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Yamaha XT660Z 2008 Service Manual

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2008
SERVICE MANUAL
XT660Z
11D-F8197-E0

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Summary of Contents for Yamaha XT660Z 2008

  • Page 1 2008 SERVICE MANUAL XT660Z 11D-F8197-E0...
  • Page 2 XT660Z (2008) SERVICE MANUAL © 2008 by Yamaha Motor Italia S.p.A. First edition, May 2008 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Italia S.p.A. is expressly prohibited. Printed in Italy...
  • Page 3 EAS00020 NOTICE This manual was produced by the Yamaha Motor Italia S.p.A. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu- al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehi- cles.

  • Page 4: How To Use This Manual

    EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...

  • Page 5: Symbols

    EAS20100 1. Serviceable with engine mounted SYMBOLS 2. Filling fluid 3. Lubricant The following symbols are used in this manual 4. Special tool for easier understanding. 5. Tightening torque 6. Wear limit, clearance NOTE: 7. Engine speed The following symbols are not relevant to every 8.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL INJECTION SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 7: General Information

    GENERAL INFORMATION IDENTIFICATION.................... 1-1 VEHICLE IDENTIFICATION NUMBER............. 1-1 MODEL LABEL..................1-1 FEATURES ..................... 1-2 OUTLINE OF THE FI SYSTEM ..............1-2 FI SYSTEM....................1-3 INSTRUMENT FUNCTIONS ..............1-4 IMPORTANT INFORMATION ................ 1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-7 REPLACEMENT PARTS ................1-7 GASKETS, OIL SEALS AND O-RINGS ...........

  • Page 9: Identification

    IDENTIFICATION IDENTIFICATION EAS00170 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS00180 MODEL LABEL The model label “1” is affixed to the frame under the seat. This information will be needed to or- der spare parts.

  • Page 10: Features

    FEATURES EAS00019 FEATURES EAS00896 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temper- ature.

  • Page 11: Fi System

    FEATURES EAS00897 FI SYSTEM The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fu- el pressure that is applied to the injector at 324 kPa (3.24 kg/cm , 46.1 psi) higher than the intake manifold pressure.

  • Page 12: Instrument Functions

    FEATURES INSTRUMENT FUNCTIONS NOTE: • Be sure to turn the key to "ON" before using EAUB1500 the "SELECT" and "RESET" buttons. Multi-function display • For the U.K. only: To switch the speedometer and odometer/tripmeter displays between kilometers and miles, push the "SELECT" and "RESET"...
  • Page 13 FEATURES Tripmeter and tachometer modes Clock mode 1. “SELECT” button 1. Clock 2. “RESET” button 2. “SELECT” button 3. “RESET” button Pushing the "SELECT" button switches the dis- play between the tripmeter modes "TRIP 1" and NOTE: "TRIP 2" in the following order: The clock is displayed even when the key is turned to "OFF".
  • Page 14 FEATURES NOTE: If the multifunction display indicates an error code, note the code number, and then check This fuel meter is equipped with a selfdiagnosis the vehicle. Refer to “IMMOBILIZER SYSTEM” system. If the electrical circuit is defective all on page 8-29. the segments will start flashing.

  • Page 15: Important Information

    5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but...

  • Page 16: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.

  • Page 17: Checking The Connections

    CHECKING THE CONNECTIONS EAS20250 Pocket tester CHECKING THE CONNECTIONS 90890-03112 Check the leads, couplers, and connectors for stains, rust, moisture, etc. NOTE: 1. Disconnect: • If there is no continuity, clean the terminals. • Lead • Coupler • When checking the wire harness, perform steps (1) to (3).

  • Page 18: Special Tools

    SPECIAL TOOLS 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 im- provised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 19 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pressure gauge 90890-03153 Fuel pressure adapter 90890-03176 Radiator cap tester 6-2, 6-3 90890-01325 Radiator cap tester adaptor 90890-01352 Radiator cap tester adapter 90890-01497 Radiator tester adapter 90890-01496 Thickness gauge 90890-03079 Valve spring compressor attachment 5-20, 5-25 90890-01243 Valve spring compressor...
  • Page 20 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages 5-15, 5-17 Slide hammer bolt 90890-01083 Weight 90890-01084 Piston pin puller set 5-27 90890-01304 Valve guide remover (ø 6) 5-21 90890-04064 Valve guide installer (ø 6) 5-21 90890-04065 Valve guide reamer (ø 6) 5-21 90890-04066 Valve lapper...
  • Page 21 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Universal clutch holder 5-35, 5-37 90890-04086 Crankcase separating tool 5-67 90890-01135 Crankshaft installer pot 5-68 90890-01274 Crankshaft installer bolt 90890-01275 Adapter 5-68 90890-04130 Spacer (crankshaft installer) 90890-04144 Middle driven shaft bearing driver 6-10 90890-04058 Mechanical seal installer...
  • Page 22 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Fork seal driver weight 4-53, 4-54 90890-01367 Fork seal driver attachment (ø 43) 90890-01374 Yamaha bond No. 1215 5-55, 5-62, 90890-85505 5-64, 6-10 1-14...

  • Page 23: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS .................2-10 ELECTRICAL SPECIFICATIONS ..............2-13 TIGHTENING TORQUES ................2-16 GENERAL TIGHTENING TORQUE SPECIFICATIONS ......2-16 ENGINE TIGHTENING TORQUES ............2-17 CHASSIS TIGHTENING TORQUES ............2-21 LUBRICATION POINTS AND LUBRICANT TYPES ........2-25 ENGINE....................2-25 CHASSIS....................2-27 COOLING SYSTEM DIAGRAMS..............2-28 LUBRICATION CHART..................2-32 LUBRICATION DIAGRAMS..............2-33 CABLE ROUTING ..................2-41...

  • Page 25: General Specifications

    GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Model code 11D1 (EUR) Dimensions Overall length 2246 mm (88.42 in) Overall width 864 mm (34.01 in) Overall height 1477 mm (58.14 in) Seat height 896 mm (35.27 in) Wheelbase 1500 mm (59.05 in) Ground clearance 260 mm (10.23 in) Minimum turning radius 1958 mm (77.08 in)

  • Page 26: Engine Specifications

    ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Engine Engine type Liquid-cooled, 4-stroke, SOHC Displacement 660 cm (40.27 cu·in) Cylinder arrangement Forward-inclined single cylinder Bore x stroke 100.0 x 84.0 mm (3.94 x 3.31 in) Compression ratio 10.00 : 1 Engine idling speed 1,400-1,600 r/min Water temperature 80 °C (176 °F) Oil temperature...
  • Page 27 ENGINE SPECIFICATIONS Cooling system Radiator capacity (including all routes) 1.20 L (1.25 US qt) (1.06 Imp.qt) Coolant reservoir capacity 0.50 L (0.52 US qt) (0.44 Imp.qt) (up to the maximum level mark) Radiator cap opening pressure 110.0-140.0 kPa (16.0-20.3 psi) (1.10-1.40 kg/cm Radiator core Width...
  • Page 28 ENGINE SPECIFICATIONS Exhaust B 37.007-37.107 mm (1.4570-1.4609 in) Limit 36.907 mm (1.4530 in) Exhaust (depth) 6.179 mm (0.2432 in) Camshaft runout limit 0.030 mm (0.0012 in) Valve timing Intake - open (B.T.D.C.) 25° Intake - closed (A.B.D.C.) 55° Exhaust - open (B.B.D.C.) 60°...
  • Page 29 ENGINE SPECIFICATIONS Valve face width B (intake) 1.910-2.620 mm (0.075-0.103 in) Valve face width B (exhaust) 1.910-2.620 mm (0.075-0.103 in) Valve seat width C (intake) 1.00-1.20 mm (0.0394-0.0472 in) Limit 1.6 mm (0.06 in) Valve seat width C (exhaust) 1.00-1.20 mm (0.0394-0.0472 in) Limit 1.6 mm (0.06 in) Valve margin thickness D (intake)
  • Page 30 ENGINE SPECIFICATIONS Cylinder head valve seat width (intake) 1.00-1.20 mm (0.0394-0.0472 in) Limit 1.6 mm (0.06 in) Cylinder head valve seat width (exhaust) 1.00-1.20 mm (0.0394-0.0472 in) Limit 1.6 mm (0.06 in) Valve face material Stellite Valve seat material (intake) Valve seat material (exhaust) PB1W Valve springs...
  • Page 31 ENGINE SPECIFICATIONS Piston Piston-to-cylinder clearance 0.030-0.055 mm (0.0012-0.0022 in) Limit 0.13 mm (0.0051 in) Diameter D 99.955-99.970 mm (3.9352-3.9358 in) Height H 10.0 mm (0.39 in) Offset 0.50 mm (0.0197 in) Offset direction Intake side Piston pin bore inside diameter 23.004-23.015 mm (0.9057-0.9061 in) Limit 23.045 mm (0.9073 in)
  • Page 32 ENGINE SPECIFICATIONS Connecting rod Connecting rod length 135.90-136.10 mm (5.3503-5.3582 in) Crankshaft Width A 74.95-75.00 mm (2.9508-2.9528 in) Runout limit C 0.040 mm (0.0016 in) Big end side clearance D 0.350-0.650 mm (0.0138-0.0256 in) Limit 1.0 mm (0.04 in) Big end radial clearance E 0.010-0.025 mm (0.0004-0.0010 in) Small end free play F 0.16-0.40 mm (0.0063-0.0157 in)
  • Page 33 ENGINE SPECIFICATIONS Transmission Transmission type Constant mesh, 5-speed Primary reduction system Spur gear Primary reduction ratio 75/36 (2.083) Secondary reduction system Chain drive Secondary reduction ratio 45/15 (3.000) Operation Left-foot operation Gear ratios gear 30/12 (2.500) gear 26/16 (1.625) gear 23/20 (1.150) gear 20/22 (0.909)
  • Page 34 CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Frame Frame type Diamond Caster angle 28° Trail 113.0 mm (4.44 in) Front wheel Wheel type Spoke wheel Rim size 21 x 1.85 Material Aluminum Wheel travel 210 mm (8.26 in) Radial wheel runout limit 1.2 mm (0.047 in) Lateral wheel runout limit 0.8 mm (0.031 in) Rear wheel...

  • Page 35: Chassis Specifications

    CHASSIS SPECIFICATIONS High-speed riding Front 210 kPa (30 psi) (2.1 kgf/cm ) (2.1 bar) Rear 230 kPa (33 psi) (2.3 kgf/cm ) (2.3 bar) Front brakes Brake type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Brake discs Diameter x thickness 298.0 x 4.5 mm (11.73 x 0.18 in) Minimum thickness...
  • Page 36 CHASSIS SPECIFICATIONS Spring Free length 580.0 mm (22.83 in) Installed length 572.0 mm (22.51 in) Spring rate (K1) 4.4 N/mm (25.11 lb/in) (0.44 kg/mm) Spring stroke (K1) 0.0-210.0 mm (0-8.26 in) Optional spring available Fork oil Recommended oil Fork oil 10W or equivalent Quantity (each front fork leg) 650.0 cm (21.97 US oz) (22.87 Imp.oz)

  • Page 37: Electrical Specifications

    ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Engine control unit Model/manufacturer TBDF84/DENSO Ignition system Ignition system type Transistorized coil ignition (digital) Ignition timing 5.0° (B.T.D.C.) at 1450 r/min Advancer type Electrical Pickup coil resistance/color 192-288 at 20 °C (68 °F)/ Ω...
  • Page 38 ELECTRICAL SPECIFICATIONS Bulbs (voltage/wattage x quantity) Headlight 12 V 55.0 W x 2 Auxiliary light 12 V 5.0 W x 2 Tail/brake light Front turn signal light 12 V 10.0 W x 2 Rear turn signal light 12 V 10.0 W x 2 Indicator light (voltage/wattage x quantity) Meter lighting LED (backlight)
  • Page 39 ELECTRICAL SPECIFICATIONS Hazard flasher device Turn signal blinking frequency 75-95 cycles/min Wattage 10 W x 2 +3.4 W Relay unit Model/manufacturer G8R-30Y-V4/OMRON Coil resistance 162.0-198.0 Ω Diode Headlight relay Model/manufacturer ACM33211 M04/MATSUSHITA Radiator fan Model/manufacturer VA31-A100-46A/SPAL Fan motor relay Model/manufacturer ACM33211 M04/MATSUSHITA Intake air pressure sensor Thermostat type/manufacturer...

  • Page 40: Tightening Torques

    TIGHTENING TORQUES TIGHTENING TORQUES EAS00030 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a criss- cross pattern and progressive stages until the specified tightening torque is reached.

  • Page 41: Engine Tightening Torques

    TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Thread Q’ty Item Tightening torque Remarks size Cylinder head stud bolts 20 Nm (20 m·kg, 14 ft·lb) (exhaust pipe) Cylinder head (left side) 50 Nm (5.0 m·kg, 36 ft·lb) L=145 mm (5.71 in) Cylinder head (right side) 50 Nm (5.0 m·kg, 36 ft·lb) L=135 mm (5.31 in) Cylinder head (center lower side)
  • Page 42 TIGHTENING TORQUES Thread Q’ty Item Tightening torque Remarks size Water jacket joint 10 Nm (1.0 m·kg, 7.2 ft·lb) Crankcase cover (right) 10 Nm (1.0 m·kg, 7.2 ft·lb) Oil strainer 10 Nm (1.0 m·kg, 7.2 ft·lb) Oil pump 10 Nm (1.0 m·kg, 7.2 ft·lb) Oil baffle plate 2 4 Nm (0.4 m·kg, 2.9 ft·lb) Oil pump assembly...
  • Page 43 TIGHTENING TORQUES Thread Q’ty Item Tightening torque Remarks size Shift shaft spring stopper 22 Nm (2.2 m·kg, 16 ft·lb) Torque limiter cover 10 Nm (1.0 m·kg, 7.2 ft·lb) A.C.magneto cover 10 Nm (1.0 m·kg, 7.2 ft·lb) A.C.magneto rotor 80 Nm (8.0 m·kg, 58 ft·lb) A.C.magneto lead holder 10 Nm (1.0 m·kg, 7.2 ft·lb) Crankcase (left side)
  • Page 44 TIGHTENING TORQUES Cylinder head tightening sequence: 2-20...

