly, it will wear out quickly.
  • Page 126 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING AND ADJUSTING THE STEERING HEAD 3. Remove: • handlebar protector cover (XT660X) • handlebar protector (XT660X) • handlebar holder caps • upper handlebar holders 1 • handlebar 2 4.

  • Page 127: Checking The Front Fork

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK d. Check the steering head for looseness or binding by turning the front fork all the way in both directions.

  • Page 128: Adjusting The Rear Shock Absorber Assembly

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE FRONT FORK/ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3. Hold the motorcycle upright and apply the front brake. 4. Check: • front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly.

  • Page 129: Checking The Tires

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE TIRES EAS00166 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: • tire pressure Out of specification → Regulate. WARNING •...
  • Page 130 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE TIRES XT660X Basic weight (with oil and a 186.0 kg (410 lb) full fuel tank) Maximum 186.0 kg (410 lb) load* Cold tire Front Rear pressure 210 kPa 210 kPa...
  • Page 131 Tube or tubeless Tubeless wheel tire • After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design.

  • Page 132: Checking And Tightening The Spokes

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE TIRES/ CHECKING AND TIGHTENING THE SPOKES WARNING New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done.

  • Page 133: Checking And Lubricating The Cables

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS AND BRAKE PEDAL/ LUBRICATING THE SIDESTAND EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables.

  • Page 134: Electrical System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING AND CHARGING THE BATTERY EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: •...
  • Page 135 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte.
  • Page 136 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING AND CHARGING THE BATTERY 5. Charge: Ambient temperature Charging • battery (refer to the appropriate charging method illustration) WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit CAUTION: voltage.
  • Page 137 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger Charger Ammeter NOTE: Measure the open-circuit Leave the battery unused for voltage prior to charging. more than 30 minutes before measuring its open-circuit voltage.
  • Page 138 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger NOTE: Measure the open-circuit Leave the battery unused for voltage prior to charging. more than 30 minutes before measuring its open-circuit voltage.

  • Page 139: Checking The Fuses

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1, then the negative battery lead 2.
  • Page 140 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE FUSES 2. Check: • fuse 1 • fuse box 1 2 • fuse box 2 3 M MMM M MMM M MMM M MMM M MMM a.

  • Page 141: Replacing The Headlight Bulb

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULB WARNING Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rat- ing may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could...

  • Page 142: Adjusting The Headlight Beam

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM 5. Install: • headlight bulb • headlight bulb holder • headlight bulb holder cover CAUTION: Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be...

  • Page 143: Setting The Digital Clock

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SETTING THE DIGITAL CLOCK EAS00187 SETTING THE DIGITAL CLOCK 1. Set: • digital clock 1 M MMM M MMM M MMM M MMM M MMM a. Set the main switch to “ON”. b.

  • Page 144: Chas

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS email: info@motomatrix.co.uk...
  • Page 145 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISC............... 4-1 FRONT WHEEL ..................4-2 REMOVING THE FRONT WHEEL............4-3 CHECKING THE FRONT WHEEL ............4-3 CHECKING THE FRONT BRAKE DISC ........... 4-6 INSTALLING THE FRONT WHEEL ............
  • Page 146 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK....................4-51 REMOVING THE FRONT FORK LEGS..........4-55 DISASSEMBLING THE FRONT FORK LEGS ........4-55 CHECKING THE FRONT FORK LEGS ..........4-57 ASSEMBLING THE FRONT FORK LEGS ..........4-58 INSTALLING THE FRONT FORK LEGS ..........

  • Page 147: Front Wheel And Brake Disc

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT WHEEL AND BRAKE DISC EAS00512 CHASSIS FRONT WHEEL AND BRAKE DISC 18 Nm (1.8 m kg, 13 ft • • 59 Nm (5.9 m kg, 43 ft •...

  • Page 148: Front Wheel

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT WHEEL AND BRAKE DISC EAS00518 FRONT WHEEL Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the order listed. Oil seal Bearing Spacer For assembly, reverse the disassembly procedure.

  • Page 149: Removing The Front Wheel

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT WHEEL AND BRAKE DISC EAS00519 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
  • Page 150 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT WHEEL AND BRAKE DISC 3. Check: • spokes Bends/damage → Replace. Loose → Tighten. Tap the spokes with a screwdriver. NOTE: A tight spoke will emit a clear, ringing tone, a loose spoke will sound flat.
  • Page 151 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT WHEEL AND BRAKE DISC 7. Check: • wheel bearings Front wheel turns roughly or is loose → Replace the wheel bearings. • oil seals Damage/wear → Replace. 8.

  • Page 152: Checking The Front Brake Disc

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT WHEEL AND BRAKE DISC EAS00527 CHECKING THE FRONT BRAKE DISC 1. Check: • brake disc Damage/galling → Replace. 2. Measure: • brake disc deflection Out of specification → Correct the brake disc deflection or replace the brake disc.

  • Page 153: Installing The Front Wheel

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT WHEEL AND BRAKE DISC 4. Adjust: • brake disc deflection M MMM M MMM M MMM M MMM M MMM a. Remove the brake disc. b.

  • Page 154: Adjusting The Front Wheel Static Balance

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT WHEEL AND BRAKE DISC 2. Tighten: • wheel axle 1 59 Nm (5.9 m · kg, 43 ft · lb) • wheel axle pinch bolts 2 18 Nm (1.8 m ·...
  • Page 155 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT WHEEL AND BRAKE DISC 2. Find: • front wheel’s heavy spot NOTE: Place the front wheel on a suitable balancing stand. M MMM M MMM M MMM M MMM M MMM...

  • Page 156: Rear Wheel, Brake Disc, And Rear Wheel Sprocket

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EAS00550 REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET REAR WHEEL 105 Nm (10.5 m kg, 75 ft •...
  • Page 157 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 105 Nm (10.5 m kg, 75 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 16 Nm (1.6 m kg, 11 ft •...

  • Page 158: Brake Disc And Rear Wheel Sprocket

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET BRAKE DISC AND REAR WHEEL SPROCKET 13 Nm (1.3 m kg, 9.4 ft • • 69 Nm (6.9 m kg, 50 ft •...
  • Page 159 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET Order Job/Part Q’ty Remarks Disassembling the rear wheel Remove the parts in the order listed. Bearing Oil seal Spacer For assembly, reverse the disassembly procedure.

  • Page 160: Removing The Rear Wheel

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EAS00561 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over.

  • Page 161: Checking The Rear Brake Disc

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 2. Check: • tire • rear wheel Damage/wear → Replace. Refer to “CHECKING THE TIRES” in chap- ter 3. 3.

  • Page 162: Checking The Rear Wheel Drive Hub

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 3. Measure: • brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification → Replace. Brake disc thickness limit (mini- mum) 4.5 mm (0.18 in)

  • Page 163: Checking And Replacing The Rear Wheel Sprocket

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EAS00568 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Check: • rear wheel sprocket More than 1/4 tooth a wear → Replace the rear wheel sprocket.

  • Page 164: Adjusting The Rear Wheel Static Balance

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 2. Install: • rear wheel • washer (O) • rear axle • washer (N) • rear axle nut NOTE: Install the washer with the “N”...

  • Page 165: Front And Rear Brakes

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS (XT660R) 14 Nm (1.4 m kg, 10 ft • • 40 Nm (4.0 m kg, 29 ft •...

  • Page 166: Front Brake Pads (Xt660X)

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES FRONT BRAKE PADS (XT660X) 14 Nm (1.4 m kg, 10 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Part Q’ty...

  • Page 167: Rear Brake Pads

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00578 REAR BRAKE PADS 14 Nm (1.4 m kg, 10 ft • • Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed.

  • Page 168: Replacing The Front Brake Pads

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. •...
  • Page 169 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES 2. Measure: È • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 1.0 mm (0.04 in) È...

  • Page 170: Replacing The Rear Brake Pads

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES d. Install new brake pads and new brake pad È springs. NOTE: The arrow a on the brake pad spring must point in the direction of rotation. È...
  • Page 171 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES 3. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 1.0 mm (0.04 in) 4.

  • Page 172: Front Brake Master Cylinder

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER 7 Nm (0.7 m kg, 5.1 ft • • 6 Nm (0.6 m kg, 4.3 ft • •...
  • Page 173 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES 7 Nm (0.7 m kg, 5.1 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 30 Nm (3.0 m kg, 22 ft •...
  • Page 174 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00585 Order Job/Part Q’ty Remarks Disassembling the front brake mas- Remove the parts in the order listed. ter cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly...

