null User manual

null  User manual
2004
XT660R(S)
XT660X(S)
5VK1-AE1
SERVICE MANUAL
EAS00000
XT660R(S)/XT660X(S) 2004
SERVICE MANUAL
©2003 by MBK Industrie
First edition, December 2003
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
MBK Industrie
is expressly prohibited.
EAS00002
NOTICE
This manual was produced by MBK Industrie primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should
have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the
vehicle unsafe and unfit for use.
Yamaha is continually striving to improve all its models. Modifications and significant changes in
specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in
future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
_
EAS00004
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or death
to the motorcycle operator, a bystander or a person checking or repairing
the motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
EAS00007
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are
laid out with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter.
Refer to “SYMBOLS”.
2 Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section
title(s) appears.
3 Sub-section titles appear in smaller print than the section title.
4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6 Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8 Jobs requiring more information (such as special tools and technical data) are described sequentially.
1
EAS00008
2
GEN
INFO
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.
SPEC
3
4
CHK
ADJ
1 General information
2 Specifications
3 Periodic checks and adjustments
4 Chassis
5 Engine
6 Cooling system
7 Fuel injection system
8 Electrical system
9 Troubleshooting
CHAS
5
6
ENG
COOL
7
8
FI
–
ELEC
9
Symbols 0 to G indicate the following.
0
0 Serviceable with engine mounted
A Filling fluid
B Lubricant
C Special tool
D Tightening torque
E Wear limit, clearance
F Engine speed
G Electrical data
TRBL
SHTG
A
B
C
D
+
T.
R.
E
F
G
H
I
J
G
E
K
M
L
B
M
M
LS
N
Symbols H to M in the exploded diagrams
indicate the types of lubricants and lubrication
points.
Symbols N to O in the exploded diagrams
indicate the following.
O
LT
H Engine oil
I Gear oil
J Molybdenum-disulfide oil
K Wheel-bearing grease
L Lithium-soap-based grease
M Molybdenum-disulfide grease
New
N Apply locking agent (LOCTITE®)
O Replace the part
EAS00010
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
COOLING SYSTEM
FUEL INJECTION SYSTEM
GEN
INFO
1
SPEC
2
CHK
ADJ
3
CHAS
4
ENG
5
COOL
6
FI
7
–
ELECTRICAL SYSTEM
TROUBLESHOOTING
+
ELEC
8
TRBL
SHTG
9
GEN
INFO
1
GEN
INFO
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION..................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL.......................................................................................... 1-1
FEATURES...................................................................................................... 1-2
OUTLINE ...................................................................................................1-2
FI SYSTEM................................................................................................1-3
IMPORTANT INFORMATION ......................................................................... 1-4
PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-4
REPLACEMENT PARTS...........................................................................1-4
GASKETS, OIL SEALS AND O-RINGS .................................................... 1-4
LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-5
BEARINGS AND OIL SEALS .................................................................... 1-5
CIRCLIPS ..................................................................................................1-5
CHECKING THE CONNECTIONS ..................................................................1-6
SPECIAL TOOLS ............................................................................................ 1-7
GEN
INFO
MOTORCYCLE IDENTIFICATION
GEN
INFO
EAS00014
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is
stamped into the right side of the steering head
pipe.
EAS00018
MODEL LABEL
The model label 1 is affixed to the frame. This
information will be needed to order spare
parts.
1-1
FEATURES
GEN
INFO
EAS00019
FEATURES
EAS00896
OUTLINE
The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In a conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the
combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet
used in the respective chamber.
Despite the same volume of intake air, the fuel volume requirement varies with the engine operating
conditions, such as acceleration, deceleration, or operation under a heavy load. Carburetors that
meter the fuel through the use of jets have been provided with various auxiliary devices, so that an
optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine.
As the requirements for engines to deliver more performance and cleaner exhaust gases increase,
it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To
accommodate this need, this model has adopted an electronically controlled fuel injection (FI) system in place of a conventional carburetor system. This system can achieve an optimum air-fuel ratio
required by the engine at all times by using a microprocessor that regulates the fuel injection volume
according to the engine operating conditions detected by various sensors.
Adoption of the FI system has resulted in a highly precise fuel supply, improved engine response,
better fuel economy, and reduced exhaust emissions. Furthermore, the air induction system (AI system) has been placed under computer control together with the FI system in order to realize cleaner
exhaust gases.
1
2
3
4
6 7
5
8
9
0
A
K
J
1 Air cut-off valve
2 Air induction system
solenoid
3 Engine trouble warning light
4 Fuel tank
5 Fuel pump
6 Fuel hose
I
H
G
7 Fuel injector
8 Throttle position sensor
9 Intake air temperature
sensor
0 Air filter case
A Fuel injection system
relay
F
E
D
B Battery
C Catalytic converter
D ECU
E Lean angle cut-off
switch
F Fast idle unit
G Crankshaft position
sensor
1-2
C
B
H Coolant temperature
sensor
I Spark plug
J Intake air pressure
sensor
K Ignition coil
FEATURES
GEN
INFO
EAS00897
FI SYSTEM
The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the injector at 324 kPa (3.24 kg/cm2, 46.1 psi) higher than the intake
manifold pressure. Accordingly, when the energizing signal from the ECU energizes the injector, the
fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the
passage remains open. Therefore, the longer the length of time the injector is energized (injection
duration), the greater the volume of fuel that is supplied. Conversely, the shorter the length of time
the injector is energized (injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from
the throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake air temperature sensor, and coolant temperature sensor enable the ECU to determine the injection duration. The injection timing is determined through the signal from the crankshaft position sensor. As a
result, the volume of fuel that is required by the engine can be supplied at all times in accordance
with the driving conditions.
Illustration is for reference only.
2
È
1
#1
É
5
4 7
3
6
8
9
1 Fuel pump
2 Pressure regulator
3 Fuel injector
4 Throttle body
5 Intake air temperature
sensor
6 Throttle position sensor
7 Intake air pressure
sensor
Ê
0
8 ECU
9 Coolant temperature
sensor
0 Crankshaft position
sensor
1-3
È Fuel system
É Air system
Ê Control system
IMPORTANT INFORMATION
GEN
INFO
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to “SPECIAL TOOLS”.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders, pistons and other parts that have been
“mated” through normal wear. Mated parts
must always be reused or replaced as an
assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of disassembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS00021
REPLACEMENT PARTS
Use only genuine Yamaha parts for all
replacements. Use oil and grease recommended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EAS00022
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
1-4
IMPORTANT INFORMATION
GEN
INFO
EAS00023
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
1 and cotter pins. After the bolt or nut has
been tightened to specification, bend the lock
tabs along a flat of the bolt or nut.
EAS00024
BEARINGS AND OIL SEALS
Install bearings and oil seals 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.
1 Oil seal
CAUTION:
_
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
1 Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip 1, make sure the
sharp-edged corner 2 is positioned opposite
the thrust 3 that the circlip receives.
4 Shaft
1-5
CHECKING THE CONNECTIONS
GEN
INFO
EAS00026
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• lead
• coupler
• connector
2. Check:
• lead
• coupler
• connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect several times.
3. Check:
• all connections
Loose connection → Connect properly.
NOTE:
If the pin 1 on the terminal is flattened, bend it
up.
_
4.
•
•
•
Connect:
lead
coupler
connector
NOTE:
Make sure all connections are tight.
_
5. Check:
• continuity
(with the pocket tester)
Pocket tester
90890-03112
NOTE:
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
_
1-6
SPECIAL TOOLS
GEN
INFO
EAS00027
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. 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.
Tool No.
Slide hammer bolt
90890-01083
Weight
90890-01084
Tool name/Function
Slide hammer bolt
Weight
These tools are used to remove or install
the rocker arm shafts.
Crankcase separating tool
90890-01135
This tool is used to remove the crankshaft.
Attachment
90890-01243
Compressor
90890-04019
Valve spring compressor attachment
Valve spring compressor
These tools are used to remove or install
the valve assemblies.
Ring nut wrench
90890-01268
This tool is used to loosen or tighten the
steering ring nuts.
Pot
90890-01274
Bolt
90890-01275
Crankshaft installer pot
Crankshaft installer bolt
These tools are used to install the crankshaft.
Piston pin puller set
90890-01304
This tool is used to remove the piston pin.
Radiator cap tester
90890-01325
This tool is used to check the cooling system.
1-7
Illustration
SPECIAL TOOLS
Tool No.
T-handle
90890-01326
Holder
90890-01460
Tool name/Function
GEN
INFO
Illustration
T-handle
Damper rod holder
These tools are used to hold the damper
rod holder when removing or installing
the damper rod.
Radiator cap tester adaptor
90890-01352
This tool is used to check the cooling system.
Flywheel puller
150
90890-01362
80
60
M8 × 60 mm M8 × 80 mm M8 × 150 mm
M8
M8
This tool is used to remove the A.C. magneto rotor.
Weight
90890-01367
Attachment
90890-01374
Fork seal driver weight
Fork seal driver attachment (ø43)
These tools are used to install the oil
seal, dust seal, and the outer tube bushing of the front fork legs.
Steering nut wrench
90890-01403
This tool is used to loosen or tighten the
steering ring nuts.
Radiator tester adapter
90890-01496
This tool is used to check the cooling system.
Radiator cap tester adapter
90890-01497
This tool is used to check the cooling system.
Sheave holder
90890-01701
This tool is used to hold the A.C. magneto
rotor when loosen or tighten the A.C.
magneto rotor nut.
1-8
M8
SPECIAL TOOLS
Tool No.
Tool name/Function
Thickness gauge
90890-03079
This tool is used to measure the valve
clearance.
Compression gauge
90890-03081
These tools are used to measure the
engine compression.
Pocket tester
90890-03112
This tool is used to check the electrical
system.
Timing light
90890-03141
This tool is used to check the ignition timing.
Pressure gauge
90890-03153
This tool is needed to measure fuel pressure.
Digital circuit tester
90890-03174
This tool is used to check electrical system.
Fuel pressure adapter
90890-03176
This tool is needed to measure fuel pressure.
Driver
90890-04058
Installer
90890-04132
Middle driven shaft bearing driver
Mechanical seal installer
These tools are used to install the
mechanical seal.
1-9
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Valve guide remover (ø 6)
90890-04064
This tool is needed to remove and install
the valve guides.
Valve guide installer (ø 6)
90890-04065
This tool is needed to install the valve
guides.
Valve guide reamer (ø 6)
90890-04066
This tool is needed to rebore the new
valve guides.
Adaptor (Compression gauge)
90890-04082
This tool is needed to measure engine
compression.
Universal clutch holder
90890-04086
This tool is needed to hold the clutch
boss when removing or installing the
boss nut.
Valve lapper
90890-04101
This tool is used for lapping the valve.
Adapter
90890-04130
Spacer
90890-04144
Adapter
Spacer (crankshaft installer)
These tools are used to install the crankshaft.
Ignition checker
90890-06754
This tool is used to check the ignition system components.
1 - 10
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Yamaha bond No. 1215
90890-85505
This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces).