  • Page 45: Chassis Tightening Torques

    TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Thread Q’ty Item Tightening torque Remarks size Engine/Frame mounting/ Oil tank: Engine front and stay engine 65 Nm (6.5 m·kg, 47 ft·lb) Stay engine (engine front) 65 Nm (6.5 m·kg, 47 ft·lb) and frame Engine rear under and frame 65 Nm (6.5 m·kg, 47 ft·lb) Stay engine (engine top) 65 Nm (6.5 m·kg, 47 ft·lb)
  • Page 46 TIGHTENING TORQUES Thread Q’ty Item Tightening torque Remarks size Union bolt and front master 30 Nm (3.0 m·kg, 22 ft·lb) cylinder Brake hose clamp and front fork 9 Nm (0.9 m·kg, 6.6 ft·lb) Front fork under bracket 21 Nm (2.1 m·kg, 15.4 ft·lb) and inner tube Front fender and front fork 6 Nm (0.6 m·kg, 4.3 ft·lb)
  • Page 47 TIGHTENING TORQUES Thread Q’ty Item Tightening torque Remarks size Rear reflector and bracket license 1 Nm (0.1 m·kg, 0.7 ft·lb) Assist grip and frame 25 Nm (2.5 m·kg, 18.0 ft·lb) End tail and frame 7 Nm (0.7 m·kg, 5.1 ft·lb) Ignition coil and frame 4 Nm (0.4 m·kg, 2.9 ft·lb) Regulator and tank recovery stay...
  • Page 48 TIGHTENING TORQUES Thread Q’ty Item Tightening torque Remarks size Union bolt tightening (front caliper) 30 Nm (3.0 m·kg, 22 ft·lb) Hose brake clamp upper and 10 Nm (1.0 m·kg, 7.2 ft·lb) front stay Bleeder tightening (front) 14 Nm (1.4 m·kg, 10 ft·lb) Holder brake hose and fork 10 Nm (1.0 m·kg, 7.2 ft·lb) Rear wheel shaft and nut...

  • Page 49: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Cylinder head tightening bolts Cylinder tightening bolts Crankshaft pin Timing chain sprocket inner surface Connecting rod big end thrust surface Piston pin Piston and ring groove Balancer weight tightening nut A.C.
  • Page 50 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Shift shaft spacer Yamaha bond Crankcase mating surface No.1215 Yamaha bond A.C. magnet lead grommet (A.C. magneto cover) No.1215 Yamaha bond Oil seal holder tightening bolt No.1215 Yamaha bond Oil delivery hose 2 tightening bolt No.1215...

  • Page 51: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES CHASSIS Lubrication point Lubricant Front wheel oil seal lips (left and right) Rear wheel oil seal lips (left and right) Rear wheel drive hub contact surface Rear arm pivot shaft outer surface and bush outer surface and oil seal lip Dust cover thrust surface Rear arm and rear shock absorber mounting bolt outer surface...

  • Page 52: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS00033 COOLING SYSTEM DIAGRAMS 2-28...
  • Page 53 COOLING SYSTEM DIAGRAMS 1. Water jacket joint 2. Water pump outlet hose 3. Water pump outlet pipe 4. Water pump A. From the radiator B. To the cylinder 2-29...
  • Page 54 COOLING SYSTEM DIAGRAMS 2-30...
  • Page 55 COOLING SYSTEM DIAGRAMS 1. Fast idle plunger outlet hose 2. Coolant reservoir hose 3. Coolant reservoir breather hose 4. Radiator cap 5. Radiator 6. Coolant reservoir cap 7. Coolant reservoir 8. Radiator outlet hose 9. Water pump 10. Radiator fan 11.

  • Page 56: Lubrication Chart

    LUBRICATION CHART LUBRICATION CHART Camshaft Cylinder head Oil tank Oil filter Drive axle Crankshaft Main axle Connecting Check ball Oil pump rotor 1 Oil pump rotor 2 Oil strainer Oil pan : Pressure feed : Splashed scavenge 2-32...

  • Page 57: Lubrication Diagrams

    LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 2-33...
  • Page 58 LUBRICATION DIAGRAMS 1. Oil delivery hose 2 2. Oil strainer 3. Oil delivery hose 1 4. Oil tank 5. Breather hose 2-34...
  • Page 59 LUBRICATION DIAGRAMS 2-35...
  • Page 60 LUBRICATION DIAGRAMS 1. Oil delivery pipe 2 2. Oil delivery pipe 1 3. Oil filter 4. Oil pump 2-36...
  • Page 61 LUBRICATION DIAGRAMS 2-37...
  • Page 62 LUBRICATION DIAGRAMS 1. Oil delivery hose 2 2. Oil delivery pipe 2 3. Oil filter 4. Oil pump rotor 1 5. Oil pump rotor 2 6. Main axle 7. Oil delivery pipe 3 A. To oil tank 2-38...
  • Page 63 LUBRICATION DIAGRAMS 2-39...
  • Page 64 LUBRICATION DIAGRAMS 1. Camshaft 2. Oil delivery pipe 1 3. Oil filter 4. Main axle 5. Drive axle 6. Crankshaft 2-40...

  • Page 65: Cable Routing

    CABLE ROUTING CABLE ROUTING 2-41...
  • Page 66 CABLE ROUTING WARNING Proper cable and lead routing are essential to insure safe motorcycle operation. 1. Front flasher light lead wire (R) 2. Front flasher (R) 3. Switch handle lead (R) 4. Front brake light switch lead 5. Throttle cables 6.
  • Page 67 CABLE ROUTING 2-43...
  • Page 68 CABLE ROUTING 1. Throttle cables 2. Clamp 3. Speed meter assembly 4. Speed meter cable 5. To speed meter cable 6. Clutch cable 7. Switch handle lead (L) 8. Front flasher (L) 9. Front flasher light lead wire (L) 10. Clamp 11.
  • Page 69 CABLE ROUTING 2-45...
  • Page 70 CABLE ROUTING 1. Front brake hose 2. Bolt union 3. Front brake hose holder [F] Stop the turning of brake hose end by this boss. [G] Stop the turning of brake hose end by this surface. 2-46...
  • Page 71 CABLE ROUTING 2-47...
  • Page 72 CABLE ROUTING 1. Clamp 2. Throttle Position System lead 3. Water temperature sensor lead 4. Ignition coil lead 5. Ignition coil 6. Air Induction System lead wire 7. Air Induction System lead 8. Main switch lead 9. Main switch 10. Clutch wire 11.
  • Page 73 CABLE ROUTING 2-49...
  • Page 74 CABLE ROUTING 1. Wire plus lead 2. Starter motor lead 3. Wire harness 4. ECU 5. Clamp 6. Wire minus lead 7. Speed sensor lead 8. Rear stop switch 9. Radiator fan motor relay 10. Rear stop switch lead 11. Headlight relay 12.
  • Page 75 CABLE ROUTING 2-51...
  • Page 76 CABLE ROUTING 1. Speed meter cable 2. To front flasher 3. Main switch 4. Immobilizer lead 5. Clamp 6. Immobilizer lead 7. Clamp 8. Clamp 9. Speed sensor lead 10. Fuel pump 11. Throttle wire 12. Starter motor lead 13. A.C. magneto lead wire 14.
  • Page 77 CABLE ROUTING 2-53...
  • Page 78 CABLE ROUTING 1. Fuse box 2. Clamp 3. Clamp 4. Clamp 5. Tail light 6. License light 7. License light lead wire 8. Clamp 9. Rear flasher light lead wire 10. Battery box 11. ECU 12. Battery 2-54...
  • Page 79 CABLE ROUTING 2-55...
  • Page 80 CABLE ROUTING 1. Switch handle lead (R)/Front stop switch lead 2. Clamp 3. Throttle wire 4. Clamp 5. Wire harness 6. Speed sensor lead 7. Fuel pump lead 8. Clamp 9. Fuel hose 10. Air temperature sensor 11. Fuel injector lead 12.
  • Page 81 CABLE ROUTING 2-57...
  • Page 82 CABLE ROUTING 1. Clamp 2. Start wire harness installation 3. Starter motor lead 4. ECU lead 5. Starter relay fuse 6. Wire plus lead 7. Starter relay 8. Lean angle cut-off switch 9. Lean angle cut-off switch lead wire 10. Clamp 11.
  • Page 83 CABLE ROUTING 2-59...
  • Page 84 CABLE ROUTING 1. Bolt union 2. Brake hose 3. Rear stop switch 4. Clamp hose [A] Add Loctite® 243 2-60...

  • Page 85: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE AND LUBRICATION CHART ...... 3-1 ENGINE......................3-3 ADJUSTING THE VALVE CLEARANCE ..........3-3 ADJUSTING THE ENGINE IDLING SPEED ..........3-5 ADJUSTING THE THROTTLE CABLE FREE PLAY ........ 3-5 CHECKING THE SPARK PLUG ...............
  • Page 86 LUBRICATING THE SIDESTAND.............3-28 LUBRICATING THE REAR SUSPENSION ..........3-29 LUBRICATING THE SWINGARM PIVOTS..........3-29 ELECTRICAL SYSTEM..................3-30 CHECKING AND CHARGING THE BATTERY ........3-30 CHECKING THE FUSES................3-30 REPLACING THE HEADLIGHT BULB .............3-30 REPLACING AN AUXILIARY LIGHT BULB ..........3-31 TAIL/BRAKE LIGHT..................3-31 REPLACING A TURN SIGNAL LIGHT BULB ..........3-32 REPLACING THE LICENSE PLATE LIGHT BULB ........3-32 ADJUSTING THE HEADLIGHT BEAM ............3-32...

  • Page 87: Periodic Maintenance

    • From 50,000 km, repeat the maintenance intervals starting from 10,000 km. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (x 1,000 km) ANNUAL...
  • Page 88 PERIODIC MAINTENANCE ODOMETER READING (x 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK Sidestand ✓ ✓ ✓ ✓ ✓ ✓ 17 * • Check operation. switch Front fork ✓ ✓ ✓ ✓ • Check operation and for oil leakage. 18 * (See page 3-25) Shock absorber...

  • Page 89: Engine

    ENGINE ENGINE EAS00049 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead 5.
  • Page 90 ENGINE NOTE: c. Turn the adjusting screw “3” in direction “a” or “b” until the specified valve clearance is To position the piston at top dead center (TDC) obtained. on the compression stroke, align the “I” mark “c” on the camshaft sprocket with the stationary pointer “d”...

  • Page 91: Adjusting The Engine Idling Speed

    ENGINE 3. Adjust: • Engine idling speed ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the throttle stop screw “1” in direction “a” or “b” until the specified engine idling speed is obtained. Direction “a” Engine idling speed is increased. Direction “b” Engine idling speed is decreased. •...

  • Page 92: Checking The Spark Plug

    ENGINE Direction “a” Throttle cable free play is increased. Direction “b” Throttle cable free play is decreased. 2. Adjust: • Throttle cable free play NOTE: When the throttle is opened, the accelerator cable “1” is pulled. c. Tighten the locknut. Throttle body end WARNING a.

  • Page 93: Checking The Ignition Timing

    ENGINE 1. Remove: • Timing mark accessing screw “1” 5. Clean: • Spark plug (with a spark plug cleaner or wire brush) 2. Connect: 6. Measure: • Timing light (onto the spark plug lead) • Spark plug gap “a” (with a thickness gauge) Out of specification →...

  • Page 94: Measuring The Compression Pressure

    ENGINE EAS00067 Compression pressure MEASURING THE COMPRESSION (at sea level) PRESSURE Minimum 600 kPa (6.0 kg/cm , 85.3 psi) NOTE: Standard Insufficient compression pressure will result in 650 kPa (6.5 kg/cm , 92.4 psi) a loss of performance. Maximum 700 kPa (7.0 kg/cm , 99.6 psi) 1.

  • Page 95: Checking The Engine Oil Level

    ENGINE EAS00069 Recommended oil CHECKING THE ENGINE OIL LEVEL Refer to the chart for the engine 1. Place the vehicle on a level surface and hold oil grade which is best suited it in an upright position. for certain atmospheric temper- atures.

  • Page 96: Changing The Engine Oil

    ENGINE EAS00076 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. To reach the drain bolt of the crankcase and the drain bolt of the oil tank, remove the en- gine guard “2”...

  • Page 97: Adjusting The Clutch Cable Free Play

    ENGINE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Engine oil drain bolt (oil tank) (along with the gasket) a. Slightly loosen the bleed bolt “1 Engine oil drain bolt (oil tank) 18 Nm (1.8 m·kg, 12.9 ft·lb) • Oil filter element drain bolt Oil filter element drain bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) 11.Fill: •...

  • Page 98: Replacing The Air Filter Element And Cleaning The Check Hose

    ENGINE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ EAS00086 REPLACING THE AIR FILTER ELEMENT Handlebar end AND CLEANING THE CHECK HOSE a. Slide back the rubber cover. Replacing the air filter element b. Loosen the locknut “1”. 1. Remove: c. Turn the adjusting bolt “2” in direction “a” or •...

  • Page 99: Checking The Throttle Body Joint

    ENGINE Cleaning the air filter check hose 1. Check: • Air filter check hose “1” Accumulated dirt or water → Clean. 2. Remove: • Check hose cap “2” 3. Install: • Fuel tank Refer to “FUEL TANK” on page 7-1. •...

