Page 1 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys YZF-R6T YZF-R6TC SUPPLEMENTARY SERVICE MANUAL LIT-11616-18-45 5SL-28197-12 email: info@motomatrix.co.uk...
Page 2 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YZF-R6T / YZF-R6TC. For complete service information procedures it is necessary to use this Sup- plementary Service Manual together with the following manual. YZF-R6R / YZF-R6SR / YZF-R6RC / YZF-R6SRC SERVICE MANUAL:...
Page 3: Important Manual Information
If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
Page 4: 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 5 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS00008 SYMBOLS The following symbols are not relevant to every vehicle. Symbols indicate the subject of each chapter. General information Specifications Periodic checks and adjustments Chassis Engine Cooling system Fuel injection system Electrical system...
Page 6: Table Of Contents
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONTENTS GENERAL INFORMATION SPECIAL TOOLS......... SPECIFICATIONS GENERAL SPECIFICATIONS .
Page 7 TROUBLESHOOTING ........YZF-R6T / YZF-R6TC WIRING DIAGRAM...
Page 8: General Information
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS INFO EAS00027 GENERAL INFORMATION 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 9: Specifications
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC GENERAL SPECIFICATIONS / ENGINE SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5SLR (USA except for CAL) • • • 5SLS (CAL) Dimensions Overall length 2,045 mm (80.5 in) •...
Page 10: 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 Caster angle 24.5° • • • Trail 95 mm (3.74 in) • • • Front tire Size 120 / 70 ZR17 M / C (55W) •...
Page 11: Electrical Specifications
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS SPECIFICATIONS / SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Front suspension Spring Free length 248.8 mm (9.80 in) 243.8 mm (9.60 in) Installed length 244.3 mm (9.62 in) •...
Page 12: Tightening Torques
Q’ty Remarks size m•kg ft•lb Clutch boss Use a lock washer Cylinder identification sensor Bolt 0.75 Yamaha bond No.1215 CHASSIS TIGHTENING TORQUES Tightening torque Thread Item Remarks size m•kg ft•lb Handlebar and front fork Front fender and front fork Rear brake master cylinder and footrest bracket...
Page 13: Cable Routing
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING CABLE ROUTING Right handlebar switch lead Pass the right handlebar switch lead inside the Clutch cable front brake hoses and over the throttle cables. Main switch lead Install the throttle cables to the hook so that the Left handlebar switch lead...
Page 14 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Clamp it at the position of 50 mm (1.97 in) to 65 Install the relay to the rib of the headlight. mm (2.56 in) from the upper face of the under (Location for the left and right relays is alternative.) bracket with the plastic locking tie.
Page 15 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Throttle stop screw Pass the ignition coil lead outside of the radiator Coolant reservoir tank hose hose. Cover 8 Pass the coolant reservoir tank hose under the Radiator fan motor lead (right) frame and right side of the throttle body.
Page 16 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Route the radiator fan motor lead (right) by the out- Clamp the clutch cable so that it is positioned in side of the clutch cable. this range.
Page 17 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Throttle cable (return side) Pass the main switch lead under the left handlebar Throttle cable (pull side) switch lead and then to the right side of the vehi- Starter motor lead cle.
Page 18 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Pass the fuel tank drain hose, fuel tank breather Pass the sidestand switch lead, oil level switch hose through the clamp of the coolant reservoir lead and A.C.
Page 19 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Right handlebar switch lead Fuel tank drain hose (except for Main switch lead Radiator fan motor lead (right) CAL) Wire harness Sub wire harness Fuel hose (return side, except Throttle cables Headlight lead...
Page 20 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Neutral switch lead coupler (connector 1 pole) Route the headlight and meter leads under the Fuel hose (return side, for CAL) frame’s lower part from the hollow section of the Canister hose (for CAL) cover 2.
Page 21 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Pass the fuel tank breather hose and fuel tank To the coolant reservoir tank drain hose over the fuel hose and fuel return hose. To the intake air temperature sensor (air filter One rotation is possible for a twist of fuel tank case)
Page 22 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Upper or lower position relation between the left Point the tip of the plastic locking tie to the rear handlebar switch lead, right handlebar switch lead side of the vehicle.
Page 23 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING The clamp by the side of a hose comes below an attachment clamp. Insert until it sets. Poss the canister hose over fuel return hose and under the fuel hose.
Page 24 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Starter motor lead Push the starter motor lead in the clamping sec- Battery tions (two points) or the battery box assembly and Battery positive lead secure it.
Page 25 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Insert it to the back end of the rib in the battery box Route the tail / brake light lead above the projection assembly. part.
Page 26 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Connect the negative lead and the wire harness. Install the starting circuit cut-off relay to the deep- est position after placing the tail / brake light lead and turn signal light lead in the guide.
Page 27: Periodic Checks And Adjustments
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00135 PERIODIC CHECKS AND ADJUSTMENTS BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the hydraulic brake system when- ever: • the system is disassembled. •...
Page 28 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys BLEEDING THE HYDRAULIC BRAKE SYSTEM f. Fully pull the brake lever or fully press down the brake pedal and hold it in posi- tion. g. Loosen the bleed screw. NOTE: NOTE: Loosening the bleed screw will release the...
Page 29: Adjusting The Front Fork Legs
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE FRONT FORK LEGS EAS00155 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING • Always adjust both front fork legs evenly. Uneven adjustment can result in poor han- dling and loss of stability.
Page 30 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE FRONT FORK LEGS 1. Adjust: • rebound damping a. Turn the adjusting screw in direction Rebound damping is Direction increased (suspension is harder). Rebound damping is Direction decreased (suspension is softer).
Page 31: Chassis
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 6 Nm (0.6 m•kg, 4.3 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 35 Nm (3.5 m•kg, 25 ft•lb) 91 Nm (9.1 m•kg, 66 ft•lb) 21 Nm (2.1 m•kg, 15 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb)
Page 32: 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 5 Nm (0.5 m•kg, 3.6 ft•lb) 35 Nm (3.5 m•kg, 25 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) Order Job / Part Q’ty...
Page 33: 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 13 Nm (1.3 m•kg, 9.4 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) Order Job / Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed.
Page 34 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES 13 Nm (1.3 m•kg, 9.4 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) Order Job / Part Q’ty Remarks Brake master cylinder Front brake switch For installation, reverse the removal procedure.
Page 35 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00585 6 Nm (0.6 m•kg, 4.3 ft•lb) Order Job / Part Q’ty Remarks Disassembling the front brake Disassemble the parts in the order listed. master cylinder Brake master cylinder kit Bleed screw...
Page 36: Front Brake Calipers
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS 6 Nm (0.6 m•kg, 4.3 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 35 Nm (3.5 m•kg, 25 ft•lb) Order Job / Part Q’ty...
Page 37 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00615 5 Nm (0.5 m•kg, 3.6 ft•lb) Order Job / Part Q’ty Remarks Disassembling the front brake Disassemble the parts in the order listed. calipers NOTE: NOTE:...
Page 38: Assembling And Installing The Front Brake Master Cylinder
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00607 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 39 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES 4. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING •...
Page 40: Front Fork
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK EAS00647 FRONT FORK FRONT FORK LEGS 32 Nm (3.2 m•kg, 23 ft•lb) 26 Nm (2.6 m•kg, 19 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) Order Job / Part...
Page 41 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK EAS00648 15 Nm (1.5 m•kg, 11 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) Order Job / Part Q’ty Remarks Disassembling the front fork legs Disassemble the parts in the order listed.
Page 42 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK 15 Nm (1.5 m•kg, 11 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) Order Job / Part Q’ty Remarks Washer Damper rod assembly bolt Copper washer...
Page 43: Disassembling The Front Fork Legs
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK EAS00652 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Remove: • cap bolt (from the damper adjusting rod) •...
Page 44: Checking The Front Fork Legs
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK 4. Remove: • damper rod assembly bolt • damper rod assembly NOTE: NOTE: While holding the damper rod assembly with the damper rod holder , loosen the damper rod assembly bolt.
Page 45: Assembling The Front Fork Legs
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK CAUTION: • The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particu- larly sensitive to foreign material. •...
Page 46 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK WARNING Always use new copper washer. CAUTION: Allow the damper rod assembly to slide slowly down the inner tube until it pro- trudes from the bottom of the inner tube. Be careful not to damage the inner tube.
Page 47 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK CAUTION: Make sure the numbered side of the oil seal faces up. NOTE: NOTE: • Before installing the oil seal, lubricate its lips with lithium-soap-based grease. •...
Page 48 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK 8. Install: • rod puller • rod puller attachment (onto the damper rod Rod puller 90890-01437, YM-01437 Rod puller attachment 90890-01436, YM-01436 9. Fill: •...
Page 49 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK e. Press down on the spacer with the fork spring compressor f. Pull up the rod puller and install the rod holder between the nut and the spacer NOTE:...
Page 50: Swingarm And Drive Chain
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS SWINGARM AND DRIVE CHAIN EAS00709 SWINGARM AND DRIVE CHAIN CHECKING THE DRIVE CHAIN 1. Measure: • Measure the dimension between 15-links on the inner side and outer side of the roller and calculate the dimension between pin centers.
Page 51 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS SWINGARM AND DRIVE CHAIN CAUTION: This motorcycle has a drive chain with small rubber O-rings between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain sol- vents (e.g., benzine), or a coarse brush to clean the drive chain.
Page 52: Cooling System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL RADIATOR EAS00454 COOLING SYSTEM RADIATOR 10 Nm (1.0 m•kg, 7.2 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb) Order Job / Part Q’ty Remarks Removing the radiator...
Page 53 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL RADIATOR 10 Nm (1.0 m•kg, 7.2 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb) Order Job / Part Q’ty Remarks Radiator cap For installation, reverse the removal procedure.
Page 54: Electrical System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRICAL SYSTEM ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main switch Battery Fuse (main) Starter relay Starter motor Fuse (ignition) Starting circuit cut-off relay Sidestand switch Neutral switch Engine stop switch...
Page 55: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. The starter motor fails to turn. Refer to “CHECKING AND CHARGING Check: THE BATTERY”...
Page 56 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC ELECTRIC STARTING SYSTEM EAS00759 4. Starting circuit cut-off relay • Disconnect the starting circuit cut-off relay coupler from the wire harness. • Connect the pocket tester (Ω × 1) and bat- tery (12 V) to the starting circuit cut-off relay coupler as shown.
Page 57 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC ELECTRIC STARTING SYSTEM EAS00752 EAS00766 9. Sidestand switch 12. Wiring • Check the sidestand switch for continuity. • Check the entire starting system’s wiring. Refer to “CHECKING THE SWITCHES”. Refer to “CIRCUIT DIAGRAM”.
Page 58: Cooling System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM Main switch Coolant temperature sensor Battery Radiator fan motor relay Fuse (main) Fuse (radiator fan motor left) Fuse (ignition) Fuse (radiator fan motor right) Radiator fan motor (left) Radiator fan motor (right)
Page 59 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC COOLING SYSTEM EAS00808 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. • The radiator fan motor fails to turn. Refer to “CHECKING AND CHARGING •...
Page 60 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 (left and right) • Disconnect the radiator fan motor relay from • Disconnect the radiator fan motor coupler the wire harness.
Page 61 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC COOLING SYSTEM EAS00812 6. Coolant temperature sensor • Remove the coolant temperature sensor. • Connect the pocket tester (Ω × 1k) to the coolant temperature sensor as shown.
Page 62 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys YZF-R6T/YZF-R6TC WIRING DIAGRAM email: info@motomatrix.co.uk...
Page 63 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys YZF-R6T / YZF-R6TC WIRING DIAGRAM Main switch Horn A.C. magneto Turn signal relay Rectifier / regulator Rear turn signal light (right) Fuse (backup) Rear turn signal light (left)
Page 64 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN email: info@motomatrix.co.uk...
Page 65 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
Page 66 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
Page 67 SUPPLEMENTARY SERVICE MANUAL 2003 by Yamaha Motor Corporation, U.S.A. First edition, September 2003 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-17-46 email: info@motomatrix.co.uk...
Page 68 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
Page 69 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 70 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS00008 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis...
Page 71 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS ........ENGINE SPECIFICATIONS .
Page 72 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
Page 73: 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 5SLD (USA except for CAL) 5SLE (CAL) ENGINE SPECIFICATIONS Item Standard Limit Throttle bodies ID mark 5SL1 00 (5SLD), 5SL4 10 (5SLE) Throttle valve size...
Page 74: Tightening Torques
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Item Item Fastener Fastener Q’ty Q ty Remarks Remarks size mSkg ftSlb Oil cooler Bolt Yamaha bond Cylinder identification sensor Bolt No.1215 email: info@motomatrix.co.uk –2–...
Page 75: Cable Routing
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING CABLE ROUTING Right handlebar switch lead A Pass the right handlebar switch lead inside the front Clutch cable brake hoses and over the throttle cables. Immobilizer unit lead, main switch lead and left han- B Install the throttle cables to the hook so that the pull- dlebar switch lead...
Page 76 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING F Pass the horn lead by the outside of the throttle I Set in the coupler between the head light’s hollow cable and clamp it to the forefront of upper face of section and the duct.