1 - 11
GEN
INFO
Illustration
SPEC
2
SPEC
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................2-2
CHASSIS SPECIFICATIONS ........................................................................2-11
ELECTRICAL SPECIFICATIONS .................................................................2-16
CONVERSION TABLE .................................................................................. 2-19
GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................2-19
TIGHTENING TORQUE................................................................................. 2-20
ENGINE TIGHTENING TORQUE ........................................................... 2-20
CHASSIS TIGHTENING TORQUES.......................................................2-23
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-25
ENGINE................................................................................................... 2-25
CHASSIS.................................................................................................2-27
COOLING SYSTEM DIAGRAMS .................................................................. 2-28
LUBRICATION CHART................................................................................. 2-30
LUBRICATION DIAGRAMS..........................................................................2-31
CABLE ROUTING ......................................................................................... 2-35
SPEC
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Model code
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
Weight
Wet (with oil and a full fuel tank)
Maximum load (total of cargo, rider,
passenger, and accessories)
Standard
Limit
XT660R: 5VK1 (Europe)
5VK2 (AUS)
5VK3 (GB)
XT660X: 1D21 (Europe)
1D22 (AUS)
1D23 (GB)
-------------------
2,240 mm (88.2 in) (XT660R)
2,150 mm (84.6 in) (XT660X)
845 mm (33.3 in) (XT660R)
865 mm (34.1 in) (XT660X)
1,230 mm (48.4 in) (XT660R)
1,210 mm (47.6 in) (XT660X)
865 mm (34.1 in) (XT660R)
870 mm (34.3 in) (XT660X)
1,505 mm (59.3 in) (XT660R)
1,490 mm (58.7 in) (XT660X)
210 mm (8.27 in) (XT660R)
205 mm (8.07 in) (XT660X)
2,400 mm (94.5 in)
----------------------------------------
181 kg (399 lb) (XT660R)
186 kg (410 lb) (XT660X)
186 kg (410 lb)
----------
2-1
ENGINE SPECIFICATIONS
SPEC
ENGINE SPECIFICATIONS
Item
Engine
Engine type
Displacement
Cylinder arrangement
Bore × stroke
Compression ratio
Engine idling speed
Water temperature
Oil temperature
Standard compression pressure
(at sea level)
Fuel
Recommended fuel
Fuel tank capacity
Total (including reserve)
Reserve only
Engine oil
Lubrication system
Recommended oil
-20 -10 0 10 20 30 40 50 ˚C
Standard
Limit
Liquid-cooled, 4-stroke, SOHC
660 cm3 (40.27 cu · in)
Forward-inclined single cylinder
100.0 × 84.0 mm (3.94 × 3.31 in)
10.00 : 1
1,300 ~ 1,500 r/min
80 °C (176 °F)
55 ~ 60 °C (131 ~ 140 °F)
650 kPa (6.5 kg/cm2, 92.4 psi)
at 800 r/min
----------------------------
Premium unleaded gasoline only
----
15.0 L (3.30 Imp gal, 3.96 US gal)
5.0 L (1.10 Imp gal, 1.32 US gal)
-------
Dry sump
----
Refer to the chart for engine oil grade.
API service SE, SF, SG type or higher
----
2.90 L (2.55 Imp qt, 3.07 US qt)
2.50 L (2.20 Imp qt, 2.64 US qt)
2.60 L (2.29 Imp qt, 2.75 US qt)
----------
Paper
40.0 ~ 80.0 kPa
(0.40 ~ 0.80 kg/cm2, 5.8 ~ 11.6 psi)
Oil filter chamber
-------
SAE 10W-30
SAE 10W-40
SAE 15W-40
SAE 20W-40
SAE 20W-50
Quantity
Total amount
Periodic oil change
With oil filter replacement
Oil filter
Oil filter type
Bypass valve opening pressure
Pressure check location
2-2
----
ENGINE SPECIFICATIONS
Item
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip clearance
Outer-rotor-to-oil-pump-housing
clearance
Oil-pump-housing-to-inner-rotor-andouter-rotor clearance
Cooling system
Radiator capacity
Radiator cap opening pressure
Radiator core
Width
Height
Depth
Coolant reservoir
Capacity
<From low to full level>
Water pump
Water pump type
Reduction ratio
Maximum impeller shaft tilt
Starting system type
Fuel injector
Model/manufacturer
Quantity
Spark plug
Model/manufacturer × quantity
Spark plug gap
Cylinder head
Volume
Maximum warpage
SPEC
Standard
Trochoid
0.07 ~ 0.12 mm (0.0028 ~ 0.0047 in)
0.03 ~ 0.08 mm (0.0012 ~ 0.0031 in)
0.03 ~ 0.08 mm (0.0012 ~ 0.0031 in)
Limit
---0.2 mm
(0.008 in)
0.15 mm
(0.0059 in)
0.15 mm
(0.0059 in)
1.00 L (0.88 Imp, 1.06 US qt)
110.0 ~ 140.0 kPa
(1.10 ~ 1.40 kg/cm2, 16.0 ~ 20.3 psi)
-------
280.0 mm (11.02 in)
158.0 mm (6.22 in)
23.0 mm (0.91 in)
----------
0.25 L (0.22 Imp, 0.26 US qt)
0.15 L (0.13 Imp, 0.16 US qt)
-------
Single-suction centrifugal pump
27/28 (0.964)
---Electric starter
------0.15 mm
(0.006 in)
----
297500-0390/DENSO
1
-------
CR7E/NGK × 1
0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
-------
59.10 ~ 60.50 cm3 (3.61 ~ 3.69 cu · in)
----
2-3
---0.03 mm
(0.0012 in)
ENGINE SPECIFICATIONS
Item
Standard
Camshaft
Drive system
Intake camshaft lobe dimensions
Chain drive (left)
SPEC
Limit
----
A
B
Measurement A
43.488 ~ 43.588 mm (1.7121 ~ 1.7161 in) 43.338 mm
(1.7062 in)
36.959 ~ 37.059 mm (1.4551 ~ 1.4590 in) 36.840 mm
(1.4504 in)
Measurement B
Exhaust camshaft lobe dimensions
A
B
Measurement A
Measurement B
Valve timing
Intake - open (B.T.D.C.)
Intake - closed (A.B.D.C.)
Exhaust - open (B.B.D.C.)
Exhaust - closed (A.T.D.C.)
Overlap angle “A”
Maximum camshaft runout
Timing chain
Model/number of links
Tensioning system
43.129 ~ 43.229 mm (1.6980 ~ 1.7019 in) 42.983 mm
(1.6922 in)
37.007 ~ 37.107 mm (1.4570 ~ 1.4609 in) 36.886 mm
(1.4522 in)
25°
55°
60°
20°
45°
----
---------------0.040 mm
(0.0016 in)
98 × RH2010/126
Automatic
2-4
-------
SPEC
ENGINE SPECIFICATIONS
Item
Standard
Rocker arm/rocker arm shaft
Rocker arm inside diameter
Limit
12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) 12.036 mm
(0.4739 in)
11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in) 11.955 mm
(0.4707 in)
0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in)
0.081 mm
(0.0032 in)
Shaft outside diameter
Arm-to-shaft clearance
Valves, valve seats, valve guides
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
0.09 ~ 0.13 mm (0.0035 ~ 0.0051 in)
0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in)
B
-------
C
D
A
Head Diameter
Valve head diameter A
Intake
Exhaust
Valve face width B
Intake
Exhaust
Valve seat width C
Intake
Exhaust
Valve margin thickness D
Intake
Exhaust
Valve stem diameter
Intake
Exhaust
Valve guide inside diameter
Intake
Exhaust
Face Width
Seat Width
Margin Thickness
37.90 ~ 38.10 mm (1.4921 ~ 1.5000 in)
31.90 ~ 32.10 mm (1.2559 ~ 1.2638 in)
-------
2.260 mm (0.0890 in)
1.91 ~ 2.62 mm (0.075 ~ 0.103 in)
-------
1.00 ~ 1.20 mm (0.0394 ~ 0.0472 in)
1.00 ~ 1.20 mm (0.0394 ~ 0.0472 in)
0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in)
0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in)
5.975 ~ 5.990 mm (0.2352 ~ 0.2358 in)
5.960 ~ 5.975 mm (0.2346 ~ 0.2352 in)
6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in)
6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in)
2-5
1.6 mm
(0.06 in)
1.6 mm
(0.06 in)
------5.945 mm
(0.2341 in)
5.930 mm
(0.2335 in)
6.05 mm
(0.2382 in)
6.05 mm
(0.2382 in)
ENGINE SPECIFICATIONS
Item
Valve-stem-to-valve-guide clearance
Intake
Exhaust
Standard
0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in)
0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in)
Valve stem runout
----
Valve seat width
Intake
1.00 ~ 1.20 mm (0.0394 ~ 0.0472 in)
Exhaust
1.00 ~ 1.20 mm (0.0394 ~ 0.0472 in)
Valve springs
Free length
Intake
40.38 mm (1.59 in)
Exhaust
40.38 mm (1.59 in)
Installed length (valve closed)
Intake
Exhaust
Compressed spring force (installed)
Intake
Exhaust
SPEC
Limit
0.08 mm
(0.0031 in)
0.10 mm
(0.0039 in)
0.010 mm
(0.0004 in)
1.6 mm
(0.06 in)
1.6 mm
(0.06 in)
38.36 mm
(1.51 in)
38.36 mm
(1.51 in)
35.00 mm (1.38 in)
35.00 mm (1.38 in)
-------
171 ~ 197 N
(17.44 ~ 20.09 kg, 38.44 ~ 44.29 lb)
171 ~ 197 N
(17.44 ~ 20.09 kg, 38.44 ~ 44.29 lb)
-------
Spring tilt
Intake
----
2.5°/1.8 mm
(2.5°/0.071 in)
Exhaust
----
2.5°/1.8 mm
(2.5°/0.071 in)
Winding direction (top view)
Intake
Exhaust
Clockwise
Clockwise
2-6
-------
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Cylinder
Cylinder arrangement
Bore × stroke
Compression ratio
Bore
Forward-inclined single cylinder