  • Page 100: Checking The Exhaust System

    ENGINE CAUTION: Make sure the breather hoses are routed correctly. EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex- haust pipes and gaskets. 1. Check: • Exhaust pipes “1” • Muffler “2” EAS00102 CHECKING THE COOLANT LEVEL Cracks/damage →...

  • Page 101: Checking The Cooling System

    ENGINE CAUTION: • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. • Use only distilled water. However, if dis- tilled water is not available, soft water may be used.

  • Page 102: Changing The Coolant

    ENGINE EAS00105 CHANGING THE COOLANT 1. Remove: • Panel “1” (right) Refer to “FUEL TANK” on page 7-1. • Radiator cap WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam 5.
  • Page 103 ENGINE Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity Total amount 1.20 L (1.05 Imp qt, 1.26 US qt) Coolant reservoir capacity 0.50 L 11.Install: (0.44 Imp qt, 0.56 US qt) •...

  • Page 104: Chassis

    CHASSIS CHASSIS WARNING A soft or spongy feeling in the brake lever EAA00810 ADJUSTING THE FRONT BRAKE can indicate the presence of air in the brake system. Before the vehicle is operat- 1. Adjust: ed, the air must be removed by bleeding •...

  • Page 105: Checking The Brake Fluid Level

    CHASSIS Locknut 18 Nm (1.8 m·kg, 13 ft·lb) WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. Before the vehicle is operat- ed, the air must be removed by bleeding the brake system.

  • Page 106: Checking The Front And Rear Brake Pads And Brake Pad Pins

    CHASSIS EAS00118 EAS00131 CHECKING THE FRONT AND REAR CHECKING THE FRONT AND REAR BRAKE PADS AND BRAKE PAD PINS BRAKE HOSES The following procedure applies to all of the The following procedure applies to all of the brake pads. brake hoses and brake hose clamps. 1.

  • Page 107: Bleeding The Hydraulic Brake System

    CHASSIS EAS00134 g. Loosen the bleed screw. BLEEDING THE HYDRAULIC BRAKE NOTE: SYSTEM Loosening the bleed screw will release the WARNING pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully ex- Bleed the hydraulic brake system when- tend.

  • Page 108: Adjusting The Drive Chain Slack

    CHASSIS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the bolt “1”. b. Remove the shift pedal “2”. c. Install the shift pedal at the correct position. d. Install the bolt, and then tighten it to the specified torque. Shift pedal bolt 20 Nm (2.0 m·kg, 14.7 ft·lb) LOCTITE ®...

  • Page 109: Lubricating The Drive Chain

    CHASSIS d. Tighten the locknuts to specification. Locknut 16 Nm (1.6 m·kg, 11 ft·lb) EAS00142 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained prop- erly, it will wear out quickly. Therefore, the drive 3.

  • Page 110: Checking The Front Fork

    CHASSIS NOTE: Make sure the lock washer tabs “a” sit correct- ly in the ring nut slots “b”. NOTE: Set the torque wrench at a right angle to the steering nut wrench. Steering nut wrench 7. Install: 90890-01403 • Upper bracket •...

  • Page 111: Adjusting The Front Fork

    CHASSIS 4. Hold the motorcycle upright and apply the Direction (a) front brake. Spring preload is increased 5. Check: (suspension is harder) • Front fork operation Direction (b) Push down hard on the handlebar several Spring preload is decreased times and check if the front fork rebounds (suspension is softer) smoothly.

  • Page 112: Checking The Tires

    CHASSIS NOTE: Adjust the spring preload with the special wrench included in the owner’s tool kit. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting ring “1” in direction “a” or “b”. NOTE: Align the appropriate notch in the adjusting ring “1” with the position indicator “2” on the shock absorber.
  • Page 113 Damage/wear → Replace the tire. WARNING After extensive tests, the tires listed below Minimum tire tread depth have been approved by Yamaha Motor Co. 1.6 mm (0.063 in) Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design.

  • Page 114: Checking The Wheels

    CHASSIS EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in- ner and outer cables. WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement. Replace damaged outer cable and inner CHECKING THE WHEELS cables as soon as possible.

  • Page 115: Lubricating The Rear Suspension

    CHASSIS LUBRICATING THE REAR SUSPENSION The pivoting points of the rear suspension must be lubricated at the intervals specified in the pe- riodic maintenance and lubrication chart. Recommended lubricant Lithium-soap-based grease LUBRICATING THE SWINGARM PIVOTS The swingarm pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.

  • Page 116: Electrical System

    ELECTRICAL SYSTEM ELECTRICAL SYSTEM Low beam ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ EAS21760 a. Remove: CHECKING AND CHARGING THE • Headlight bulb cover “1” BATTERY Refer to “ELECTRICAL COMPONENTS” on page 8-49. EAS21770 CHECKING THE FUSES Refer to “ELECTRICAL COMPONENTS” on page 8-48. REPLACING A HEADLIGHT BULB NOTE: This model is equipped with quartz bulb head- b.

  • Page 117: Replacing An Auxiliary Light Bulb

    ELECTRICAL SYSTEM High beam ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove: • Headlight bulb cover “1” b. Remove: • Auxiliary light socket “1” (together with the bulb, by pulling it out) • Defective bulb “2” (by pulling it out) b. Remove: • Headlight bulb holder “1” •...

  • Page 118: Replacing A Turn Signal Light Bulb

    ELECTRICAL SYSTEM REPLACING A TURN SIGNAL LIGHT BULB 1. Replace: • Turn signal light bulb ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove: • Turn signal light lens screw “1” • Turn signal light lens “2” • Turn signal light bulb “3” Push in and turn the bulb counterclockwise. b.
  • Page 119 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE SEAT AND THE ASSIST GRIPS ......... 4-1 REMOVING THE COWLING ..............4-2 REMOVING THE HEADLIGHT ............... 4-3 REMOVING THE REAR FENDER COVER, LICENSE BRACKET AND TAIL/BRAKE LIGHT ASSEMBLY ............ 4-4 REMOVING THE AIR FILTER CASE AND CRANKCASE BREATHER CHAMBER ................
  • Page 120 ASSEMBLING THE REAR BRAKE CALIPER .........4-39 INSTALLING THE REAR BRAKE CALIPER ..........4-39 REMOVING THE REAR BRAKE MASTER CYLINDER ......4-40 CHECKING THE REAR BRAKE MASTER CYLINDER......4-41 ASSEMBLING THE REAR BRAKE MASTER CYLINDER ......4-41 INSTALLING THE REAR BRAKE MASTER CYLINDER ......4-41 HANDLEBAR....................4-43 REMOVING THE HANDLEBAR ...............4-45 CHECKING THE HANDLEBAR ...............4-45 INSTALLING THE HANDLEBAR..............4-45...

  • Page 121: General Chassis

    GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat and the assist grips Order Job/Parts to remove Q’ty Remarks Turn counterclockwise. Seat Tail cover Assist grip (right and left) Cover (right and left) Cover For installation, reverse the removal procedure.
  • Page 122 GENERAL CHASSIS Removing the cowling and the front fender Order Job/Parts to remove Q’ty Remarks Windshield Panel Headlight/Front turn signal light (left and right) couplers 1/1/1 Disconnect. Panel (left) Panel (right) Headlight assembly Front fender For installation, reverse the removal procedure.

  • Page 123: Removing The Headlight

    GENERAL CHASSIS Removing the headlight Order Job/Parts to remove Q’ty Remarks Cowling body Headlight assembly Meter assembly Stay For installation, reverse the removal procedure.

  • Page 124: Removing The Rear Fender Cover, License Bracket And Tail/Brake Light Assembly

    GENERAL CHASSIS Removing the rear fender cover, license bracket and tail/brake light assembly Order Job/Parts to remove Q’ty Remarks Battery stay Battery CAUTION: • When removing the battery: First, dis- connect the negative battery lead, and then positive battery lead. •...

  • Page 125: Removing The Air Filter Case And Crankcase Breather Chamber

    GENERAL CHASSIS Removing the air filter case and crankcase breather chamber TO E/G Order Job/Parts to remove Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case joint clamp screw Loosen.

  • Page 126: Installing The Air Filter Case Joint Clamp

    GENERAL CHASSIS INSTALLING THE AIR FILTER CASE JOINT CLAMP 1. Install: • Air filter case joint clamp “1” NOTE: To install the air filter case joint clamp, align slot “a” with the projection “b” on the air filter case.
  • Page 127 FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs Order Job/Parts to remove Q’ty Remarks NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. Front brake caliper (left and right) Front wheel axle pinch bolt Loosen.
  • Page 128 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer For assembly, reverse the disassembly procedure.

  • Page 129: Front Wheel

    FRONT WHEEL EAS21900 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Loosen: • Front wheel axle pinch bolts “1” •...

  • Page 130: Assembling The Front Wheel

    FRONT WHEEL 3. Inspect: • Spoke(s) Bent/Damaged → Replace. Loose spoke(s) → Tighten. Turn the wheel and hit the spokes gently with a screwdriver. NOTE: A well tightened spoke makes a distinct, sharp noise: a loose spoke makes a dull, muffled noise.

  • Page 131: Adjusting The Front Wheel Static Balance

    FRONT WHEEL f. Repeat steps (d) through (f) several times until all the marks come to rest at the same EAS21970 spot. ADJUSTING THE FRONT WHEEL STATIC g. The spot where all the marks come to rest is BALANCE the front wheel’s heavy spot “X”. NOTE: •...

  • Page 132: Checking The Front Brake Discs

    FRONT WHEEL ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 3. Lubricate: • Oil seal lips a. Turn the front wheel and make sure it stays • Collars at each position shown. Recommended lubricant Lithium-soap-based grease 4. Install: • Front wheel NOTE: Install the tire and wheel with the mark “1” pointing in the direction of wheel rotation.
  • Page 133 FRONT WHEEL 8. Tighten: • Wheel axle pinch bolt “3” • Wheel axle pinch bolt “4” 9. Retighten: • Wheel axle pinch bolt “3” Front wheel axle pinch bolt 18 Nm (1.8 m·kgf, 13 ft·lbf) CAUTION: Apply the front brake several times, and then while holding the brake lever in, push down hard on the handlebar several times to check for proper fork operation.

  • Page 134: Rear Wheel

    REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel Order Job/Parts to remove Q’ty Remarks NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. Rear wheel axle nut Drive chain adjusting locknut (left and right) Loosen.
  • Page 135 REAR WHEEL Removing the rear brake disc and rear wheel sprocket Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel sprocket Collar (brake disc side) Collar (wheel sprocket side) Spacer Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper For installation, reverse the removal procedure.
  • Page 136 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Bearing Spacer Oil seal For installation, reverse the removal procedure. 4-16...

  • Page 137: Removing The Rear Wheel

    REAR WHEEL EAS22040 REMOVING THE REAR WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING 2 2 2 Securely support the vehicle so that there is no danger of it falling over. 2. Loosen: • Wheel axle nut “1” EAS22080 NOTE: DISASSEMBLING THE REAR WHEEL...

  • Page 138: Checking The Rear Wheel Drive Hub

    REAR WHEEL EAS22110 Rear wheel sprocket self-locking CHECKING THE REAR WHEEL DRIVE HUB 1. Check: 70 Nm (7.0 m·kg, 51 ft·lb) • Rear wheel drive hub “1” Cracks/damage → Replace. NOTE: • Rear wheel drive hub dampers “2” Tighten the self-locking nuts in stages and in a Damage/wear →...

  • Page 139: Installing The Rear Wheel (Rear Brake Disc)

    REAR WHEEL EAS22160 INSTALLING THE REAR WHEEL (REAR BRAKE DISC) 1. Install: • Rear brake disc Rear brake disc bolt 14 Nm (1.4 m·kg, 10 ft·lb) LOCTITE ® NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. 2.
  • Page 140 FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake hose holder Front brake caliper Pin retainer Pad fastening pin Front brake pad Brake pad spring For installation, reverse the removal procedure.

  • Page 141: Front Brake

    FRONT BRAKE Removing the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-21. Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake lever Front brake light switch connector Disconnect.
  • Page 142 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Master cylinder kit Spring Master cylinder Push rod For assembly, reverse the disassembly procedure. 4-22...
  • Page 143 FRONT BRAKE Removing the front brake calipers Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-21. Brake hose holder Front brake hose union bolt Copper washer Front brake hose...
  • Page 144 FRONT BRAKE Disassembling the front brake calipers Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Pin retainer Pad fastening pin Front brake pad Brake pad spring Caliper braket Bleed screw For assembly, reverse the disassembly procedure.

  • Page 145: Introduction

    FRONT BRAKE EAS22220 c. Remove the brake caliper. INTRODUCTION d. Hold the dial gauge at a right angle against the brake disc surface. EWA14100 WARNING Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components un- less absolutely necessary.

  • Page 146: Replacing The Front Brake Pads

    FRONT BRAKE d. Measure the brake disc deflection. 2. Install: e. If out of specification, repeat the adjustment • Brake pad spring steps until the brake disc deflection is within • Brake pads specification. NOTE: f. If the brake disc deflection cannot be Always install new brake pads and a brake pad brought within specification, replace the spring as a set.

  • Page 147: Removing The Front Brake Calipers

    FRONT BRAKE 4. Check: EAS22300 REMOVING THE FRONT BRAKE • Brake fluid level CALIPERS Below the minimum level mark “a” → Add the The following procedure applies to both of the recommended brake fluid to the proper lev- brake calipers. Refer to “CHECKING THE BRAKE FLUID NOTE: LEVEL”...

  • Page 148: Checking The Front Brake Calipers

    FRONT BRAKE EAS22390 EAS22450 CHECKING THE FRONT BRAKE CALIPERS INSTALLING THE FRONT BRAKE CALIPERS Recommended brake component The following procedure applies to both of the replacement schedule brake calipers. Brake pads If necessary 1. Install: • Brake pads Brake hoses Every four years •...