Page 77 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Throttle stop screw D Pass the clutch cable inside of the coolant reservoir Coolant reservoir tank hose tank hose and radiator return hoses. Pickup coil lead E Assemble as “...
Page 78 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING L Clamp the clutch cable by routing the upper end of the clamp along with the bottom end of the hose clamp assembly. email: info@motomatrix.co.uk –6–...
Page 79 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Throttle cable (return side) A Pass the main switch lead under the left handlebar Throttle cable (pull side) switch lead and then to the right side of the vehicle. Starter motor lead B Pass the throttle stop cable by the left side of the Coolant reservoir tank breather hose...
Page 80 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING F Pass the coolant reservoir tank breather hose M To the throttle body through the clamp of under the coolant reservoir N To the radiator fan motor relay and fuse box tank.
Page 81 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Right handlebar switch lead Crankshaft position sensor lead Fuel hose (feed side, except for Sub wire harness coupler CAL) Head light lead Fuel tank breather hose (except Crankcase breather hose Meter lead for CAL)
Page 82 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Throttle cables Sidestand switch lead coupler Neutral switch lead coupler Throttle sub-lead 1 (white 6 (blue 2 poles) (connector 1 pole) poles) A.C. magneto lead coupler Fuel hose (return side, for CAL) Throttle sub-lead 2 (black 6 (white 3 poles)
Page 83 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING A To the headlight F Connect the couplers (4 units) at the frame side B Make sure not to drop the headlight sub wire har- hole.
Page 84 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING L To the neutral switch U Pass the wire harness between frame and coolant M Insert the wire harness wrapping clamp to the frame hose.
Page 85 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING AA Branching leads to the fuse box and radiator fan AF Tip of the plastic locking tie should point to the motor relay shall pass through the guide section downward outside of the vehicle.
Page 86 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Fuel pump assembly C Direction of which is sufficient as the knob of a clip. Fuel tank drain hose D Air opening Fuel tank breather hose (except for CAL) E Install the breather hose without projecting canister Clamp nipple out of the breather hose.
Page 87: Periodic Checks And Adjustments
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK EAS00040 PERIODIC CHECKS AND ADJUSTMENTS FUEL TANK 7 Nm (0.7 mSkg, 5.1 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 4 Nm (0.4 mSkg, 2.9 ftSlb) Order Job/Part Q’ty...
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: S fuel pump 4 Nm (0.4 mSkg, 2.9 ftSlb) NOTE: S Do not damage the installation surfaces of the fuel tank when installing the fuel pump.
Page 89: Fuel Injection System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR INDUCTION SYSTEM FUEL INJECTION SYSTEM AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Air cut-off valve A To cylinder #1 and #2 2 Reed valve B To cylinder #3 and #4 3 To air filter case email: info@motomatrix.co.uk...
Page 90: Electrical
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC ELECTRICAL COMPONENTS ELECTRICAL ELECTRICAL COMPONENTS Coolant temperature sensor Speed sensor Intake air temperature sensor Crankshaft position sensor Intake air pressure sensor Cylinder identification sensor Lean angle cut-off switch Radiator fan motor relay Atmospheric pressure sensor Headlight relay (on / off)
Page 91 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC IGNITION SYSTEM EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM Main switch Ignition coil Battery Spark plug Fuse (main) Neutral switch Fuse (ignition) Crankshaft position sensor Starting circuit cut-off relay Lean angle cut-off switch Sidestand switch Engine stop switch...
Page 92: Ignition System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC IGNITION SYSTEM EAS00737 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The ignition system fails to operate (no Refer to “CHECKING AND CHARGING spark or intermittent spark).
Page 93 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC IGNITION SYSTEM EAS00743 4. Ignition spark gap The following procedure applies to all of the spark plugs. S Disconnect the spark plug cap from the spark plug. S Connect the ignition checker and ignition coil...
Page 94 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC IGNITION SYSTEM EAS00748 EAS00750 8. Engine stop switch 6. Crankshaft position sensor resistance S Check the engine stop switch for continuity. S Disconnect the crankshaft position sensor Refer to “CHECKING THE SWITCHES”.
Page 95 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC IGNITION SYSTEM EAS00753 12. Starting circuit cut-off relay NOTE: When you switch the positive and negative S Disconnect the starting circuit cut-off relay tester probes, the readings in the above chart coupler from the wire harness.
Page 96 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC IGNITION SYSTEM Replace lean angle cut-off switch. EAS00754 14. Wiring S Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. S Is the ignition system’s wiring properly con- nected and without defects? Replace the ignitor Properly connect or...
Page 97: Lighting System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM email: info@motomatrix.co.uk –25–...
Page 98 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC LIGHTING SYSTEM Main switch Battery Fuse (main) High beam indicator light Meter light Fuse (headlight) Headlight relay (on / off) Headlight relay (dimmer) Fuse (park) Pass switch Dimmer switch Headlight License light...
Page 99: 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 ! black/yellow 1. The headlight and the high beam indicator Negative tester probe ! black light fail to come on.
Page 100 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC LIGHTING SYSTEM EAS00789 EAS00790 2. The meter light fails to come on. 3. The tail/brake light fails to come on. 1. Meter light (LEDs) 1. Tail/brake light (LEDs) S Check the meter light for continuity.
Page 101 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC LIGHTING SYSTEM EAS00792 4. The license light fails to come on. 1. License light bulb and socket S Check the license light bulb and socket for continuity.
Page 102 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys YZF-R6S/YZF-R6SC WIRING DIAGRAM email: info@motomatrix.co.uk...
Page 103: Yzf-R6S/Yzf-R6Sc Wiring Diagram
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys YZF-R6S/YZF-R6SC WIRING DIAGRAM Main switch Rear turn signal light (right) A.C. magneto Rear turn signal light (left) Rectifier/ regulator Front turn signal / position light (right) Fuse (backup) Front turn signal / position light (left) Battery Headlight...
Page 104 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
Page 105 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
Page 106 YZF-R6RC/YZF-R6SRC SERVICE MANUAL 2002 by Yamaha Motor Corporation, U.S.A. First edition, December 2002 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-16-45 email: info@motomatrix.co.uk...
Page 107 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
Page 108 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 109 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS00008 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis...
Page 110 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS00012 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 111 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ......VEHICLE IDENTIFICATION NUMBER .
Page 112 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE OIL LUBRICATION CHART ......2-30 LUBRICATION DIAGRAMS .
Page 113 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS ........... . 3-39 ADJUSTING THE FRONT BRAKE .
Page 114 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT AND REAR BRAKES ........4-16 FRONT BRAKE PADS .
Page 115 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR SHOCK ABSORBER ASSEMBLY ......4-68 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER...
Page 116 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS ....... . 5-21 REMOVING THE VALVES .
Page 117 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PAN AND OIL PUMP ........5-54 REMOVING THE OIL PAN .
Page 118 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAPTER 6 COOLING SYSTEM RADIATOR ........... CHECKING THE RADIATOR .
Page 119 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAPTER 8 ELECTRICAL ELECTRICAL COMPONENTS ........CHECKING SWITCH CONTINUITY .
Page 120 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL PUMP SYSTEM ......... 8-46 CIRCUIT DIAGRAM .
Page 121 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys UNSTABLE HANDLING ........FAULTY LIGHTING OR SIGNALING SYSTEM .
Page 122: 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. EAS00018 MODEL LABEL The model label 1 is affixed to the frame.
Page 123: Features
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES INFO EAS00896 FEATURES OUTLINE OF FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature.
Page 124: 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 only 284 kPa (2.84 kg/cm ) higher than the intake manifold pressure.
Page 125: Instrument Function
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES INFO INSTRUMENT FUNCTION Multi-function display The multi-function display is equipped with the following: S a speedometer (which shows the riding speed) S an odometer (which shows the total distance traveled) S two tripmeters (which show the distance traveled since they were last set to zero)
Page 126 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES INFO Display brightness and shift timing indica- tor light control mode This mode cycles through five control functions, allowing you to make the following settings in the order listed below.
Page 127 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES INFO To set the shift timing indicator light activation function NOTE: S The indicator light activation function can be set between 10,000 and 16,000 r/min. S From 10,000 r/min to 12,000 r/min, the indicatar light can be set in increments of 500 r/min. S From 12,000 r/min to 16,000 r/min, the indicatar light can be set in increments of 200 r/min.
Page 128: Important Information
5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
Page 129: 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 130: 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: S lead S coupler S connector 2.
Page 131: 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 inappropriate tools or improvised techniques.
Page 132 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Oil filter wrench 90890-01426 YU-38411 This tool is needed to loosen or tighten the oil filter cartridge. Rod puller Rod puller 90890-01437 Rod puller attachment...
Page 133 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Piston ring compressor 90890-04044 YM-04044 This tool is used to compress piston rings when installing the cylinder. Carburetor angle driver 90890-03158 This tool is used to turn the pilot screw when adjusting the engine idling speed.
Page 134 Tool name/Function Illustration Vacuum/pressure pump gauge set 90890-06756 YB-35956 This tool used to measure the vacuum pres- sure. Yamaha bond No. 1215 90890-85505 ACC-11001- 05-01 This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces). email: info@motomatrix.co.uk...
Page 135: 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 5SL3 (USA except for CAL) 5SL4 (CAL) 5SL7 (USA except for CAL) 5SL8 (CAL) Dimensions Overall length 2,025 mm (79.7 in) Overall width 690 mm (27.2 in)
Page 136: 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, DOHC Displacement 600 cm (36.61 cu.in) Cylinder arrangement Forward-inclined parallel 4-cylinder Bore stroke 65.5 44.5 mm (2.58 1.75 in) Compression ratio...
Page 137 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil filter Oil filter type Formed 80 X 120 kPa (0.8 X 1.2 kg/cm Bypass valve opening pressure 0.8 X 1.2 bar, 11.6 X 17.4 psi) Oil pump Oil pump type Trochoid...
Page 138 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshafts Drive system Chain drive (right) 23.008 X 23.029 mm (0.9058 X 0.9067 in) Camshaft cap inside diameter 22.967 X 22.980 mm (0.9042 X 0.9047 in) Camshaft journal diameter 0.028 X 0.062 mm (0.0011 X 0.0024 in) Camshaft-journal-to-camshaft-...
Page 139 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ENGINE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links RH2015 /120 Tensioning system Automatic Valves, valve seats, valve guides Valve clearance (cold) 0.13 X 0.20 mm (0.0051 X 0.0079 in) Intake 0.23 X 0.30 mm (0.0091 X 0.0118 in) Exhaust...
Page 140 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve springs Free length Intake (inner) 35.7 mm (1.41 in) 33.9 mm (1.33 in) Intake (outer) 40.3 mm (1.59 in) 38.3 mm (1.50 in) Exhaust 41.7 mm (1.64 in) 39.6 mm (1.56 in)
Page 141 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston 0.010 X 0.035 mm (0.0004 X 0.0014 in) Piston-to-cylinder clearance 0.055 mm (0.0022 in) 65.475 X 65.490 mm (2.5778 X 2.5783 in) Diameter D Height H 4 mm (0.16 in)
Page 142 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ENGINE SPECIFICATIONS Item Standard Limit Connecting rods 0.028 X 0.052 mm (0.0011 X 0.0020 in) Crankshaft-pin-to-big-end-bearing 0.09 mm clearance (0.0035 in) Bearing color code 1 = Blue 2 = Black 3 = Brown 4 = Green Crankshaft 51.85 X 52.55 mm (2.04 X 2.06 in) Width A...
Page 143 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ENGINE SPECIFICATIONS Item Standard Limit Transmission Transmission type Constant mesh, 6-speed Primary reduction system Spur gear Primary reduction ratio 86/44 (1.955) Secondary reduction system Chain drive Secondary reduction ratio 48/16 (3.000) Operation...
Page 144 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ENGINE SPECIFICATIONS Item Standard Limit Throttle position sensor 4.85 X 5.15 kΩ at 20_C (68_F) Resistance 0.63 X 0.73 V Output voltage (at idle) Throttle bodies Model (manufacturer) quantity 38EIS (MIKUNI)
Page 145: 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 Trail 86 mm (3.39 in) Front wheel Wheel type Cast wheel Size 17 M/C MT3.50 Material Aluminum...
Page 146 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type Tubeless Size 180/55 ZR17 M/C (73W) Model (manufacturer) Pilot SPORT B (MICHELIN) D208L (DUNLOP) Tire pressure (cold) 0 X 90 kg (0 X 198 lb) 250 kPa (2.5 kgf/cm , 2.5 bar, 35.6 psi)
Page 147 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front suspension Suspension type Telescopic fork Front fork type Coil spring/oil damper Front fork travel 120 mm (4.72 in) Spring Free length 249.3 mm (9.81 in) 244.3 mm (9.62 in)
Page 148 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CHASSIS SPECIFICATIONS Item Standard Limit Steering Steering bearing type Angular bearing Rear suspension Suspension type Swingarm (link suspension) Rear shock absorber assembly Coil spring/gas-oil damper type Rear shock absorber assembly 60 mm (2.36 in) travel...
Page 149: 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 DC. CDI Ignition timing 10_ BTDC at 1,300 r/min (USA except for CAL) 5_ BTDC at 1,300 r/min (CAL) 248 X 372 Ω...