  • Page 175: Rear Brake Master Cylinder

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER 30 Nm (3.0 m kg, 22 ft • • 18 Nm (1.8 m kg, 13 ft • •...
  • Page 176 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES 30 Nm (3.0 m kg, 22 ft • • 18 Nm (1.8 m kg, 13 ft • • 23 Nm (2.3 m kg, 17 ft •...
  • Page 177 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00587 Order Job/Part Q’ty Remarks Disassembling the rear brake mas- Remove the parts in the order listed. ter cylinder Hose joint Brake master cylinder kit Refer to “ASSEMBLING THE REAR BRAKE MASTER CYLINDER”.

  • Page 178: Disassembling The Front Brake Master Cylinder

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system.

  • Page 179: Checking The Front And Rear Brake Master Cylinders

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00592 È CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to both of the brake master cylinders. 1. Check: •...

  • Page 180: Assembling And Installing The Front Brake Master

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES 5. Check: • brake hoses Cracks/damage/wear → Replace. EAS00598 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid.
  • Page 181 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES 3. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING •...

  • Page 182: Cylinder

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00608 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING • All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid DOT 4 •...
  • Page 183 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES 2. Install: • right side heel plate 23 Nm (2.3 m · kg, 17 ft · lb) • copper washers • brake hose 1 •...
  • Page 184 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES 4. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 5. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level.

  • Page 185: Front Brake Caliper (Xt660R)

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00612 FRONT BRAKE CALIPER (XT660R) 40 Nm (4.0 m kg, 29 ft • • 30 Nm (3.0 m kg, 22 ft • •...
  • Page 186 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00614 14 Nm (1.4 m kg, 10 ft • • Order Job/Part Q’ty Remarks Disassembling the front brake cali- Remove the parts in the order listed. Brake pad clip Brake pad pin Refer to “INSTALLING THE FRONT...

  • Page 187: Front Brake Caliper (Xt660X)

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES FRONT BRAKE CALIPER (XT660X) 30 Nm (3.0 m kg, 22 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Part Q’ty...
  • Page 188 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES 14 Nm (1.4 m kg, 10 ft • • Order Job/Part Q’ty Remarks Disassembling the front brake cali- Remove the parts in the order listed. Brake pad clip Brake pad pin Refer to “INSTALLING THE FRONT...

  • Page 189: Rear Brake Caliper

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 4 Nm (0.4 m kg, 2.9 ft •...
  • Page 190 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00617 14 Nm (1.4 m kg, 10 ft • • Order Job/Part Q’ty Remarks Disassembling the rear brake cali- Remove the parts in the order listed. Brake caliper bracket Brake pad clip Brake pad pin...

  • Page 191: Removing The Front Brake Caliper

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00619 È REMOVING THE FRONT BRAKE CALIPER NOTE: Before removing the brake caliper, drain the brake fluid from the entire brake system. 1.

  • Page 192: Checking The Front And Rear Brake Calipers

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00633 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Brake hoses Every four years Every years and whenever the...

  • Page 193: Installing The Front Brake Caliper

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00634 INSTALLING THE FRONT BRAKE CALIPER 1. Install: • brake pad springs • brake pads • brake pad pin(s) • brake pad clip(s) Refer to “FRONT BRAKE PADS”.
  • Page 194 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES 3. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING •...

  • Page 195: Installing The Rear Brake Caliper

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00642 INSTALLING THE REAR BRAKE CALIPER 1. Install: • brake caliper springs • brake pads • brake pad pin • brake pad clip Refer to “REAR BRAKE PADS”.
  • Page 196 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES WARNING • Use only the designated brake fluid. Other brake fluids may cause the piston seals to deteriorate, causing leakage and poor brake performance. •...

  • Page 197: Front Fork

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK EAS00646 FRONT FORK 18 Nm (1.8 m kg, 13 ft • • 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 198 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK 18 Nm (1.8 m kg, 13 ft • • 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 199 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK EAS00648 18 Nm (1.8 m kg, 13 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Disassembling the front fork legs Remove the parts in the order listed.
  • Page 200 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK 18 Nm (1.8 m kg, 13 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Oil seal Washer Refer to “ASSEMBLING THE FRONT Outer tube bushing...

  • Page 201: Removing The Front Fork Legs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over.
  • Page 202 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK 2. Drain: • fork oil NOTE: Stroke the outer tube several times while draining the fork oil. 3. Remove: • dust seal 1 • oil seal clip 2 (with a flat-head screwdriver) CAUTION: Do not scratch the inner tube.

  • Page 203: Checking The Front Fork Legs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK • Avoid bottoming the inner tube into the outer tube during the above procedure, as the oil flow stopper will be damaged. L LLL L LLL L LLL L LLL...

  • Page 204: Assembling The Front Fork Legs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK 3. Check: • damper rod 1 Damage/wear → Replace. Obstruction → Blow out all of the oil pas- sages with compressed air. • oil flow stopper 2 Damage →...
  • Page 205 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK 2. Lubricate: • inner tube’s outer surface Recommended lubricant Fork oil 10 W or equivalent 3. Tighten: • damper rod bolt 1 Damper rod bolt 30 Nm (3.0 m ·...
  • Page 206 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK 5. Install: • oil seal 1 (with the fork seal driver weight 2 and fork seal driver attachment 3) CAUTION: Make sure the numbered side of the oil seal faces up.
  • Page 207 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK 8. Fill: • front fork leg (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) XT660R 640.0 cm (22.53 Imp oz, 21.64 US oz) XT660X 600.0 cm...

  • Page 208: Installing The Front Fork Legs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: • front fork leg Temporarily tighten the lower bracket pinch bolts.

  • Page 209: Handlebar

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS HANDLEBAR EAS00664 HANDLEBAR 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 210 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS HANDLEBAR 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 211: Removing The Handlebar

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2.
  • Page 212 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS HANDLEBAR 2. Install: • handlebar 1 • upper handlebar holders 2 23 Nm (2.3 m · kg, 17 ft · lb) • handlebar protector (XT660X) • handlebar protector cover (XT660X) CAUTION: •...
  • Page 213 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS HANDLEBAR 4. Install: • left handlebar switch 1 NOTE: Align the projection a on the left handlebar switch with the hole b in the handlebar. 5. Install: •...
  • Page 214 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS HANDLEBAR 8. Install: • brake master cylinder • brake master cylinder holder Refer to “FRONT AND REAR BRAKES”. 9. Adjust: • clutch cable free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PLAY”...

  • Page 215: Steering Head

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS STEERING HEAD EAS00675 STEERING HEAD LOWER BRACKET 32 Nm (3.2 m kg, 23 ft • • 130 Nm (13.0 m kg, 94 ft • • 23 Nm (2.3 m kg, 17 ft •...
  • Page 216 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS STEERING HEAD 32 Nm (3.2 m kg, 23 ft • • 130 Nm (13.0 m kg, 94 ft • • 23 Nm (2.3 m kg, 17 ft •...

  • Page 217: Removing The Lower Bracket

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS STEERING HEAD EAS00679 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2.

  • Page 218: Installing The Steering Head

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS STEERING HEAD 3. Replace: • bearings • bearing races M MMM M MMM M MMM M MMM M MMM a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer.
  • Page 219 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS STEERING HEAD 3. Install: • upper bracket • steering stem nut NOTE: Temporarily tighten the steering stem nut. 4. Install: • front fork legs Refer to “INSTALLING THE FRONT FORK LEGS”.

  • Page 220: Rear Shock Absorber Assembly

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY 59 Nm (5.9 m kg, 43 ft • • 59 Nm (5.9 m kg, 43 ft • •...
  • Page 221 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS REAR SHOCK ABSORBER ASSEMBLY 59 Nm (5.9 m kg, 43 ft • • 59 Nm (5.9 m kg, 43 ft • • 42 Nm (4.2 m kg, 30 ft •...

  • Page 222: Handling The Rear Shock Absorber

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00686 HANDLING THE REAR SHOCK ABSORBER WARNING This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following informa- tion.

  • Page 223: Removing The Rear Shock Absorber Assembly

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00690 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over.

  • Page 224: Checking The Rear Shock Absorber Assembly

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: • rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly. •...

  • Page 225: Installing The Rear Shock Absorber Assembly

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00697 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: • bearings • bolts Recommended lubricant Lithium-soap-based grease 2. Install: • rear shock absorber assembly NOTE: When installing the rear shock absorber assembly, lift up the swingarm.