  • Page 149: Removing The Front Brake Master Cylinder

    FRONT BRAKE 2. Fill: 5. Check: • Brake fluid reservoir • Brake lever operation Soft or spongy feeling → Bleed the brake (with the specified amount of the recom- mended brake fluid) system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-21. Recommended fluid DOT 4 EAS22490...

  • Page 150: Checking The Front Brake Master Cylinder

    FRONT BRAKE EAS22510 EAS22520 CHECKING THE FRONT BRAKE MASTER ASSEMBLING THE FRONT BRAKE CYLINDER MASTER CYLINDER 1. Check: EWA13520 • Brake master cylinder “1” WARNING Damage/scratches/wear → Replace. • Before installation, all internal brake com- • Brake fluid delivery passages ponents should be cleaned and lubricated (brake master cylinder body) with clean or new brake fluid.
  • Page 151 FRONT BRAKE EWA13090 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake flu- ids may result in a harmful chemical reac- tion, leading to poor brake performance.

  • Page 152: Rear Brake

    REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to “REMOVING THE REAR WHEEL” on page 4-17. Brake pad clip Brake pad pin Rear brake pad Brake pad spring Blade screw For installation, reverse the removal procedure.
  • Page 153 REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-21. Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir Brake fluid reservoir hose Rear brake switch...
  • Page 154 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake hose joint Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly procedure. 4-34...
  • Page 155 REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-21. Rear wheel Refer to “REMOVING THE REAR WHEEL” on page 4-17. Rear brake hose union bolt Copper washer Rear brake hose Rear brake caliper...
  • Page 156 REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Brake caliper bracket Brake pad clip Brake pad pin Brake pad Brake pad spring Bleed screw For installation, reverse the removal procedure. 4-36...

  • Page 157: Introduction

    REAR BRAKE EAS22560 Brake disc thickness limit INTRODUCTION 4.5 mm (0.18 in) EWA14100 WARNING 5. Adjust: Disc brake components rarely require dis- assembly. Therefore, always follow these • Brake disc deflection Refer to “CHECKING THE FRONT BRAKE preventive measures: DISCS” on page 4-25. •...

  • Page 158: Removing The Rear Brake Caliper

    REAR BRAKE NOTE: 5. Check: • Brake pedal operation Always install new brake pads and brake pad Soft or spongy feeling → Bleed the brake springs as a set. system. Refer to “BLEEDING THE HYDRAULIC ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ BRAKE SYSTEM” on page 3-21. a.

  • Page 159: Checking The Rear Brake Caliper

    REAR BRAKE EWA13550 EWA13610 WARNING WARNING • Cover the brake caliper piston with a rag. Whenever a brake caliper is disassembled, Be careful not to get injured when the pis- replace the brake caliper piston seals. ton is expelled from the brake caliper. •...

  • Page 160: Removing The Rear Brake Master Cylinder

    REAR BRAKE • When refilling, be careful that water does • Rear wheel not enter the brake fluid reservoir. Water Refer to “REAR WHEEL” on page 4-14. will significantly lower the boiling point of • Copper washers the brake fluid and could cause vapor •...

  • Page 161: Checking The Rear Brake Master Cylinder

    REAR BRAKE NOTE: Recommended fluid To collect any remaining brake fluid, place a DOT 4 container under the master cylinder and the end of the brake hose. 1. Install: • Brake master cylinder kit 2. Remove: • Joint “1” • Cotter pin NOTE: •...
  • Page 162 REAR BRAKE 2. Install: EWA13090 WARNING • Right side plate • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to Right side plate bolt “1” deteriorate, causing leakage and poor 23 Nm (2.3 m·kg, 17 ft·lb) brake performance.

  • Page 163: Handlebar

    HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar Order Job/Parts to remove Q’ty Remarks Rearview mirror (left and right) Plastic band Front brake light switch coupler Disconnect. Brake master cylinder holder Brake master cylinder Grip end Throttle cable holder Right handlebar switch Throttle cable Throttle grip Clutch switch coupler...
  • Page 164 HANDLEBAR Removing the handlebar Order Job/Parts to remove Q’ty Remarks Upper handlebar holder Handlebar For installation, reverse the removal procedure. 4-44...

  • Page 165: Removing The Handlebar

    HANDLEBAR EAS22860 Handlebar switch bolt REMOVING THE HANDLEBAR 1.5 Nm (0.15 m·kg, 1.05 ft·lb) 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: •...
  • Page 166 HANDLEBAR 4. Install: • Front brake master cylinder “1” • Front brake master cylinder holder “2” NOTE: • Make sure that the "UP" mark “a” with the bracket is pointed upward. • Align the punch mark “b” on the handlebar with the gap of the master cylinder bracket.
  • Page 167 HANDLEBAR 9. Install: NOTE: • Handlebar grip “1” Refer to “CABLE ROUTING” on page 2-42. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 11.Install: a. Apply a thin coat of rubber adhesive onto the • Left rear view mirror “1” left end of the handlebar. • Right rear view mirror “2” b.

  • Page 168: Front Fork

    FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Front wheel Refer to “FRONT WHEEL” on page 4-7. Front fender Refer to “GENERAL CHASSIS” on page 4-1.
  • Page 169 FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Cap bolt O-ring Spacer Washer Front fork spring Piston ring Damper rod assembly Inner tube Inner tube bushing Clamp Rubber protector Oil flow stopper...
  • Page 170 FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks Outer tube bushing Outer tube Copper washer Damper rod assembly bolt For assembly, reverse the disassembly procedure. 4-50...

  • Page 171: Removing The Front Fork Legs

    FRONT FORK EAS00649 3. Remove: REMOVING THE FRONT FORK LEGS • Dust seal “1” The following procedure applies to both of the • Oil seal clip “2” front fork legs. (with a flat-head screwdriver) 1. Stand the motorcycle on a level surface. CAUTION: WARNING Do not scratch the inner tube.

  • Page 172: Checking The Front Fork Legs

    FRONT FORK CAUTION: 3. Check: • Excessive force will damage the oil seal • Damper rod “1” and bushing. A damaged oil seal or bush- Damage/ wear Replace. Obstruction → Blow out all of the oil pas- ing must be replaced. •...

  • Page 173: Assembling The Front Fork Legs

    FRONT FORK EAS00659 Recommended lubricant ASSEMBLING THE FRONT FORK LEGS Fork oil 10W or equivalent The following procedure applies to both of the front fork legs. 3. Tighten: WARNING • Damper rod assembly bolt “1” • Make sure the oil levels in both front fork legs are equal.
  • Page 174 FRONT FORK NOTE: Adjust the oil seal clip so that it fits into the out- er tube’s groove. 5. Install: • Oil seal “1” (with the fork seal driver weight and fork seal driver attachment) 7. Install: • Dust seal “1” CAUTION: (with the fork seal driver weight) Make sure the numbered side of the oil seal...
  • Page 175 F F R R O O N N T T F F O O R R K K 9. Measure: N N O O T T E E : : • Install the spring with the smaller pitch “a” fac- •...
  • Page 176 FRONT FORK WARNING Make sure the brake hoses are routed prop- erly. 4-56...

  • Page 177: Steering Head

    STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Front wheel Refer to “FRONT WHEEL” on page 4-7. Front fender Refer to “GENERAL CHASSIS” on page 4-1.
  • Page 178 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Bearing cover Bearing Lower bearing For installation, reverse the removal procedure. 4-58...

  • Page 179: Removing The Lower Bracket

    STEERING HEAD EAS00679 EAS00681 REMOVING THE LOWER BRACKET CHECKING THE STEERING HEAD 1. Stand the motorcycle on a level surface. 1. Wash: • Bearings WARNING Securely support the motorcycle so that Recommended cleaning solvent there is no danger of it falling over. Kerosene 2.
  • Page 180 STEERING HEAD 4. Install: Steering nut wrench • Upper bracket 90890-01403 • Washer • Steering stem nut 5. Install: Lower ring nut • Front fork legs (initial tightening torque) Refer to “INSTALLING THE FRONT FORK 45 Nm (4.5 m·kg, 33 ft·lb) LEGS”.

  • Page 181: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks Flange nut Bolt Flange nut Flange bolt Rear shock absorber assembly For installation, reverse the removal procedure. 4-61...

  • Page 182: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS23180 EAS23230 HANDLING THE REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER ASSEMBLY EWA13740 WARNING 1. Stand the vehicle on a level surface. This rear shock absorber contains highly WARNING compressed nitrogen gas. Before handling Securely support the vehicle so that there is the rear shock absorber, read and make no danger of it falling over.
  • Page 183 REAR SHOCK ABSORBER ASSEMBLY 4. Install: • Rear shock absorber assembly “1” (onto the arm relay) • Bolt “4” • Flange nut “5” 5. Tighten: • Flange nut “5” Rear shock absorber assembly nut (arm relay) 45 Nm (4.5 m·kg, 33 ft·lb) 4-63...

  • Page 184: Swingarm

    SWINGARM EAS23330 SWINGARM Removing the swingarm, arm relay and connecting rod Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to “REAR WHEEL” on page 4-14. Rear shock absorber assembly Refer to “REAR SHOCK ABSORBER ASSEMBLY” on page 4-62. Special nut Loosen.
  • Page 185 SWINGARM Removing the swingarm, arm relay and connecting rod Order Job/Parts to remove Q’ty Remarks Swingarm Drive chain From the swingarm. Guard seal Thrust cover Oil seal Bush Bearing Solid bush Oil seal Chain puller Bolt Flange nut For installation, reverse the removal procedure.

  • Page 186: Removing The Swingarm

    SWINGARM EAS23350 REMOVING THE SWINGARM 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. 2.

  • Page 187: Installing The Swingarm

    SWINGARM Recommended cleaning solvent Special nut Kerosene 8 Nm (0.8 m·kg, 5.8 ft·lb) • Pivot shaft flange nut “7” 4. Check: • Thrust cover Pivot shaft flange nut • Dust seal 92 Nm (9.2 m·kg, 66 ft·lb) • Oil seal Damage/wear →...
  • Page 188 SWINGARM 10. Install: Location “c” of bearings • Rear shock absorber assembly (right and left) Refer to “REAR SHOCK ABSORBER 5 mm (0.196 in) ASSEMBLY” on page 4-62. • Rear wheel 8. Install: Refer to “REAR WHEEL” on page 4-14. •...

  • Page 189: Chain Drive

    CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive sprocket and drive chain Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to “REAR WHEEL” on page 4-14. Rear shock absorber assembly Refer to “REAR SHOCK ABSORBER ASSEMBLY” on page 4-62. Swingarm Refer to “SWINGARM”...

  • Page 190: Removing The Drive Chain

    CHAIN DRIVE EAS23410 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.

  • Page 191: Removing The Drive Sprocket

    CHAIN DRIVE 3. Remove: • Drive sprocket nut “1” • Lock washer “2” • Drive sprocket “3” 4. Check: • O-rings “1” Damage •Replace the drive chain. • Drive chain rollers “2” EAS23460 Damage/wear → Replace the drive chain. CHECKING THE DRIVE SPROCKET •...
  • Page 192 CHAIN DRIVE 2. Install: • Drive sprocket “1” • Lock washer “2” • Drive sprocket nut “3” Drive sprocket nut 120 Nm (12.0 m·kg, 85 ft·lb) NOTE: • Install the drive sprocket “1” and drive sprock- et nut “3” in the direction shown. •...

  • Page 193: Engine

    ENGINE ENGINE REMOVAL..................5-1 INSTALLING THE ENGINE ..............5-7 CYLINDER HEAD................... 5-8 REMOVING THE CYLINDER HEAD ............5-9 CHECKING THE CYLINDER HEAD ............5-9 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER ................5-10 CHECKING THE TIMING CHAIN TENSIONER ........5-10 CHECKING THE CAMSHAFT SPROCKET ..........5-11 INSTALLING THE CYLINDER HEAD............5-11 ROCKER ARMS AND CAMSHAFT...............5-14 REMOVING THE ROCKER ARMS AND CAMSHAFT......5-15...
  • Page 194 OIL PUMP.......................5-40 CHECKING THE OIL PUMP ..............5-43 CHECKING THE OIL DELIVERY PIPES AND HOSES ......5-43 ASSEMBLING THE OIL PUMP ..............5-44 INSTALLING THE OIL PUMP..............5-44 BALANCER DRIVEN GEAR................5-45 REMOVING THE BALANCER DRIVEN GEAR AND BALANCER DRIVE GEAR ...............5-46 CHECKING THE BALANCER DRIVEN GEAR, WATER PUMP DRIVE GEAR, PRIMARY DRIVE GEAR, AND BALANCER DRIVE GEAR....................5-46 INSTALLING THE BALANCER DRIVEN GEAR AND...

  • Page 195: Engine Removal

    ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the exhaust pipes and muffler Order Job/Parts to remove Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Radiator cover (right and left) Refer to “RADIATOR” on page 6-1. Rear mud guard and rear fender Refer to “GENERAL CHASSIS”...
  • Page 196 ENGINE REMOVAL Removing the oil pipes Order Job/Parts to remove Q’ty Remarks Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” on page 3-10. Engine guard Oil tank outlet pipe Oil tank inlet pipe Oil tank breather hose Disconnect. For installation, reverse the removal procedure.
  • Page 197 ENGINE REMOVAL Removing the leads, cables, hoses, and ignition coil Order Job/Parts to remove Q’ty Remarks Coolant Drain. Refer to “CHANGING THE COOLANT” on page 3-16. Radiator Refer to “RADIATOR” on page 6-1. Rear wheel Refer to “REAR WHEEL” on page 4-14. Rear shock absorber assembly Refer to “REAR SHOCK ABSORBER ASSEMBLY”...
  • Page 198 ENGINE REMOVAL Removing the leads, cables, hoses, and ignition coil Order Job/Parts to remove Q’ty Remarks Neutral switch connector Disconnect. Speed sensor coupler Disconnect. Ignition coil lead Disconnect. Ignition coil Intake air pressure sensor coupler Disconnect. Vacuum hose Intake air pressure sensor Clutch cable For installation, reverse the removal procedure.
  • Page 199 ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks NOTE: Place a suitable stand under the frame and engine. CAUTION: When remove the engine loosen first all of the nuts and bolts. CAUTION: When install the engine install first all of the nuts and bolts, and then tighten them to specified torques.
  • Page 200 ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Engine front bracket Engine rear mounting bolt/nut Engine For installation, reverse the removal procedure.