100.0 × 84.0 mm (3.94 × 3.31 in)
10 : 1
100.000 ~ 100.010 (3.9370 ~ 3.9374 in)
Maximum taper
----
Maximum out-of-round
----
Piston
Piston-to-cylinder clearance
Limit
---------100.080 mm
(3.9402 in)
0.05 mm
(0.002 in)
0.05 mm
(0.002 in)
0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in)
0.13 mm
(0.0051 in)
99.955 ~ 99.970 mm (3.9352 ~ 3.9358 in)
----
Diameter D
H
D
Height H
Piston pin bore (in the piston)
Diameter
10.0 mm (0.39 in)
----
23.004 ~ 23.015 mm (0.9057 ~ 0.9061 in) 23.045 mm
(0.9073 in)
0.50 mm (0.0197 in)
---Intake side
----
Offset
Offset direction
Piston pin
Outside diameter
22.991 ~ 23.000 (0.9052 ~ 0.9055 in)
Piston-pin-to-piston-pin-bore clearance
Piston rings
Top ring
0.004 ~ 0.024 mm (0.0002 ~ 0.0009 in)
22.971 mm
(0.9044 in)
0.074 mm
(0.0029 in)
B
T
Ring type
Dimensions (B × T)
End gap (installed)
Barrel
1.20 × 3.80 mm (0.047 × 0.150 in)
0.20 ~ 0.35 mm (0.0079 ~ 0.0138 in)
Ring side clearance
0.030 ~ 0.080 mm (0.0012 ~ 0.0031 in)
2-7
------0.60 mm
(0.0236 in)
0.13 mm
(0.0051 in)
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Limit
2nd ring
B
T
Ring type
Dimensions (B × T)
End gap (installed)
Taper
1.20 × 4.00 mm (0.047 × 0.157 in)
0.35 ~ 0.50 mm (0.0138 ~ 0.0197 in)
Ring side clearance
0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in)
------0.85 mm
(0.0335 in)
0.11 mm
(0.0043 in)
Oil ring
B
T
Dimensions (B × T)
End gap (installed)
Ring side clearance
Crankshaft
2.50 × 3.40 mm (0.098 × 0.134 in)
0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in)
0.060 ~ 0.150 mm (0.0024 ~ 0.0059 in)
----------
F
C
C
E
D
A
Width A
Maximum runout C
74.95 ~ 75.00 mm (2.9508 ~ 2.9528 in)
----
Big end side clearance D
0.350 ~ 0.650 mm (0.0138 ~ 0.0256 in)
Big end radial clearance E
Small end free play F
Balancer
Balancer drive method
0.010 ~ 0.025 mm (0.0004 ~ 0.0010 in)
0.16 ~ 0.40 (0.0063 ~ 0.0157 in)
Gear
2-8
---0.04 mm
(0.0016 in)
1.0 mm
(0.04 in)
----------
ENGINE SPECIFICATIONS
Item
Clutch
Clutch type
Clutch release method
Operation
Clutch cable free play
(at the end of the clutch lever)
Friction plates 1
(inside dia.: 120 mm)
Thickness
Standard
Wet, multiple disc
Outer pull, rack and pinion pull
Left-hand operation
10.0 ~ 15.0 mm (0.39 ~ 0.59 in)
2.90 ~ 3.10 mm (0.114 ~ 0.122 in)
Plate quantity
Friction plates 2
Thickness
4
Plate quantity
Friction plates 3
(inside dia.: 128 mm)
Thickness
2
Plate quantity
Clutch plates
Thickness
Plate quantity
Maximum warpage
1
Clutch spring
Free length
Spring quantity
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratios
1st gear
2nd gear
3rd gear
4th gear
5th gear
2.92 ~ 3.08 mm (0.115 ~ 0.121 in)
2.90 ~ 3.10 mm (0.114 ~ 0.122 in)
SPEC
Limit
-------------
2.80 mm
(0.110 in)
---2.80 mm
(0.110 in)
----
2.80 mm
(0.110 in)
----
1.50 ~ 1.70 mm (0.059 ~ 0.067 in)
6
----
------0.20 mm
(0.0079 in)
55.6 mm (2.19 in)
52.82 mm
(2.08 in)
----
5
Constant mesh, 5-speed
Spur gear
75/36 (2.083)
Chain drive
45/15 (3.000)
Left-foot operation
-------------------
30/12 (2.500)
26/16 (1.625)
23/20 (1.150)
20/22 (0.909)
20/26 (0.769)
----------------
2-9
ENGINE SPECIFICATIONS
Item
Standard
Maximum main axle runout
----
Maximum drive axle runout
----
Shifting mechanism
Shift mechanism type
Decompression device
Device type
Air filter type
Fuel pump
Pump type
Model/manufacturer
Consumption amperage <maximum>
Output pressure
Throttle body
Model/manufacturer × quantity
Intake vacuum pressure
Throttle cable free play (at the flange
of the throttle grip)
ID mark
Throttle valve size
SPEC
Limit
0.08 mm
(0.0031 in)
0.08 mm
(0.0031 in)
Shift drum and guide bar
----
Auto decomp
Oil-coated paper element
-------
Electrical
5VK/DENSO
3.5 A
294 kPa (2.94 kg/cm2, 41.8 psi)
-------------
44EHS/MIKUNI × 1
37.6 ~ 40.2 kPa
(282 ~ 302 mmHg, 11.1 ~ 11.9 inHg)
3.0 ~ 5.0 mm (0.12 in ~ 0.20 mm)
-------
5VK1 00
#50
-------
2 - 10
----
CHASSIS SPECIFICATIONS
SPEC
CHASSIS SPECIFICATIONS
Item
Frame
Frame type
Caster angle
Trail
Front wheel
Wheel type
Rim
Size
Material
Wheel travel
Standard
Diamond
27.25° (XT660R)
26° (XT660X)
107 mm (4.21 in) (XT660R)
94 mm (3.70 in) (XT660X)
----------------
Spoke wheel
----
21 × 1.85 (XT660R)
17M/C × MT3.50 (XT660X)
Aluminum
225 mm (8.86 in) (XT660R)
200 mm (7.87 in) (XT660X)
----------------
Wheel runout
Maximum radial wheel runout
----
Maximum lateral wheel runout
----
Wheel axle bending limit
Rear wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Maximum radial wheel runout
Maximum lateral wheel runout
Wheel axle bending limit
Limit
2.0 mm
(0.08 in)
2.0 mm
(0.08 in)
0.25 mm
(0.01 in)
----
Spoke wheel
----
17M/C × MT2.75 (XT660R)
17M/C × MT4.25 (XT660X)
Aluminum
200.0 mm (7.87 in)
-------------
----
2.0 mm
(0.08 in)
2.0 mm
(0.08 in)
0.25 mm
(0.01 in)
-------
2 - 11
CHASSIS SPECIFICATIONS
Item
Front tire
Tire type
Size
Model/manufacturer
Tire pressure (cold)
0 ~ 90 kg (0 ~ 198 lb)
90 (198 lb) ~ Maximum load*
Off-road riding
Minimum tire tread depth
Rear tire
Tire type
Size
Model/manufacturer
Tire pressure (cold)
0 ~ 90 kg (0 ~ 198 lb)
90 (198 lb) ~ Maximum load*
Off-road riding
Minimum tire tread depth
SPEC
Standard
Limit
With tube
90/90-21M/C 54S, 90/90-21M/C 54T
(XT660R)
120/70R 17M/C 58 H (XT660X)
TOURANCE FRONT/METZELER,
SIRAC/MICHELIN (XT660R)
DRAGON/PIRELLI (XT660X)
-------
200 kPa (2.00 kgf/cm, 29 psi) (XT660R)
210 kPa (2.10 kgf/cm, 30 psi) (XT660X)
200 kPa (2.00 kgf/cm, 29 psi) (XT660R)
220 kPa (2.20 kgf/cm, 31 psi) (XT660X)
* Load is the total weight of the cargo,
rider, passenger and accessories.
200 kPa (2.00 kgf/cm, 29 psi) (XT660R)
----
-------------
----------
---1.6 mm
(0.063 in)
With tube
130/80-17M/C 65S, 130/80-17M/C 65T
(XT660R)
160/60R 17M/C 69H (XT660X)
TOURANCE/METZELER, SIRAC A/
MICHELIN (XT660R)
DRAGON/PIRELLI (XT660X)
-------
200 kPa (2.00 kgf/cm, 29 psi) (XT660R)
210 kPa (2.10 kgf/cm, 30 psi) (XT660X)
225 kPa (2.25 kgf/cm, 33 psi) (XT660R)
230 kPa (2.30 kgf/cm, 33 psi) (XT660X)
* Load is the total weight of the cargo,
rider, passenger and accessories.
200 kPa (2.00 kgf/cm, 29 psi) (XT660R)
----
-------------
2 - 12
----------
---1.6 mm
(0.063 in)
CHASSIS SPECIFICATIONS
Item
Standard
Front brakes
Brake type
Operation
Recommended fluid
Brake discs
Diameter × thickness
SPEC
Limit
Single-disc brake
Right-hand operation
DOT 4
-------------
Minimum thickness
298.0 × 4.5 mm (11.73 × 0.18 in)
(XT660R)
320.0 × 4.5 mm (12.60 × 0.18 in)
(XT660X)
----
Maximum deflection
----
Pad thickness
inner
4.1 mm (0.16 in) (XT660R)
5.2 mm (0.20 in) (XT660X)
Pad thickness
outer
4.1 mm (0.16 in) (XT660R)
5.2 mm (0.20 in) (XT660X)
Master cylinder inside diameter
Caliper cylinder inside diameter
Rear brake
Brake type
Operation
Brake pedal position (below the top
of the rider footrest)
Recommended fluid
Brake discs
Diameter × thickness
Minimum thickness
Maximum deflection
12.7 mm (0.50 in)
32.00 mm × 1 (1.26 in × 1) and
30.00 mm × 1 (1.18 in × 1) (XT660R)
34.00 mm × 2 (1.34 in × 2) and
30.00 mm × 2 (1.18 in × 2) (XT660X)
4.0 mm
(0.16 in)
0.15 mm
(0.006 in)
1.0 mm
(0.04 in)
1.0 mm
(0.04 in)
1.0 mm
(0.04 in)
1.0 mm
(0.04 in)
----------
Single-disc brake
Right-foot operation
12.0 mm (0.47 in)
----------
DOT 4
----
245 × 5.0 mm (9.65 × 0.20 in)
-------
Pad thickness
inner
5.5 mm (0.22 in)
Pad thickness
outer
5.5 mm (0.22 in)
Master cylinder inside diameter
Caliper cylinder inside diameter
----
12.7 mm (0.50 in)
34.00 mm × 1 (1.34 in × 1)
2 - 13
---4.5 mm
(0.18 in)
0.15 mm
(0.006 in)
1.0 mm
(0.04 in)
1.0 mm
(0.04 in)
-------
CHASSIS SPECIFICATIONS
Item
Steering
Steering bearing type
Lock to lock angle (left)
Lock to lock angle (right)
Front suspension
Suspension type
Front fork type
Front fork travel
Spring
Free length
SPEC
Standard
Taper roller bearing
44.0°
44.0°
----------
Telescopic fork
Coil spring/oil damper
225.0 mm (8.86 in) (XT660R)
200.0 mm (7.87 in) (XT660X)
-------------
633.0 mm (24.92 in) (XT660R)
593.0 mm (23.35 in) (XT660X)
Spacer length
Installed length
Spring rate (K1)
Spring stroke (K1)
Spring rate (K2)
Spring stroke (K2)
Optional spring available
Fork oil
Recommended oil
Quantity (each front fork leg)
Level (from the top of the inner
tube, with the inner tube fully compressed, and without the fork
spring)
Inner tube outer diameter
Inner tube bearing
Limit
0 mm (0 in)
628.0 mm (24.72 in) (XT660R)
588.0 mm (23.15 in) (XT660X)