  • Page 226: Swingarm And Drive Chain

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS SWINGARM AND DRIVE CHAIN EAS00700 SWINGARM AND DRIVE CHAIN 10 Nm (1.0 m kg, 7.2 ft 59 Nm (5.9 m kg, 43 ft • • • •...
  • Page 227 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS SWINGARM AND DRIVE CHAIN 10 Nm (1.0 m kg, 7.2 ft 59 Nm (5.9 m kg, 43 ft • • • • 23 Nm (2.3 m kg, 17 ft •...

  • Page 228: Removing The Swingarm

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS SWINGARM AND DRIVE CHAIN EAS00703 REMOVING THE SWINGARM 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.

  • Page 229: Removing The Drive Sprocket

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS SWINGARM AND DRIVE CHAIN REMOVING THE DRIVE SPROCKET NOTE: Loosen the drive sprocket nut before removing the rear wheel. 1. Remove: • drive sprocket cover • chain guard 2.

  • Page 230: Checking The Drive Chain

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS SWINGARM AND DRIVE CHAIN 2. Check: • pivot shaft Roll the pivot shaft on a flat surface. Bends → Replace. WARNING Do not attempt to straighten a bent pivot shaft.
  • Page 231 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS SWINGARM AND DRIVE CHAIN 2. Check: • drive chain Stiffness → Clean and lubricate or replace. 3. Clean: • drive chain M MMM M MMM M MMM M MMM M MMM a.

  • Page 232: Installing The Swingarm

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS SWINGARM AND DRIVE CHAIN 5. Lubricate: • drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 6. Check: • drive sprocket • rear wheel sprocket More than 1/4 tooth a wear →...
  • Page 233 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS SWINGARM AND DRIVE CHAIN 3. Install: • swingarm • pivot shaft • pivot shaft nut 92 Nm (9.2 m · kg, 66 ft · lb) 4. Install: •...
  • Page 234 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...

  • Page 235: Eng

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
  • Page 236 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAPTER 5 ENGINE ENGINE REMOVAL ..................5-1 EXHAUST PIPES AND MUFFLERS ............5-1 LEADS, CABLES, HOSES, AND IGNITION COIL ........5-2 ENGINE..................... 5-5 INSTALLING THE ENGINE............... 5-7 CYLINDER HEAD.................... 5-8 REMOVING THE CYLINDER HEAD............5-10 CHECKING THE CYLINDER HEAD ............5-11 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET...
  • Page 237 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH ......................5-40 CLUTCH COVER ..................5-40 PULL LEVER SHAFT ................5-41 CLUTCH ....................5-42 REMOVING THE CLUTCH ..............5-44 CHECKING THE FRICTION PLATES.............5-44 CHECKING THE CLUTCH PLATES ............5-45 CHECKING THE CLUTCH SPRINGS.............5-45 CHECKING THE CLUTCH HOUSING ............5-46 CHECKING THE CLUTCH BOSS............
  • Page 238 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE ....................5-69 CRANKCASE BEARINGS............... 5-71 SEPARATING THE CRANKCASE............5-72 CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE 3 ..... 5-72 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDES ..5-73 CHECKING THE BEARINGS AND OIL SEALS........
  • Page 239 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...

  • Page 240: Engine

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL EAS00188 ENGINE ENGINE REMOVAL EXHAUST PIPES AND MUFFLERS 27 Nm (2.7 m kg, 19 ft 27 Nm (2.7 m kg, 19 ft • • • •...

  • Page 241: Leads, Cables, Hoses, And Ignition Coil

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL LEADS, CABLES, HOSES, AND IGNITION COIL Apply sealant 10 Nm (1.0 m kg, 7.2 ft • • Yamaha bond No. 1215 90890-85505 ∗ 7 Nm (0.7 m kg, 5.1 ft • • 16 Nm (1.6 m kg, 11 ft •...
  • Page 242 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Apply sealant 10 Nm (1.0 m kg, 7.2 ft • • Yamaha bond No. 1215 90890-85505 ∗ 7 Nm (0.7 m kg, 5.1 ft • •...
  • Page 243 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Apply sealant 10 Nm (1.0 m kg, 7.2 ft • • Yamaha bond No. 1215 90890-85505 ∗ 7 Nm (0.7 m kg, 5.1 ft • •...

  • Page 244: Engine

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL EAS00191 ENGINE 73 Nm (7.3 m kg, 53 ft • • 55 Nm (5.5m kg, 40 ft • • 73 Nm (7.3 m kg, 53 ft •...
  • Page 245 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL 73 Nm (7.3 m kg, 53 ft • • 55 Nm (5.5m kg, 40 ft • • 73 Nm (7.3 m kg, 53 ft • •...

  • Page 246: Installing The Engine

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL EAS00192 INSTALLING THE ENGINE 1. Install: • engine front bracket 1 • engine front bracket bolt/nut 2 • engine front mounting bolt/nut 3 • engine rear mounting bolt/nut 4 •...

  • Page 247: Cylinder Head

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD EAS00221 CYLINDER HEAD 20 Nm (2.0 m kg, 14 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 50 Nm (5.0 m kg, 36 ft •...
  • Page 248 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD 20 Nm (2.0 m kg, 14 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 50 Nm (5.0 m kg, 36 ft •...

  • Page 249: Removing The Cylinder Head

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD EAS00225 REMOVING THE CYLINDER HEAD 1. Align: • “I” mark a on the A.C. magneto rotor (with the stationary pointer b on the A.C. magneto cover) M MMM M MMM M MMM...

  • Page 250: Checking The Cylinder Head

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD EAS00229 CHECKING THE CYLINDER HEAD 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damag- ing or scratching: •...

  • Page 251: Checking The Tappet Covers And Camshaft Sprocket Cover

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD EAS00212 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER 1. Check: • tappet covers 1 • camshaft sprocket cover 2 • O-rings 3 Damage/wear → Replace the defective part(s).
  • Page 252 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD 2. Install: • cylinder head • washers • cylinder head bolts NOTE: • Lubricate the cylinder head bolt threads and muting surface with engine oil. •...
  • Page 253 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD c. Install the timing chain 1 onto the camshaft sprocket 2, then the camshaft sprocket onto the camshaft, and then finger tighten the camshaft sprocket bolts. NOTE: To install the camshaft sprocket sprocket, install the projection 3 on the camshaft...
  • Page 254 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD d. Install the spring and timing chain tensioner cap bolt. Timing chain tensioner cap bolt 20 Nm (2.0 m · kg, 14 ft · lb) L LLL L LLL L LLL...

  • Page 255: Rocker Arms And Camshaft

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ROCKER ARMS AND CAMSHAFT ROCKER ARMS AND CAMSHAFT 14 Nm (1.4 m kg, 10 ft • • 14 Nm (1.4 m kg, 10 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 256 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ROCKER ARMS AND CAMSHAFT 14 Nm (1.4 m kg, 10 ft • • 14 Nm (1.4 m kg, 10 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 257: Removing The Rocker Arms And Camshaft

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ROCKER ARMS AND CAMSHAFT EAS00202 REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Loosen: • locknuts • adjusting screws 2. Remove: • camshaft retainer 1 3. Remove: • intake rocker arm shaft •...

  • Page 258: Checking The Decompression System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ROCKER ARMS AND CAMSHAFT 2. Measure: • camshaft lobe dimensions a and b Out of specification → Replace the cam- shaft. Camshaft lobe dimensions Intake a 43.488 ~ 43.588 mm (1.7121 ~ 1.7161 in) <Limit>: 43.388 mm (1.7062 in)

  • Page 259: Checking The Rocker Arms And Rocker Arm Shafts

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ROCKER ARMS AND CAMSHAFT EAS00206 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to both of the rocker arms and rocker arm shafts. 1.

  • Page 260: Installing The Camshaft And Rocker Arms

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ROCKER ARMS AND CAMSHAFT 5. Calculate: • rocker-arm-to-rocker-arm-shaft clearance NOTE: Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter. Above 0.081 mm (0.0032 in) →...
  • Page 261 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ROCKER ARMS AND CAMSHAFT 3. Install: • decompressor lever pin 1 • decompressor lever 2 NOTE: Install the decompressor lever pin 1 and decompressor lever 2 in the camshaft 3 as shown in the illustration.

  • Page 262: Valves And Valve Springs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs Cylinder head Refer to “CYLINDER HEAD”.

  • Page 263: Removing The Valves

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal.

  • Page 264: Checking The Valves And Valve Guides

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS 3. Remove: • valve spring retainer 1 • valve spring 2 • valve stem seal 3 • valve spring seat 4 • valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place.
  • Page 265 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS 2. Replace: • valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. M MMM M MMM M MMM...