Page 150 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Indicator light (voltage /wattage quantity) Neutral indicator light High beam indicator light Oil level indicator light Turn signal indicator light Fuel level warning light Coolant temparture indicator light Engine trouble warning light Shift timing indicator light...
Page 151 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Fuses (amperage quantity) Main fuse 40 A Fuel injection system fuse 15 A Headlight fuse 20 A Signaling system fuse 15 A Ignition fuse 15 A Radiator fan motor fuse...
Page 152: Conversion Table
CONVERSION TABLE/ Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE All specification data in this manual are SPECIFICATIONS listed in SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC dard fasteners with a standard ISO thread...
Page 153: Tightening Torques
Bolt Camshaft caps Bolt Cylinder head cover Bolt Camshaft cap oil check bolt Bolt Reed valve cover Bolt Yamaha bond No.1215 Air-cut valve stay Bolt Camshaft sprockets Bolt Connecting rod caps 15 + 150_ 1.5 + 150_ 11 + 150_...
Page 154 Fastener Q’ty Q ty Remarks Remarks size mSkg ftSlb Generator rotor cover Bolt Clutch cover Bolt Yamaha bond Clutch cover Bolt No.1215 Pickup coil rotor cover Bolt Clutch cable holder Bolt Pickup coil rotor cover Bolt Shift shaft cover Bolt...
Page 155 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC TIGHTENING TORQUES Cylinder head tightening sequence: Crankcase tightening sequence. email: info@motomatrix.co.uk 2-21...
Page 156: Chassis Tightening Torques
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening Thread Item Item Remarks Remarks size mSkg ftSlb Upper bracket and front fork Steering stem nut 11.3 Handlebar and front fork Handlebar and upper bracket Lower ring nut See NOTE 1...
Page 157 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC TIGHTENING TORQUES Tightening Thread Item Item Remarks Remarks size mSkg ftSlb Rear brake hose union bolt Sidestand bracket and frame Front wheel axle shaft and bolt Rear wheel axle nut 11.0 Front brake caliper and front fork...
Page 158: Lubrication Points And Lubricant Types
Transmission gears (wheel and pinion) Main axle and drive axle Shift drum bearing Shift forks and shift fork guide bars Shift shaft Shift shaft boss Yamaha bond Cylinder head cover mating surface No.1215 Yamaha bond Crankcase mating surface No.1215 Yamaha bond Generator rotor cover (stator coil assembly lead grommet) No.1215...
Page 159: 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 Lubricant Steering bearings and bearing races (upper and lower) Front wheel oil seal (right and left) Rear wheel oil seal Front axle shaft Rear wheel drive hub oil seal Rear wheel drive hub mating surface...
Page 160 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC COOLING SYSTEM DIAGRAMS COOLING SYSTEM DIAGRAMS Radiator Oil cooler email: info@motomatrix.co.uk 2-26...
Page 161 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC COOLING SYSTEM DIAGRAMS Water pump Oil cooler Radiator email: info@motomatrix.co.uk 2-27...
Page 162 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC COOLING SYSTEM DIAGRAMS Oil cooler Water pump email: info@motomatrix.co.uk 2-28...
Page 163 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC COOLING SYSTEM DIAGRAMS Radiator Thermostat email: info@motomatrix.co.uk 2-29...
Page 164: Engine Oil Lubrication Chart
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ENGINE OIL LUBRICATION CHART ENGINE OIL LUBRICATION CHART email: info@motomatrix.co.uk 2-30...
Page 165: Lubrication Diagrams
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS Oil level switch Oil cooler Relief valve email: info@motomatrix.co.uk 2-31...
Page 166 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC LUBRICATION DIAGRAMS Oil pump Exhaust camshaft Intake camshaft Oil strainer email: info@motomatrix.co.uk 2-32...
Page 167 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC LUBRICATION DIAGRAMS Oil cooler Oil strainer Oil level switch Oil pump email: info@motomatrix.co.uk 2-33...
Page 168 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC LUBRICATION DIAGRAMS Main axle Oil pump Relief valve email: info@motomatrix.co.uk 2-34...
Page 169 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC LUBRICATION DIAGRAMS Cylinder head Intake camshaft Exhaust camshaft Crankshaft email: info@motomatrix.co.uk 2-35...
Page 170 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC LUBRICATION DIAGRAMS Main axle Drive axle email: info@motomatrix.co.uk 2-36...
Page 171: Cable Routing
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING CABLE ROUTING Right handlebar switch lead A Pass the right handlebar switch lead inside the front Clutch cable brake hoses and over the throttle cables. Main switch lead and left handlebar switch lead B Install the throttle cables to the hook so that the pull- Throttle cable (return side)
Page 172 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING F Pass the horn lead by the outside of the throttle J Install the relay to the rib of the headlight. cables and clamp it to the forefront of upper face of (Location for the left and right relays is alternative.) the under bracket.
Page 173 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Throttle stop screw D Pass the clutch cable inside of the coolant reservoir Coolant reservoir tank hose tank hose and radiator return hoses. Crankshaft position sensor lead E The punch mark starting point should be lower than Rear brake light switch lead the clamp’s top end.
Page 174 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING K Put and apply the hose clamp to it. L Pass the crankshaft position sensor lead over the throttle stop screw. email: info@motomatrix.co.uk 2-40...
Page 175 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Throttle cable (return side) A Pass the main switch lead under the left handlebar Throttle cable (pull side) switch lead and then to the right side of the vehicle. Starter motor lead B Pass the throttle stop cable by the left side of the Canister hose (for CAL)
Page 176 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING F Pass the fuel tank drain hose and fuel tank breather M Route it above the radiator hose. hose through the clamp of the coolant reservoir N Pass the throttle cable between the guide of the tank.
Page 177 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Right handlebar switch lead Starter motor lead Throttle sub-lead 2 (black 6 Sub wire harness Fuel hose (feed side) poles) Cover 8 Canister hose (for CAL) Oil level switch lead coupler Ignition coil lead Crankcase breather hose...
Page 178 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING A To the headlight G From the radiator B Make sure not to drop the headlight sub wire har- H Pass the coolant reservoir tank hose through for- ness beneath the projection of the duct.
Page 179 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING P To the coolant reservoir tank X Clamp the wire harness, left and right handlebar Q To the intake air temperature sensor (air filter case) switch leads and main switch lead.
Page 180 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING AB To the fuse box and fan motor relay AC Pass the throttle cables over the cover 2. AD Point the tip of the plastic locking tie to the rear side of the vehicle.
Page 181 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Battery A Push the starter motor lead in the clamping sections Battery positive lead (two points) or the battery box assembly and secure Starter relay Turn signal relay B Fit the plastic cover in the starter relay after the Pressure sensor...
Page 182 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING H The knob section should be positioned in this area. Q Point the opening to the rear side of the vehicle. I Pass the turn signal lead by the outside of the right R Connect the tail / brake light lead coupler.
Page 183 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING For California Fuel pump assembly A Install the roll over valve until it contacts with the fuel Canister hose tank’s nipple. Canister B Install the O-ring with its lip pointed upward. Breather hose C Install the clip with its tab pointed in the upward Blance hose...
Page 184: Periodic Checks And Adjustments
Air induction system and hose for damage. (See page 7-35) S Replace any damaged parts. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. ** California only GENERAL MAINTENANCE AND LUBRICATION CHART...
Page 185 S Check air pressure. (See page 3-55) S Correct if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24,000 mi (37,000 km) 36 months, repeat the maintenance intervals starting from 4,000 mi (7,000 km) or 6 months.
Page 186: Seats
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SEATS EAS00039 SEATS 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part Q’ty Remarks Removing the seats Remove the parts in the order listed. Passenger seat Rider seat For installation, reverse the removal procedure.
Page 187: Fuel Tank
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK EAS00040 FUEL TANK 7 Nm (0.7 mSkg, 5.1 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Rider seat Refer to “SEATS”.
Page 188: 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 cap with a pump. 2. Remove: S fuel return hose S fuel hose CAUTION: S Be sure to disconnect the fuel hose by...
Page 189: 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: S fuel pump 4 Nm (0.4 mSkg, 2.9 ftSlb) NOTE: S Do not damage the installation surfaces of the fuel tank when installing the fuel pump.
Page 190: Cowlings
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COWLINGS COWLINGS Order Job/Part Q’ty Remarks Removing the cowlings Remove the parts in the order listed. Rider and passenger seats Refer to “SEATS”. Front cowling inner panel (left and right) Front turn signal light lead couplers Disconnect.
Page 191: Removal
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COWLINGS REMOVAL 1. Remove: S rear cowling S side cowlings NOTE: To remove the quick fastener, push its center with a screwdriver, then pull the fastener out. INSTALLATION 1.
Page 192: Air Filter Case
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR FILTER CASE AIR FILTER CASE 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Removing the air filter case Remove the parts in the order listed. Rider seat Refer to “SEATS”.
Page 193: Engine
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE VALVE CLEARANCE EAS00045 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: S Valve clearance adjustment should be made on a cold engine, at room temperature.
Page 194 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE VALVE CLEARANCE 4. Measure: S valve clearance Out of specification ! Adjust. Valve clearance (cold) Intake valve 0.13 X 0.20 mm (0.0051 X 0.0079 in) Exhaust valve 0.23 X 0.30 mm (0.0091 X 0.0118 in)
Page 195 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE VALVE CLEARANCE 5. Remove: S camshafts NOTE: S Refer to “DISASSEMBLING THE ENGINE – CAMSHAFT AND CYLINDER HEAD” in chap- ter 5. S When removing the timing chain and cam- shafts, fasten the timing chain with a wire to re- trieve it if it falls into the crankcase.
Page 196 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE VALVE CLEARANCE c. Round off the original valve pad number ac- cording to the following table. Last digit Rounded value 0 or 2 EXAMPLE: Original valve pad number = 148 (thickness =1.48 mm (0.058 in)) Rounded value = 150 d.
Page 197 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE VALVE CLEARANCE NOTE: S Refer to “ASSEMBLING AND ADJUSTING THE ENGINE – CYLINDER HEAD AND CAM- SHAFT” in chapter 5. S Lubricate the camshaft bearings, camshaft lobes and camshaft journals.
Page 198 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE VALVE CLEARANCE INTAKE INSTALLED PAD NUMBER MEASURED 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 CLEARANCE 0.00 X 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225...
Page 199: Synchronizing The Throttle Bodies
ADJUSTING THE VALVE CLEARANCE/ Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SYNCHRONIZING THE THROTTLE BODIES 7. Install: S all removed parts NOTE: For installation, reverse the removal procedure. SYNCHRONIZING THE THROTTLE BODIES NOTE: Prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed should be properly adjusted and the ignition tim- ing should be checked.
Page 200 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SYNCHRONIZING THE THROTTLE BODIES 5. Install: S air filter case Refer to “AIR FILTER CASE”. S fuel tank Refer to “FUEL TANK”. 6. Start the engine and let it warm up for several minutes.
Page 201: Adjusting The Engine Idling Speed
SYNCHRONIZING THE THROTTLE BODIES/ Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE ENGINE IDLING SPEED 9. Measure: S engine idling speed Out of specification ! Adjust. Make sure that the vacuum pressure is within specification.
Page 202: Adjusting The Throttle Cable Free Play
ADJUSTING THE ENGINE IDLING SPEED/ Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE THROTTLE CABLE FREE PLAY 4. Adjust: S engine idling speed a. Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained.
Page 203 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE THROTTLE CABLE FREE PLAY 3. Adjust: S throttle cable free play NOTE: When the throttle is opened, the accelerator cable 1 is pulled. Throttle body side a.
Page 204: Checking The Spark Plugs
ADJUSTING THE THROTTLE CABLE FREE PLAY/ Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE SPARK PLUGS 4. Install: S left frame side cover Refer to “COWLINGS”. S air filter case Refer to “AIR FILTER CASE”. S fuel tank Refer to “FUEL TANK”.
Page 205: Measuring The Compression Pressure
CHECKING THE SPARK PLUGS/ Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys MEASURING THE COMPRESSION PRESSURE 6. Measure: S spark plug gap a (with a wire Thickness gauge) Out of specification ! Regap. Spark plug gap 0.6 X 0.7 mm (0.0236 X 0.0276 in) 7.
Page 206 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys MEASURING THE COMPRESSION PRESSURE CAUTION: Before removing the spark plugs, use com- pressed air to blow away any dirt accumu- lated in the spark plug wells to prevent it from falling into the cylinders.
Page 207: Checking The Engine Oil Level
MEASURING THE COMPRESSION PRESSURE/ Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE ENGINE OIL LEVEL d. If the compression pressure is below the minimum specification, pour a teaspoonful of engine oil into the spark plug bore and mea- sure again.
Page 208: Changing The Engine Oil
CHECKING THE ENGINE OIL LEVEL/ Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHANGING THE ENGINE OIL Recommended oil At 5_C (40_F) or higher A Yamalube 4 (20W40) or SAE 20W40 type SE motor At 15_C (60_F) or lower B Yamalube 4 (10W30) or SAE 10W30 type SE motor NOTE:...
Page 209 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHANGING THE ENGINE OIL 6. If the oil filter cartridge is also to be replaced, perform the following procedure. a. Remove the oil filter cartridge 1 with an oil filter wrench 2 .