3.75 N/mm (0.38 kg/mm, 21.41 lb/in)
(XT660R)
3.75 N/mm (0.38 kg/mm, 21.41 lb/in)
(XT660X)
0 ~ 120.0 mm (0 ~ 4.72 in) (XT660R)
0 ~ 120.0 mm (0 ~ 4.72 in) (XT660X)
6.00 N/mm (0.61 kg/mm, 34.26 lb/in)
(XT660R)
6.00 N/mm (0.61 kg/mm, 34.26 lb/in)
(XT660X)
120.0 ~ 225.0 mm (4.72 ~ 8.86 in)
(XT660R)
120.0 ~ 200.0 mm (4.72 ~ 7.87 in)
(XT660X)
No
Fork oil 10 W or equivalent
640.0 cm3 (22.53 Imp oz, 21.64 US oz)
(XT660R)
600.0 cm3 (21.12 Imp oz, 20.29 US oz)
(XT660X)
125.0 mm (4.92 in) (XT660R)
125.0 mm (4.92 in) (XT660X)
43.0 mm (1.69 in)
----
2 - 14
620 mm
(24.41 in)
581 mm
(22.87 in)
----------------------------------------------------
---0.2 mm
(0.0079 in)
CHASSIS SPECIFICATIONS
Item
Rear suspension
Suspension type
Rear shock absorber assembly type
Rear shock absorber assembly travel
Spring
Free length
Standard
Swingarm (monocross)
Coil spring/gas-oil damper
65.0 mm (2.56 in)
216.0 mm (8.50 in)
SPEC
Limit
----------
205 mm
(8.07 in)
Installed length
206.0 mm (8.11 in)
---Spring rate (K1)
125.00 N/mm (12.75 kg/mm, 713.75 lb/in)
---Spring stroke (K1)
0 ~ 65.0 mm (0 ~ 2.56 in)
---Optional spring available
No
---2
Standard spring preload gas/air pres- 980 kPa (9.8 kg/cm , 139.4 psi)
---sure
Swingarm
Free play
(at the end of the swingarm)
Radial
---1.0 mm
(0.04 in)
Axial
---1.0 mm
(0.04 in)
Drive chain
Type/manufacturer
DID520VP/DAIDO
---Link quantity
110
---Drive chain slack
40.0 ~ 55.0 mm (1.57 ~ 2.17 in)
---Maximum 15-link section
240.5 mm (9.47 in)
----
2 - 15
ELECTRICAL SPECIFICATIONS
SPEC
ELECTRICAL SPECIFICATIONS
Item
System voltage
Ignition system
Ignition system type
Ignition timing
Advancer type
Crankshaft position senor resistance/
color
Transistorized coil ignition unit
model/manufacturer
Ignition coil
Model/manufacturer
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
Spark plug cap
Material
Resistance
Charging system
System type
Model/manufacturer
Nominal output
Stator coil resistance/color
Rectifier/regulator
Regulator type
Model/manufacturer
No-load regulated voltage
Rectifier capacity
Withstand voltage
Battery
Battery type/manufacturer
Battery voltage/capacity
Ten hour rate amperage
Headlight type
Indicator light
(voltage/wattage × quantity)
Neutral indicator light
High beam indicator light
Fuel level warning light
Turn signal indicator light
Engine trouble warning light
Coolant temperature warning light
Immobilizer system indicator light
Standard
Limit
12 V
----
Transistorized coil ignition (digital)
9.0° BTDC at 1,400 r/min
Electric
192 ~ 288 Ω at 20 °C (68 °F)
blue/yellow–green/white
TBDF08/DENSO
-------------
JO300/DENSO
6.0 mm (0.24 in)
3.4 ~ 4.6 Ω at 20 °C (68 °F)
10.4 ~ 15.6 kΩ at 20 °C (68 °F)
-------------
Rubber
10.0 kΩ at 20 °C (68 °F)
-------
A.C. magneto
LMX51/DENSO
14.0 V/20.8 A at 5,000 r/min
0.224 ~ 0.336 Ω at 20 °C (68 °F)
white–white
-------------
Semiconductor, short circuit
SH713AA/SHINDENGEN
14.1 ~ 14.9 V
35.0 A
200.0 V
----------------
GT9B-4/GS
12 V/8.0 AH
0.8 A
Halogen bulb
-------------
LED × 1
LED × 1
LED × 1
LED × 1
LED × 1
LED × 1
LED × 1
----------------------
2 - 16
----
ELECTRICAL SPECIFICATIONS
Item
Bulbs (voltage/wattage × quantity)
Headlight
Auxiliary light
Tail/brake light
Front turn signal light
Rear turn signal light
Meter lighting
Electric starting system
System type
Starter motor
Model/manufacturer
Power output
Armature coil resistance
Brushes
Overall length
Spring force
Commutator diameter
Mica undercut
Starter relay
Model /manufacturer
Amperage
Coil resistance
Horn
Horn type
Model/manufacturer × quantity
Maximum amperage
Performance
Coil resistance
Turn signal/hazard relay
Relay type
Model/manufacturer
Self-cancelling device built-in
Turn signal blinking frequency
Wattage
Relay unit
Model/manufacturer
Coil resistance
Diode
Throttle position sensor
Model/manufacturer
Resistance
Standard
SPEC
Limit
12 V 55.0 W/60.0 W × 1
12 V 5.0 W × 1
12 V 5.0 W/21.0 W × 1
12 V 10.0 W × 2
12 V 10.0 W × 2
EL
-------------------
Constant mesh
----
SM-13/MITSUBA
0.80 kW
0.025 ~ 0.035 Ω at 20 °C (68 °F)
----------
12.5 mm (0.49 in)
7.65 ~ 10.01 N
(780 ~ 1,021 gf, 27.51 ~ 36.01 oz)
28.0 mm (1.10 in)
0.70 mm (0.028 in)
5.00 mm
(0.20 in)
---27 mm
(1.06 in)
----
MS5F-561/JIDECO
180.0 A
4.18 ~ 4.62 Ω at 20 °C (68 °F)
----------
Plane
YF-12/NIKKO × 1
3.0 A
105 ~ 120 db/2 m (6.6 ft)
1.15 ~ 1.25 Ω at 20 °C (68 °F)
----------------
Full-transistor
FE218BH /DENSO
No
75 ~ 95 cycles/min.
10 W × 2 + 3.4 W
----------------
G8R-30Y-V4/OMRON
162 ~ 198 Ω
Yes
----------
5PS1/MIKUNI
4.0 ~ 6.0 kΩ
-------
2 - 17
ELECTRICAL SPECIFICATIONS
Item
Headlight relay
Model/manufacturer
Radiator fan
Model/manufacturer
Fan motor relay
Model/manufacturer
Intake air pressure sensor
Thermostat type/manufacturer
Output voltage
Intake air temperature sensor
Model/manufacturer
Resistance
Coolant temperature sensor
Model/manufacturer
Resistance
Fuses (amperage × quantity)
Main fuse
Signaling system fuse
Headlight fuse
Ignition fuse
Fuel injection system fuse
Radiator fan motor fuse
Parking lighting fuse
Backup fuse (immobilizer unit, meter
assembly)
Reserve fuse
Standard
SPEC
Limit
ACM33211 M04/MATSUSHITA
----
5VW/KTM
----
ACM33211 M04/MATSUSHITA
----
5PS1/DENSO
3.4 ~ 3.8 V
-------
5VU1/DENSO
2.21 ~ 2.69 kΩ at 20 °C (68 °F)
0.290 ~ 0.354 kΩ at 80 °C (176 °F)
----------
5PS1/DENSO
2.32 ~ 2.59 kΩ at 20 °C (68 °F)
0.310 ~ 0.326 kΩ at 80 °C (176 °F)
0.140 ~ 0.145 kΩ at 110 °C (230 °F)
-------------
30 A × 1
10 A × 1
20 A × 1
10 A × 1
10 A × 1
7.5 A × 1
10 A × 1
10 A × 1
-------------------------
30 A × 1
20 A × 1
10 A × 1
7.5 A × 1
-------------
2 - 18
CONVERSION TABLE/
GENERAL TIGHTENING TORQUE SPECIFICATIONS
SPEC
EAS00028
EAS00030
CONVERSION TABLE
GENERAL TIGHTENING TORQUE
SPECIFICATIONS
All specification data in this manual are listed
in SI and METRIC UNITS.
Use this table to convert METRIC unit data to
IMPERIAL unit data.
Ex.
METRIC
MULTIPLIER
IMPERIAL
** mm
×
0.03937
=
** in
2 mm
×
0.03937
=
0.08 in
CONVERSION TABLE
METRIC TO IMPERIAL
Metric unit
m · kg
Tightening torque m · kg
cm · kg
cm · kg
Weight
kg
g
Multiplier
Imperial unit
7.233
86.794
0.0723
0.8679
ft · lb
in · lb
ft · lb
in · lb
2.205
0.03527
lb
oz
Speed
km/hr
0.6214
mph
Distance
km
m
m
cm
mm
0.6214
3.281
1.094
0.3937
0.03937
mi
ft
yd
in
in
Volume/
Capacity
cc (cm3)
cc (cm3)
lt (liter)
lt (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP liq.)
cu · in
qt (IMP liq.)
gal (IMP liq.)
Misc.
kg/mm
kg/cm2
Centigrade
(°C)
55.997
14.2234
9/5+32
lb/in
psi (lb/in2)
Fahrenheit (°F)
This chart specifies tightening torques for standard fasteners with a standard ISO thread
pitch. Tightening torque specifications for special components or assemblies are provided
for each chapter of this manual. To avoid
warpage, tighten multi-fastener assemblies in
a crisscross pattern and progressive stages
until the specified tightening torque is reached.
Unless otherwise specified, tightening torque
specifications require clean, dry threads. Components should be at room temperature.
A: Distance between flats
B: Outside thread diameter
A
(nut)
2 - 19
B
(bolt)
General tightening
torques
Nm
m · kg
ft · lb
10 mm
6 mm
6
0.6
4.3
12 mm
8 mm
15
1.5
11
14 mm
10 mm
30
3.0
22
17 mm
12 mm
55
5.5
40
19 mm
14 mm
85
8.5
61
22 mm
16 mm
130
13.0
94
TIGHTENING TORQUE
SPEC
TIGHTENING TORQUE
ENGINE TIGHTENING TORQUE
Part to be tightened
Cylinder head (exhaust pipe)
Cylinder head (left side)
= 145 mm (5.71 in)
Cylinder head (right side)
= 135 mm (5.31 in)
Cylinder head (center lower side)
Cylinder head
Spark plug
Cylinder (left side)
= 116 mm (4.57 in)
1st
2nd
Cylinder (right side)
= 109 mm (4.29 in)
1st
2nd
Cylinder
Tappet cover (exhaust side)
Tappet cover (intake side)
Camshaft sprocket cover
Camshaft sprocket
Camshaft retainer
Valve adjusting screw
Balancer driven gear
Part name
Thread
Q’ty
size
Tightening torque
Nm m · kg ft · lb
Remarks
Stud bolt
M8
4
15
1.5
11
Bolt
M9
2
50
5.0
36
E
Bolt
M9
2
50
5.0
36
E
Bolt
Bolt
—
M9
M6
M10S
2
2
1
45
10
13
4.5
1.0
1.3
32
7.2
9.4
Bolt
M10
2
15
1.5
11
50
5.0
36
2
15
1.5
11
2
4
4
2
2
2
4
50
10
10
10
10
20
10
14
5.0
1.0
1.0
1.0
1.0
2.0
1.0
1.4
36
7.2
7.2
7.2
7.2
14
7.2
10
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
Nut
M10
M6
M6
M6
M6
M7
M6
M6
M18
1
70
7.0
50
E
E
E
LT
Use a lock
washer.
E
Primary drive gear
Nut
M20
1
80
8.0
58
Use the lock
washer.