  • Page 201: Installing The Engine

    ENGINE REMOVAL EAS00192 3. Tighten: INSTALLING THE ENGINE • Engine rear mounting bolt/nut “1” 1. Install: • Engine front bracket bolt/nut (upper) “3” • Engine (on the frame) • Engine front bracket bolt/nut (lower) “3” 2. Install: • Engine front mounting bracket bolt/nut •...

  • Page 202: Cylinder Head

    CYLINDER HEAD EAS00221 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Timing mark accessing screw/crank-shaft Refer to “ADJUSTING THE VALVE end accessing screw CLEARANCE” on page 3-3. Spark plug Camshaft sprocket cover/O-ring Tappet cover/O-ring Air cut-off valve outlet pipe...

  • Page 203: Removing The Cylinder Head

    CYLINDER HEAD EAS00225 3. Loosen: REMOVING THE CYLINDER HEAD • Timing chain tensioner cap bolt 1. Align: 4. Remove: • “I” mark “a” on the A.C. magneto rotor (with • Timing chain tensioner the stationary pointer “b” on the A.C. mag- (along with the gasket) neto cover) •...

  • Page 204: Checking The Tappet Covers And Camshaft Sprocket Cover

    CYLINDER HEAD 2. Check: EAS00212 CHECKING THE TAPPET COVERS AND • Cylinder head CAMSHAFT SPROCKET COVER Damage/scratches → Replace. 1. Check: • Cylinder head water jacket Mineral deposits/rust → Eliminate. • Tappet covers “1” • Camshaft sprocket cover “2” 3. Measure: •...

  • Page 205: Checking The Camshaft Sprocket

    CYLINDER HEAD CHECKING THE CAMSHAFT SPROCKET 1. Check: • Camshaft sprocket Wear/damage → Replace the camshaft sprocket and timing chain as a set. a. 1/4 of a tooth b. Correct 1. Roller 2. Sprocket EAS00231 INSTALLING THE CYLINDER HEAD 4. Install: 1.
  • Page 206 CYLINDER HEAD a. Remove the timing chain tensioner cap bolt “1”, copper washer “2” and spring “3”. b. Release the timing chain tensioner one-way cam “4” and push the timing chain tensioner rod “5” all the way into the timing chain ten- sioner housing.
  • Page 207 CYLINDER HEAD NOTE: Check that the “I” mark “a” on the A.C. magne- to rotor is aligned with the stationary pointer “b” on the A.C. magneto cover. • “I” mark “c” NOTE: Check that the “I” mark “c” on the camshaft sprocket is aligned with the stationary pointer “d”...
  • Page 208 ROCKER ARMS AND CAMSHAFT ROCKER ARMS AND CAMSHAFT Removing the rocker arms and camshaft Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-8. Bearing retainer Rocker arm shaft Rocker arm Locknut/valve adjuster Camshaft CAUTION: Do not disassemble the camshaft assembly.

  • Page 209: Rocker Arms And Camshaft

    ROCKER ARMS AND CAMSHAFT EAS00202 EAS00205 REMOVING THE ROCKER ARMS AND CHECKING THE CAMSHAFT CAMSHAFT 1. Check: • Camshaft lobes 1. Loosen: Blue discoloration/pitting/scratches → • Locknuts Replace the camshaft and camshaft sprock- • Adjusting screws 2. Remove: 2. Measure: •...

  • Page 210: Checking The Decompression System

    ROCKER ARMS AND CAMSHAFT 3. Measure: 2. Check: • Camshaft runout • Rocker arm shaft Out of specification → Replace. Blue discoloration/excessive wear/pitting/ scratches → Replace or check the lubrica- tion system. Camshaft runout limit 3. Measure: 0.030 mm (0.0012 in) •...

  • Page 211: Installing The Camshaft And Rocker Arms

    ROCKER ARMS AND CAMSHAFT Above 0.081 mm (0.0032 in) → Replace the defective part(s). Rocker-arm-to-rocker-arm-shaft clearance 0.009-0.037 mm (0.0004-0.0015 in) <Limit>: 0.081 mm (0.0032 in) EAS00220 INSTALLING THE CAMSHAFT AND 4. Install: ROCKER ARMS • Camshaft “1” 1. Install: NOTE: •...
  • Page 212 ROCKER ARMS AND CAMSHAFT 7. Install: • Camshaft retainer • Camshaft retainer bolts Camshaft retainer bolts 10 Nm (1.0 m·kg, 7.2 ft·lb) LOCTITE ® 5-18...

  • Page 213: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-8. Rocker arms/rocker arm shafts/camshaft Refer to “ROCKER ARMS AND CAMSHAFT” on page 5-14. Valve cotter Valve spring retainer Valve spring...

  • Page 214: Removing The Valves

    VALVES AND VALVE SPRINGS EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
  • Page 215 VALVES AND VALVE SPRINGS b. Install the new valve guide with the valve guide installer “2” and valve guide remover “1”. Valve-stem-to-valve-guide clearance Intake 0.010-0.037 mm (0.0004-0.0015 in) c. After installing the valve guide, bore the <Limit>: 0.08 mm (0.0031 in) valve guide with the valve guide reamer “3”...

  • Page 216: Checking The Valve Seats

    VALVES AND VALVE SPRINGS EAS00240 3. Eliminate: CHECKING THE VALVE SEATS • Carbon deposits The following procedure applies to all of the (from the valve face and valve seat) valves and valve seats. 4. Check: 1. Eliminate: • Valve face •...

  • Page 217: Checking The Valve Springs

    VALVES AND VALVE SPRINGS 4. Lap: • Valve face • Valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a coarse lapping compound “a” to the valve face.

  • Page 218: Installing The Valves

    VALVES AND VALVE SPRINGS EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: • Valve stem end (with an oil stone) 2. Measure: • Compressed valve spring force “a” Out of specification → Replace the valve spring.
  • Page 219 VALVES AND VALVE SPRINGS NOTE: • Install the valve spring with the larger pitch “a” facing up. • Install the valve spring with its painted end facing up. b. Smaller pitch 4. Install: • Valve cotters NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor “1”...

  • Page 220: Cylinder And Piston

    CYLINDER AND PISTON EAS00251 CYLINDER AND PISTON Removing the cylinder and piston Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-8. Timing chain guide (exhaust) Water jacket joint O-ring Cylinder Cylinder gasket Dowel pin Piston pin clip Piston pin Piston...

  • Page 221: Removing The Cylinder And Piston

    CYLINDER AND PISTON EAS00253 NOTE: REMOVING THE CYLINDER AND When removing a piston ring, open the end PISTON gap with your fingers and lift the other side of 1. Remove: the ring over the piston crown. • Piston pin clips “1” •...

  • Page 222: Checking The Piston Rings

    CYLINDER AND PISTON EAS00263 CHECKING THE PISTON RINGS 1. Measure: • Piston ring side clearance Out of specification → Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clear- ance, eliminate any carbon deposits from the piston ring grooves and piston rings.

  • Page 223: Checking The Piston Pin

    CYLINDER AND PISTON 3. Measure: Piston pin bore inside diameter • Piston ring end gap 23.004-23.015 mm Out of specification → Replace the piston ring. (0.9057-0.9061 in) <Limit>: 23.045 mm (0.9073 in) NOTE: The oil ring expander spacer’s end gap cannot be measured.
  • Page 224 CYLINDER AND PISTON 5. Offset: • piston ring end gaps a. Top ring b. Upper oil ring rail c. Oil ring expander d. Lower oil ring rail e. 2 ring f. 20 mm (0.79 in) å Exhaust side 2. Install: •...
  • Page 225 CYLINDER AND PISTON 8. Tighten: • Cylinder bolts Cylinder bolts “1” L = 116 mm (4.57 in) 15 Nm (1.5 m·kg, 11 ft·lb) 50 Nm (5.0 m·kg, 36 ft·lb) Cylinder bolts “2” L = 109 mm (4.29 in) 15 Nm (1.5 m·kg, 11 ft·lb) 50 Nm (5.0 m·kg, 36 ft·lb) Cylinder bolts (timing chain side) “3”...

  • Page 226: Clutch

    CLUTCH EAS00273 CLUTCH Removing the clutch cover Order Job/Parts to remove Q’ty Remarks Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” on page 3-10. Clutch cable Clutch cable holder Clutch cover Gasket Dowel pin For installation, reverse the removal procedure.

  • Page 227: Clutch

    CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Circlip Washer Pull lever Pull lever spring Pull lever shaft Oil seal Bearing For installation, reverse the removal procedure. 5-33...
  • Page 228 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Clutch spring Pressure plate Pull rod Friction plate 1 Inside diameter (plate with notched tabs) = 119 mm (4.69 in) Clutch plate Friction plate 2 Inside diameter (plate with no notched tabs) = 119 mm (4.69 in) Friction plate 3 Inside diameter (plate with notched tabs) =...

  • Page 229: Removing The Clutch

    CLUTCH EAS00275 EAS00280 REMOVING THE CLUTCH CHECKING THE FRICTION PLATES 1. Remove: The following procedure applies to all of the • Clutch cover “1” friction plates. NOTE: 1. Check: • Friction plate “1” Loosen each bolt 1/4 of a turn at a time, in •...

  • Page 230: Checking The Clutch Springs

    CLUTCH 2. Measure: EAS00284 CHECKING THE CLUTCH HOUSING • Clutch plate warpage 1. Check: (with a surface plate and thickness gauge • Clutch housing dogs “1”) Damage/pitting/wear → Deburr the clutch Out of specification → Replace the clutch housing dogs or replace the clutch housing. plates as a set.

  • Page 231: Checking The Pressure Plate

    CLUTCH EAS00286 CHECKING THE PRESSURE PLATE 1. Check: • Pressure plate “1” Cracks/damage → Replace. • Bearing “2” Damage/wear → Replace. EAS00299 INSTALLING THE CLUTCH 1. Install: • Clutch boss • Lock washer • Clutch boss nut “1” NOTE: EAS00287 CHECKING THE PULL LEVER SHAFT Lubricate the crankshaft end threads with en- gine oil.
  • Page 232 CLUTCH 4. Lubricate: • Friction plates • Clutch plates (with the recommended lubricant) Recommended lubricant Engine oil 5. Install: • Clutch damper spring seat “1” • Clutch damper spring “2” 6. Install: • Friction plate 3 “3” • Clutch springs •...
  • Page 233 CLUTCH NOTE: 12.Adjust: • Install the pull lever with the “UP” mark facing • Clutch cable free play Refer to “ADJUSTING THE CLUTCH CA- • Align the punch mark “a” on the pull lever with BLE FREE PLAY” on page 3-11. the punch mark “b”...

  • Page 234: Oil Pump

    OIL PUMP OIL PUMP Removing the oil pump Order Job/Parts to remove Q’ty Remarks Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” on page 3-10. Coolant Drain. Refer to “CHANGING THE COOLANT” on page 3-16. Water pump assembly Refer to “WATER PUMP” on page 6-7. Clutch cable holder/clutch housing Refer to “CLUTCH”...
  • Page 235 OIL PUMP Removing the oil pump Order Job/Parts to remove Q’ty Remarks Circlip Oil pump driven gear Oil baffle plate 2 Oil pump Oil pump gasket O-ring For installation, reverse the removal procedure. 5-41...
  • Page 236 OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil pump housing 1/oil seal Oil pump outer rotor 1 Dowel pin Oil pump inner rotor 1 Oil pump housing cover/oil seal Dowel pin Oil pump shaft Dowel pin Oil pump inner rotor 2 Oil pump outer rotor 2 Oil pump housing 2...

  • Page 237: Checking The Oil Pump

    OIL PUMP EAS00364 CHECKING THE OIL PUMP 1. Check: • Oil pump driven gear “1” • Oil pump housing 1 “2” • Oil pump housing cover “3” • Oil pump housing 2 “4” Cracks/damage/wear → Replace the defec- tive part(s). 2.

  • Page 238: Assembling The Oil Pump

    OIL PUMP EAS00375 EAS00376 ASSEMBLING THE OIL PUMP INSTALLING THE OIL PUMP 1. Lubricate: 1. Install: • Oil pump inner rotor 1 • Oil pump gasket • Oil pump inner rotor 2 • Oil pump • Oil pump outer rotor 1 •...

  • Page 239: Balancer Driven Gear

    BALANCER DRIVEN GEAR BALANCER DRIVEN GEAR Removing the balancer driven gear Order Job/Parts to remove Q’ty Remarks Water pump assembly Refer to “WATER PUMP” on page 6-7. Clutch housing Refer to “CLUTCH” on page 5-32. Crankcase cover (right) Refer to “OIL PUMP” on page 5-40. Balancer driven gear nut Primary drive gear nut Lock washer...

  • Page 240: Removing The Balancer Driven Gear And Balancer Drive Gear

    BALANCER DRIVEN GEAR REMOVING THE BALANCER DRIVEN INSTALLING THE BALANCER DRIVEN GEAR AND BALANCER DRIVE GEAR GEAR AND BALANCER DRIVE GEAR 1. Straighten the lock washer tab. 1. Install: 2. Loosen: • Washer • Balancer driven gear nut “1” • Balancer drive gear “1” •...
  • Page 241 BALANCER DRIVEN GEAR NOTE: Place an aluminum plate “a” between the teeth of the balancer drive gear and balancer driven gear. 3. Bend the lock washer tab. 5-47...