  • Page 266: Checking The Valve Seats

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS 6. Measure: • valve stem runout Out of specification → Replace the valve. NOTE: • When installing a new valve, always replace the valve guide. •...
  • Page 267 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS 4. Lap: • valve face • valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped.

  • Page 268: Checking The Valve Springs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS EAS00241 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 269: Installing The Valves

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: • valve stem end (with an oil stone) 2.
  • Page 270 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS 4. Install: • valve cotters NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attach- ment 2.

  • Page 271: Cylinder And Piston

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER AND PISTON EAS00251 CYLINDER AND PISTON 1st 15 Nm (1.5 m kg, 11 ft • • 2nd 50 Nm (5.0 m kg, 36 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 272 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER AND PISTON 1st 15 Nm (1.5 m kg, 11 ft • • 2nd 50 Nm (5.0 m kg, 36 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 273: Removing The Cylinder And Piston

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER AND PISTON EAS00253 REMOVING THE CYLINDER AND PISTON 1. Remove: • piston pin clips 1 • piston pin 2 • piston 3 CAUTION: Do not use a hammer to drive the piston pin out.
  • Page 274 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER AND PISTON 2. Measure: • piston-to-cylinder clearance M MMM M MMM M MMM M MMM M MMM a. Measure cylinder bore “C” with the cylinder bore gauge. NOTE: Measure cylinder bore “C”...

  • Page 275: Checking The Piston Rings

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER AND PISTON EAS00263 CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance Out of specification → Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clear- ance, eliminate any carbon deposits from the...

  • Page 276: Checking The Piston Pin

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER AND PISTON EAS00265 CHECKING THE PISTON PIN 1. Check: • piston pin Blue discoloration/grooves → Replace the piston pin, and then check the lubrication system. 2. Measure: •...

  • Page 277: Installing The Piston And Cylinder

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER AND PISTON EAS00267 INSTALLING THE PISTON AND CYLINDER 1. Install: • top ring 1 • 2nd ring 2 • oil ring expander 3 • lower oil ring rail 4 •...
  • Page 278 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER AND PISTON 5. Offset: • piston ring end gaps 120˚ a Top ring b Upper oil ring rail c Oil ring expander 120˚ 120˚ d Lower oil ring rail e 2nd ring f 20 mm (0.79 in) È...

  • Page 279: Clutch Cover

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH EAS00273 CLUTCH CLUTCH COVER 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed.

  • Page 280: Pull Lever Shaft

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH PULL LEVER SHAFT Order Job/Part Q’ty Remarks Removing the pull lever shaft Remove the parts in the order listed. Circlip Circlip Washer Pull lever Pull lever spring Pull lever shaft Oil seal Bearing...
  • Page 281 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH EAS00274 CLUTCH (5) (5) 90 Nm (9.0 m kg, 65 ft • • 9 Nm (0.9 m kg, 6.5 ft • • Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed.
  • Page 282 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH (5) (5) 90 Nm (9.0 m kg, 65 ft • • 9 Nm (0.9 m kg, 6.5 ft • • Order Job/Part Q’ty Remarks Clutch boss nut Refer to “REMOVING THE CLUTCH”...

  • Page 283: Removing The Clutch

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH EAS00275 REMOVING THE CLUTCH 1. Remove: • clutch cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

  • Page 284: Checking The Clutch Plates

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH 2. Measure: • friction plate 1 thickness • friction plate 2 thickness • friction plate 3 thickness Out of specification → Replace the friction plates as a set. NOTE: Measure the friction plate at four places.

  • Page 285: Checking The Clutch Housing

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH 2. Measure: • clutch spring free length a Out of specification → Replace the clutch springs as a set. Clutch spring free length 55.6 mm (2.19 in) <Limit>: 52.82 mm (2.08 in) EAS00284 CHECKING THE CLUTCH HOUSING...

  • Page 286: Checking The Primary Driven Gear

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH 2. Check: • pull rod bearing Damage/wear → Replace. EAS00292 CHECKING THE PRIMARY DRIVEN GEAR 1. Check: • primary driven gear Damage/wear → Replace the primary drive gear and clutch housing as a set.
  • Page 287 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH 4. Lubricate: • friction plates • clutch plates (with the recommended lubricant) Recommended lubricant Engine oil 5. Install: • clutch damper spring seat 1 • clutch damper spring 2 •...
  • Page 288 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH NOTE: • To install the clutch cover, position the pull rod so that the teeth face towards that rear of the motorcycle. • Tighten the clutch cover bolts in stages and in a crisscross pattern.

  • Page 289: Oil Pump

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP OIL PUMP 20 Nm (2.0 m kg, 14 ft • • 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 290 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP 20 Nm (2.0 m kg, 14 ft • • 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 291 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP EAS00360 Order Job/Part Q’ty Remarks Disassembling the oil pump Remove the parts in the order listed. Oil pump housing 1/oil seal Oil pump outer rotor 1 Dowel pin Oil pump inner rotor 1 Oil pump housing cover/oil seal...

  • Page 292: Checking The Oil Pump

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP EAS00364 CHECKING THE OIL PUMP 1. Check: • oil pump driven gear 1 • oil pump housing 1 2 • oil pump housing cover 3 •...

  • Page 293: Checking The Oil Delivery Pipes And Hoses

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP EAS00367 CHECKING THE OIL DELIVERY PIPES AND HOSES The following procedure applies to all of the oil delivery pipes and hoses. 1. Check: • oil delivery pipe •...

  • Page 294: Installing The Oil Pump

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP EAS00376 INSTALLING THE OIL PUMP 1. Install: • oil pump gasket • oil pump • oil baffle plate 2 10 Nm (1.0 m · kg, 7.2 ft · lb) •...

  • Page 295: Balancer Driven Gear

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys BALANCER DRIVEN GEAR BALANCER DRIVEN GEAR 70 Nm (7.0 m kg, 50 ft • • 80 Nm (8.0 m kg, 58 ft • • Order Job/Part Q’ty Remarks Removing the balancer driven gear Remove the parts in the order listed.
  • Page 296 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys BALANCER DRIVEN GEAR 70 Nm (7.0 m kg, 50 ft • • 80 Nm (8.0 m kg, 58 ft • • Order Job/Part Q’ty Remarks Water pump drive gear Primary drive gear Balancer drive gear Refer to “INSTALLING THE BALANCER...

  • Page 297: Removing The Balancer Driven Gear And Balancer Drive Gear

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys BALANCER DRIVEN GEAR REMOVING THE BALANCER DRIVEN GEAR AND BALANCER DRIVE GEAR 1. Straighten the lock washer tab. 2. Loosen: • balancer driven gear nut 1 • primary drive gear nut 2 NOTE: Place an aluminum plate a between the teeth of the balancer driven gear 3 and balancer...

  • Page 298: Installing The Balancer Driven Gear And Balancer Drive Gear

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys BALANCER DRIVEN GEAR INSTALLING THE BALANCER DRIVEN GEAR AND BALANCER DRIVE GEAR 1. Install: • washer • balancer drive gear 1 • straight key 2 • balancer driven gear 3 •...

  • Page 299: Shift Shaft

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHIFT SHAFT EAS00327 SHIFT SHAFT SHIFT SHAFT AND STOPPER LEVER 16 Nm (1.6 m kg, 11 ft • • 22 Nm (2.2 m kg, 16 ft • •...
  • Page 300 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHIFT SHAFT 16 Nm (1.6 m kg, 11 ft • • 22 Nm (2.2 m kg, 16 ft • • Order Job/Part Q’ty Remarks Stopper lever spring Refer to “INSTALLING THE SHIFT SHAFT”.

  • Page 301: Checking The Shift Shaft

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHIFT SHAFT EAS00329 CHECKING THE SHIFT SHAFT 1. Check: • shift shaft 1 • shift shaft pawl 2 Bends/damage/wear → Replace. • shift shaft spring 3 Damage/wear → Replace. EAS00330 CHECKING THE STOPPER LEVER 1.

  • Page 302: Starter Clutch And A.c. Magneto

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STARTER CLUTCH AND A.C. MAGNETO EAS00341 STARTER CLUTCH AND A.C. MAGNETO Apply sealant Yamaha bond No. 1215 90890-85505 80 Nm (8.0 m kg, 58 ft • •...
  • Page 303 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STARTER CLUTCH AND A.C. MAGNETO Apply sealant Yamaha bond No. 1215 90890-85505 80 Nm (8.0 m kg, 58 ft • • 30 Nm (3.0 m kg, 22 ft •...