M
Timing chain tensioner
Timing chain tensioner cap
Timing chain guide (intake)
Thermostat cover
Coolant temperature sensor
Water pump cover
Water pump assembly
Water pump outlet pipe
Water jacket joint
Crankcase cover (right)
Bolt
Bolt
Bolt
Bolt
—
Bolt
Bolt
Bolt
Bolt
Bolt
M6
M16
M6
M6
M12
M6
M6
M6
M6
M6
2 - 20
2
1
2
2
1
3
2
1
2
9
10
20
8
10
18
10
10
10
10
10
1.0
2.0
0.8
1.0
1.8
1.0
1.0
1.0
1.0
1.0
7.2
14
5.8
7.2
13
7.2
7.2
7.2
7.2
7.2
TIGHTENING TORQUE
Part to be tightened
Oil strainer
Oil pump
Oil baffle plate 2
Oil pump assembly
Engine oil drain bolt (crankcase)
Oil filter element cover
Oil filter drain bolt
Engine oil drain bolt (oil tank)
Bleed bolt (oil filter element)
Oil delivery pipe 1
Oil delivery pipe 2
Oil delivery hose 1
Oil delivery hose 2
Throttle body joint clamp screw
Air filter case joint clamp screw
Air filter case
Exhaust pipe and exhaust pipe
bracket
Exhaust pipe bracket and frame
Exhaust pipe and muffler
Exhaust pipe
Muffler
Exhaust pipe and muffler
Air cut-off valve outlet pipe
Clutch cover
Clutch cable holder
Clutch spring
Clutch boss
Shift shaft spring stopper
Torque limiter cover
A.C. magneto cover
A.C. magneto rotor
A.C. magneto lead holder
Crankcase (left side)
Crankcase (right side)
Lead holder
Bearing retainer
Part name
Thread
Q’ty
size
SPEC
Tightening torque
Nm m · kg ft · lb
Bolt
Screw
Bolt
Screw
Bolt
Bolt
Bolt
Bolt
Bolt
Union Bolt
Bolt
Union Bolt
Bolt
Bolt
—
—
Bolt
M6
M6
M5
M6
M14
M6
M6
M8
M5
M10
M6
M8
M6
M6
M4
M5
M6
3
3
2
1
1
2
1
1
1
2
1
2
1
2
2
1
4
10
10
4
7
30
10
10
18
5
20
10
18
10
10
6
4
10
1.0
1.0
0.4
0.7
3.0
1.0
1.0
1.8
0.5
2.0
1.0
1.8
1.0
1.0
0.6
0.4
1.0
7.2
7.2
2.9
5.1
22
7.2
7.2
13
3.6
14
7.2
13
7.2
7.2
4.3
2.9
7.2
Bolt
M8
2
27
2.7
19
Bolt
Bolt
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
Bolt
Bolt
Bolt
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
M8
M8
M8
M8
M8
M6
M6
M6
M6
M20
M8
M6
M6
M16
M6
M6
M6
M6
M6
2
1
4
4
2
2
7
2
5
1
1
4
8
1
1
6
8
2
3
23
12
20
27
20
10
10
10
9
90
22
10
10
80
10
10
10
10
10
2.3
1.2
2.0
2.7
2.0
1.0
1.0
1.0
0.9
9.0
2.2
1.0
1.0
8.0
1.0
1.0
1.0
1.0
1.0
17
8.7
14
19
14
7.2
7.2
7.2
6.5
65
16
7.2
7.2
58
7.2
7.2
7.2
7.2
7.2
2 - 21
Remarks
LT
LT
LT
Sealant
LT
E
E
LT
E
LT
LT
TIGHTENING TORQUE
Part to be tightened
Part name
Thread
Q’ty
size
SPEC
Tightening torque
Nm m · kg ft · lb
Starter clutch
Stator coil
Crankshaft position sensor
Starter motor and crankcase
Starter motor lead
Brush holder and starter motor yoke
Starter motor assembly
Drive axle oil seal retainer
Bolt
Bolt
Bolt
Bolt
Nut
Nut
Bolt
Nut
M8
M6
M5
M6
M6
M6
M5
M6
3
3
2
2
1
1
2
2
30
10
7
10
5
11
5
10
3.0
1.0
0.7
1.0
0.5
1.1
0.5
1.0
22
7.2
5.1
7.2
3.6
8
3.6
7.2
Drive sprocket
Nut
M18
1
120
12.0
85
Neutral switch
Speed sensor
Shift pedal
Intake air pressure sensor
Bolt
Bolt
Bolt
Nut
M6
M6
M6
M6
2
1
1
2
4
10
16
7
0.4
1.0
1.6
0.7
2.9
7.2
11
5.1
Cylinder head tightening sequence:
2
3
1
4
2 - 22
Remarks
LT
LT
LT
Sealant
Use the lock
washer.
LT
TIGHTENING TORQUE
SPEC
CHASSIS TIGHTENING TORQUES
Thread
size
Part to be tightened
Engine mounting:
Engine upper bracket and frame
Engine upper bracket and engine
Engine front bracket and frame
Engine front bracket and engine
Engine and frame
Radiator cap retainer
Coolant reservoir
Chain tensioner (upper and lower)
Pivot shaft and nut
Rear shock absorber and frame
Relay arm and frame
Relay arm and connecting arm
Swingarm and connecting arm
Relay arm and rear shock absorber
Chain cover and swingarm
Stabilizer (XT660X)
Chain protector and swingarm
Drive sprocket cover
Upper bracket pinch bolt
Lower handlebar holder and upper bracket
Steering stem nut
Lower ring nut (steering stem)
Upper handlebar holder and lower handlebar
holder
Front brake master cylinder holder
Clutch lever holder
Front brake master cylinder and brake lever
Grip end
Front brake hose union bolt
Front mud guard (XT660R)
Front mud guard and front fork protector
(XT660R)
Stabilizer and front mud guard (XT660X)
Stabilizer, front mud guard, and front fork
(XT660R)
Front brake hose holder and front fork
Upper bracket pinch bolt
Lower bracket pinch bolt
Cap bolt
Damper rod bolt
2 - 23
Tightening torque
Nm m · kg ft · lb
M10
M10
M10
M10
M10
M6
M6
M8
M14
M14
M14
M14
M14
M10
M6
M6
M6
M6
M8
M10
M22
M25
73
55
73
73
73
7
5
23
92
59
59
59
59
42
7
7
7
10
23
32
130
—
7.3
5.5
7.3
7.3
7.3
0.7
0.5
2.3
9.2
5.9
5.9
5.9
5.9
4.2
0.7
0.7
0.7
1.0
2.3
3.2
13.0
—
53
40
53
53
53
5.1
3.6
17
66
43
43
43
43
30
5.1
5.1
5.1
7.2
17
23
94
—
M8
23
2.3
17
M6
M5
M6
M6
M10
M6
7
7
6
7
30
7
0.7
0.7
0.6
0.7
3.0
0.7
5.1
5.1
4.3
5.1
22
5.1
M6
7
0.7
5.1
M6
7
0.7
5.1
M8
16
1.6
11
M6
M8
M8
M50
M12
10
23
23
18
30
1.0
2.3
2.3
1.8
3.0
7.2
17
17
13
22
Remarks
LS
LS
LS
LS
LS
See NOTE.
LS
LT
TIGHTENING TORQUE
Thread
size
Part to be tightened
Fuel tank and frame
Fuel pump and fuel tank
Rectifier/regulator and air filter case
ECU and air filter case
Horn bracket and frame
Side panels (left and right) and frame
Grab bar, rear cover and frame
Rear mud guard and frame
Tail/brake light and rear mud guard
Rear mud guard and rear fender
Rear fender and frame
Front fender and frame
Front fork protector and front cowling assembly
Front brake disc and wheel
Front wheel axle
Front wheel axle pinch bolt
Front brake caliper
Brake caliper bleed screw
Rear wheel axle nut
Chain drive adjusting locknut
Rear wheel sprocket and hub
Rear brake disc and wheel
Left side heel plate
Right side heel plate and rear brake master cylinder
Brake pedal position locknut
Footrest bracket and frame (right)
Rear brake hose holder and swingarm
Rear brake hose union bolt
Rear brake caliper protector (front side)
Rear brake caliper protector (rear side)
SPEC
Tightening torque
Nm m · kg ft · lb
M6
M5
M6
M6
M6
M6
M8
M6
M6
M6
M6
M6
M6
M8
M16
M8
M10
M10
M16
M8
M10
M6
M6
10
4
7
7
10
7
23
7
4
7
7
7
8
23
59
18
40
14
105
16
69
13
10
1.0
0.4
0.7
0.7
1.0
0.7
2.3
0.7
0.4
0.7
0.7
0.7
0.8
2.3
5.9
1.8
4.0
1.4
10.5
1.6
6.9
1.3
1.0
7.2
2.9
5.1
5.1
7.2
5.1
17
5.1
2.9
5.1
5.1
5.1
5.8
17
43
13
29
10
75
11
50
9.4
7.2
M8
23
2.3
17
M8
M10
M6
M10
M6
M6
18
48
7
30
7
4
1.8
4.8
0.7
3.0
0.7
0.4
13
35
5.1
22
5.1
2.9
Remarks
LT
LT
NOTE:
1. First, tighten the lower ring nut approximately 43 Nm (4.3 m · kg, 31 ft · lb) by using the torque
wrench, then loosen the ring nut completely.
2. Retighten the lower ring nut 7 Nm (0.7 m · kg, 5.1 ft · lb) by using the torque wrench.
2 - 24
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
EAS00031
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication Point
Symbol
Oil seal lips
LS
O-rings
LS
Bearings
E
Cylinder head tightening bolts
E
Cylinder tightening bolts
E
Crankshaft pin
E
Timing chain sprocket inner surface
M
Connecting rod big end thrust surface
E
Piston pin
E
Piston and ring groove
E
Balancer weight tightening nut
E
A.C. magnet rotor tightening nut inner surface
E
Valve stems (intake and exhaust)
M
Valve stem ends (intake and exhaust)
M
Rocker arm shaft
E
Camshaft lobes
M
Decompressor lever pin
E
Decompressor lever spring
E
Water pump impeller shaft
E
Oil pump rotors (inner and outer)
E
Oil pump shaft
E
Torque limiter
E
Starter clutch idle gear thrust surface
E
Starter clutch idle gear inner surface
E
Starter clutch gear (inner and outer)
E
Starter clutch assembly
E
Primary drive gear tightening nut
M
Primary driven gear
E
Clutch boss tightening nut
E
Push rod
M
Transmission gears (wheel and pinion)
M
Main and drive axle
M
Shift forks
E
Shift drum
E
Shift shaft
E
Shift shaft spacer
E
2 - 25
LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication Point
SPEC
Symbol
Crankcase mating surface
Yamaha bond
No.1215
A.C. magnet lead grommet (A.C. magneto cover)
Yamaha bond
No.1215
Oil seal holder tightening bolt
Yamaha bond
No.1215
Oil delivery hose 2 tightening bolt
Yamaha bond
No.1215
2 - 26
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
EAS00032
CHASSIS
Lubrication Point
Symbol
Front wheel oil seal lips (left and right)
LS
Rear wheel oil seal lips (left and right)
LS
Rear wheel drive hub contact surface
LS
Rear arm pivot shaft outer surface and bush outer surface and oil seal lip
LS
Dust cover thrust surface
LS
Relay arm and rear shock absorber mounting bolt outer surface
LS
Relay arm and rear shock absorber oil seal lips
LS
Relay arm and swingarm mounting bolt outer surface
LS
Relay arm and swingarm oil seal lips
LS
Relay arm and connecting arm mounting bolt outer surface
LS
Relay arm and connecting arm oil seal lips
LS
Brake pedal outer surface
LS
Rear brake master cylinder pin outer surface
LS
Steering head pipe bearings (upper and lower)
LS
Steering head pipe bearing races (upper and lower)
LS
Tube guide (throttle grip) inner surface
LS
Clutch lever pivot bolt outer surface
LS
Sidestand sliding surface and collar outer surface
LS
Footrest pivoting point
LS
Footrest spring end
LS
Chain tensioner collar (upper and lower) outer surface
LS
Rear axle shaft outer surface
LS
Passenger footrest pivoting point
LS
2 - 27
SPEC
COOLING SYSTEM DIAGRAMS
EAS00033
COOLING SYSTEM DIAGRAMS
1 Water jacket joint
2 Water pump outlet hose
3 Water pump outlet pipe
4 Water pump
È From the radiator
É To the cylinder
1
2
1
A
3
5VK
È
2
5VK00
3
A
4
É
È
4
2 - 28
COOLING SYSTEM DIAGRAMS
1 Fast idle plunger outlet hose
2 Coolant reservoir breather hose
3 Coolant reservoir hose
4 Radiator cap
5 Radiator
6 Coolant reservoir cap
7 Coolant reservoir
8 Radiator outlet hose
9 Water pump
0 Radiator fan
A Radiator inlet hose
1
2 3
SPEC
È From the fast idle plunger
É To the cylinder
Ê From the thermostat
4
5
È
6
7
8
É
Ê
5
A
9
0
2 - 29
LUBRICATION CHART
SPEC
LUBRICATION CHART
: Pressure feed
: Splashed scavenge
Camshaft
Cylinder head
Drive axle
Oil tank
Oil filter
Crankshaft
Main axle
Check ball
Connecting
rod
Oil pump
rotor 1
Oil pump
rotor 2
Oil strainer
Oil pan
2 - 30
LUBRICATION DIAGRAMS
SPEC
EAS00034
LUBRICATION DIAGRAMS
1 Oil delivery hose 2
2 Oil strainer
3 Oil delivery hose 1
A-A
1
A
A
3
2
2 - 31
2
LUBRICATION DIAGRAMS
SPEC
1 Oil delivery pipe 2
2 Oil delivery pipe 1
3 Oil filter
4 Oil pump
3
A-A
1
2
A
3
A
4
2 - 32
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
SPEC
È To oil tank
È
2
3
1
7
6
5
2 - 33
4
LUBRICATION DIAGRAMS
SPEC
1 Camshaft
2 Oil delivery pipe 1
3 Oil filter
4 Main axle
5 Drive axle
6 Crankshaft
2
1
6
3
5
4
2 - 34
CABLE ROUTING
EAS00035
CABLE ROUTING
1 Left handlebar switch lead
2 Clutch switch lead
3 Clutch cable
4 Front brake light switch lead
5 Right handlebar switch lead
6 Throttle cable
7 Headlight lead
8 Meter assembly lead
9 Main switch lead
0 Immobilizer unit lead
2 - 35
SPEC
CABLE ROUTING
È When fastening the front brake light switch lead,
leave some slack in the lead at the area shown.