Page 210: Measuring The Engine Oil Pressure
CHANGING THE ENGINE OIL/ Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys MEASURING THE ENGINE OIL PRESSURE 10. Install: S engine oil filler cap S coolant reservoir tank Refer to “CHANGING THE COOLANT”. S bottom cowling Refer to “COWLINGS”.
Page 211 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys MEASURING THE ENGINE OIL PRESSURE 6. Measure: S engine oil pressure (at the following conditions) Engine oil pressure 240 kPa (2.4 kg/cm , 2.4 bar, 34.1 psi) Engine speed Approx.
Page 212: 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: S clutch cable free play a Out of specification ! Adjust. Clutch cable free play (at the end of the clutch lever) 10 X 15 mm (0.39 X 0.59 in) 2.
Page 213: Cleaning The Air Filter Element
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLEANING THE AIR FILTER ELEMENT EAS00086 CLEANING THE AIR FILTER ELEMENT 1. Remove: S rider seat Refer to “SEATS”. S fuel tank Refer to “FUEL TANK”. 2. Remove: S air filter case cover 1 S air filter element 3.
Page 214: Cleaning The Air Intake System Surge Tanks
CLEANING THE AIR INTAKE SYSTEM SURGE TANKS/ Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE THROTTLE BODY JOINTS EAS00092 CLEANING THE AIR INTAKE SYSTEM SURGE TANKS The following procedure applies to both air in- take system surge tanks.
Page 215: Checking The Fuel And Breather Hoses
CHECKING THE FUEL AND BREATHER HOSES/ Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE CRANKCASE BREATHER HOSE EAS00096 CHECKING THE FUEL AND BREATHER HOSES The following procedure applies to all of the fuel and breather hoses.
Page 216: Checking The Exhaust System
CHECKING THE EXHAUST SYSTEM/ Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE COOLANT LEVEL EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex- haust pipes and gaskets. 1. Remove: S bottom cowling Refer to “COWLINGS”.
Page 217: Checking The Cooling System
CHECKING THE COOLANT LEVEL/ Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE COOLING SYSTEM 2. Check: S coolant level The coolant level should be between the maximum level mark a and minimum level mark b .
Page 218: Changing The Coolant
CHECKING THE COOLING SYSTEM/ Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHANGING THE COOLANT 2. Check: S radiator 1 S radiator inlet hose 2 S radiator outlet hose 3 S oil cooler 4 S oil cooler inlet hose 5 S oil cooler outlet hose 6 S water jacket outlet joint 7 S water jacket hose 8...
Page 219 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHANGING THE COOLANT 3. Disconnect: S coolant reservoir cap 1 4. Drain: S coolant (from the coolant reservoir tank) 5. Remove: S radiator cap 1 CAUTION: A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot.
Page 220 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHANGING THE COOLANT 10. Install: S coolant reservoir tank 11. Connect: S coolant reservoir hose 12. Fill: S cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol...
Page 221 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHANGING THE COOLANT S Use only distilled water. However, if dis- tilled water is not available, soft water may be used. S If coolant comes into contact with painted surfaces, immediately wash them with wa- ter.
Page 222: Chassis
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE FRONT BRAKE EAS00107 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: S brake lever position (distance a from the throttle grip to the brake lever) NOTE: S While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position.
Page 223: Adjusting The Rear Brake
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE REAR BRAKE EAS00110 ADJUSTING THE REAR BRAKE 1. Check: S brake pedal position (distance a bottom of the footrest bracket) Out of specification ! Adjust. Brake pedal position (below the bottom of the footrest bracket) 7 X 11 mm (0.28 X 0.43 in)
Page 224: Checking The Brake Fluid Level
ADJUSTING THE REAR BRAKE/ Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE BRAKE FLUID LEVEL 3. Adjust: S rear brake light switch Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”. EAS00115 CHECKING THE BRAKE FLUID LEVEL 1.
Page 225: Adjusting The Rear Brake Light Switch
CHECKING THE BRAKE FLUID LEVEL/ Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE REAR BRAKE LIGHT SWITCH CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. NOTE: In order to ensure a correct reading of the brake fluid level, make sure the top of the brake fluid...
Page 226: Checking The Front And Rear Brake Pads
CHECKING THE FRONT AND REAR BRAKE PADS/ Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE FRONT AND REAR BRAKE HOSES EAS00122 CHECKING THE FRONT AND REAR BRAKE PADS The following procedure applies to all of the brake pads.
Page 227: Bleeding The Hydraulic Brake System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00135 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the hydraulic brake system whenev- S the system is disassembled. S a brake hose is loosened, disconnected or replaced.
Page 228: Adjusting The Shift Pedal
BLEEDING THE HYDRAULIC BRAKE SYSTEM/ Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE SHIFT PEDAL h. Tighten the bleed screw and then release the brake lever or brake pedal. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose.
Page 229: Adjusting The Drive Chain Slack
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE DRIVE CHAIN SLACK EAS00140 ADJUSTING THE DRIVE CHAIN SLACK NOTE: The drive chain slack must be checked at the tightest point on the chain. CAUTION: A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swin-...
Page 230: Lubricating The Drive Chain
ADJUSTING THE DRIVE CHAIN SLACK/ Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATING THE DRIVE CHAIN Direction Drive chain is tightened. Direction Drive chain is loosened. NOTE: To maintain the proper wheel alignment, adjust both sides evenly.
Page 231: Checking And Adjusting The Steering Head
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING AND ADJUSTING THE STEERING HEAD EAS00146 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over.
Page 232 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING AND ADJUSTING THE STEERING HEAD c. Loosen the lower ring nut 4 completely, then tighten it to specification. WARNING Do not overtighten the lower ring nut. Lower ring nut (final tightening torque) 14 Nm (1.4 mSkg, 10 ftSlb)
Page 233: Checking The Front Fork
CHECKING AND ADJUSTING THE STEERING HEAD/ Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE FRONT FORK Steering head tension 200 X 500 g e. Repeat the above procedure on the opposite handlebar. f. If the steering head tension is out of specifi- cation (both handlebars should be within specification), remove the upper bracket and loosen or tighten the upper ring nut.
Page 234: Adjusting The Front Fork Legs
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE FRONT FORK LEGS EAS00155 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING S Always adjust both front fork legs evenly. Uneven adjustment can result in poor han- dling and loss of stability.
Page 235 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE FRONT FORK LEGS 1. Adjust: S rebound damping a. Turn the adjusting screw 1 in direction a or Rebound damping is Direction increased (suspension is harder).
Page 236: Adjusting The Rear Shock Absorber Assembly
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EAS00158 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING Securely support the motorcycle so that there is no danger of it falling over. Spring preload CAUTION: Never go beyond the maximum or minimum...
Page 237 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 1. Adjust: S rebound damping a. Turn the adjusting screw 1 in direction a or Rebound damping is Direction increased (suspension is harder).
Page 238: Checking The Tires
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE TIRES EAS00162 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: S tire pressure Out of specification ! Regulate. WARNING S The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.
Page 239 Ltd. for this model. The front and rear tires should always be by the same manufactur- er and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle. email: info@motomatrix.co.uk 3-56...
Page 240: Checking The Wheels
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE TIRES/CHECKING THE WHEELS Front tire Manufacturer Size Model DUNLOP 120/60ZR 17 D208FL M/C (55W) MICHELIN 120/60ZR 17 Pilot M/C (55W) SPORTS N Rear tire Manufacturer Size Model DUNLOP...
Page 241: Checking And Lubricating The Cables
CHECKING AND LUBRICATING THE CABLES / Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATING THE LEVERS AND PEDALS / LUBRICATING THE SIDESTAND/ LUBRICATING THE REAR SUSPENSION EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in- ner and outer cables.
Page 242: 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 poi- sonous and highly caustic sulfuric acid.
Page 243 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 possible to check the charge state of the battery by mea- suring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
Page 244 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING AND CHARGING THE BATTERY 5. Charge: Charging Ambient temperature 20_C S battery (refer to the appropriate charging method il- lustration) WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit CAUTION:...
Page 245 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 Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 minutes after the machine is stopped. Connect a charged and NOTE: AMP meter to the battery...
Page 246 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 Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 minutes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging.
Page 247: Checking The Fuses
CHECKING AND CHARGING THE BATTERY/ Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE FUSES 6. Install: S battery 7. Connect: S battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1 , and then the negative battery lead 2 .
Page 248 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE FUSES Pocket tester 90890-03112, YU-3112 b. If the pocket tester indicates “∞”, replace the fuse. 3. Replace: S blown fuse a. Set the main switch to “OFF”. b.
Page 249: Replacing The Headlight Bulbs
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REPLACING THE HEADLIGHT BULBS EAS00183 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Remove: S front cowling inner panels Refer to “COWLINGS”. 2.
Page 250: Adjusting The Headlight Beams
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE HEADLIGHT BEAMS EAS00185 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1. Remove: S front cowling inner panels Refer to “COWLINGS”. 2.
Page 251: Front Wheel And Brake Discs
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 7 Nm (0.7 mSkg, 5.1 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) 91 Nm (9.1 mSkg, 66 ftSlb) 18 Nm (1.8 mSkg, 13 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb)
Page 252 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT WHEEL AND BRAKE DISCS EAS00518 Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the order listed. Oil seal (left and right) Wheel bearing (left and right) Spacer For assembly, reverse the disassembly...
Page 253: Removing The Front Wheel
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT WHEEL AND BRAKE DISCS EAS00521 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 254 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT WHEEL AND BRAKE DISCS 3. Measure: S radial wheel runout 1 S lateral wheel runout 2 Over the specified limits ! Replace. Radial wheel runout limit 1 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
Page 255: Checking The Brake Discs
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT WHEEL AND BRAKE DISCS EAS00533 CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs. 1. Check: S brake discs Damage/galling ! Replace. 2.
Page 256: Installing The Front Wheel
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT WHEEL AND BRAKE DISCS Brake disc bolt Front: 18 Nm (1.8 mSkg, 13 ftSlb) Rear: 30 Nm (3.0 mSg, 22 ftSlb)  LOCTITE d. Measure the brake disc deflection. e.
Page 257: 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 DISCS 8. Tighten wheel axle pinch bolt 2 , and then pinch bolt 1 to specified torque. 9. Retighten pinch bolt 2 to the specified torque.
Page 258 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT WHEEL AND BRAKE DISCS a. Spin the front wheel. b. When the front wheel stops, put an “X ” mark at the bottom of the wheel. c.
Page 259: Rear Wheel And Brake Disc
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS REAR WHEEL AND BRAKE DISC EAS00551 REAR WHEEL AND BRAKE DISC REAR WHEEL 23 Nm (2.3 mSkg, 17 ftSlb) 28 Nm (2.8 mSkg, 20 ftSlb) 110 Nm (11 mSkg, 80 ftSlb) Order Job/Part Q’ty...
Page 260: Rear Brake Disc And Rear Wheel Sprocket
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS REAR WHEEL AND BRAKE DISC EAS00556 REAR BRAKE DISC AND REAR WHEEL SPROCKET 30 Nm (3.0 mSkg, 22 ftSlb) 100 Nm (10 mSkg, 72 ftSlb) Order Job/Part Q’ty Remarks...
Page 261 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS REAR WHEEL AND BRAKE DISC EAS00560 Order Job/Part Q’ty Remarks Disassembling the rear wheel Disassemble the parts in the order listed. Collar Bearing Spacer Oil seal Circlip Bearing For installation, reverse the disassembly...
Page 262: Removing The Rear Wheel
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS REAR WHEEL AND BRAKE DISC 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. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
Page 263: Checking The Rear Wheel
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS REAR WHEEL AND BRAKE DISC EAS00565 CHECKING THE REAR WHEEL 1. Check: S wheel axle S rear wheel S wheel bearings S oil seals Refer “CHECKING FRONT WHEEL”.
Page 264: Installing The Rear Wheel
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS REAR WHEEL AND BRAKE DISC 2. Replace: S rear wheel sprocket a. Remove the self-locking nuts and the rear wheel sprocket. b. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the sprocket.
Page 265: Adjusting The Rear Wheel Static Balance
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS REAR WHEEL AND BRAKE DISC EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: S After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. S Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed.
Page 266 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 6 Nm (0.6 mSkg, 4.3 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) Order Job/Part Q’ty...
Page 267: Front And Rear Brakes
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES REAR BRAKE PADS 6 Nm (0.6 mSkg, 4.3 ftSlb) 28 Nm (2.8 mSkg, 20 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 18 Nm (1.8 mSkg, 13 ftSlb) 2.5 Nm (0.25 mSkg, 1.8 ftSlb) Order Job/Part...
Page 268: 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 disas- sembly. Therefore, always follow these preventive measures: WARNING S Never disassemble brake components un- less absolutely necessary.
Page 269 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES 2. Remove: S brake pad clips 1 S brake pad pin 2 S brake pad spring 3 3. Remove: S brake pads 1 4.
Page 270 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES a. Connect a clear plastic hose 1 tightly to the bleed screw 2 . Put the other end of the hose into an open container. b.
Page 271: Replacing The Rear Brake Pads
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00583 REPLACING THE REAR BRAKE PADS NOTE: When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disas- semble the brake caliper.