  • Page 304: Removing The A.c. Magneto Rotor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STARTER CLUTCH AND A.C. MAGNETO EAS00346 REMOVING THE A.C. MAGNETO ROTOR 1. Remove: • torque limiter cover CAUTION: Do not remove the bearing 1. 2. Remove: • A.C. magneto cover NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern.

  • Page 305: Checking The Stator Coil And Crankshaft Position Sensor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STARTER CLUTCH AND A.C. MAGNETO CHECKING THE STATOR COIL AND CRANKSHAFT POSITION SENSOR 1. Check: • stator coil • crankshaft position sensor Damage → Replace the crankshaft position sensor/stator assembly.

  • Page 306: Checking The Torque Limiter

    7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: Align the projection a on the stator coil with the slot b in the A.C. magneto cover. 2. Apply: • Yamaha bond No. 1215 1 (into the slits) Yamaha bond No. 1215 90890-85505 3. Install: •...
  • Page 307 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STARTER CLUTCH AND A.C. MAGNETO 5. Tighten: • A.C. magneto rotor nut 1 80 Nm (8.0 m · kg, 58 ft · lb) NOTE: • While holding the A.C. magneto rotor 2 with the sheave holder 3, tighten the A.C.

  • Page 308: Crankcase

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE CRANKCASE 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 309 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • •...

  • Page 310: Crankcase Bearings

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE CRANKCASE BEARINGS Apply sealant 10 Nm (1.0 m kg, 7.2 ft • • Yamaha bond No. 1215 ∗ 90890-85505 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty...

  • Page 311: Separating The Crankcase

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE SEPARATING THE CRANKCASE 1. Separate: • right crankcase 1 • left crankcase 2 M MMM M MMM M MMM M MMM M MMM a. Remove the crankcase bolts. NOTE: •...

  • Page 312: Checking The Timing Chain And Timing Chain Guides

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE 2. Check: • oil delivery pipe 3 Cracks/damage → Replace. • oil delivery pipe holes 1 Clogged → Blow out with compressed air. EAS00207 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDES 1.

  • Page 313: Assembling The Crankcase

    Install the bearing retainer with the “OUT” mark a facing up. 3. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 4. Apply: • Yamaha bond No. 1215 1 (to the mating surfaces of both crankcase halves) Yamaha bond No. 1215 90890-85505...
  • Page 314 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE 6. Fit the right crankcase onto the left crank- case. Tap lightly on the case with a soft hammer. CAUTION: Before installing and torquing the crank- case bolts, be sure to check whether the transmission is functioning properly by manually rotating the shift drum in both...

  • Page 315: Crankshaft

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT EAS00381 CRANKSHAFT CRANKSHAFT AND BALANCER Order Job/Part Q’ty Remarks Removing the crankshaft and bal- Remove the parts in the order listed. ancer Crankcase Separate. Refer to “CRANKCASE”. Balancer Crankshaft Refer to “REMOVING THE CRANK-...

  • Page 316: Removing The Crankshaft Assembly

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT EAS00388 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: • crankshaft 1 NOTE: • Remove the crankshaft with the crankcase separating tool 2. • Make sure the crankcase separating tool is centered over the crankshaft.

  • Page 317: Installing The Crankshaft

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT M MMM M MMM M MMM M MMM M MMM a. The crankshaft 1 and the crankshaft pin 2 oil passages must be properly intercon- nected with a tolerance of less than 1 mm (0.04 in).

  • Page 318: Transmission

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION EAS00419 TRANSMISSION Order Job/Part Q’ty Remarks Removing the transmission, shift Remove the parts in the order listed. drum, and shift forks Crankcase Separate. Refer to “CRANKCASE”. Shift fork “C”...

  • Page 319: Main Axle

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION MAIN AXLE Order Job/Part Q’ty Remarks Disassembling the main axle Remove the parts in the order listed. Circlip 2nd pinion gear Toothed lock washer Toothed washer retainer 5th pinion gear Toothed spacer Toothed washer...

  • Page 320: Drive Axle

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION DRIVE AXLE Order Job/Part Q’ty Remarks Disassembling the drive axle Remove the parts in the order listed. Circlip Washer Refer to “ASSEMBLING THE MAIN AXLE AND DRIVE AXLE”. 1st wheel gear 4th wheel gear Circlip...

  • Page 321: Checking The Shift Forks

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: • shift fork cam follower 1 • shift fork pawl 2 Bends/damage/scoring/wear →...

  • Page 322: Assembling The Main Axle And Drive Axle

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION 2. Measure: • drive axle runout (with a centering device and dial gauge 1) Out of specification → Replace the drive axle. Drive axle runout limit 0.08 mm (0.0031 in) 3.

  • Page 323: Installing The Transmission

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION INSTALLING THE TRANSMISSION 1. Install: • shift fork “L” 1 (to drive axle) • shift fork “C” 2 (to main axle) • shift fork “R” 3 (to drive axle) •...

  • Page 324: Cool

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL email: info@motomatrix.co.uk...
  • Page 325 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL CHAPTER 6 COOLING SYSTEM RADIATOR ...................... 6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR..............6-4 THERMOSTAT ....................6-5 CHECKING THE THERMOSTAT.............. 6-6 INSTALLING THE THERMOSTAT............6-6 WATER PUMP....................6-8 DISASSEMBLING THE WATER PUMP..........
  • Page 326 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL email: info@motomatrix.co.uk...

  • Page 327: Cooling System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL RADIATOR EAS00454 COOLING SYSTEM RADIATOR 7 Nm (0.7 m kg, 5.1 ft • • 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed.
  • Page 328 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL RADIATOR 7 Nm (0.7 m kg, 5.1 ft • • 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Part Q’ty Remarks Radiator outlet hose Refer to “INSTALLING THE RADIA- TOR”.

  • Page 329: Checking The Radiator

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL RADIATOR EAS00455 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction → Clean. Apply compressed air to the rear of the radi- ator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver.

  • Page 330: Installing The Radiator

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL RADIATOR EAS00456 INSTALLING THE RADIATOR 1. Install: • radiator inlet hose 1 • radiator outlet hose 2 • hose clamps 3 NOTE: Install the radiator inlet hose and radiator out- let hose so that each hose contacts the respective projection a.

  • Page 331: Thermostat

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL THERMOSTAT EAS00460 THERMOSTAT 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the thermostat Remove the parts in the order listed.

  • Page 332: Checking The Thermostat

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL THERMOSTAT EAS00462 CHECKING THE THERMOSTAT 1. Check: • thermostat 1 Does not open at 71 ~ 85 °C (159.8 ~ 185 °F) → Replace. M MMM M MMM M MMM M MMM...
  • Page 333 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL THERMOSTAT 2. Install: • radiator inlet hose 1 • hose clamp 2 NOTE: Install the radiator inlet hose 1 so that it con- tacts the projection on the thermostat cover a. 3.

  • Page 334: Water Pump

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL WATER PUMP EAS00468 WATER PUMP 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 335 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL WATER PUMP 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 336 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL WATER PUMP Order Job/Part Q’ty Remarks Disassembling the water pump Remove the parts in the order listed. Circlip Impeller shaft gear Refer to “ASSEMBLING THE WATER PUMP”.

  • Page 337: Disassembling The Water Pump

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL WATER PUMP EAS00470 DISASSEMBLING THE WATER PUMP 1. Remove: • water pump seal 1 NOTE: Tap out the water pump seal from water pump housing in the direction of the arrow shown. 2 Water pump housing 2.

  • Page 338: Assembling The Water Pump

    NOTE: • Install the water pump seal with the special tools. • Before installing the water pump, apply Yamaha bond No.1215 2 to the water pump housing 3. Mechanical seal installer 4 90890-04132 Middle driven shaft bearing driver 90890-04058 Yamaha bond No.1215...
  • Page 339 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL WATER PUMP 3. Install: • rubber damper 1 • rubber damper holder 2 NOTE: Before installing the rubber damper, apply tap water or coolant onto its outer surface. 4.

  • Page 340: Installing The Water Pump

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL WATER PUMP EAS00478 INSTALLING THE WATER PUMP 1. Install: • water pump outlet hose 1 • O-rings • water pump outlet pipe (to the water pump assembly) 10 Nm (1.0 m ·...
  • Page 341 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
  • Page 342 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAPTER 7 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM................7-1 WIRING DIAGRAM ................... 7-2 ECU SELF-DIAGNOSTIC FUNCTION............7-3 ALTERNATE OPERATION CONTROL (FAIL-SAFE ACTION) ....7-4 FAIL-SAFE ACTION TABLE ..............7-4 TROUBLESHOOTING CHART ..............7-6 DIAGNOSTIC MODE ................
  • Page 343 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...