É Fasten the right handlebar switch lead, front
brake light switch lead, and throttle cables with a
plastic band. Face the end of the plastic band
forward.
Ê Fasten the clutch cable with a cable holder.
Ë Fasten the left handlebar switch lead and clutch
switch lead with a plastic band. Face the end of
the plastic band forward.
SPEC
Ì Route the throttle cables, left handlebar switch
lead, right handlebar switch lead, front brake
light switch lead, and clutch switch lead in front
of the steering column, then the clutch cable,
then the headlight lead and meter assembly
lead, and finally the main switch lead and immobilizer unit lead.
2 - 36
CABLE ROUTING
1 Front turn signal light lead (right)
2 Meter assembly lead
3 Auxiliary light lead
4 Front turn signal light lead (left)
5 Headlight lead
6 Sub-wire harness
SPEC
È Fasten the sub-wire harness and meter assembly lead with a plastic band. Fasten the sub-wire
harness at the white tape. Face the end of the
plastic band forward.
É Make sure that there is no slack in the meter
assembly lead between the meter assembly and
the plastic band. The rubber boot on the meter
assembly can be bent as shown.
Ê Place the slack of the left and right front turn signal light leads between the headlight assembly
and front cowling assembly.
2 - 37
CABLE ROUTING
Ë Fasten the left and right front turn signal light
leads to the headlight stay with a plastic locking
tie.
Ì Pass the left and right front turn signal light leads
in front of the headlight stay.
Í Only the left side is shown in this illustration.
Route the right front turn signal light lead in the
same way.
Î Pass the left and right front turn signal light leads
between the headlight stay and front fork protector.
SPEC
Ï 0 ~ 5 mm (0 ~ 0.20 in) for both left and right
sides
2 - 38
CABLE ROUTING
1 Ignition coil lead
2 Main switch coupler
3 Immobilizer unit coupler
4 Air induction system lead
5 Horn lead
6 Horn
7 Ignition coil
8 Spark plug lead
9 Clutch cable
0 Oil delivery pipe 1
A Wire harness
SPEC
B Fast idle plunger outlet hose
È Fasten the fast idle plunger outlet hose and ignition coil leads with a hose holder. Install the
hose holder with its fastener facing down.
É Fasten the wire harness, main switch lead, and
immobilizer unit lead to the frame with a plastic
band.
A
B-B
BÏ
Ë
Ê
4
3
É
È
2
1
B
5
B
A
6
7 Ì
A
Í
Î
8
9
0
9
A-A
2 - 39
CABLE ROUTING
SPEC
Ì Fasten the clutch cable to the horn bracket with
a cable holder.
Í Install the cable holder as high as possible.
Î Fasten the clutch cable and oil delivery pipe 1
with a cable holder.
Ï Route the fast idle plunger outlet hose to the
inside of the line shown in the illustration so that
it is not pinched between the frame and right
side panel.
Ê Fasten the main switch lead, immobilizer unit
lead, and horn switch lead with a plastic locking
tie. To fasten the leads, connect the couplers,
and then turn the handlebar completely to the
left.
Ë Fasten the main switch lead, immobilizer unit
lead, and clutch cable with a plastic band under
the engine oil filler cap. To fasten the leads and
cable, connect the couplers, and then turn the
handlebar completely to the left.
A
B-B
BÏ
Ë
Ê
4
3
É
È
2
1
B
5
B
A
6
7 Ì
A
Í
Î
8
9
0
9
A-A
2 - 40
SPEC
CABLE ROUTING
1 Rear brake light switch lead
2 Negative battery lead
3 Lean angle cut-off switch lead
4 Throttle position sensor lead
5 Coolant temperature sensor lead
6 Turn signal/hazard relay
7 Headlight relay
8 Radiator fan motor relay
9 Relay unit
È Fasten the wire harness, negative battery lead,
and rear brake light switch lead to the frame with
a plastic locking tie.
É Fasten the rear brake light switch lead to the
frame with a plastic locking tie.
Ê Fasten the wire harness to the frame at the
white tape with a plastic locking tie.
Ë Route the negative battery lead behind the lean
angle cut-off switch bracket.
Ì Route the rear brake light switch lead between
the air filter case and the frame.
È
1
9
8
7
6
Ì
Ë
É
2 - 41
È
É
2
Ê
3
4
5
CABLE ROUTING
1 Neutral switch connector
2 Crankshaft position sensor
coupler
3 A.C. magneto coupler
4 Speed sensor lead
5 Intake air temperature sensor
lead
6 ECU lead
7 Starter motor lead
8 Sidestand switch lead
9 Speed sensor
0 A.C. magneto lead
A Oil tank breather hose
B Oil delivery hose 2
C Radiator fan motor lead
D Throttle cable
E Headlight lead
F Meter assembly lead
G Left handlebar switch lead
H Right handlebar switch lead
I Front brake light switch lead
J Clutch switch lead
F G
E
SPEC
K Immobilizer unit lead
L Clutch cable
M Main switch lead
N Air-filter-to-air-cut-off-valve
hose
O Wire harness
G
H
E
H
D
I J
I
J
B
M LK
A-A
B-B
D
F
C
C-C
D
È
É
A
Ê
B
C
A
Ë 1 2 3 4 Ì 567
D
B
E
C
E
Ó
D
N
C
B
O
A
E-E
D
Ò
Ñ
B
A
Ð
8
Ï
F-F
F
F
0
9
2 - 42
8
Î Í
CABLE ROUTING
É Fasten the left handlebar switch lead, right handlebar switch lead, headlight lead, meter assembly lead, front brake light switch lead, clutch
switch lead, radiator fan motor lead, and throttle
cables with a plastic locking tie. To fasten the
leads and cables, connect the couplers, and
then turn the handlebar completely to the right.
Ê Route the oil tank breather hose on the outside
of the throttle cables.
È Fasten the left handlebar switch lead, right handlebar switch lead, headlight lead, meter assembly lead, front brake light switch lead, and clutch
switch lead to the frame with a plastic locking tie.
To fasten the leads, connect the couplers, and
then turn the handlebar completely to the right.
F G
E
SPEC
G
H
E
H
D
I J
I
J
B
M LK
A-A
B-B
D
F
C
C-C
D
È
É
A
Ê
B
C
A
Ë 1 2 3 4 Ì 567
D
B
E
C
E
Ó
D
N
C
B
O
A
E-E
D
Ò
Ñ
B
A
Ð
8
Ï
F-F
F
F
0
9
2 - 43
8
Î Í
CABLE ROUTING
Ï Fasten the neutral switch lead, crankshaft position sensor lead, sidestand switch lead, speed
sensor lead, starter motor lead, and A.C. magneto lead with a plastic band.
Ð Fasten the neutral switch lead, crankshaft position sensor lead, sidestand switch lead, speed
sensor lead, and starter motor lead with a plastic
band.
Ñ Fasten the air-filter-to-air-cut-off-valve hose, oil
tank breather hose, and oil delivery hose 2 with
a plastic clamp.
Ë Fasten the wire harness to the frame at the
white tape with a plastic locking tie.
Ì Fasten the starter motor lead to the frame with a
plastic locking tie.
Í Fasten the sidestand switch lead to the frame
with a plastic locking tie.
Î Route the sidestand switch lead at the front end
of the left side heel plate.
F G
E
SPEC
G
H
E
H
D
I J
I
J
B
M LK
A-A
B-B
D
F
C
C-C
D
È
É
A
Ê
B
C
A
Ë 1 2 3 4 Ì 567
D
B
E
C
E
Ó
D
N
C
B
O
A
E-E
D
Ò
Ñ
B
A
Ð
8
Ï
F-F
F
F
0
9
2 - 44
8
Î Í
CABLE ROUTING
SPEC
Ò Fasten the wire harness, air-filter-to-air-cut-offvalve hose, and oil delivery hose 2 with a plastic
clamp.
Ó Fasten the left handlebar switch lead, right handlebar switch lead, headlight lead, meter assembly lead, front brake light switch lead, and clutch
switch lead with a plastic band.
F G
E
G
H
E
H
D
I J
I
J
B
M LK
A-A
B-B
D
F
C
C-C
D
È
É
A
Ê
B
C
A
Ë 1 2 3 4 Ì 567
D
B
E
C
E
Ó
D
N
C
B
O
A
E-E
D
Ò
Ñ
B
A
Ð
8
Ï
F-F
F
F
0
9
2 - 45
8
Î Í
CABLE ROUTING
1 Starter motor lead
2 Fuse box 1 lead
3 Fuse box 2 lead
4 Tail/brake light lead
5 Rear turn signal light lead
6 Seat lock cable
7 Positive battery lead
8 Starter relay lead
9 Rectifier/regulator lead
SPEC
È Fasten the wire harness and starter motor lead
to the frame with a plastic locking tie.
É 45°
Ê Fasten the wire harness to the frame with a plastic band.
4
1 È 2
3
É
É
5
Ê
6
7
8
9
2 - 46
SPEC
CABLE ROUTING
1 Immobilizer unit coupler
2 Intake air temperature sensor
3 Fuel injector lead
4 Fuel pump lead
5 Fuel sender lead
6 Oil tank breather hose
È 0 ~ 10 mm (0 ~ 0.39 in)
É 30 ~ 40 mm (1.18 ~ 1.57 in)
Ê 5 ~ 15 mm (0.20 ~ 0.59 in)
Ë Fasten the wire harness to the frame with a plastic locking tie.
Ì To the fuel tank
Í 0 ~ 5 mm (0 ~ 0.20 in)
For F, GB
È
È
1
1
6
Ê
É
A
Ê
A
Ë
Ë
5
2
Ì
3
4
Í
Í
2 - 47
CABLE ROUTING
1 Battery
2 Negative battery lead
3 Tail/brake light coupler
4 Rear turn signal light connector
5 Seat lock cable
6 Anti-theft alarm coupler
7 Fuse box 2
8 Positive battery lead
9 Fuse box 1
0 Rear fender
A Rear fender cover
SPEC
È Fasten the tail/brake light lead with two plastic
locking ties so that the coupler is positioned to
the inside of where the relays (turn signal/hazard
relay, headlight relay, radiator fan motor relay,
and relay unit) branch off from the wire harness.
É To relays (turn signal/hazard relay, headlight
relay, radiator fan motor relay, and relay unit)
Ê Fasten the rear turn signal light leads and tail/
brake light lead with a lead holder.
È
É
Î
9
8
7
1
2
6
5
Í
Ì
A
3
A
Ë
0
4
Ê
A
Ï
A-A
2 - 48
CABLE ROUTING
SPEC
Ë Connect the couplers so that they are not
pinched between the rear fender and rear fender
cover.
Ì Fasten the wire harness to the frame with a plastic locking tie.
Í 0 ~ 5 mm (0 ~ 0.20 in)
Î 0 ~ 10 mm (0 ~ 0.39 in)
Ï The tail/brake light coupler and the rear turn signal light lead should not be lower than the line
shown in the illustration.