Page 272 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES a. Connect a clear plastic hose 1 tightly to the bleed screw 2 . Put the other end of the hose into an open container. b.
Page 273: 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 30 Nm (3.0 mSkg, 22 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed.
Page 274 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES 30 Nm (3.0 mSkg, 22 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) Order Job/Part Q’ty Remarks Brake master cylinder bracket Brake master cylinder Front brake switch For installation, reverse the removal procedure.
Page 275 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 Disassemble the parts in the order listed. master cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly procedure.
Page 276: 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 18 Nm (1.8 mSkg, 13 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job/Part Q’ty Remarks Removing the rear brake master Remove the parts in the order listed.
Page 277 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 master Disassemble the parts in the order listed. cylinder Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly procedure.
Page 278: 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 279: 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 EAS00593 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to both of the brake master cylinders. 1. Check: S brake master cylinder Damage/scratches/wear ! Replace.
Page 280: 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 EAS00607 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid.
Page 281 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES NOTE: S While holding the brake hose, tighten the union bolt as shown. S Turn the handlebars to the left and right to make sure the brake hose does not touch oth- er parts (e.g., wire harness, cables, leads).
Page 282: Cylinder
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES 6. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...
Page 283 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
Page 284: Front Brake Calipers
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS 7 Nm (0.7 mSkg, 5.1 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job/Part Q’ty...
Page 285 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00615 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job/Part Q’ty Remarks Disassembling the front brake Disassemble the parts in the order listed. calipers NOTE: The following procedure applies to both...
Page 286: 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 mSkg, 22 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 28 Nm (2.8 mSkg, 20 ftSlb) Order Job/Part Q’ty...
Page 287 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00617 2.5 Nm (0.25 mSkg, 1.8 ftSlb) 18 Nm (1.8 mSkg, 13 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job/Part Q’ty Remarks Disassembling the rear brake caliper Disassemble the parts in the order listed.
Page 288: Disassembling The Front Brake Calipers
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00625 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system.
Page 289 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00627 DISASSEMBLING THE REAR BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S union bolt 1 S copper washers 2 S brake hose 3...
Page 290 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 Piston seals Every two years Brake hoses Every four years Brake fluid...
Page 291 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES EAS00640 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid.
Page 292 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES 3. Fill: S brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid.
Page 293: Assembling And Installing The Rear Brake Caliper
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.
Page 294 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT AND REAR BRAKES WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
Page 295: Front Fork
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK EAS00647 FRONT FORK FRONT FORK LEGS 33 Nm (3.3 mSkg, 24 ftSlb) 26 Nm (2.6 mSkg, 19 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job/Part...
Page 296 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK EAS00648 23 Nm (2.3 mSkg, 17 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) Order Job/Part Q’ty Remarks Disassembling the front fork legs Disassemble the parts in the order listed.
Page 297 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK 23 Nm (2.3 mSkg, 17 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) Order Job/Part Q’ty Remarks Damper rod assembly Inner tube Oil seal Washer...
Page 298 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 299 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK EAS00655 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Loosen: S nut 1 2. Remove: S cap bolt 2 (from the damper rod assembly) 3.
Page 300 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK Damper rod holder 90890-01473 7. Remove: S damper rod assembly 8. Remove: S inner tube S oil seal S inner tube bushing a. Hold the front fork leg horizontally. b.
Page 301 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK CAUTION: S The front fork leg has a built-in damper ad- justing rod and a very sophisticated inter- nal construction, which are particularly sensitive to foreign material. S When disassembling and assembling the front fork leg, do not allow any foreign ma- terial to enter the front fork.
Page 302 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK WARNING Always use new copper washers. CAUTION: Allow the damper rod assembly to slide slowly down the inner tube 1 until it pro- trudes from the bottom of the inner tube. Be careful not to damage the inner tube.
Page 303 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK 5. Install: S washer S oil seal 1 (with the fork seal driver weight and fork seal driver attachment) CAUTION: Make sure the numbered side of the oil seal faces up.
Page 304 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK 9. Fully compress the front fork leg. 10. Fill: S front fork leg (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 0.49 L (0.43 Imp qt, 0.52 US qt) Recommended oil Suspension oil “01”...
Page 305 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK 14. Measure: S front fork leg oil level a Out of specification ! Correct. Front fork leg oil level (from the top of the inner tube, with the inner tube fully compressed, and without the spring) 106 mm (4.17 in)
Page 306 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK e. Install the cap bolt and finger tighten it. WARNING S Before installing the cap bolt, apply grease onto the O-ring. S Always use a new cap bolt O-ring. f.
Page 307 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS FRONT FORK 5. Install: S handlebar S handlebar pinch bolt 1 33 Nm (3.3 mSkg, 24 ftSlb) S handlebar bolt 2 13 Nm (1.3 mSkg, 9.4 ftSlb) WARNING Make sure the brake hoses are routed prop- erly.
Page 308: Handlebars
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS HANDLEBARS EAS00665 HANDLEBARS 33 Nm (3.3 mSkg, 24 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 11 Nm (1.1 mSkg, 8.0 ftSlb) 33 Nm (3.3 mSkg, 24 ftSlb)
Page 309 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS HANDLEBARS EAS00667 REMOVING THE HANDLEBARS 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 310 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS HANDLEBARS EAS00674 INSTALLING THE HANDLEBARS 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 311 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS HANDLEBARS 5. Install: S clutch lever holder 1 11 Nm (1.1 mSkg, 8.0 ftSlb) NOTE: Align the slit on the clutch lever holder with the punch mark a on the left handlebar. 6.
Page 312 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS HANDLEBARS 10. Adjust: S clutch cable free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PLAY” in chapter 3. Clutch cable free play (at the end of the clutch lever) 10 X 15 mm (0.39 X 0.59 in) 11.
Page 313: Steering Head
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS STEERING HEAD EAS00676 STEERING HEAD UNDER BRACKET 26 Nm (2.6 mSkg, 19 ftSlb) 113 Nm (11.3 mSkg, 82 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 52 Nm (5.2 mSkg, 38 ftSlb) 14 Nm (1.4 mSkg, 10 ftSlb) Order Job/Part...
Page 314 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS STEERING HEAD 26 Nm (2.6 mSkg, 19 ftSlb) 113 Nm (11.3 mSkg, 82 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 52 Nm (5.2 mSkg, 38 ftSlb) 14 Nm (1.4 mSkg, 10 ftSlb) Order Job/Part...
Page 315: Removing The Under Bracket
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS STEERING HEAD EAS00679 REMOVING THE UNDER 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 316: Installing The Steering Head
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS STEERING HEAD 3. Replace: S bearings S bearing races a. Remove the bearing races 1 from the steer- ing head pipe with a long rod 2 and hammer. b.
Page 317 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS STEERING HEAD 3. Install: S upper bracket S washer 113 Nm (11.3 mSkg, 82 ftSlb) S steering stem nut NOTE: Temporarily tighten the steering stem nut. 4.
Page 318: 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 52 Nm (5.2 mSkg, 38 ftSlb) 44 Nm (4.4 mSkg, 32 ftSlb) 44 Nm (4.4 mSkg, 32 ftSlb) Order Job/Part Q’ty...
Page 319 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS REAR SHOCK ABSORBER ASSEMBLY 52 Nm (5.2 mSkg, 38 ftSlb) 44 Nm (4.4 mSkg, 32 ftSlb) 44 Nm (4.4 mSkg, 32 ftSlb) Order Job/Part Q’ty Remarks Oil seal/bearing/collar 6/3/3 Oil seal/bearing/collar...
Page 320: Handling The Rear Shock Absorber And Gas Cylinder
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00687 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER WARNING This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you under- stand...
Page 321: 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 EAS00694 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 322: Checking The Connecting Rod And Relay Arms
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS REAR SHOCK ABSORBER ASSEMBLY S spring Damage/wear ! Replace the rear shock ab- sorber assembly. S gas cylinder Damage/gas leaks ! Replace. S bushings Damage/wear ! Replace. S dust seals Damage/wear ! Replace.
Page 323: 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 16 Nm (1.6 mSkg, 12 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 95 Nm (9.5 mSkg, 69 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job/Part...
Page 324 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS SWINGARM AND DRIVE CHAIN 16 Nm (1.6 mSkg, 12 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 95 Nm (9.5 mSkg, 69 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job/Part Q’ty...
Page 325: 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 326: Removing The Drive Chain
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS SWINGARM AND DRIVE CHAIN EAS00704 REMOVING THE DRIVE CHAIN 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 327: Checking The Drive Chain
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS SWINGARM AND DRIVE CHAIN 4. Check: S dust covers 1 S spacer 2 Damage/wear ! Replace. S bearings Damage/pitting ! Replace. EAS00709 CHECKING THE DRIVE CHAIN 1.
Page 328 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS SWINGARM AND DRIVE CHAIN CAUTION: This motorcycle has a drive chain with small rubber O-rings 1 between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain.
Page 329: Installing The Swingarm
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAS SWINGARM AND DRIVE CHAIN EAS00711 INSTALLING THE SWINGARM 1. Lubricate: S bearings S spacers S dust covers S pivot shaft Recommended lubricant Lithium-soap-based grease 2. Install: S pivot shaft adjust bolt 1 6 Nm (0.6 mSkg, 4.3 ftSlb) S swingarm...
Page 330: Overhauling The Engine
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE OVERHAULING THE ENGINE ENGINE DRIVE SPROCKET 10 Nm (1.0 mSkg, 7.2 ftSlb) 6.5 Nm (0.65 mSkg, 4.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 90 Nm (9.0 mSkg, 65 ftSlb) Order Job/Part...
Page 331: Exhaust Pipe
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE EAS00189 EXHAUST PIPE 20 Nm (2.0 mSkg, 15 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) Order Job/Part Q’ty...
Page 332: Leads And Hoses
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE EAS00188 LEADS AND HOSES 20 Nm (2.0 mSkg, 15 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Disconnecting the leads and hoses Disconnect the parts in the order listed.
Page 333 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE 20 Nm (2.0 mSkg, 15 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Clutch cable Ground lead Stator coil assembly coupler Disconnect.
Page 334 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE EAS00191 ENGINE 45 Nm (4.5 mSkg, 33 ftSlb) 45 Nm (4.5 mSkg, 33 ftSlb) 45 Nm (4.5 mSkg, 33 ftSlb) 45 Nm (4.5 mSkg, 33 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part...
Page 335: Installing The Engine
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE EAS00192 INSTALLING THE ENGINE 1. Install: S engine bracket 1 (to the engine) 45 Nm (4.5 mSkg, 33 ftSlb) S engine mounting adjust bolts (temporary tighten) 2.
Page 336 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE Pivot shaft wrench 90890-01471, YM-01471 Pivot shaft wrench adapter 90890-01476 5. Tighten: S nuts 1 (rear engine mounting bolts) 45 Nm (4.5 mSkg, 33 ftSlb) NOTE: First tighten the lower self-locking nut.
Page 337: Camshafts
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS EAS00194 CAMSHAFTS CYLINDER HEAD COVER 10 Nm (1.0 mSkg, 7.2 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the cylinder head cover Remove the parts in the order listed.
Page 338 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS EAS00196 CAMSHAFTS 10 Nm (1.0 mSkg, 7.2 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part...
Page 339: Removing The Camshafts
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS EAS00198 REMOVING THE CAMSHAFTS 1. Remove: S pickup rotor cover Refer to “CRANKSHAFT POSITION SEN- SOR AND PICKUP ROTOR”. 2. Align: S “T” mark a on the pickup rotor (with the crankcase mating surface b ) a.
Page 340: Checking The Camshafts
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS 7. Remove: S intake camshaft 1 S exhaust camshaft 2 NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire a . 8.
Page 341 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS 3. Measure: S camshaft runout Out of specification ! Replace. Camshaft runout limit 0.06 mm (0.0024 in) 4. Measure: S camshaft-journal-to-camshaft-cap clear- ance Out of specification ! Measure the camshaft journal diameter.
Page 342: Checking The Timing Chain, Camshaft Sprockets, And Timing Chain Guides
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS EAS00208 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides. 1. Check: S timing chain 1 Damage/stiffness ! Replace the timing chain and camshaft sprockets as a set.
Page 343: Installing The Camshafts
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS b. Remove the screwdriver and slowly release the timing chain tensioner rod. c. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly.
Page 344 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS 3. Install: S dowel pins S exhaust camshaft caps S intake cmashaft caps NOTE: S Make sure each camshaft cap is installed in its original place. S Make sure the arrow mark a on each cam- shaft cap points towards the right side of the engine.
Page 345 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS 6. Install: S timing chain tensioner a. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod ful- ly clockwise with a thin screwdriver 1 . b.
Page 346 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS 10. Measure: S valve clearance Out of specification ! Adjust. Refer to “ADJUSTING THE VALVE CLEAR- ANCE” in chapter 3. email: info@motomatrix.co.uk 5-17...
Page 347: Cylinder Head
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD EAS00221 CYLINDER HEAD 19 Nm (1.9 mSkg, 14 ftSlb) 50 Nm (5.0 mSkg, 36 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed.