  • Page 344: Fuel Injection System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS00894 FUEL INJECTION SYSTEM EAS00895 FUEL INJECTION SYSTEM 1 Air cut-off valve 9 Intake air temperature sensor H Coolant temperature sensor 2 Air induction system solenoid 0 Air filter case I Spark plug 3 Engine trouble warning light...

  • Page 345: Wiring Diagram

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS00898 WIRING DIAGRAM 1 Crankshaft position sensor 3 Neutral switch 4 Main switch 6 Battery 7 Main fuse 0 Fuel injection system fuse D Engine stop switch I Fuel injection system relay J Sidestand switch K Fuel pump...

  • Page 346: Ecu Self-Diagnostic Function

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS00899 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function to ensure the normal operation of the fuel injec- tion system. If a malfunction is detected in the fuel injection system, the self-diagnostic function immediately operates the engine with alternate operating instructions and the engine trouble warn- ing light comes on to alert the rider of the malfunction.

  • Page 347: Alternate Operation Control (Fail-Safe Action)

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS00901 Checking for a defective engine trouble warning light bulb The engine trouble warning light comes on for 1.4 seconds after the main switch is turned to “ON” or when the start switch is pushed.

  • Page 348: Communication Error With Meter

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault Item Symptom Fail-safe action Startability Driveability code No. Lean angle cut-off The motorcycle has over- switch (latch up turned. — detected) Faulty ignition Open circuit is detected in the primary lead of the ignition —...

  • Page 349: Troubleshooting Chart

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS00904 TROUBLESHOOTING CHART Engine operation is not normal or the engine trouble warning light is on. The engine trouble warning light may not come on even if the engine operation is not normal. The engine trouble warning light comes on.

  • Page 350: Diagnostic Mode

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS00905 DIAGNOSTIC MODE Setting the diagnostic mode 1. Set the main switch to “OFF” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump.
  • Page 351 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM 8. Verify the operation of the sensor or actua- tor. • Sensor operation The data representing the operating condi- tions of the sensor appears on the odome- ter/fuel reserve tripmeter/tripmeter 2 LCD.

  • Page 352: Diagnostic Monitoring Code Table

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS00906 Diagnostic monitoring code table Fault Symptom Probable cause of malfunction Diagnostic code code No. No normal signals are received from • Open or short circuit in wire harness the crankshaft position sensor.
  • Page 353 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault Symptom Probable cause of malfunction Diagnostic code code No. An error is detected while reading or • Malfunction in ECU (The CO adjustment value is not writing on EEPROM.
  • Page 354 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Diagnostic Data displayed on meter Item Action code (reference value) Lean angle cut-off switch Displays the lean angle cut-off switch values. Upright: 0.4 ~ 1.4 V Overturned: 3.7 ~ 4.4 V Fuel system voltage (bat- Displays the fuel system voltage (battery voltage).

  • Page 355: Troubleshooting Details

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS00908 TROUBLESHOOTING DETAILS This section describes the countermeasures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order in the “TROUBLESHOOTING CHART”.
  • Page 356 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit is detected from the intake air pressure sensor. Used diagnostic code No. 03 (intake air pressure sensor) Order Item/components Check or maintenance job...
  • Page 357 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor hose is disconnected or clogged. Used diagnostic code No. 03 (intake air pressure sensor) Order Item/components Check or maintenance job Restore method Disconnected, clogged, kinked, or...
  • Page 358 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom The throttle position sensor is detected stuck. Used diagnostic code No. 01 (throttle position sensor) Order Item/components Check or maintenance job Restore method Defective throttle position sensor Replace the sensor if it is defective.
  • Page 359 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit is detected from the intake air temperature sensor. Used diagnostic code No. 05 (intake air temperature sensor) Order Item/components Check or maintenance job...
  • Page 360 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom The motorcycle has overturned. Used diagnostic code No. 08 (lean angle cut-off switch) Order Item/components Check or maintenance job Restore method The motorcycle has overturned.
  • Page 361 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the speed sensor. B. Open or short circuit is detected in the neutral switch. Used diagnostic code No.
  • Page 362 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the speed sensor. B. Open or short circuit is detected in the neutral switch. Used diagnostic code No.
  • Page 363 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom The ECU is unable to monitor the battery voltage. Used diagnostic code No. 09, 50 (fuel system voltage) Order Item/components Check or maintenance job Restore method Coupler connections...
  • Page 364 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Error is detected while reading or writing on EEPROM (CO adjustment value). Used diagnostic code No. 60 (EEPROM improper cylinder indication) Order Item/components Check or maintenance job...
  • Page 365 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signals are received from the ECU. Used diagnostic code No. – – Order Item/components Check or maintenance job Restore method Coupler connections Check the couplers for any pins that may have...

  • Page 366: Throttle Body Assembly

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODY ASSEMBLY EAS00909 THROTTLE BODY ASSEMBLY 10 10 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Part Q’ty Remarks Removing the throttle body assem- Remove the parts in the order listed.
  • Page 367 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODY ASSEMBLY 10 10 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Part Q’ty Remarks Fast idle plunger outlet hose Disconnect. Fast idle plunger inlet hose Pilot air hose Throttle body joint clamp screw Loosen.
  • Page 368 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODY ASSEMBLY Order Job/Part Q’ty Remarks Disassembling the throttle body Remove the parts in the order listed. assembly Throttle position sensor Fuel injection pipe Fuel injector Throttle body CAUTION: Do not disassemble the throttle body.

  • Page 369: Checking The Fuel Injector

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODY ASSEMBLY EAS00912 CHECKING THE FUEL INJECTOR 1. Check: • fuel injector Damage → Replace. R/L R/B 2. Check: • fuel injector resistance M MMM M MMM M MMM M MMM M MMM...

  • Page 370: Installing The Throttle Body Assembly

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODY ASSEMBLY INSTALLING THE THROTTLE BODY ASSEMBLY 1. Install: • throttle body joint clamps NOTE: Align the projection a on the throttle body joint with the slot b in the throttle body joint clamp. 2.

  • Page 371: Checking The Fuel Pump

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODY ASSEMBLY EAS00819 CHECKING THE FUEL PUMP WARNING Gasoline is extremely flammable and under certain circumstances there can be a dan- ger of an explosion or fire. Be extremely careful and note the following points: •...

  • Page 372: Checking And Adjusting The Throttle Position

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODY ASSEMBLY 2. Check: • fuel pressure M MMM M MMM M MMM M MMM M MMM a. Remove the fuel tank. Refer to “FUEL TANK” in chapter 3. b.
  • Page 373 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODY ASSEMBLY 1. Check: • throttle position sensor (removed from the throttle body) M MMM M MMM M MMM M MMM M MMM a. Disconnect the throttle position sensor cou- pler from the throttle position sensor.
  • Page 374 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODY ASSEMBLY Throttle position sensor resis- tance 0 ~ 5 ± 1.0 kΩ at 20 °C (68 °F) (yellow — black/blue) L LLL L LLL L LLL L LLL L LLL 2.

  • Page 375: Air Induction System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR INDUCTION SYSTEM EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned exhaust gases by injecting fresh air (second- ary air) into the exhaust port, reducing the emission of hydrocarbons.

  • Page 376: Air Induction System Diagrams

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Air filter case 2 Reed valve 3 Air cut-off valve 4 Exhaust port 7 - 33 email: info@motomatrix.co.uk...

  • Page 377: Air Cut-Off Valve Assembly

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR INDUCTION SYSTEM AIR CUT-OFF VALVE ASSEMBLY Order Job/Part Q’ty Remarks Removing the air cut-off valve Remove the parts in the order listed. assembly Right side panel Refer to “COWLING AND COVER”...
  • Page 378 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR INDUCTION SYSTEM Order Job/Part Q’ty Remarks Disassembling the air cut-off valve Remove the parts in the order listed. assembly Air cut-off valve cover Reed valve assembly Air cut-off valve For assembly, reverse the disassembly procedure.

  • Page 379: Checking The Air Induction System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR INDUCTION SYSTEM EAS00918 CHECKING THE AIR INDUCTION SYSTEM 1. Check: • hoses Loose connections → Connect properly. Cracks/damage → Replace. • pipe Cracks/damage → Replace. Refer to “CYLINDER HEAD” in chapter 5. 2.