  • Page 242: Shift Shaft

    SHIFT SHAFT EAS00327 SHIFT SHAFT AND STOPPER LEVER Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Water pump assembly Refer to “WATER PUMP” on page 6-7. Clutch housing Refer to “CLUTCH” on page 5-32. Crankcase cover (right) Refer to “OIL PUMP”...
  • Page 243 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Washer Shift shaft spring stopper For installation, reverse the removal procedure. 5-49...

  • Page 244: Checking The Shift Shaft

    SHIFT SHAFT EAS00329 NOTE: CHECKING THE SHIFT SHAFT • Hook the ends of the stopper lever spring on- 1. Check: to the stopper lever and the crankcase boss • Shift shaft “1” “4”. • Shift shaft pawl “2” • Mesh the stopper lever with the shift drum Bends/damage/wear →...
  • Page 245 STARTER CLUTCH AND A.C. MAGNETO EAS00341 STARTER CLUTCH AND A.C. MAGNETO Removing the starter clutch and A.C. magneto Order Job/Parts to remove Q’ty Remarks Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” on page 3-10. Starter motor Refer to “ELECTRIC STARTER” on page 5-56.
  • Page 246 STARTER CLUTCH AND A.C. MAGNETO Removing the starter clutch and A.C. magneto Order Job/Parts to remove Q’ty Remarks Starter clutch idle gear A.C. magneto rotor Starter clutch Woodruff key Starter clutch gear Bearing Washer For installation, reverse the removal procedure. 5-52...

  • Page 247: Starter Clutch And A.c. Magneto

    STARTER CLUTCH AND A.C. MAGNETO EAS00346 REMOVING THE A.C. MAGNETO ROTOR 1. Remove: • Torque limiter cover CAUTION: Do not remove the bearing “1”. 4. Remove: • A.C. magneto rotor “1” (with the flywheel puller “2”) • Woodruff key NOTE: Use the rotor puller.

  • Page 248: Checking The Starter Clutch

    STARTER CLUTCH AND A.C. MAGNETO EAS00351 CHECKING THE STARTER CLUTCH 1. Check: • Starter clutch rollers “1” Damage/wear → Replace. CHECKING THE TORQUE LIMITER 1. Check: • Torque limiter Damage/wear → Replace. 2. Check: • Starter clutch idle gear “1” •...
  • Page 249 STARTER CLUTCH AND A.C. MAGNETO 2. Apply: NOTE: • Yamaha bond No. 1215 “1” (into the slits) • While holding the A.C. magneto rotor “2” with the sheave holder “3”, tighten the A.C. mag- neto rotor nut. Yamaha bond No. 1215 •...
  • Page 250 ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Crankcase-to-crankcase-breather-chamber hose Disconnect. Air-filter-to-crankcase-breather-chamber hose Disconnect. Crankcase breather chamber Starter motor lead Disconnect. Negative battery lead Disconnect. Crankcase breather chamber bracket Starter motor For installation, reverse the removal procedure.

  • Page 251: Electric Starter

    ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks Circlip Disconnect. Starter motor gear Disconnect. O-ring Front bracket Disconnect. Shims Disconnect. Lock washer Rear bracket Shims Brush holder assembly Brush Armature coil O-ring Starter motor yoke For assembly, reverse the disassembly procedure.

  • Page 252: Checking The Starter Motor

    ELECTRIC STARTER ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ EAS24790 CHECKING THE STARTER MOTOR a. Measure the armature assembly resistances with the pocket tester. 1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. Pocket tester 2. Measure: 90890-03112 • Commutator diameter “a” Out of specification → Replace the starter Armature coil motor.

  • Page 253: Assembling The Starter Motor

    ELECTRIC STARTER 3. Install: • Rear bracket NOTE: Align the slot “a” in the rear bracket with the tab “b” on the brush seat. 7. Check: • Gear teeth Damage/wear → Replace the gear. 8. Check: • Bearing • Oil seal Damage/wear →...

  • Page 254: Crankcase

    CRANKCASE CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Cylinder head Refer to “CYLINDER HEAD” on page 5-8. Cylinder/piston Refer to “CYLINDER AND PISTON” on page 5-26. A.C. magneto Refer to “STARTER CLUTCH AND A.C. MAGNETO”...
  • Page 255 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Crankcase (left) Dowel pin/O-ring Dowel pin Oil strainer Oil delivery pipe 3 O-ring For installation, reverse the removal procedure. 5-61...
  • Page 256 CRANKCASE Removing the crankcase bearings Order Job/Parts to remove Q’ty Remarks Crankshaft/balancer Refer to “CRANKSHAFT” on page 5-66. Transmission Refer to “TRANSMISSION” on page 5-69. Oil seal holder Oil seal Bearing retainer Bearing For installation, reverse the removal procedure. 5-62...

  • Page 257: Separating The Crankcase

    CRANKCASE SEPARATING THE CRANKCASE CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE 3 1. Separate: • Right crankcase “1” 1. Check: • Left crankcase “2” • Oil strainer Damage → Replace. Contaminants → Clean with engine oil. 2. Check: • Oil delivery pipe 3 Cracks/damage →...

  • Page 258: Checking The Bearings And Oil Seals

    2. Check: faces and crankcase mating surfaces. • Oil seals 4. Apply: Damage/wear → Replace. • Yamaha bond No. 1215 “1” EAS00399 (to the mating surfaces of both crankcase CHECKING THE CRANKCASE halves) 1. Thoroughly wash the crankcase halves in a mild solvent.
  • Page 259 CRANKCASE 11.Install: CAUTION: • Speed sensor Before installing and torquing the crank- case bolts, be sure to check whether the Speed sensor bolts transmission is functioning properly by 10 Nm (1.0 m·kg, 7.2 ft·lb) manually rotating the shift drum in both directions.

  • Page 260: Crankshaft

    CRANKSHAFT EAS00381 CRANKSHAFT Removing the crankshaft and balancer Order Job/Parts to remove Q’ty Remarks Crankcase Separate. Refer to “CRANKCASE” on page 5-60. Balancer Crankshaft For installation, reverse the removal procedure. 5-66...

  • Page 261: Removing The Crankshaft Assembly

    CRANKSHAFT EAS00388 3. Measure: REMOVING THE CRANKSHAFT • Crankshaft runout “c” ASSEMBLY Out of specification → Replace the crank- 1. Remove: shaft, bearing or both. • Crankshaft “1” NOTE: NOTE: Turn the crankshaft slowly. • Remove the crankshaft with the crankcase separating tool “2”.

  • Page 262: Installing The Crankshaft

    CRANKSHAFT EAS00408 INSTALLING THE CRANKSHAFT 1. Install: • Crankshaft “1” NOTE: Install the crankshaft with the crankshaft in- staller pot, crankshaft installer bolt, adapter and spacer (crankshaft installer). Crankshaft installer pot “2” 90890-01274 Crankshaft installer bolt “3” 90890-01275 Adapter “4” 90890-04130 Spacer (crankshaft installer) “5”...

  • Page 263: Transmission

    TRANSMISSION EAS00419 TRANSMISSION Removing the transmission, shift drum, and shift forks Order Job/Parts to remove Q’ty Remarks Crankcase Separate. Refer to “CRANKCASE” on page 5-60. Shift fork “C” Shift fork “R” Shift fork “L” Shift drum Main axle assembly Spacer Drive axle assembly For installation, reverse the removal procedure.
  • Page 264 TRANSMISSION Disassembling the main axle Order Job/Parts to remove Q’ty Remarks Circlip pinion gear Toothed lock washer Toothed washer retainer pinion gear Toothed spacer Toothed washer Refer to “ASSEMBLY THE MAIN AXLE AND DRIVE AXLE” on page 5-73. Circlip pinion gear pinion gear Main axle/1 pinion gear...
  • Page 265 TRANSMISSION Disassembling the drive axle Order Job/Parts to remove Q’ty Remarks Circlip Washer Refer to “ASSEMBLY THE MAIN AXLE AND DRIVE AXLE” on page 5-73. wheel gear wheel gear Circlip Toothed washer wheel gear wheel gear wheel gear Drive axle O-ring For assembly, reverse the disassembly procedure.

  • Page 266: Checking The Shift Forks

    TRANSMISSION EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: • Shift fork cam follower “1” • Shift fork pawl “2” Bends/damage/scoring/wear → Replace the shift fork. EAS00425 CHECKING THE TRANSMISSION 1. Measure: •...

  • Page 267: Assembling The Main Axle And Drive Axle

    TRANSMISSION 3. Check: • Transmission gears Blue discoloration/pitting/wear → Replace the defective gear(s). • Transmission gear dogs Cracks/damage/rounded edges → Replace the defective gear(s). 4. Check: • Transmission gear engagement (each pinion gear to its respective wheel gear) INSTALLING THE TRANSMISSION Incorrect →...
  • Page 268 TRANSMISSION 2. Check: • Shift operation Unsmooth operation → Repair. NOTE: • Apply engine oil to each gear and bearing thoroughly. • Before assembling the crankcase, make sure that the transmission is in neutral and that the gears turn freely. 5-74...

  • Page 269: Cooling System

    COOLING SYSTEM RADIATOR ..................... 6-1 CHECKING THE RADIATOR ..............6-2 INSTALLING THE RADIATOR ..............6-2 THERMOSTAT....................6-4 CHECKING THE THERMOSTAT ............. 6-5 INSTALLING THE THERMOSTAT ............6-5 WATER PUMP....................6-7 DISASSEMBLING THE WATER PUMP........... 6-9 CHECKING THE WATER PUMP ............. 6-9 ASSEMBLING THE WATER PUMP............6-10 INSTALLING THE WATER PUMP ............

  • Page 271: Radiator

    RADIATOR EAS00454 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Coolant Drain. Refer to “CHANGING THE COOLANT” on page 3-16. Radiator cover Radiator cap Coolant reservoir cap Coolant reservoir hose Coolant reservoir breather hose Coolant throttle body hose Disconnect.

  • Page 272: Checking The Radiator

    RADIATOR EAS00455 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radi- ator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- 4. Check: head screwdriver. •...
  • Page 273 RADIATOR 4. Measure: • Radiator cap opening pressure Bellow the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-2. 2. Fill: • Cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” on page 3-16.

  • Page 274: Thermostat

    THERMOSTAT EAS00460 THERMOSTAT Removing the thermostat Order Job/Parts to remove Q’ty Remarks Coolant Drain. Refer to “CHANGING THE COOLANT” on page 3-16. Coolant temperature sensor coupler Hose clamp Radiator inlet hose Disconnect. Thermostat cover O-ring Thermostat Coolant temperature sensor Copper washer For installation, reverse the removal procedure.

  • Page 275: Checking The Thermostat

    THERMOSTAT EAS00462 2. Check: CHECKING THE THERMOSTAT • Thermostat cover 1. Check: • Thermostat housing (cylinder head) Cracks/damage → Replace. • Thermostat “1” Does not open at 71-85 °C (159.8-185 °F) → Replace. EAS00466 INSTALLING THE THERMOSTAT 1. Install: • Thermostat “1” •...
  • Page 276 THERMOSTAT 3. Install: • Copper washer • Coolant temperature sensor Coolant temperature sensor 18 Nm (1.8 m·kg, 13 ft·lb) CAUTION: Use extreme care when handling the cool- ant temperature sensor. Replace the sen- sor if it is dropped or subjected to a strong impact.
  • Page 277 WATER PUMP EAS00468 WATER PUMP Removing the water pump Order Job/Parts to remove Q’ty Remarks NOTE: It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil. Coolant Drain. Refer to “CHANGING THE COOLANT”...
  • Page 278 WATER PUMP Disassembling the water pump Order Job/Parts to remove Q’ty Remarks Circlip Impeller shaft gear Washer Impeller shaft assembly Water pump seal Oil seal Bearing O-ring Water pump housing For assembly, reverse the disassembly procedure.

  • Page 279: Water Pump

    WATER PUMP EAS00470 DISASSEMBLING THE WATER PUMP 1. Remove: • Water pump seal “1” NOTE: Tap out the water pump seal from water pump housing in the direction of the arrow shown. 2. Water pump housing EAS00474 CHECKING THE WATER PUMP 1.

  • Page 280: Assembling The Water Pump

    Out of specification → Repeat steps (3) and tools. (4). • Before installing the water pump, apply Yamaha bond No.1215 “2” to the water pump CAUTION: housing “3”. Make sure the rubber damper and rubber damper holder are flush with the impeller.

  • Page 281: Installing The Water Pump

    WATER PUMP NOTE: 5. Install: • Install the water pump outlet hose so that it • Impeller shaft assembly “1” contacts the projection “a” on the water jacket • Washer joint. • Pin • Before installing the water pump outlet pipe, •...
  • Page 282 WATER PUMP 6. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-2. 6-12...
  • Page 283 FUEL INJECTION SYSTEM FUEL TANK ....................7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP..............7-2 INSTALLING THE FUEL PUMP ............... 7-3 INSTALLING THE FUEL HOSE..............7-3 CHECKING THE FUEL SENDER ............7-3 THROTTLE BODY ASSEMBLY ..............7-4 CHECKING THE FUEL INJECTOR............
  • Page 285 FUEL TANK FUEL TANK Removing the fuel tank and fuel pump Order Job/Parts to remove Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel Drain. Headlight panel (right and left) Turn signal light coupler Disconnect. Fuel tank panel (right and left) Fuel pump coupler Disconnect.

  • Page 286: Fuel Tank

    FUEL TANK REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Seat Refer to “GENERAL CHASSIS” on page 4-1. • Bolts “1” • Panels “2” (right and left) EC5YU1029 CAUTION: Although the fuel has been removed from...

  • Page 287: Installing The Fuel Pump

    FUEL TANK INSTALLING THE FUEL PUMP 1. Install: • Fuel pump NOTE: • Do not damage the installation surfaces of the fuel tank when installing the fuel pump. • Always use a new fuel pump gasket. • Align the projection “A” on the fuel pump with the slot in the fuel pump bracket.