Page 348: Removing The Cylinder Head
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD EAS00222 REMOVING THE CYLINDER HEAD 1. Remove: S cylinder head bolts NOTE: S Loosen the bolts in the proper sequence as shown. S Loosen each bolt 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them.
Page 349: Installing The Cylinder Head
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD EAS00233 INSTALLING THE CYLINDER HEAD 1. Install: S gasket S dowel pins 2 2. Install: S cylinder head NOTE: Pass the timing chain through the timing chain cavity.
Page 350: 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 Remove the valves and valve springs Remove the parts in the order listed. Cylinder head Refer to “CYLINDER HEAD”.
Page 351 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Exhaust valve upper spring seat Exhaust valve spring Refer to “REMOVING/INSTALLING Exhaust valve oil seal THE VALVES”. Exhaust valve lower spring seat Exhaust valve Exhaust valve guide For installation, reverse the removal...
Page 352 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS EAS00238 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 353 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019, YM-04019 Valve spring compressor attachment 90890-04108, YM-01253 4. Remove: S upper spring seat 1 S valve spring outer 2 S valve spring inner (intake only) 3 S valve 4 S oil seal 5...
Page 354 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS 2. Replace: S 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. a.
Page 355 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS 5. Measure: S valve margin thickness a Out of specification ! Replace the valve. Valve margin thickness 0.6 X 0.8 mm (0.0236 X 0.0315 in) <Limit>: 0.5 mm (0.02 in) 6.
Page 356 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS NOTE: Where the valve seat and valve face contacted one another, the blueing will have been re- moved. 4. Lap: S valve face S valve seat NOTE: After replacing the cylinder head or replacing...
Page 357 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS j. Measure the valve seat width c again. If the valve seat width is out of specification, reface and lap the valve seat. EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the...
Page 358 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS 3. Measure: S valve spring tilt a Out of specification ! Replace the valve spring. Spring tilt limit Intake valve spring (inner) 2.5_/1.6 mm (0.06 in) (outer) 2.5_/1.8 mm (0.07 in) Exhaust valve spring...
Page 359 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS NOTE: S Make sure that each valve is installed in its original place. S Install the valve springs with the larger pitch a facing up.
Page 360: Starter Clutch And Generator
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STARTER CLUTCH AND GENERATOR EAS00341 STARTER CLUTCH AND GENERATOR STATOR COIL ASSEMBLY 10 Nm (1.0 mSkg, 7.2 ftSlb) 32 Nm (3.2 mSkg, 23 ftSlb) 75 Nm (7.5 mSkg, 54 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order...
Page 361 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STARTER CLUTCH AND GENERATOR 10 Nm (1.0 mSkg, 7.2 ftSlb) 32 Nm (3.2 mSkg, 23 ftSlb) 75 Nm (7.5 mSkg, 54 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part...
Page 362 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STARTER CLUTCH AND GENERATOR EAS00347 REMOVING THE GENERATOR 1. Remove: S rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in chap- ter 3. S buttom cowling S left side cowling Refer to “COWLINGS”...
Page 363 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STARTER CLUTCH AND GENERATOR 5. Remove: S generator rotor 1 (with the flywheel puller 2 and flywheel pull- er attachment) S woodruff key CAUTION: To protect the end of the crankshaft, place an appropriate sized socket between the fly- wheel puller set’s center bolt and the crank- shaft.
Page 364 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STARTER CLUTCH AND GENERATOR EAS00351 CHECKING THE STARTER CLUTCH 1. Check: S starter clutch rollers 1 Damage/wear ! Replace. 2. Check: S starter clutch idle gear 1 S starter clutch drive gear 2 Burrs/chips/roughness/wear ! Replace the defective part(s).
Page 365 Sheave holder 90890-01701, YS-01880-A 3. Apply: S sealant (onto the stator coil assembly lead grommet) Yamaha bond No.1215 90890-85505, ACC-11001-05-01 4. Install: S stator coil 5. Install: S generator rotor cover 12 Nm (1.2 mSkg, 8.7 ftSlb) email: info@motomatrix.co.uk...
Page 366 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STARTER CLUTCH AND GENERATOR NOTE: Tighten the generator rotor cover bolts in stages and in a crisscross pattern. 6. Fill: S engine oil Refer to “CHANGING THE ENGINE OIL” in chapter 3.
Page 367: 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 22 Nm (2.2 mSkg, 16 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the shift shaft and stopper Remove the parts in the order listed.
Page 368 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHIFT SHAFT 22 Nm (2.2 mSkg, 16 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Stopper lever Collar Washer Shift shaft spring stopper For installation, reverse the removal procedure.
Page 369 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHIFT SHAFT EAS00328 CHECKING THE SHIFT SHAFT 1. Check: S shift shaft 1 Bends/damage/wear ! Replace. S shift shaft spring 2 Damage/wear ! Replace. EAS00330 CHECKING THE STOPPER LEVER 1.
Page 370 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order...
Page 371 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part...
Page 372 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR REMOVING THE PICKUP ROTOR 1. Remove: S clutch cable holder 1 S pickup rotor cover 2 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern.
Page 373 3 , tighten the pickup rotor bolt. Sheave holder 90890-01701, YS-01880-A 3. Apply: S sealant (onto the crankshaft position sensor lead grommet) Yamaha bond No.1215 90890-85505, ACC-11001-5-01 4. Install: S pickup rotor cover S clutch cable holder NOTE: S When installing the pickup rotor cover, align the timing chain guide (intake side) pin 1 of the with the hole 2 in the pickup rotor cover.
Page 374 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH EAS00273 CLUTCH CLUTCH COVER 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the clutch cover Removing the parts in the order listed. Bottom cowling Refer to “COWLINGS”...
Page 375 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH Order Job/Part Q’ty Remarks Disassembling the clutch cover Disassemble the parts in the order listed. Circlip Washer Pull lever Pull lever spring Oil seal Bearing For assembly, reverse the disassembly procedure.
Page 376 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH EAS00274 CLUTCH 70 Nm (7.0 mSkg, 51 ftSlb) 8 Nm (0.8 mSkg, 5.8 ftSlb) Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Compression spring Pressure plate Pull rod...
Page 377 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH EAS00276 REMOVING THE CLUTCH 1. Remove: S clutch cover 1 S gasket 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 378 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH 2. Measure: S friction plate thickness Out of specification ! Replace the friction plates as a set. NOTE: Measure the friction plate at four places. Friction plate thickness 2.9 X 3.1 mm (0.114 X 0.122 in) <Limit>: 2.8 mm (0.110 in) EAS00281...
Page 379 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH 2. Measure: S clutch spring free length a Out of specification ! Replace the clutch springs as a set. Clutch spring free length 50 mm (1.97 in) <Limit>: 49 mm (1.93 in) EAS00284 CHECKING THE CLUTCH HOUSING...
Page 380 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH EAS00287 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1. Check: S pull lever shaft pinion gear teeth a S pull rod teeth b Damage/wear ! Replace the pull rod and pull lever shaft pinion gear as a set.
Page 381 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH 5. Install: S friction plates S clutch plates NOTE: First, install a clutch plate and then alternate be- tween a friction plate and a friction plate. a.
Page 382 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH 9. Install: S clutch cover S gasket NOTE: S Install the pull rod so that the teeth a face to- wards the rear of the motorcycle. Then, install the clutch cover.
Page 383: Oil Pan And Oil Pump
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PAN AND OIL PUMP EAS00356 OIL PAN AND OIL PUMP 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 43 Nm (4.3 mSkg, 31 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb)
Page 384 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PAN AND OIL PUMP 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 43 Nm (4.3 mSkg, 31 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order...
Page 385 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PAN AND OIL PUMP 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Disassembling the oil pump Disassemble the parts in the order listed. assembly Oil pump cover Oil pump inner rotor Oil pump outer rotor...
Page 386 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PAN AND OIL PUMP EAS00362 REMOVING THE OIL PAN 1. Remove: S oil level switch 1 S oil pan 2 S oil pan gasket S dowel pins NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern.
Page 387 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PAN AND OIL PUMP 3. Check: S oil pump operation Rough movement ! Repeat steps (1) and (2) or replace the defective part(s). EAS00365 CHECKING THE RELIEF VALVE 1.
Page 388 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PAN AND OIL PUMP EAS00374 ASSEMBLING THE OIL PUMP 1. Lubricate: S inner rotor S outer rotor S oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2.
Page 389 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PAN AND OIL PUMP EAS00378 INSTALLING THE OIL STRAINER 1. Install: S oil strainer 1 S relief valve 2 NOTE: Make sure to check the arrow mark a located on the oil strainer housing for the front and rear direction of the engine and then install the oil strainer so that its arrow mark points to the front...
Page 390 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE CRANKCASE 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the crankcase Remove the parts in the order listed. Engine Refer to “ENGINE”.
Page 391 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Thrust plate Washer Plate For installation, reverse the removal procedure. email: info@motomatrix.co.uk 5-62...
Page 392 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE EAS00384 DISASSEMBLING THE CRANKCASE 1. Place the engine upside down. 2. Remove: S crankcase bolts NOTE: S Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern.
Page 393 ASSEMBLING THE CRANKCASE 1. Lubricate: S crankshaft journal bearings (with the recommended lubricant) Recommended lubricant Engine oil 2. Apply: S sealant Yamaha bond No. 1215 90890-85505, ACC-1109-05-01 email: info@motomatrix.co.uk 5-64...
Page 394 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings. Do not apply sealant to within 2 X 3 mm of the crankshaft journal bearings.
Page 395: Connecting Rods And Pistons
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS EAS00252 CONNECTING RODS AND PISTONS 15 Nm (1.5 mSkg, 11 ftSlb) +150_ Order Job/Part Q’ty Remarks Removing the connecting rods and Remove the parts in the order listed. pistons Lower crankcase Refer to “CRANKCASE”.
Page 396 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS EAS00393 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the connecting rods and pistons. 1. Remove: S connecting rod cap 1 S big end bearings NOTE: Identify the position of each big end bearing so...
Page 397 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS EAS00387 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: S crankshaft assembly S crankshaft journal upper bearings (from the upper crankcase) Refer to “CRANKSHAFT”. NOTE: Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place.
Page 398 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS 65.50 X 65.51 mm Cylinder bore “C” (2.5787 X 2.5791 in) 65.56 mm Wear limit (2.5811 in) Taper limit “T” 0.05 mm (0.002 in) Out of round “R”...
Page 399 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS Piston ring side clearance Top ring 0.030 X 0.065 mm (0.0012 X 0.0026 in) <Limit>: 0.115 mm (0.0045 in) 2nd ring 0.030 X 0.065 mm (0.0012 X 0.0026 in) <Limit>: 0.125 mm (0.0049 in) 2.
Page 400 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS 2. Measure: S piston pin outside diameter a Out of specification ! Replace the piston pin. Piston pin outside diameter 15.991 X 16.000 mm (0.6296 X 0.6299 in) <Limit>: 15.971 mm (0.6288 in) 3.
Page 401 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS CAUTION: Do not interchange the big end bearings and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing clear- ance and prevent engine damage, the big end bearings must be installed in their origi- nal positions.
Page 402 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS e. Tighten the connecting rod nuts. Connecting rod nut 15 Nm (1.5 mSkg, 11 ftSlb) + 150_ f. Replace the connecting rod bolts and nuts with new ones.
Page 403 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS 2. Select: S big end bearings (P1 X P4) NOTE: S The numbers A stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes.
Page 404 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS 2. Install: S piston 1 (onto the respective connecting rod 2 ) S piston pin 3 S piston pin clip NOTE: S Apply engine oil onto the piston pin. S Make sure that the “Y”...
Page 405 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS 6. Install: S big end bearings S connecting rod assembly (into the cylinder and onto the crankshaft pin) S connecting rod cap (onto the connecting rod) NOTE: S Align the projections on the big end bearings with the notches in the connecting rods and...
Page 406 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONNECTING RODS AND PISTONS e. Tighten the nut further to reach the specified angle (150_). WARNING When the nut is tightened more than the spe- cified angle, do not loosen the nut and then retighten it.
Page 407 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT EAS00381 CRANKSHAFT Order Job/Part Q’ty Remarks Removing the crankshaft Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. Connecting rod caps Refer to “CONNECTING RODS AND PISTONS”.
Page 408 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT EAS00395 CHECKING THE CRANKSHAFT 1. Measure: S crankshaft runout Out of specification ! Replace the crank- shaft. Crankshaft runout Less than 0.03 mm (0.0012 in) 2. Check: S crankshaft journal surfaces S crankshaft pin surfaces S bearing surfaces...
Page 409 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT c. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crank- case. NOTE: Align the projections a on the crankshaft jour- nal upper bearings with the notches b in the up- per crankcase.
Page 410 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT g. Remove the lower crankcase and the crank- shaft journal lower bearings.  h. Measure the compressed Plastigauge width c on each crankshaft journal. If the crankshaft-journal-to-crankshaft-jour- nal-bearing clearance is out of specification, select replacement crankshaft journal bear- ings.
Page 411 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT EAS00407 INSTALLING THE CRANKSHAFT 1. Install: S crankshaft journal upper bearings 1 (into the upper crankcase) NOTE: S Align the projections a on the crankshaft jour- nal upper bearings with the notches b in the upper crankcase.
Page 412 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION EAS00419 TRANSMISSION TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part...