È
É
Î
9
8
7
1
2
6
5
Í
Ì
A
3
A
Ë
0
4
Ê
A
Ï
A-A
2 - 49
CABLE ROUTING
1 Front brake hose
2 Front brake master cylinder
3 Front mud guard
4 Front brake caliper
5 Front fork boss
SPEC
È To install the brake hose holders, align the edge
of each holder with the upper edge of the recess
in the brake hose.
É Route the front brake hose so that its alignment
mark is facing toward the rear of the motorcycle.
Ê 30 ~ 50°
Ë Fasten the front brake hose with the brake hose
holders.
2 - 50
CABLE ROUTING
Ì Route the front brake hose between the front
fork and front mud guard and between the
bosses on the front fork.
Í When installing the brake hose onto the brake
caliper, make sure that the brake pipe touches
the brake caliper as shown.
Î When installing the brake hose onto the brake
caliper, make sure that the brake pipe touches
the projection on the brake caliper.
2 - 51
SPEC
CABLE ROUTING
1 Brake fluid reservoir
2 Brake fluid reservoir hose
3 Rear brake light switch
4 Rear brake master cylinder
5 Rear brake hose
6 Rear brake caliper
SPEC
È When installing the brake hose onto the brake
master cylinder, make sure that the brake pipe
touches the brake master cylinder as shown.
É Fasten the rear brake hose with the brake hose
holder.
Ê When installing the brake hose onto the brake
caliper, make sure that the brake pipe touches
the brake caliper as shown.
2 - 52
CHK
ADJ
3
CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION.............................................................................................. 3-1
PERIODIC MAINTENANCE AND LUBRICATION CHART ............................ 3-1
COWLING AND COVER ................................................................................. 3-3
COVER...................................................................................................... 3-3
COWLING .................................................................................................3-4
FUEL TANK..................................................................................................... 3-5
REMOVING THE FUEL TANK ..................................................................3-6
REMOVING THE FUEL PUMP .................................................................3-6
INSTALLING THE FUEL PUMP................................................................3-7
INSTALLING THE FUEL HOSE ................................................................3-7
AIR FILTER CASE .......................................................................................... 3-8
REAR MUD GUARD AND REAR FENDER ..............................................3-8
AIR FILTER CASE .................................................................................. 3-10
INSTALLING THE AIR FILTER CASE JOINT CLAMP ........................... 3-12
ENGINE .........................................................................................................3-13
ADJUSTING THE VALVE CLEARANCE ................................................ 3-13
ADJUSTING THE EXHAUST GAS VOLUME .........................................3-16
ADJUSTING THE ENGINE IDLING SPEED ...........................................3-17
ADJUSTING THE THROTTLE CABLE FREE PLAY ..............................3-17
CHECKING THE SPARK PLUG ............................................................. 3-19
CHECKING THE IGNITION TIMING.......................................................3-20
MEASURING THE COMPRESSION PRESSURE..................................3-21
CHECKING THE ENGINE OIL LEVEL....................................................3-23
CHANGING THE ENGINE OIL ...............................................................3-24
ADJUSTING THE CLUTCH CABLE FREE PLAY................................... 3-27
CHECKING THE AIR FILTER ELEMENT ............................................... 3-28
CHECKING THE THROTTLE BODY JOINT...........................................3-29
CHECKING THE FUEL HOSE ................................................................3-29
CHECKING THE BREATHER HOSE......................................................3-30
CHECKING THE EXHAUST SYSTEM....................................................3-30
CHECKING THE COOLANT LEVEL.......................................................3-31
CHECKING THE COOLING SYSTEM ....................................................3-31
CHANGING THE COOLANT................................................................... 3-32
CHK
ADJ
CHASSIS ....................................................................................................... 3-36
ADJUSTING THE REAR BRAKE PEDAL ............................................... 3-36
CHECKING THE BRAKE FLUID LEVEL................................................. 3-37
CHECKING THE FRONT AND REAR BRAKE PADS
AND BRAKE PAD PINS .........................................................................3-38
ADJUSTING THE REAR BRAKE LIGHT SWITCH .................................3-38
CHECKING THE FRONT AND REAR BRAKE HOSES.......................... 3-39
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-40
ADJUSTING THE SHIFT PEDAL............................................................ 3-41
ADJUSTING THE DRIVE CHAIN SLACK ............................................... 3-42
LUBRICATING THE DRIVE CHAIN ........................................................ 3-44
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-44
CHECKING THE FRONT FORK ............................................................. 3-46
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY.................. 3-47
CHECKING THE TIRES..........................................................................3-48
CHECKING AND TIGHTENING THE SPOKES...................................... 3-51
CHECKING AND LUBRICATING THE CABLES .................................... 3-52
LUBRICATING THE LEVERS AND BRAKE PEDAL ..............................3-52
LUBRICATING THE SIDESTAND........................................................... 3-52
ELECTRICAL SYSTEM................................................................................. 3-53
CHECKING AND CHARGING THE BATTERY....................................... 3-53
CHECKING THE FUSES ........................................................................3-58
REPLACING THE HEADLIGHT BULB....................................................3-60
ADJUSTING THE HEADLIGHT BEAM ...................................................3-61
SETTING THE DIGITAL CLOCK ............................................................ 3-62
INTRODUCTION/PERIODIC MAINTENANCE AND
LUBRICATION CHART
CHK
ADJ
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAS00037
PERIODIC MAINTENANCE AND LUBRICATION CHART
NOTE:
• The annual checks must be performed every year, except if a kilometer-based maintenance
is performed instead.
• 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.
No.
1 *
Fuel line
(See page 3-29)
2
Spark plug
(See page 3-19)
Valves
3 *
(See page 3-13)
ODOMETER READING (× 1,000 km)
10
20
30
40
ANNUAL
CHECK
• Check fuel hoses for cracks or damage.
√
√
√
√
√
• Check condition.
• Clean and regap.
√
ITEM
CHECK OR MAINTENANCE JOB
1
√
• Replace.
√
√
• Check valve clearance.
• Adjust.
√
√
√
√
4
Air filter element
(See page 3-28)
• Replace.
5
Clutch
(See page 3-27)
• Check operation.
• Adjust.
√
√
√
√
√
• Check operation, fluid level and vehicle for fluid
leakage.
√
√
√
√
√
Front brake
6 * (See page 3-37,
3-38)
Rear brake
7 * (See page 3-36,
3-37, 3-38)
Brake hoses
8 *
(See page 3-39)
• Replace brake pads.
√
Whenever worn to the limit
• Check operation, fluid level and vehicle for fluid
leakage.
√
• Replace brake pads.
√
√
√
√
√
Whenever worn to the limit
√
• Check for cracks or damage.
• Replace.
√
√
√
√
Every 4 years
Wheels
9 * (See page 4-3,
4-14)
• Check runout, spoke tightness and for damage.
• Tighten spokes if necessary.
Tires
10 *
(See page 3-48)
•
•
•
•
√
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
√
√
√
√
√
√
√
√
√
11 *
Wheel bearings
(See page 4-3)
• Check bearing for looseness or damage.
√
√
√
√
12 *
Swingarm
(See page 4-83)
• Check operation and for excessive play.
√
√
√
√
13
Drive chain
(See page 3-42,
4-84)
• Check chain slack.
Every 500 km and after washing the motorcycle or
• Make sure that the rear wheel is properly aligned.
riding in the rain
• Clean and lubricate.
Steering bearings
14 * (See page 3-44,
4-71)
• Check bearing play and steering for roughness.
• Lubricate with lithium-soap-based grease.
3-1
√
√
√
√
Every 20,000 km
√
PERIODIC MAINTENANCE AND LUBRICATION CHART
CHK
ADJ
ODOMETER READING (× 1,000 km)
10
20
30
40
ANNUAL
CHECK
• Make sure that all nuts, bolts and screws are
properly tightened.
√
√
√
√
√
Sidestand
(See page 3-53)
• Check operation.
• Lubricate.
√
√
√
√
√
17 *
Sidestand switch
(See page 8-5)
• Check operation.
√
√
√
√
√
18 *
Front fork
(See page 3-46)
• Check operation and for oil leakage.
√
√
√
√
• Check operation and shock absorber for oil leakage.
√
√
√
√
√
√
√
√
No.
ITEM
15 *
Chassis fasteners
(See page 2-23)
16
Shock absorber
19 * assembly
(See page 3-47)
CHECK OR MAINTENANCE JOB
1
√
Rear suspension
relay arm and con20 * necting arm pivot- • Check operation.
ing points
(See page 4-78)
Electronic fuel
21 * injection
(See page 3-17)
• Adjust engine idling speed.
√
√
√
√
√
√
√
√
√
√
√
22
Engine oil
(See page 3-23,
3-24)
• Change.
• Check oil level and vehicle for oil leakage.
√
23
Engine oil filter
element
(See page 3-24)
• Replace.
√
Cooling system
24 * (See page 3-31,
3-32)
Front and rear
brake switches
25 *
(See page 3-38,
8-5)
26
Moving parts and
cables
(See page 3-52)
• Check coolant level and vehicle for coolant leakage.
√
√
• Change.
√
√
√
√
√
Every 3 years
√
• Check operation.
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
• Lubricate.
Throttle grip hous- • Check operation and free play.
• Adjust the throttle cable free play if necessary.
27 * ing and cable
• Lubricate the throttle grip housing and cable.
(See page 3-17)
Air induction sys28 * tem
(See page 7-36)
• Check the air cut-off valve, reed valve, and hose
for damage.
• Replace the entire air induction system if necessary.
Mufflers and
29 * exhaust pipes
(See page 3-30)
• Check the screw clamps for looseness.
Lights, signals and
• Check operation.
30 * switches
• Adjust headlight beam.
(See page 3-61)
NOTE:
• Replace the air filter element more frequently if you are riding in unusually wet or dusty areas.
• Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder, and change the
brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-2
COWLING AND COVER
CHK
ADJ
COWLING AND COVER
COVER
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
1
3
4
5
4
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
2
T.
R.
Order
1
2
3
4
5
Job/Part
Removing the cover
Seat
Left side panel
Right side panel
Grab bar
Rear cover
Q’ty
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
Remove the parts in the order listed.
1
1
1
2
1
For installation, reverse the removal procedure.
3-3
COWLING AND COVER
CHK
ADJ
COWLING
5
3
4
2
1
R.
R.
1
2
3
4
5
T
.
T.
Order
8 Nm (0.8 m • kg, 5.8 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Job/Part
Removing the cowling
Seat/side panels (left and right)
Fuel tank
Front fender
Front fork protector
Meter assembly coupler
Sub-wire harness coupler
Front cowling assembly
Q’ty
1
1
2
1
1
Remarks
Remove the parts in the order listed.
Refer to “COWLING AND COVER”.
Refer to “FUEL TANK”.
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
3-4
FUEL TANK
CHK
ADJ
EAS00040
FUEL TANK
T.
9
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
4
5
3
10
8
2
6
7
1
Order
1
2
3
4
5
6
7
8
Job/Part
Removing the fuel tank
Seat/side panels (left and right)
Fuel
Fuel tank left side cover
Fuel tank right side cover
Intake air guide
Fuel tank plate
Damper 1
Fuel pump coupler
Fuel sender coupler
Fuel hose
9
10
Fuel tank
Damper 2
Q’ty
1
1
1
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “COWLING AND COVER”.
Drain.
Disconnect.
Disconnect.
Refer to “REMOVING THE FUEL TANK”
and “INSTALLING THE FUEL HOSE”.
1
1
For installation, reverse the removal procedure.
3-5
FUEL TANK
CHK
ADJ
REMOVING THE FUEL TANK
1. Extract the fuel in the fuel tank through the
fuel tank filler tube with a pump.