  • Page 288: Throttle Body Assembly

    THROTTLE BODY ASSEMBLY THROTTLE BODY ASSEMBLY Removing the throttle body assembly Order Job/Parts to remove Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 4-5. Coolant Drain.
  • Page 289 THROTTLE BODY ASSEMBLY Removing the throttle body assembly Order Job/Parts to remove Q’ty Remarks Throttle body joint clamp Throttle body joint For installation, reverse the removal procedure.
  • Page 290 THROTTLE BODY ASSEMBLY Disassembling the throttle body assembly Order Job/Parts to remove Q’ty Remarks Throttle position sensor Fuel injection pipe Fuel injector Refer to “AIR FILTER CASE” on page 4-5. Throttle body CAUTION: Do not disassemble the throttle body. For assembly, reverse the disassembly procedure.

  • Page 291: Checking The Fuel Injector

    THROTTLE BODY ASSEMBLY EAS00912 b. Blow out all of the passages with com- CHECKING THE FUEL INJECTOR pressed air. 1. Check: • Fuel injector Damage → Replace. INSTALLING THE THROTTLE BODY ASSEMBLY 2. Check: • Fuel injector resistance 1. Install: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 292: Checking The Fuel Pump

    THROTTLE BODY ASSEMBLY ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 3. Install: • Throttle body assembly a. Fill the fuel tank. b. Put the end of the fuel hose into an open NOTE: container. Align the projection “a” on the throttle body as- c. Connect a battery (DC 12 V) to the fuel sembly with the slot “b”...

  • Page 293: Checking The Throttle Position Sensor

    THROTTLE BODY ASSEMBLY d. Connect the fuel pump coupler “4” and fuel • Tester positive lead → blue “1” sender coupler “5” to the fuel pump. • Tester negative lead → black/blue “2” Refer to “FUEL TANK” on page 7-1. e.
  • Page 294 THROTTLE BODY ASSEMBLY c. Turn the main switch to “ON”. d. Measure the throttle position sensor voltage. e. Adjust the throttle position sensor angle so that the voltage is within the specified range. Output voltage (at idle) 0.63-0.73 V f. After adjusting the throttle position sensor angle, tighten the throttle position sensor screws “3”...

  • Page 295: Air Induction System

    AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM EAS00917 AIR CUT-OFF VALVE EAS00507 The air cut-off valve is controlled by the signals AIR INJECTION from the ECU in accordance with the combus- The air induction system burns unburned ex- tion conditions. Ordinarily, the air cut-off valve haust gases by injecting fresh air (secondary opens to allow the air to flow during idle and air) into the exhaust port, reducing the emission...

  • Page 296: Air Induction System Diagrams

    AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1. Air filter case 2. Reed valve 3. Air cut-off valve 4. Exhaust port 7-12...

  • Page 297: Air Cut-Off Valve Assembly

    AIR INDUCTION SYSTEM AIR CUT-OFF VALVE ASSEMBLY Removing the air cut-off valve assembly Order Job/Parts to remove Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Air induction system solenoid coupler Disconnect.
  • Page 298 AIR INDUCTION SYSTEM Disassembling the air cut-off valve assembly Order Job/Parts to remove Q’ty Remarks Air cut-off valve cover Reed valve assembly Air cut-off valve For assembly, reverse the disassembly procedure. 7-14...

  • Page 299: Checking The Air Induction System

    AIR INDUCTION SYSTEM EAS00918 CHECKING THE AIR INDUCTION SYSTEM 1. Check: • Hoses Loose connections → Connect properly. Cracks/damage → Replace. • Pipe Cracks/damage → Replace. Refer to “CYLINDER HEAD” on page 5-8. 2. Check: • Reed valve • Reed valve stopper •...
  • Page 300 FUEL INJECTION SYSTEM EAS00895 FUEL INJECTION SYSTEM 1. Fuel tank 12. Catalytic converter 2. Engine trouble warning light 13. Fuel injection system relay 3. Ignition coil 14. Battery 4. Spark plug 15. Intake air temperature sensor 5. Fuel pump 16. Coolant temperature sensor 6.

  • Page 301: Fuel Injection System

    FUEL INJECTION SYSTEM WIRING DIAGRAM 7-17...
  • Page 302 FUEL INJECTION SYSTEM 1. Crankshaft position sensor 3. Neutral switch 4. Main switch 7. Battery 8. Main fuse 12. Relay unit 14. Fuel injection system relay 16. Ignition coil 17. Spark plug 18. Fuel injector 19. O 2 sensor 20. Air induction system solenoid 21.

  • Page 303: Ecu's Self-Diagnostic Function

    FUEL INJECTION SYSTEM ECU’S SELF-DIAGNOSTIC FUNCTION • To inform the rider that the fuel injection sys- tem is not functioning correctly, the engine The ECU is equipped with a self-diagnostic trouble warning light flashes when the start function in order to ensure that the engine con- switch is being pushed to start the engine.

  • Page 304: Self-Diagnostic Function Table

    FUEL INJECTION SYSTEM EAS27380 SELF-DIAGNOSTIC FUNCTION TABLE If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate for the type of malfunction.
  • Page 305 FUEL INJECTION SYSTEM Fault Item Symptom Fail-safe action Startability Driveability code No. Vehicle system Power supply to the fuel power supply injection system relay is not — (monitor voltage) normal. ECU internal Faulty ECU memory. When malfunction this malfunction is detected, —...

  • Page 306: Troubleshooting Chart

    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 comes on. The engine trouble warning light does not come on.

  • Page 307: Diagnostic Mode

    FUEL INJECTION SYSTEM HAS00905 DIAGNOSTIC MODE It is possible to monitor the sensor output data FI Diagnostic Tool or check the activation of actuators with the FI 1600rpm 35ßC diagnostic tool connected to the vehicle and set to the normal mode or the diagnostic monitor- ing mode.
  • Page 308 FUEL INJECTION SYSTEM NOTE: • “DIAG” appears on the LCD of the FI diag- nostic tool. • “POWER” LED (Green) comes on. 4. Press the “UP” button to select the CO ad- justment mode “CO” or the diagnostic mode “DIAG”. 5.
  • Page 309 FUEL INJECTION SYSTEM EAS00906 Diagnostic monitoring code table Fault Symptom Probable cause of malfunction Diagnostic code code No . No normal signals are received from • Open or short circuit in wire harness the crankshaft position sensor. • Defective crankshaft position sensor •...
  • Page 310 FUEL INJECTION SYSTEM Fault Symptom Probable cause of malfunction Diagnostic code code No . Open circuit is detected in the • Open circuit in wire harness primary lead of the ignition coil. • Malfunction in ignition coil • Malfunction in ECU cut-off •...
  • Page 311 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: • Check the intake air temperature and coolant temperature as close as possible to the intake air tem- perature sensor and the coolant temperature sensor respectively.
  • Page 312 FUEL INJECTION SYSTEM Data displayed on the Diagnostic Item Action FI diagnostic tool (reference value) code Radiator fan motor relay The engine stop switch is set to “ “, the radiator Check that the operating sound of the fan motor relay operates 5 times, 5 seconds each radiator fan motor relay is generated time (2 seconds on, 3 seconds off), and the engine and that the radiator fan motor is...

  • Page 313: Troubleshooting Details

    FUEL INJECTION SYSTEM TROUBLESHOOTING DETAILS This section describes the countermeasures per fault code number displayed on the FI diagnostic tool. Check and service the items or components that are the probable cause of the malfunction fol- lowing the order given. After the check and service of the malfunctioning part has been completed, reset the FI diagnostic tool display according to the “Reinstatement method”.
  • Page 314 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit is detected from the intake air pressure sensor. Used diagnostic code No. 03 (intake air pressure sensor) Order Item/components Check or maintenance job Restore method Coupler connections Check the couplers for any pins that may have Reinstated by crank- Intake air pressure sensor coupler pulled out.
  • Page 315 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor hose is disconnected or clogged. Used diagnostic code No. 03 (intake air pressure sensor) Order Item/components Check or maintenance job Restore method Disconnected, clogged, kinked, or Repair or replace the hose. Reinstated by start- pinched intake air pressure sensor ing the engine and...
  • Page 316 FUEL INJECTION SYSTEM Fault code No. Symptom The throttle position sensor is detected stuck. Used diagnostic code No. 01 (throttle position sensor) Order Item/components Check or maintenance job Restore method Defective throttle position sensor Replace the sensor if it is defective. Reinstated by start- Refer to “THROTTLE BODY ASSEMBLY”.
  • Page 317 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit is detected from the intake air temperature sensor. Used diagnostic code No. 05 (intake air temperature sensor) Order Item/components Check or maintenance job Restore method Intake air temperature sensor Check the sensor looseness or pinching.
  • Page 318 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signal is received from the O 2 sensor. Used diagnostic code No. – – Order Item/components Check or maintenance job Restore method Installed condition of O sensor. Check the installed area for looseness or pinching. Starting the engine , warming it up until Connected state of connector...
  • Page 319 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary lead of the ignition coil. Used diagnostic code No. 30 (ignition coil) Order Item/components Check or maintenance job Restore method Coupler and connector connections Check the coupler and connector for any pins Reinstated by start- Ignition coil primary connector that may have pulled out.
  • Page 320 FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the speed sensor. B. Open or short circuit is detected in the neutral switch. → → Used diagnostic code No. 07 (speed sensor) A1 ~ A4 / No. 21 (neutral switch) B1 ~ B4 Order Item/components...
  • Page 321 FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the speed sensor. B. Open or short circuit is detected in the neutral switch. → → Used diagnostic code No. 07 (speed sensor) A1 ~ A4 / No. 21 (neutral switch) B1 ~ B4 Order Item/components...
  • Page 322 FUEL INJECTION SYSTEM Fault code No. Symptom The ECU is unable to monitor the battery voltage. Used diagnostic code No. 09, 50 (fuel system voltage) Order Item/components Check or maintenance job Restore method Coupler connections Check the couplers for any pins that may have Reinstated by start- Fuel injection system relay cou- pulled out.
  • Page 323 FUEL INJECTION SYSTEM Fault code No. Symptom Error is detected while reading or writing on EEPROM (CO adjustment value). Used diagnostic code No. 60 (EEPROM improper cylinder indication) Order Item/components Check or maintenance job Restore method Malfunction in ECU Execute the diagnostic mode. (Code No. 60) Reinstated by set- •...

  • Page 325: Electrical System

    ELECTRICAL SYSTEM IGNITION SYSTEM..................8-1 CIRCUIT DIAGRAM ................. 8-1 TROUBLESHOOTING ................8-3 ELECTRIC STARTING SYSTEM ..............8-5 CIRCUIT DIAGRAM ................. 8-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......8-7 TROUBLESHOOTING ................8-9 CHARGING SYSTEM..................8-11 CIRCUIT DIAGRAM ................. 8-11 TROUBLESHOOTING ................8-13 LIGHTING SYSTEM..................8-15 CIRCUIT DIAGRAM .................8-15 TROUBLESHOOTING ................8-17...
  • Page 326 CHECKING THE COOLANT TEMPERATURE SENSOR......8-57 CHECKING THE FUEL SENDER ............8-58 CHECKING THE SPEED SENSOR............8-58 CHECKING THE THROTTLE POSITION SENSOR........8-59 CHECKING THE FUEL PUMP..............8-59 CHECKING THE INTAKE AIR PRESSURE SENSOR ......8-60 CHECKING THE INTAKE AIR TEMPERATURE SENSOR .....8-60 CHECKING THE RADIATOR FAN MOTOR ..........8-60 CHECKING THE STARTER MOTOR ............8-61...

  • Page 327: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
  • Page 328 IGNITION SYSTEM 1. Crankshaft position sensor 3. Neutral switch 4. Main switch 7. Battery 8. Main fuse 13. Starting circuit cut-off relay 16. Ignition coil 17. Spark plug 23. ECU 27. Lean angle cut-off switch 39. Sidestand switch 42. Engine stop switch 46.

  • Page 329: Troubleshooting

    IGNITION SYSTEM EAS27150 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Side panels (left and right) 3. Fuel tank 1. Check the fuses. (Main and ignition) Replace the fuse(s).
  • Page 330 IGNITION SYSTEM 8. Check the main switch. Refer to “CHECKING THE Replace the main switch/immobilizer unit. SWITCHES” on page 8-43. 9. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 8-43. 10.Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch.

  • Page 331: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
  • Page 332 ELECTRIC STARTING SYSTEM 3. Neutral switch 4. Main switch 7. Battery 8. Main fuse 9. Starter relay 10. Starter motor 12. Relay unit 13. Starting circuit cut-off relay 39. Sidestand switch 41. Start switch 42. Engine stop switch 46. Clutch switch 67.

  • Page 333: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “I” and the main switch is turned “ON” (both switch circuits are closed), the starter motor can only operate if at least one of the following conditions is met: •...
  • Page 334 ELECTRIC STARTING SYSTEM å WHEN THE TRANSMISSION IS IN NEUTRAL ∫ WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6.

  • Page 335: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Side panels (left and right) 3. Fuel tank 1. Check the fuses. (Main and ignition) Replace the fuse(s). Refer to “CHECKING THE FUSES”...
  • Page 336 ELECTRIC STARTING SYSTEM 8. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 8-43. 9. Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch. SWITCHES” on page 8-43. 10. Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch.

  • Page 337: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-11...
  • Page 338 CHARGING SYSTEM 2. A.C. magneto 5. Rectifier/regulator 7. Battery 8. Main fuse 8-12...

  • Page 339: Troubleshooting

    CHARGING SYSTEM EAS27220 TROUBLESHOOTING The battery is not being charged. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Side panels (left and right) 3. Fuel tank 1. Check the fuses. (Main) Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 8-48.
  • Page 340 CHARGING SYSTEM 8-14...