Page 413 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Main axle assembly...
Page 414 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the main axle Disassemble the parts in the order listed. assembly Bearing 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer...
Page 415 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION Order Job/Part Q’ty Remarks Bearing housing Bearing For installation, reverse the removal procedure. email: info@motomatrix.co.uk 5-86...
Page 416 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the drive axle Disassemble the parts in the order listed. assembly Washer 1st wheel gear Collar 5th wheel gear Circlip Washer Collar 3rd wheel gear Toothed lock washer...
Page 417 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION Order Job/Part Q’ty Remarks 6th wheel gear Circlip Washer 2nd wheel gear Collar Collar Oil seal Bearing Circlip Drive axle For installation, reverse the removal procedure. email: info@motomatrix.co.uk 5-88...
Page 418 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION EAS00420 REMOVING THE TRANSMISSION 1. Remove: S main axle assembly 1  (with the Torx wrench T30) a. Insert two bolts 2 of the proper size, as shown in the illustration, into the main axle assembly bearing housing.
Page 419 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: S shift drum grooves Damage/scratches/wear ! Replace the shift drum assembly. S shift drum segment 1 Damage/wear ! Replace the shift drum as- sembly.
Page 420 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION 4. Check: S transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect ! Reassemble the transmission axle assemblies. 5. Check: S transmission gear movement Rough movement ! Replace the defective part(s).
Page 421 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION 3. Install: S shift fork “R” 1 and “L” 2 S drive axle 3 S shift fork guide bar S shift drum retainer 10 Nm (1.0 mSkg, 7.2 ftSlb) NOTE: S Install shift fork “L”...
Page 422 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL RADIATOR EAS00454 COOLING SYSTEM RADIATOR 12 Nm (1.2 mSkg, 8.7 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed.
Page 423 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL RADIATOR 12 Nm (1.2 mSkg, 8.7 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Radiator cap For installation, reverse the removal procedure.
Page 424 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL RADIATOR EAS00455 CHECKING THE RADIATOR 1. Check: S radiator fins Obstruction ! Clean. Apply compressed air to the rear of the radia- tor. Damage ! Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver.
Page 425 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL RADIATOR EAS00456 INSTALLING THE RADIATOR 1. Fill: S cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2.
Page 426: Oil Cooler
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL OIL COOLER EAS00457 OIL COOLER 10 Nm (1.0 mSkg, 7.2 ftSlb) 63 Nm (6.3 mSkg, 46 ftSlb) Order Job/Part Q’ty Remarks Removing the oil cooler Remove the parts in the order listed. Radiator assembly Refer to “RADIATOR”.
Page 427 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL OIL COOLER EAS00458 CHECKING THE OIL COOLER 1. Check: S oil cooler Cracks/damage ! Replace. 2. Check: S oil cooler inlet hose S oil cooler outlet hose Cracks/damage/wear ! Replace.
Page 428 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL THERMOSTAT EAS00461 THERMOSTAT 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the thermostat Remove the parts in the order listed. Rider seat Refer to “SEATS” chapter 3. Air filter case Refer to “AIR FILTER CASE”...
Page 429 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL THERMOSTAT EAS00462 CHECKING THE THERMOSTAT 1. Check: S thermostat 1 Does not open at 71 X 85_C (160 X 185_F) ! Replace. a. Suspend the thermostat in a container filled with water.
Page 430 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL THERMOSTAT 3. Fill: S cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 4. Check: S cooling system Leaks ! Repair or replace any faulty part.
Page 431: Water Pump
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL WATER PUMP EAS00408 WATER PUMP 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty...
Page 432 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL WATER PUMP 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Disassembling the water pump Disassemble the parts in the order listed. Water pump cover O-ring Impeller shaft Circlip...
Page 433 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL WATER PUMP EAS00471 DISASSEMBLING THE WATER PUMP 1. Remove: S circlip S impeller shaft 2. Remove: S water pump seal 1 NOTE: Remove the water pump seal from the outside of the water pump housing.
Page 434 NOTE: S Install the water pump seal with the special tools. S Before installing the water pump seal, apply Yamaha bond No.1215 or Quick Gasket 2 to the water pump housing 3 . email: info@motomatrix.co.uk 6-13...
Page 435 WATER PUMP Mechanical seal installer 90890-04078, YM-33221 4 Middle driven shaft bearing driver 90890-04058, YM-04058 5 Quick Gasket ACC-11001-05-01 Yamaha bond #1215 90890-85505 A Push down. 3. Install: S rubber damper S rubber damper holder NOTE: Before installing the rubber damper, apply tap water or coolant onto its outer surface.
Page 436 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL WATER PUMP INSTALLING THE WATER PUMP 1. Install: S water pump assembly 12 Nm (1.2 mSkg, 8.7 ftSlb) NOTE: Align the projection a at the oil pump shaft and water pump shaft groove b .
Page 437 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM Ignition coil Intake pressure Coolant temperature Atmospheric pressure Air filter case sensor sensor sensor Intake temperature Throttle position sen- Spark plug Fuel injection system sensor...
Page 438 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM WIRING DIAGRAM Main switch Battery Fuse (main) Fuse (fuel injection) Fuse (ignition) Starting circuit cut-off relay Sidestand switch Fuel pump Ignition coil Spark plug Fuel injector Neutral switch Crankshaft position sensor...
Page 439 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS00899 ECU’S SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the engine control system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Page 440 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS00902 ALTERNATE INSTRUCTIONS OPERATION CONTROL (FAIL-SAFE ACTION) If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.
Page 441 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. * Engine trouble warning light may not come on even if the engine operation is not normal. The engine trouble warning light does not come The engine trouble warning light comes on.
Page 442 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. Turn the main switch to “OFF” and set the en- gine stop switch to “ON”. 2. Disconnect the wire harness coupler from the fuel pump.
Page 443 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code table Fault Diagnostic Symptom Probable cause of malfunction code No. code S Open or short circuit in wiring sub lead. No normal signals are received from S Open or short circuit in wiring harness.
Page 444 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault Diagnostic Symptom Probable cause of malfunction code No. code S Open circuit in wiring harness. Open circuit is detected in the primary S Malfunction in ignition coil. lead of the ignition coil (#1).
Page 445 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS00907 Diagnostic mode table Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to “DIAGNOSTIC MODE”. NOTE: S Check the intake temperature and coolant temperature as close as possible to the intake temperature sensor and the coolant temperature sensor respectively.
Page 446 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Diagnostic Data displayed on meter Item Description of action code (reference value) Ignition coil #3 After 1 second has elapsed from the time the engine stop Check that spark is generated, switch has been turned from OFF to ON, it actuates ignition 5 times with the engine stop...
Page 447 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Diagnostic Data displayed on meter Item Description of action code (reference value) Headlight relay 1 After 1 second has elapsed from the time the engine stop Check the headlight relay switch has been turned from OFF to ON, it actuates the operating sound 5 times with the...
Page 448 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 449 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the crankshaft position sensor. Used diagnostic code No. – – Inspection operation item and probable Operation item and countermeasure Reinstatement cause...
Page 450 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 - open or short circuit detected. Used diagnostic code No. 03 (intake air pressure sensor) Inspection operation item and probable Operation item and countermeasure Reinstatement cause...
Page 451 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 system malfunction (clogged or detached hose). Used diagnostic code No. 03 (intake air pressure sensor) Inspection operation item and probable Operation item and countermeasuer Reinstatement...
Page 452 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open circuit is detected in the input line from the sidestand switch to the ECU. Used diagnostic code No. 20 (sidestand switch) Inspection operation item and probable Operation item and countermeasure Reinstatement...
Page 453 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit detected from the intake temperature sensor. Used diagnostic code No. 05 (intake temperature sensor) Inspection operation item and probable Operation item and countermeasure Reinstatement cause...
Page 454 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 detected from the atmospheric pressure sensor. Used diagnostic code No. 02 (atmospheric pressure sensor) Inspection operation item and probable Operation item and countermeasure Reinstatement cause...
Page 455 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) Inspection operation item and probable Operation item and countermeasure Reinstatement cause method...
Page 456 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary lead of the ignition coil (#1). Used diagnostic code No. 30 (ignition coil #1) Inspection operation item and probable Operation item and countermeasure Reinstatement cause...
Page 457 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary lead of the ignition coil (#4). Used diagnostic code No. 33 (ignition coil #4) Inspection operation item and probable Operation item and countermeasure Reinstatement cause...
Page 458 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom 1 No normal signals are received from the speed sensor. 2 Open or short circuit is detected in the neutral switch. Used diagnostic code No.
Page 459 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom The ECU is unable to monitor the battery voltage. Used diagnostic code No. 09 (fuel system voltage) Inspection operation item and probable Operation item and countermeasure Reinstatement cause...
Page 460 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 EEP-ROM (CO adjustment value). Used diagnostic No. 60 (EEP-ROM improper cylinder indication) Inspection operation item and probable Operation item and countermeasure Reinstatement...
Page 461 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signal are received from the ECU. Used diagnostic code No. – – Inspection operation item and probable Operation item and countermeasure Reinstatement cause method...
Page 462 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom Non-registered data has been received from the meter. Used diagnostic code No. – – Inspection operation item and probable Operation item and countermeasure Reinstatement cause...
Page 463: Throttle Bodies
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES THROTTLE BODIES Order Job/Part Q’ty Remarks Removing the throttle bodies Remove the parts in the order listed. Seats/fuel tank/rubber sheet Refer to “SEATS” and “FUEL TANK” in chapter 3.
Page 464 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES Order Job/Part Q’ty Remarks Throttle cable Disconnect. Plunger control unit hose Disconnect. Throttle body joint Heat protector For installation, reverse the removal procedure. email: info@motomatrix.co.uk 7-28...
Page 465 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES Order Job/Part Q’ty Remarks Removing the injector Remove the parts in the order listed. Throttle position sensor coupler Disconnect. Intake air pressure sensor Disconnect. Cylinder #1-injector coupler Disconnect.
Page 466 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES Order Job/Part Q’ty Remarks Intake air pressure sensor Fuel distributor Injector Throttle position sensor Throttle body assembly For installation, reverse the removal procedure. email: info@motomatrix.co.uk 7-30...
Page 467 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES EAS00911 CAUTION: The throttle bodies should not be disas- sembled. EAS00912 CHECKING THE INJECTOR 1. Check: S injector Damage ! Replace. EAS00913 CHECKING THE THROTTLE BODY 1.
Page 468 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES CHECKING THE PRESSURE REGULATOR 1. Check: S pressure regulator Damage ! Replace. CHECKING THE FUEL PUMP AND PRES- SURE REGULATOR OPERATION 1. Check: S pressure regulator operation a.
Page 469 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES Increase the vacuum pressure ! Fuel pressure is decreased Decrease the vacuum pressure ! Fuel pressure is increased Faulty ! Replace the pressure regulator. EAS00916 CHECKING ADJUSTING THROTTLE POSITION SENSOR...
Page 470 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES f. While slowly opening the throttle, check that the throttle position sensor resistance is with- in the specified range. The resistance does not change or it changes abruptly ! Replace the throttle position sensor.
Page 471 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 ex- haust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons.
Page 472 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Air cut-off valve A To cylinder #1 and #2 2 Reed valve B To cylinder #3 and #4 3 To air filter case email: info@motomatrix.co.uk 7-36...
Page 473 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR INDUCTION SYSTEM EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: S hoses Loose connection ! Connect properly. Cracks/damage ! Replace. S pipes Cracks/damage ! Replace. 2. Check: S reed valve 1 S reed valve stopper S reed valve seat...
Page 474 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR INDUCTION SYSTEM 5. Check S air induction system solenoid a. Remove the air induction system solenoid coupler from the wire harness. b. Connect the pocket tester (Ω 1) to the air induction system solenoid terminal as shown.
Page 475 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL ELECTRICAL COMPONENTS Main switch Sidestand switch Front brake light switch Oil level switch Clutch switch Radiator fan motor Battery Horn Starter relay Ignition coil Fuse (main) Fuse box...
Page 476 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC ELECTRICAL COMPONENTS Coolant temperature sensor Speed sensor Intake air temperature sensor Crankshaft position sensor Intake air pressure sensor Cylinder identification sensor Lean angle cut-off switch Radiator fan motor relay Atmospheric pressure sensor Headlight relay (on / off) Headlight relay (dimmer)
Page 477: 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 incorrect, check the wiring connections and if necessary, replace the switch.
Page 478 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 termi- nals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear ! Repair or replace.
Page 479: 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 continu- ity between the terminals.
Page 480 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: S bulb WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
Page 481 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: S bulb socket (for continuity) (with the pocket tester) No continuity ! Replace.
Page 482 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC IGNITION SYSTEM EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM Main switch Battery Fuse (main) Fuse (ignition) Starting circuit cut-off relay Sidestand switch Ignition coil Spark plug Neutral switch Crankshaft position sensor Lean angle cut-off switch Engine stop switch...
Page 483 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC IGNITION SYSTEM EAS00737 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The ignition system fails to operate (no Refer to “CHECKING AND CHARGING spark or intermittent spark).