  • Page 380: Elec

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC email: info@motomatrix.co.uk...
  • Page 381 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS................ 8-1 CHECKING SWITCH CONTINUITY..............8-3 CHECKING THE SWITCHES................8-5 CHECKING THE BULBS AND BULB SOCKETS .......... 8-7 TYPES OF BULBS ..................8-7 CHECKING THE CONDITION OF THE BULBS ........
  • Page 382 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC IMMOBILIZER SYSTEM................8-52 CIRCUIT DIAGRAM ................8-52 GENERAL INFORMATION ..............8-53 KEY CODE REGISTRATION ..............8-54 SELF-DIAGNOSIS MALFUNCTION CODES..........8-57 TROUBLESHOOTING ................8-58 CHECKING THE IMMOBILIZER SYSTEM ..........8-59 SELF-DIAGNOSIS..................

  • Page 383: Electrical System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1 Spark plug 8 Main switch E Lean angle cut-off switch 2 Spark plug cap 9 Fuel pump F Turn signal/hazard relay 3 Ignition coil 0 Clutch switch...
  • Page 384 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC ELECTRICAL COMPONENTS L Fuse box 2 W Speed sensor M Starter relay X Starter motor N Main fuse Y Radiator fan motor O Rectifier/regulator Z Horn P ECU [ Air induction system solenoid Q Intake air temperature sensor...

  • Page 385: Checking Switch Continuity

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC CHECKING SWITCH CONTINUITY EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch.
  • Page 386 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC CHECKING SWITCH CONTINUITY 8 - 4 email: info@motomatrix.co.uk...

  • Page 387: Checking The Switches

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the ter- minals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear →...
  • Page 388 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC CHECKING THE SWITCHES 1 Main switch 2 Horn switch 3 Pass switch 4 Dimmer switch 5 Turn signal switch 6 Hazard switch 7 Clutch switch 8 Engine stop switch 9 Start switch 0 Front brake light switch...

  • Page 389: Checking The Bulbs And Bulb Sockets

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals.

  • Page 390: Checking The Condition Of The Bulbs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: • bulb WARNING Since the headlight bulb gets extremely hot, keep flammable products and your...

  • Page 391: Checking The Condition Of The Bulb Sockets

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: •...
  • Page 392 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC CHECKING THE BULBS AND BULB SOCKETS b. Connect two jumper leads 1 from the bat- tery terminals to the respective coupler ter- minal as shown. Positive battery ter- minal →...
  • Page 393 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC CHECKING THE BULBS AND BULB SOCKETS WARNING • A wire that is used as a jumper lead must have at least the same capacity of the bat- tery lead, otherwise the jumper lead may burn.

  • Page 394: Ignition System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC IGNITION SYSTEM EAS00734 IGNITION SYSTEM CIRCUIT DIAGRAM 8 - 12 email: info@motomatrix.co.uk...

  • Page 395: Troubleshooting

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC IGNITION SYSTEM EAS00736 EAS00739 TROUBLESHOOTING 2. Battery The ignition system fails to operate (no • Check the condition of the battery. spark or intermittent spark). Refer to “CHECKING AND CHARGING THE BATTERY”...
  • Page 396 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC IGNITION SYSTEM EAS00742 EAS00744 4. Ignition spark gap 5. Spark plug cap resistance • Disconnect the spark plug cap 1 from the • Remove the spark plug cap from the spark spark plug.
  • Page 397 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC IGNITION SYSTEM EAS00746 EAS00748 6. Ignition coil resistance 7. Crankshaft position sensor resistance • Disconnect the ignition coil connectors • Disconnect the crankshaft position sensor from the ignition coil terminals.
  • Page 398 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC IGNITION SYSTEM EAS00750 EAS00754 9. Engine stop switch 11.Wiring • Check the engine stop switch for continu- • Check the entire ignition system’s wiring. ity. Refer to “CIRCUIT DIAGRAM”.

  • Page 399: Electric Starting System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 8 - 17 email: info@motomatrix.co.uk...

  • Page 400: Starting Circuit Cut-Off System Operation

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC ELECTRIC STARTING SYSTEM EAS00756 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 401: Troubleshooting

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY”...
  • Page 402 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC ELECTRIC STARTING SYSTEM EAS00759 Positive tester probe → 4. Relay unit (starting circuit cut-off relay) sky blue 1 Negative tester probe → • Disconnect the relay unit from the wire black/yellow 2 harness.
  • Page 403 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC ELECTRIC STARTING SYSTEM EAS00761 EAS00750 6. Starter relay 8. Engine stop switch • Disconnect the starter relay coupler from • Check the engine stop switch for continu- the coupler.
  • Page 404 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC ELECTRIC STARTING SYSTEM EAS00764 12.Start switch • Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the start switch OK? Replace right handlebar switch.

  • Page 405: Starter Motor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC STARTER MOTOR EAS00767 STARTER MOTOR 5 Nm (0.5 m kg, 3.6 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the starter motor...
  • Page 406 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC STARTER MOTOR Order Job/Part Q’ty Remarks Disassembling the starter motor Remove the parts in the order listed. Circlip Starter motor gear O-ring Front bracket Shims Lock washer Rear bracket Shims...

  • Page 407: Checking The Starter Motor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC STARTER MOTOR EAS00770 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor.
  • Page 408 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC STARTER MOTOR Pocket tester 90890-03112 Armature coil Commutator resistance 1 0.025 ~ 0.035 Ω at 20 °C (68 °F) Insulation resistance 2 Above 1 MΩ at 20 °C (68 °F) b.

  • Page 409: Assembling The Starter Motor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC STARTER MOTOR EAS00772 ASSEMBLING THE STARTER MOTOR 1. Install: • brush seat 1 NOTE: Align the tab a on the brush seat with the slot b in the starter motor yoke.

  • Page 410: Charging System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM 8 - 28 email: info@motomatrix.co.uk...

  • Page 411: Troubleshooting

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC CHARGING SYSTEM EAS00774 EAS00738 TROUBLESHOOTING 1. Main fuse The battery is not being charged. • Check the main fuse for continuity. Refer to “CHECKING THE FUSES” in Check: chapter 3.
  • Page 412 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC CHARGING SYSTEM EAS00775 EAS00776 3. Charging voltage 4. Stator coil resistance • Connect the pocket tester (DC 20 V) to the • Disconnect the A.C. magneto coupler from battery as shown.

  • Page 413: Lighting System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM 8 - 31 email: info@motomatrix.co.uk...

  • Page 414: Troubleshooting

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC LIGHTING SYSTEM EAS00781 EAS00738 TROUBLESHOOTING 1. Main, headlight, and parking lighting fuses Any of the following fail to come on: • Check the main, headlight, and parking headlight, high beam indicator light, tail/ lighting fuses for continuity.
  • Page 415 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC LIGHTING SYSTEM EAS00784 6. Headlight relay 4. Dimmer switch • Disconnect the headlight relay from the wire • Check the dimmer switch for continuity. harness. •...

  • Page 416: Checking The Lighting System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC LIGHTING SYSTEM EAS00788 Headlight CHECKING THE LIGHTING SYSTEM Positive tester probe → 1. The headlight and the high beam indicator yellow 1 or green 2 light fail to come on.
  • Page 417 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC LIGHTING SYSTEM EAS00790 EAS00791 2. The tail/brake light fails to come on. 3. The auxiliary light fails to come on. 1. Tail/brake light bulb and socket 1.
  • Page 418 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC LIGHTING SYSTEM 8 - 36 email: info@motomatrix.co.uk...

  • Page 419: Signaling System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM 8 - 37 email: info@motomatrix.co.uk...
  • Page 420 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC SIGNALING SYSTEM 3 Neutral switch 4 Main switch 6 Battery 7 Main fuse A Backup fuse (immobilizer unit, meter assembly) F Front brake light switch G Relay unit K Fuel pump L ECU...

  • Page 421: Troubleshooting

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC SIGNALING SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery • Any of the following fail to come on: a • Check the condition of the battery. turn signal light, an indicator light, a Refer to “CHECKING AND CHARGING warning light, or the tail/brake light THE BATTERY”...