  • Page 341: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-15...
  • Page 342 LIGHTING SYSTEM 4. Main switch 7. Battery 8. Main fuse 23. ECU 33. High beam indicator light 44. Headlight relay 49. Dimmer switch 50. Pass switch 57. Headlight 59. Tail/brake light 64. Parking lighting fuse 65. Headlight fuse 8-16...

  • Page 343: Troubleshooting

    LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight (high beam), headlight (low beam), high beam indicator light, taillight, license plate light, auxiliary light or meter light. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2.
  • Page 344 LIGHTING SYSTEM 8. Check the high beam indicator light LED. Refer to “CHECKING Replace the meter assembly. THE LEDS” on page 8-47. 9. Check the meter light LED. Refer to “CHECKING THE LEDS” Replace the meter assembly. on page 8-47. 10.

  • Page 345: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-19...
  • Page 346 SIGNALING SYSTEM 3. Neutral switch 4. Main switch 7. Battery 8. Main fuse 12. Relay unit 22. Coolant temperature sensor 23. ECU 24. Speed sensor 29. Neutral indicator light 30. Multi-function meter 31. Fuel meter 32. Turn signal indicator light 34.

  • Page 347: Troubleshooting

    SIGNALING SYSTEM EAS27290 TROUBLESHOOTING Any of the following fail to light: turn signal light, brake light or indicator light. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Side panels (left and right) 3. Fuel tank 4. Headlight assembly 1.
  • Page 348 SIGNALING SYSTEM 3. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 8-19. The circuit is OK. The tail/brake light fails to come on. 1. Check the front brake light switch. Refer to “CHECKING THE Replace the front brake light switch.
  • Page 349 SIGNALING SYSTEM 5. Check the turn signal/hazard relay. Refer to “CHECKING THE Replace the turn signal/hazard relay. TURN SIGNAL/HAZARD RELAY” on page 8-53. 6. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” system wiring.
  • Page 350 SIGNALING SYSTEM 2. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” system wiring. on page 8-19. Replace the meter assembly. The speedometer fails to operate. 1. Check the speed sensor. Refer to “CHECKING THE Replace the speed sensor.

  • Page 351: Cooling System

    COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM 8-25...
  • Page 352 COOLING SYSTEM 4. Main switch 7. Battery 8. Main fuse 23. ECU 62. Radiator fan motor 63. Radiator fan motor relay 67. Ignition fuse 68. Radiator fan motor fuse 8-26...

  • Page 353: Troubleshooting

    COOLING SYSTEM EAS27570 TROUBLESHOOTING If the radiator fan motor fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Side panels (left and right) 3. Fuel tank 1. Check the fuses. (Main, radiator fan motor and ignition).
  • Page 354 COOLING SYSTEM 8-28...

  • Page 355: Immobilizer System

    IMMOBILIZER SYSTEM ET5YU1002 IMMOBILIZER SYSTEM ET5YU1003 CIRCUIT DIAGRAM 8-29...
  • Page 356 IMMOBILIZER SYSTEM 4. Main switch 7. Battery 8. Main fuse 23. ECU 28. Multi-function meter unit 35. Immobilizer system indicator light 67. Ignition fuse 69. Backup fuse (immobilizer unit, multi-function meter unit) 71. Anti-theft alarm (optional) 72. Immobilizer unit 8-30...

  • Page 357: General Information

    IMMOBILIZER SYSTEM EAS27670 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) that can be re-registered with new codes •...
  • Page 358 IMMOBILIZER SYSTEM Parts to be replaced Main switch/immo- Key registration Accesso- bilizer unit Standard requirement ry lock* Main Immobiliz- and key switch er unit √ Standard key is lost New standard key All keys have been Code re-registering √ √ √...
  • Page 359 IMMOBILIZER SYSTEM Standby mode a. Main switch “ON” d. LED off b. Main switch “OFF” e. Standby mode on c. LED on f. Standby mode off Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced.
  • Page 360 IMMOBILIZER SYSTEM Standard key registration a. Main switch “ON” g. First standard key b. Main switch “OFF” h. Second standard key c. LED on i. Registration mode d. LED off A. Registration of the second standard key is e. Less than 5.0 s complete.

  • Page 361: Troubleshooting

    IMMOBILIZER SYSTEM EAS27700 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Side panels (left and right) 3. Fuel tank 1.

  • Page 362: Self-Diagnosis Fault Code Indication

    IMMOBILIZER SYSTEM EAS27720 SELF-DIAGNOSIS FAULT CODE INDICATION When a system malfunction occurs, the fault code number is signaled by the immobilizer system in- dicator light. Fault Part Symptom Cause Action code IMMOBILIZER Code cannot be 1. Radio wave 1. Keep magnets, UNIT transmitted between interference caused...
  • Page 363 IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code IMMOBILIZER Key code Same standard key Register another UNIT registration was attempted to be standard key. malfunction. registered two consecutive times. Unidentified code Noise interference 1. Check the wire is received. or disconnected harness and lead/cable.
  • Page 364 IMMOBILIZER SYSTEM 8-38...

  • Page 365: Electrical Components

    ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 8-39...
  • Page 366 ELECTRICAL COMPONENTS 1. Throttle position sensor 2. Coolant temperature sensor 3. Fuel injector 4. Fuel pump 5. Starter relay 6. Main fuse 7. ECU (Electronic Control Unit) 8. Turn signal/hazard relay 9. Headlight relay 10. Radiator fan motor relay 11. Relay unit 12.
  • Page 367 ELECTRICAL COMPONENTS 8-41...
  • Page 368 ELECTRICAL COMPONENTS 1. Air induction system solenoid 2. Main switch 3. Immobilizer unit 4. Right handlebar switch 5. Front brake light switch 6. Left handlebar switch 7. Clutch switch 8. Spark plug 9. Plug cap 10. Ignition coil 11. Intake air pressure sensor 12.

  • Page 369: Checking The Switches

    ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 8-43...
  • Page 370 ELECTRICAL COMPONENTS 1. Main switch 2. Clutch switch 3. Horn switch 4. Pass switch 5. Dimmer switch 6. Turn signal switch 7. Hazard switch 8. Sidestand switch 9. Front brake light switch 10. Engine stop switch 11. Start switch 12. Neutral switch 13.
  • Page 371 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

  • Page 372: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS EAS27990 1. Remove: CHECKING THE BULBS AND BULB • Bulb SOCKETS WARNING NOTE: Since headlight bulbs get extremely hot, Do not check any of the lights that use LEDs. keep flammable products and your hands away from them until they have cooled Check each bulb and bulb socket for damage down.

  • Page 373: Checking The Leds

    ELECTRICAL COMPONENTS Checking the condition of the bulb sockets Positive battery The following procedure applies to all of the → Turn signal terminal chocolate bulb sockets. indicator light (left) Negative battery 1. Check: → terminal black/white • Bulb socket (for continuity) Positive battery (with the pocket tester) →...

  • Page 374: Checking The Fuses

    ELECTRICAL COMPONENTS Immobilizer system indicator LED 1. Remove: Connect the pocket tester (kΩ x 1) to the • Seat meter coupler. 2. Check: • Fuse Positive tester probe → ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ black/white a. Connect the pocket tester to the fuse and Continuity Negative tester probe →...

  • Page 375: Checking And Charging The Battery

    ELECTRICAL COMPONENTS ECA13660 WARNING CAUTION: Never use a fuse with an amperage rating • This is a sealed battery. Never remove the other than that specified. Improvising or sealing caps because the balance be- using a fuse with the wrong amperage rat- tween cells will not be maintained and bat- ing may cause extensive damage to the tery performance will deteriorate.
  • Page 376 ELECTRICAL COMPONENTS 3. Remove: • To reduce the chance of sparks, do not • Battery plug in the battery charger until the battery 4. Check: charger leads are connected to the bat- • Battery charge tery. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Before removing the battery charger lead a.

  • Page 377: Checking The Relays

    ELECTRICAL COMPONENTS • Standard charging current is reached 12.8 V or more --- Charging is complete. Battery is good. 12.7 V or less --- Recharging is required. • Standard charging current is not reached Under 12.0 V --- Replace the battery. Replace the battery.
  • Page 378 ELECTRICAL COMPONENTS Fuel injection system relay Pocket tester 90890-03112 1. Disconnect the relay from the wire harness. 2. Connect the pocket tester (Ω x 1) and bat- tery (12 V) to the relay terminal as shown. Check the relay operation. Out of specification →...

  • Page 379: Checking The Turn Signal/Hazard Relay

    ELECTRICAL COMPONENTS b. Turn the main switch to “ON”. Radiator fan motor relay c. Measure the turn signal/hazard relay input voltage. 2. Check: • Turn signal/hazard relay output voltage Out of specification → Replace. Turn signal/hazard relay output voltage DC 12 V 1.

  • Page 380: Checking The Spark Plug Cap

    ELECTRICAL COMPONENTS EAS28070 Continuity CHECKING THE SPARK PLUG CAP Positive tester probe → 1. Check: sky blue “1” • Spark plug cap resistance Negative tester probe → Out of specification → Replace. black/yellow “2” No continuity Positive tester probe → Resistance black/yellow “2”...

  • Page 381: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS Minimum ignition spark gap 6.0 mm (0.24 in) NOTE: If the ignition spark gap is within specification, the ignition system circuit is operating normally. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the spark plug cap “2” from the spark plug. c. Measure the primary coil resistance. b.

  • Page 382: Checking The Lean Angle Cut-Off Switch

    ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω x 100) to the crankshaft position sensor coupler as shown. Pocket tester 90890-03112 • Positive tester probe → blue/yellow “1” • Negative tester probe → green/white “2” c. Turn the lean angle cut-off switch to 65°. d.

  • Page 383: Checking The Horn

    ELECTRICAL COMPONENTS EAS28180 3. Check: CHECKING THE HORN • Horn sound 1. Check: Faulty sound → Replace the horn. • Horn resistance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Out of specification →Replace. a. Disconnect the horn leads from the horn ter- minals. Coil resistance b. Connect a battery (12 V) to the horn termi- 1.15–1.25 Ω...

  • Page 384: Checking The Fuel Sender

    ELECTRICAL COMPONENTS NOTE: • Positive tester probe → green/white “1” Make sure that the coolant temperature sensor • Negative tester probe → black “2” terminals do not get wet. c. Place a thermometer “3” in the water. d. Slowly heat the water, then let it cool down to the specified temperature.

  • Page 385: Checking The Throttle Position Sensor

    ELECTRICAL COMPONENTS EAS28300 • Stop the engine before refueling. CHECKING THE THROTTLE POSITION • Do not smoke, and keep away from open SENSOR flames, sparks, or any other source of fire. 1. Remove: • If you do accidentally spill gasoline, wipe it •...

  • Page 386: Checking The Intake Air Pressure Sensor

    ELECTRICAL COMPONENTS EAS28410 Intake air temperature sensor CHECKING THE INTAKE AIR PRESSURE resistance SENSOR 2.21-2.69 Ω at 20 °C (68 °F) 1. Check: • Intake air pressure sensor output voltage ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Out of specification → Replace. a. Connect the pocket tester (Ω x 100) to the intake air temperature sensor terminal as shown.

  • Page 387: Checking The Starter Motor

    ELECTRICAL COMPONENTS CHECKING THE STARTER MOTOR 1. Check: • Starter motor ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the positive battery terminal “1” and starter motor lead “2” with a jumper lead “3”. WARNING • A wire that is used as a jumper lead must have at least the same capacity or more as that of the battery lead, otherwise the jumper lead may burn.

  • Page 389: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING..................9-1 GENERAL INFORMATION ..............9-1 STARTING FAILURES ................9-1 INCORRECT ENGINE IDLING SPEED ........... 9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE......9-2 FAULTY GEAR SHIFTING ............... 9-2 FAULTY CLUTCH..................9-2 OVERHEATING..................9-3 OVERCOOLING..................9-3 POOR BRAKING PERFORMANCE............9-3 FAULTY FRONT FORK LEGS ..............9-3 UNSTABLE HANDLING ................

  • Page 391: Troubleshooting

    TROUBLESHOOTING EAS28450 Electrical system TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) NOTE: • Blown, damaged or incorrect fuse • Improperly installed fuse The following guide for troubleshooting does 3. Spark plug not cover all the possible causes of trouble. It •...

  • Page 392: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING Electrical system EAS28550 JUMPS OUT OF GEAR 1. Battery • Discharged battery Shift shaft • Faulty battery • Incorrect shift pedal position 2. Spark plug • Improperly returned stopper lever • Incorrect spark plug gap • Incorrect spark plug heat range Shift forks •...

  • Page 393: Overheating

    TROUBLESHOOTING EAS28590 EAS28620 OVERHEATING POOR BRAKING PERFORMANCE • Worn brake pad Engine • Worn brake disc 1. Clogged coolant passages • Air in hydraulic brake system 2. Cylinder head and piston • Leaking brake fluid • Heavy carbon buildup • Faulty brake caliper seal 3.

  • Page 394: Faulty Lighting Or Signaling System

    TROUBLESHOOTING 4. Swingarm Turn signal does not come on • Faulty turn signal switch • Worn bearing or bushing • Bent or damaged swingarm • Faulty turn signal/hazard relay • Burnt-out turn signal bulb 5. Rear shock absorber assembly • Faulty rear shock absorber spring •...
  • Page 395 WIRING DIAGRAM 37. Engine trouble warning light 38. Fuel pump XT660Z 2008 39. Sidestand switch 1. Crankshaft position sensor 40. Front brake light switch 2. A.C. magneto 41. Start switch 3. Neutral switch 42. Engine stop switch 4. Main switch 43.
  • Page 396 COLOR CODE...
  • Page 398 YAMAHA MOTOR ITALIA S.P.A.
  • Page 399 XT660Z 2008 WIRING DIAGRAM...

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