Page 484 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC IGNITION SYSTEM EAS00743 EAS00747 5. Ignition coil resistance 4. Ignition spark gap The following procedure applies to all of the The following procedure applies to all of the ignition coils.
Page 485 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC IGNITION SYSTEM EAS00748 EAS00750 8. Engine stop switch 6. Crankshaft position sensor resistance S Check the engine stop switch for continuity. S Disconnect the crankshaft position sensor Refer to “CHECKING THE SWITCHES”.
Page 486 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC IGNITION SYSTEM EAS00753 12. Starting circuit cut-off relay NOTE: When you switch the positive and negative S Disconnect the starting circuit cut-off relay tester probes, the readings in the above chart coupler from the wire harness.
Page 487 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC IGNITION SYSTEM Replace lean angle cut-off switch. EAS00754 14. Wiring S Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. S Is the ignition system’s wiring properly con- nected and without defects? Replace the ignitor Properly connect or...
Page 488 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main switch Battery Fuse (main) Starter relay Starter motor Fuse (ignition) Starting circuit cut-off relay Sidestand switch Neutral switch Engine stop switch Start switch...
Page 489 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: S The transmission is in neutral (the neutral...
Page 490 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The starter motor fails to turn. Refer to “CHECKING AND CHARGING Check: THE BATTERY”...
Page 491 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC ELECTRIC STARTING SYSTEM EAS00759 4. Starting circuit cut-off relay S Disconnect the starting circuit cut-off relay coupler from the wire harness. S Connect the pocket tester (Ω 1) and bat- tery (12 V) to the starting circuit cut-off relay coupler as shown.
Page 492 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC ELECTRIC STARTING SYSTEM EAS00752 EAS00766 9. Sidestand switch 12. Wiring S Check the sidestand switch for continuity. S Check the entire starting system’s wiring. Refer to “CHECKING THE SWITCHES”. Refer to “CIRCUIT DIAGRAM”.
Page 493: Starter Motor
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC STARTER MOTOR EAS00767 STARTER MOTOR 10 Nm (1.0 mSkg, 7.2 ftSlb) 5 Nm (0.5 mSkg, 3.6 ftSlb) Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Rider seat Refer to “SEATS”...
Page 494 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC STARTER MOTOR EAS00768 7 Nm (0.7 mSkg, 5.1 ftSlb) 3.4 Nm (0.34 mSkg, 2.5 ftSlb) Order Job/Part Q’ty Remarks Disassembling the starter motor Disassembly the parts in the order listed. O-ring Front cover Lock washer...
Page 495 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC STARTER MOTOR EAS00770 CHECKING THE STARTER MOTOR 1. Check: S commutator Dirt ! Clean with 600 grit sandpaper. 2. Measure: S commutator diameter a Out of specification ! Replace the starter motor.
Page 496 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC STARTER MOTOR 5. Measure: S brush length a . Out of specification ! Replace the brushes as a set. Brush length wear limit 3.5 mm (0.14 in) 6.
Page 497: Charging System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM A.C. magneto Rectifier/ regulator Battery Fuse (main) email: info@motomatrix.co.uk 8-23...
Page 498 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC CHARGING SYSTEM EAS00774 Minimum open-circuit voltage TROUBLESHOOTING 12.8 V or more at 20_C (68_F) The battery is not being charged. S Is the battery OK? Check: 1.
Page 499 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC CHARGING SYSTEM EAS00776 4. Stator coil resistance 1 5. Stator coil resistance 2 S Disconnect stator coil lead coupler. S Remove the generator cover. S Connect the pocket tester (Ω S Connect the pocket tester (Ω...
Page 500 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM email: info@motomatrix.co.uk 8-26...
Page 501 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC LIGHTING SYSTEM Main switch Battery Fuse (main) Fuse (ignition) High beam indicator light Meter light Fuse (headlight) Headlight relay (on / off) Headlight relay (dimmer) Dimmer switch Front turn signal/position light (right) Front turn signal/position light (left) Headlight...
Page 502 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC LIGHTING SYSTEM EAS00781 Minimum open-circuit voltage TROUBLESHOOTING 12.8 V or more at 20_C (68_F) Any of the following fail to light: headlight, S Is the battery OK? high beam indicator light, taillight, licence light or meter light.
Page 503 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC LIGHTING SYSTEM 5. Headlight relay (on/off) S Disconnect the headlight relay (on/off) from the coupler. S Connect the pocket tester (Ω 1) and bat- tery (12 V) to the headlight relay (on/off) coupler as shown.
Page 504 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 ! black/yellow 1. The headlight and the high beam indicator Negative tester probe ! black light fail to come on.
Page 505 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC LIGHTING SYSTEM EAS00789 EAS00790 2. The meter light fails to come on. 3. The tail/brake light fails to come on. 1. Meter light (LEDs) 1. Tail/brake light (LEDs) S Check the meter light for continuity.
Page 506 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC LIGHTING SYSTEM EAS00792 4. The license light fails to come on. 5. The turn signal/position light fails to come 1. License light bulb and socket 1. Turn signal/position light bulb and socket S Check the license light bulb and socket for S Check the turn signal/position light bulb and continuity.
Page 507 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM email: info@motomatrix.co.uk 8-33...
Page 508 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC SIGNALING SYSTEM Main switch Battery Fuse (main) Fuse (ignition) Starting circuit cut-off relay Fuel pump Neutral switch Speed sensor Fuel level warning light Oil level warning light Neutral indicator light Tachometer Shift timing indicator light...
Page 509 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC SIGNALING SYSTEM EAS00794 TROUBLESHOOTING S Any of the following fail to light: turn sig- nal light, brake light or an indicator light. S Clean the battery S The horn fails to sound.
Page 510 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC SIGNALING SYSTEM EAS00797 2. Voltage 2. The tail/brake light fails to come on. S Connect the pocket tester (DC 20 V) to the 1. Tail/brake light (LEDs) horn connector at the horn terminal as S Check the tail/brake light for continuity.
Page 511 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC SIGNALING SYSTEM S Turn the main switch to “ON”. S Measure the voltage (DC 12 V) on brown at the turn signal relay coupler (wire harness wiring circuit This circuit is OK.
Page 512: Signaling System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC SIGNALING SYSTEM Left turn signal light Positive tester probe ! chocolate Negative tester probe ! ground Replace the meter Right turn signal light assembly. Positive tester probe ! dark green Negative tester probe ! ground 2.
Page 513 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC SIGNALING SYSTEM EAS00802 3. Voltage 5. The oil level warning light fails to come on. S Connect the pocket tester (DC 20 V) to the 1. Oil level warning light (LEDs) meter assembly coupler (wire harness side) S Check the oil level warning light for continu- as shown.
Page 514 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC SIGNALING SYSTEM 2. Fuel sender 3. Voltage S Drain the fuel from the fuel tank and remove S Connect the pocket tester (DC 20 V) to the the fuel pump from the fuel tank.
Page 515 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC SIGNALING SYSTEM 2. Speed sensor 3. Voltage S Connect the pocket tester (DC 20 V) to the S Connect the pocket tester (DC 20 V) to the speed sensor coupler (wire harness side) meter assembly coupler (wire harness as shown.
Page 516 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM Main switch Coolant temperature sensor Battery Fuse (radiator fan motor) Fuse (main) Radiator fan motor relay Fuse (ignition) Radiator fan motor email: info@motomatrix.co.uk 8-42...
Page 517 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC COOLING SYSTEM EAS00808 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. S The radiator fan motor fails to turn. S The coolant temperature indicator light Refer to “CHECKING AND CHARGING THE BATTERY”...
Page 518 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 S Disconnect the radiator fan motor coupler S Disconnect the radiator fan motor relay from the wire harness.
Page 519 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC COOLING SYSTEM EAS00812 6. Coolant temperature sensor S Remove the coolant temperature sensor. S Connect the pocket tester (Ω 1k) to the coolant temperature sensor as shown. S Immerse the coolant temperature sensor in a container filled with coolant NOTE:...
Page 520: Fuel Pump System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC FUEL PUMP SYSTEM EAS00814 FUEL PUMP SYSTEM CIRCUIT DIAGRAM Main switch Battery Fuse (main) Fuse (fuel injection) Fuse (ignition) Starting circuit cut-off relay Fuel pump Engine stop switch email: info@motomatrix.co.uk 8-46...
Page 521 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC FUEL PUMP SYSTEM EAS00815 FUEL PUMP SYSTEM Battery The ECU includes the control unit for the Fuse (main) fuel pump. Main switch Fuse (ignition) Engine stop switch Fuse (fuel injection) Starting circuit cut-off relay (fuel pump injection system relay)
Page 522 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC FUEL PUMP SYSTEM EAS00816 EAS00739 TROUBLESHOOTING 2. Battery If the fuel pump fails to operate. S Check the condition of the battery Refer to “CHECKING THE BATTERY” in Check: chapter 3.
Page 523 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC FUEL PUMP SYSTEM EAS00759 EAS00817 5. Starting circuit cut-off relay 6. Fuel pump resistance S Disconnect the starting circuit cut-off relay S Disconnect the fuel pump coupler from the coupler from the wire harness.
Page 524 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC FUEL PUMP SYSTEM EAS00819 CHECKING THE FUEL PUMP WARNING Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. Be extremely careful and note the following points: S Stop the engine before refueling.
Page 525 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC SELF-DIAGNOSIS SELF-DIAGNOSIS The YZF-R6 features a self-diagnosing system for the following circuit(-s): S Fuel sender S Oil level switch If any of these circuits are defective, their respective condition codes will be displayed on the warning light when the main switch is turn to “ON”...
Page 526 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC SELF-DIAGNOSIS TROUBLESHOOTING 1. Wire harness The warning light starts to indicate the S Check the wire harness for continuity. self-diagnosis sequence. Refer to “CIRCUIT DIAGRAM”. S Is the wire harness OK? Check: 1.
Page 527 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC SELF-DIAGNOSIS 2. Oil level switch 2. Oil level switch CIRCUIT DIAGRAM S Check the oil level switch for continuity. Refer to “The oil level warning light fails to come on”.
Page 528 TRBL Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 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 manual for checks, adjustments, and replacement of parts.
Page 529: Incorrect Engine Idling Speed
STARTING FAILURES/INCORRECT ENGINE IDLING SPEED/ TRBL Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE SHTG Switches and wiring Starting system S Faulty main switch S Faulty starter motor S Faulty engine stop switch S Faulty starter relay S Broken or shorted wiring S Faulty starting circuit cut-off relay...
Page 530: Faulty Gear Shifting
TRBL Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FAULTY GEAR SHIFTING/FAULTY CLUTCH SHTG EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT JUMPS OUT OF GEAR Refer to “CLUTCH DRAGS”. Shift shaft S Incorrect shift pedal position SHIFT PEDAL DOES NOT MOVE S Improperly returned stopper lever Shift shaft...
Page 531: Poor Braking Performance
OVERHEATING/OVERCOOLING/ TRBL Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys POOR BRAKING PERFORMANCE SHTG EAS00855 OVERHEATING ENGINE FUEL SYSTEM Cylinder head(s) and piston(s) Throttle body (-ies) S Heavy carbon buildup S Damaged or loose throttle body joint Engine oil Air filter S Incorrect oil level...
Page 532: Unstable Handling
TRBL Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FAULTY FRONT FORK LEGS/UNSTABLE HANDLING SHTG EAS00861 FAULTY FRONT FORK LEGS LEAKING OIL MALFUNCTION S Bent, damaged or rusty inner tube S Bent or damaged inner tube S Cracked or damaged outer tube S Bent or damaged outer tube S Improperly installed oil seal...
Page 533: Faulty Lighting Or Signaling System
TRBL Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FAULTY LIGHTING OR SIGNALING SYSTEM SHTG EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT COME ON TURN SIGNAL DOES NOT COME ON S Wrong headlight bulb S Faulty turn signal switch S Too many electrical accessories S Faulty turn signal relay...
Page 534 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
Page 535 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys YZF-R6R/YZF-R6SR/YZF-R6RC/YZF-R6SRC WIRING DIAGRAM Main switch Rear turn signal light (right) A.C. magneto Rear turn signal light (left) Rectifier/ regulator Front turn signal / position light (right) Fuse (backup) Front turn signal / position light (left) Battery Headlight...
Page 536 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys YZF-R6R/YZF-R6SR/YZF-R6RC/YZF-R6SRC WIRING DIAGRAM email: info@motomatrix.co.uk...
Page 537 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys YZF-R6R/YZF-R6SR/YZF-R6RC/YZF-R6SRC WIRING DIAGRAM Main switch Rear turn signal light (right) A.C. magneto Rear turn signal light (left) Rectifier/ regulator Front turn signal / position light (right) Fuse (backup) Front turn signal / position light (left) Battery Headlight...
Page 538 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PRINTED IN U.S.A. email: info@motomatrix.co.uk...

This manual is also suitable for:

Yzf-r6tc Yzf-r6r Yzf-r6sr Yzf-r6rc Yzf-r6src

Yamaha YZF-R6T Supplementary Service Manual

Table of Contents

Table of Contents

Table of Contents

Chapter 1 General Information

Chapter 2 Specifications

Chapter 3 Periodic Checks and Adjustments

Chapter 4

Chapter 5 Overhauling the Engine

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Yamaha YZF-R6T