  • Page 422: Checking The Signaling System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC SIGNALING SYSTEM EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. • Disconnect the black connector at the horn terminal. 1. Horn switch •...
  • Page 423 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC SIGNALING SYSTEM EAS00797 3. Voltage 2. The tail/brake light fails to come on. • Connect the pocket tester (DC 20 V) to the 1. Tail/brake light bulb and socket tail/brake light coupler (wire harness end) •...
  • Page 424 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC SIGNALING SYSTEM EAS00799 4. Hazard switch 3. The turn signal light, turn signal indicator light or both fail to blink. • Check the hazard switch for continuity. Refer to “CHECKING THE SWITCHES”.
  • Page 425 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC SIGNALING SYSTEM È É 6. Voltage • Connect the pocket tester (DC 20 V) to the turn signal/hazard relay coupler (wire har- ness end) as shown. Positive tester probe →...
  • Page 426 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC SIGNALING SYSTEM EAS00800 EAS00753 4. The neutral indicator light fails to come on. 3. Relay unit (diode) 1. Neutral indicator light LED • Disconnect the relay unit from the wire •...
  • Page 427 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC SIGNALING SYSTEM EAS00803 4. Voltage 5. The fuel level warning light fails to come on. • Connect the pocket tester (DC 20 V) to the 1.
  • Page 428 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC SIGNALING SYSTEM 6. The speedometer fails to come on. 3. Voltage 1. Voltage • Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness •...
  • Page 429 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC SIGNALING SYSTEM 7. The coolant temperature warning light fails 2. Speed sensor to come on. • Connect the pocket tester (DC 20 V) to the 1.
  • Page 430 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC SIGNALING SYSTEM EAS00812 3. Coolant temperature sensor • Remove the coolant temperature sensor from the engine. • Connect the pocket tester (Ω × 10) to the coolant temperature sensor 1 as shown.

  • Page 431: Cooling System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM 8 - 49 email: info@motomatrix.co.uk...

  • Page 432: Troubleshooting

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC COOLING SYSTEM EAS00808 EAS00739 TROUBLESHOOTING 2. Battery The radiator fan motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY”...
  • Page 433 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC COOLING SYSTEM EAS00809 5. Radiator fan motor relay 4. Radiator fan motor • Disconnect the radiator fan motor relay • Disconnect the radiator fan motor coupler from the wire harness.

  • Page 434: Immobilizer System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC IMMOBILIZER SYSTEM EB805000 IMMOBILIZER SYSTEM CIRCUIT DIAGRAM 8 - 52 email: info@motomatrix.co.uk...

  • Page 435: General Information

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC IMMOBILIZER SYSTEM GENERAL INFORMATION This motorcycle is equipped with an immobilizer system to help prevent theft by registering codes in standard keys. This system consists of the following: •...

  • Page 436: Key Code Registration

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC IMMOBILIZER SYSTEM KEY CODE REGISTRATION The replacement of parts or code registration of a code re-registering key or standard key may be required in the following conditions. NOTE: Each standard key is registered during production, therefore, registering the keys at purchase is not necessary.
  • Page 437 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC IMMOBILIZER SYSTEM Standard key registration: A standard key should be registered or the other standard key should be re-registered when a reg- istered standard key has been lost. The standard keys must be re-registered when the immobilizer unit or ECU has been replaced and the code re-registering key has been re-registered.
  • Page 438 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC IMMOBILIZER SYSTEM 6. Check that the engine can be started with the two registered standard keys. Registration of the second standard key less than 5.0 s less than 5.0 s less than 5.0 s less than 5.0 s...

  • Page 439: Self-Diagnosis Malfunction Codes

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC IMMOBILIZER SYSTEM SELF-DIAGNOSIS MALFUNCTION CODES When a system malfunction occurs, the malfunction code number is displayed on the multifunction display and is indicated by the immobilizer system indicator light flash patterns. Malfunction Part Symptom...

  • Page 440: Troubleshooting

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC IMMOBILIZER SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery The immobilizer system fails to operate. • Check the condition of the battery. (The immobilizer system indicator light Refer to “CHECKING AND CHARGING starts to flash in the self-diagnosis code THE BATTERY”...

  • Page 441: Checking The Immobilizer System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC IMMOBILIZER SYSTEM CHECKING THE IMMOBILIZER SYSTEM 3. Voltage 1. Immobilizer system indicator light does not • Connect the pocket tester (DC 20 V) to the go on when the main switch is set to “ON”.
  • Page 442 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC IMMOBILIZER SYSTEM 4. Voltage 5. Voltage • Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (DC 20 V) to the immobilizer unit coupler as shown.
  • Page 443 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC IMMOBILIZER SYSTEM 2. The multifunction display is not indicated. 1. Voltage • Connect the pocket tester (DC 20 V) to the meter assembly couplers as shown. Ch R/G Y G/W Y/L Dg G/L R/W...
  • Page 444 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC IMMOBILIZER SYSTEM 3. When the main switch is set to “ON”, the immobilizer system indicator light flashes after 1 sec- ond. • Check if metal or other immobilizer system keys exists near the immobilizer unit. If found, remove the metal or keys, and then check the condition again.

  • Page 445: Self-Diagnosis

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC SELF-DIAGNOSIS EAS00834 SELF-DIAGNOSIS The XT660R/XT660X features a self-diagnosing system for the following circuit: • Fuel sender (thermistor) If the circuit is defective, the condition code will be displayed on the fuel level warning light when the main switch is set to “ON”...
  • Page 446 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC SELF-DIAGNOSIS EAS00835 EAS00838 TROUBLESHOOTING 1. Fuel sender (thermistor) CIRCUIT DIAGRAM The fuel level warning light starts to indi- cates the self-diagnosis sequence. R/L G/W Check: ( BLUE ) 1.
  • Page 447 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC SELF-DIAGNOSIS EAS00842 3. Fuel sender (thermistor) • Disconnect the fuel sender coupler from the wire harness. • Connect the pocket tester (kΩ × 1) to the fuel sender as shown.
  • Page 448 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...

  • Page 449: Trbl Shtg

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRBL SHTG email: info@motomatrix.co.uk...

  • Page 450: Troubleshooting

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRBL SHTG CHAPTER 9 TROUBLESHOOTING STARTING FAILURES..................9-1 ENGINE..................... 9-1 FUEL SYSTEM..................9-1 ELECTRICAL SYSTEMS ................9-2 INCORRECT ENGINE IDLING SPEED............9-2 ENGINE..................... 9-2 FUEL SYSTEM..................9-2 ELECTRICAL SYSTEMS ................9-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE .........9-3 ENGINE.....................
  • Page 451 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRBL SHTG FAULTY LIGHTING OR SIGNALING SYSTEM..........9-6 HEADLIGHT DOES NOT COME ON ............9-6 HEADLIGHT BULB BURNT OUT.............. 9-6 TAIL/BRAKE LIGHT DOES NOT COME ON ..........9-6 TAIL/BRAKE LIGHT BULB BURNT OUT..........9-6 TURN SIGNAL DOES NOT COME ON ............

  • Page 452: Starting Failures

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRBL STARTING FAILURES SHTG EAS00844 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this man- ual for checks, adjustments, and replacement of parts.

  • Page 453: Electrical Systems

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STARTING FAILURES/ TRBL INCORRECT ENGINE IDLING SPEED SHTG ELECTRICAL SYSTEMS Battery Ignition system • Discharged battery • Faulty ECU • Faulty battery • Faulty crankshaft position sensor Fuse(s) •...

  • Page 454: Poor Medium-And-High-Speed Performance

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ TRBL FAULTY GEAR SHIFTING/FAULTY CLUTCH SHTG EAS00848 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING FAILURES”. ENGINE FUEL SYSTEM Air filter Fuel pump • Clogged air filter element •...

  • Page 455: Overheating

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OVERHEATING/OVERCOOLING/ TRBL POOR BRAKING PERFORMANCE SHTG EAS00855 OVERHEATING ENGINE FUEL SYSTEM Clogged coolant passages Throttle body • Cylinder head and piston • Faulty throttle body • Heavy carbon buildup •...

  • Page 456: Faulty Front Fork Legs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FAULTY FRONT FORK LEGS/ TRBL UNSTABLE HANDLING SHTG EAS00861 FAULTY FRONT FORK LEGS LEAKING OIL MALFUNCTION • Bent, damaged or rusty inner tube • Bent or damaged inner tube •...
  • Page 457 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRBL FAULTY LIGHTING OR SIGNALING SYSTEM SHTG EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT COME ON TURN SIGNAL DOES NOT COME ON • Wrong headlight bulb •...
  • Page 458 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys XT660R(S)/XT660X(S) 2004 WIRING DIAGRAM y Parking lighting fuse 1 Crankshaft position sensor 2 A.C. magneto z Immobilizer unit 3 Neutral switch { Anti-theft alarm (optional) 4 Main switch È...
  • Page 459 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
  • Page 460 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
  • Page 461 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
  • Page 462 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys XT660R(S)/XT660X(S) 2004 WIRING DIAGRAM Ch Lg MAIN HARNESS SUB-WIRE HARNESS Gy G/W G/W L/Y Br/R R/B O G/R Br/W B/L L/R W W W Br/R Br/R (GRAY) Br L/W R/B L/B R/L R/LR/B...

This manual is also suitable for:

Xt660rs 2004Xt660xs 2004Xt660x 2004

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