2. Remove:
• fuel hose
CAUTION:
Although the fuel has been removed from
the fuel tank be careful when removing the
fuel hose, since there may be fuel remaining in it.
a
NOTE:
• To remove the fuel hose from the fuel injection pipe, slide the cover a on the end of the
hose in the direction of the arrow shown and
then remove the hose.
• Before removing the hose, place a few rags
in the area under where it will be removed.
3. Remove:
• fuel tank
NOTE:
Do not set the fuel tank down so that the installation surface of the fuel pump is directly under
the tank. Be sure to lean the fuel tank in an
upright position.
REMOVING THE FUEL PUMP
1. Remove:
• fuel pump
CAUTION:
• Do not drop the fuel pump or give it a
strong shock.
• Do not touch the base section of the fuel
sender.
3-6
FUEL TANK
CHK
ADJ
T.
INSTALLING THE FUEL PUMP
1. Install:
4 Nm (0.4 m · kg, 2.9 ft · lb)
• fuel pump
R.
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.
• Tighten the bolts to the specified torque in
the proper tightening sequence as shown.
• Install the fuel pump in the direction shown in
the illustration.
INSTALLING THE FUEL HOSE
1. Install:
• fuel hose
CAUTION:
When installing the fuel hose, be sure to
securely connect it.
a
NOTE:
To install the fuel hose from the fuel injection
pipe, slide the cover a on the end of the hose
in the direction of the arrow shown.
3-7
CHK
ADJ
AIR FILTER CASE
AIR FILTER CASE
REAR MUD GUARD AND REAR FENDER
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
1
7
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
2
2
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
3
4
8
5
6
T.
R.
Order
1
2
Job/Part
Removing the rear mud guard and
rear fender
Seat/side panels (left and right)/rear
cover
Fuel tank
Muffler
Battery cover
Battery lead
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “COWLING AND COVER”.
Refer to “FUEL TANK”.
Refer to “ENGINE” in chapter 5.
1
2
Disconnect.
CAUTION:
First, disconnect the negative battery
lead, then the positive battery lead.
3
4
5
Battery
Tali/brake light coupler
Rear turn signal light connector
1
1
4
3-8
Disconnect.
Disconnect.
CHK
ADJ
AIR FILTER CASE
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
1
7
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
2
2
T.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
R.
3
4
8
5
6
T.
R.
Order
6
7
8
Job/Part
Fuse box 2
Rear mud guard
Rear fender
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Q’ty
1
1
1
Remarks
For installation, reverse the removal procedure.
3-9
AIR FILTER CASE
CHK
ADJ
EAS00043
AIR FILTER CASE
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
6
8
4
15
(4)
7
2
16
14
5
T.
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib)
12
11
10
1
9 17
3
T.
R.
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
13
T.
R.
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Removing the air filter case
Rear wheel
Q’ty
ECU
Rectifier/regulator
Intake air temperature sensor
Fuse box 1
Starter relay
Intake air chamber case
Air filter case cover (right)
Air filter element
Air filter case breather hose
Pilot air hose
Air filter case to air cut-off valve hose
1
1
1
1
1
1
1
1
1
1
1
3 - 10
7 Nm (0.7 m • kg, 5.1 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LS
23 Nm (2.3 m • kg, 17 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “REAR WHEEL, BRAKE DISC,
AND REAR WHEEL SPROCKET” in
chapter 4.
Disconnect.
Disconnect.
AIR FILTER CASE
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
6
CHK
ADJ
8
4
15
(4)
7
2
16
14
5
T.
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib)
12
11
10
1
9 17
3
T.
R.
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
13
T.
R.
Order
12
13
14
15
16
Job/Part
Air-filter-to-crankcase-breather-chamber hose
Drive chain tensioner
Air filter case joint clamp screw
Air filter case
Air filter case joint clamp
17
Check hose
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LS
23 Nm (2.3 m • kg, 17 ft • Ib)
Q’ty
1
Disconnect.
1
1
1
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
Loosen.
Refer to “INSTALLING THE AIR FILTER
CASE JOINT CLAMP”.
1
For installation, reverse the removal procedure.
3 - 11
AIR FILTER CASE
CHK
ADJ
INSTALLING THE AIR FILTER CASE JOINT
CLAMP
1. Install:
• air filter case joint clamp 1
b
1
a
NOTE:
To install the air filter case joint clamp, align its
slot a with the projection b on the air filter
case.
3 - 12
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
EAS00049
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
NOTE:
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
• When the valve clearance is to be measured
or adjusted, the piston must be at top dead
center (TDC) on the compression stroke.
_
1
2
1. Remove:
• seat
• side panels (left and right)
Refer to “COWLING AND COVER”.
• fuel tank
Refer to “FUEL TANK”.
• radiator
Refer to “RADIATOR” in chapter 6.
• air-filter-to-air-cut-off-valve hose
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
2. Remove:
• intake tappet cover
• exhaust tappet cover 1
• camshaft sprocket cover 2
3.
•
4.
•
Disconnect:
spark plug cap 1
Remove:
spark plug 2
1
2
5. Remove:
• timing mark accessing screw 1
• crankshaft end accessing screw 2
1
2
3 - 13
ADJUSTING THE VALVE CLEARANCE
b
CHK
ADJ
6. Measure:
• valve clearance
Out of specification → Adjust.
a
Valve clearance (cold)
Intake valve
0.09 ~ 0.13 mm
(0.0035 ~ 0.0051 in)
Exhaust valve
0.16 ~ 0.20 mm
(0.0063 ~ 0.0079 in)
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d
a. Turn the crankshaft counterclockwise.
b. When the piston is at the top dead center
(TDC) on the compression stroke, align the
“I” mark a on the A.C. magneto rotor with
the stationary pointer b on the A.C. magneto cover.
c
NOTE:
To position the piston at top dead center (TDC)
on the compression stroke, align the “I” mark
c on the camshaft sprocket with the stationary
pointer d on the cylinder head, as shown in
the illustration.
1
c. Measure the valve clearance with a thickness gauge 1.
Thickness gauge
90890-03079
Out of specification → Adjust.
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3
1
2
7. Adjust:
• valve clearance
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a. Loosen the locknut 1.
b. Insert a thickness gauge 2 between the
end of the adjusting screw and the valve tip.
c. Turn the adjusting screw 3 in direction a
or b until the specified valve clearance is
obtained.
Direction a
Valve clearance is
increased.
Direction b
Valve clearance is
decreased.
b
a
3 - 14
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
d. Hold the adjusting screw to prevent it from
moving and tighten the locknut to the specified torque.
T.
Locknut
14 Nm (1.4 m · kg, 10 ft · lb)
R.
e. Measure the valve clearance again.
f. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is
obtained.
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T.
8. Install:
• timing mark accessing screw
• crankshaft end accessing screw
9. Install:
• spark plug
13 Nm (1.3 m · kg, 9.4 ft · lb)
10.Connect:
• spark plug cap
11.Install:
• camshaft sprocket cover
R.
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
• O-rings 1 New
• intake tappet cover
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
• exhaust tappet cover
R.
New
T.
1
10 Nm (1.0 m · kg, 7.2 ft · lb)
12.Install:
• air-filter-to-air-cut-off-valve hose
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
• radiator
Refer to “RADIATOR” in chapter 6.
• fuel tank
Refer to “FUEL TANK”.
• side panels (left and right)
• seat
Refer to “COWLING AND COVER”.
3 - 15
ADJUSTING THE EXHAUST GAS VOLUME
CHK
ADJ
EAS00869
ADJUSTING THE EXHAUST GAS VOLUME
NOTE:
Be sure to set the CO density level to standard, and then adjust the exhaust gas volume.
_
1. Turn the main switch to “OFF” and set the
engine stop switch to “ ”.
2. Simultaneously press and hold the
“SELECT” and “RESET” buttons, turn the
main switch to “ON”, and continue to press
the buttons for 8 seconds or more.
NOTE:
“dIAG” appears on the odometer/fuel reserve
tripmeter/tripmeter 2 LCD.
_
3. Press the “SELECT” button to select the CO
adjustment mode “Co” or the diagnostic
mode “dIAG”.
4. After selecting “Co”, simultaneously press
the “SELECT” and “RESET” buttons for 2
seconds or more to execute the selection.
NOTE:
• The tachometer mode is executed and it is
displayed on the tripmeter 1 LCD.
• “C1” appears on the odometer/fuel reserve
tripmeter/tripmeter 2 LCD.
_
5. Press the “SELECT” and “RESET” buttons
to change the CO adjustment volume.
NOTE:
The CO adjustment volume appears on the
odometer/fuel reserve tripmeter/tripmeter 2
LCD.
• To decrease the CO adjustment volume,
press the “RESET” button.
• To increase the CO adjustment volume,
press the “SELECT” button.
_
6. Release the switch to execute the selection.
7. Turn the main switch to “OFF” to cancel the
mode.
3 - 16
ADJUSTING THE ENGINE IDLING SPEED/
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK
ADJ
EAS00054
ADJUSTING THE ENGINE IDLING SPEED
NOTE:
Prior to adjusting the engine idling speed, the
air filter element should be cleaned, and the
engine should have adequate compression.
_
1. Start the engine and let it warm up for several minutes.
2. Check:
• engine idling speed
Out of specification → Adjust.
Engine idling speed
1,300 ~ 1,500 r/min
3. Adjust:
• engine idling speed
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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.
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4. Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play (at the
flange of the throttle grip)
3.0 ~ 5.0 mm (0.12 ~ 0.20 in)
EAS00056
ADJUSTING THE THROTTLE CABLE FREE
PLAY
NOTE:
Prior to adjusting the throttle cable free play,
the engine idling speed should be adjusted
properly.
_
3 - 17
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK
ADJ
1. Check:
• throttle cable free play a
Out of specification → Adjust.
Throttle cable free play (at the
flange of the throttle grip)
3.0 ~ 5.0 mm (0.12 ~ 0.20 in)
2. Adjust:
• throttle cable free play
1
2
3
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NOTE:
When the throttle is opened, the accelerator
cable 1 is pulled.
_
a
b
Throttle body end
a. Loosen the locknut 2 on the accelerator
cable.
b. Turn the adjusting nut 3 in direction a or
b until the specified throttle cable free play
is obtained.
Direction a
Throttle cable free play
is increased.
Direction b
Throttle cable free play
is decreased.
c. Tighten the locknut.
NOTE:
If the specified throttle cable free play cannot
be obtained on the throttle body end of the
cable, adjust the free play at the handlebar end
of the cable using the adjusting nut.
_
Handlebar end
a. Loosen the locknut 1.
b. Turn the adjusting nut 2 in direction a or
b until the specified throttle cable free play
is obtained.
a
1
2 b
3 - 18
Direction a
Throttle cable free play
is increased.
Direction b
Throttle cable free play
is decreased.
ADJUSTING THE THROTTLE CABLE FREE PLAY/
CHECKING THE SPARK PLUG
CHK
ADJ
c. Tighten the locknut.
WARNING
_
After adjusting the throttle cable free play,
start the engine and turn the handlebars to
the right and to the left to ensure that this
does not cause the engine idling speed to
change.
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EAS00060
CHECKING THE SPARK PLUG
1. Disconnect:
• spark plug cap
2. Remove:
• spark plug
CAUTION:
_
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
with compressed air to prevent it from falling into the cylinder.
3. Check:
• spark plug type
Incorrect → Change.
Spark plug type (manufacturer)
CR7E (NGK)
4. Check:
• electrode 1
Damage/wear → Replace the spark plug.
• insulator 2
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
5. Clean:
• spark plug
(with a spark plug cleaner or wire brush)
6. Measure:
• spark plug gap a
(with a thickness gauge)
Out of specification → Regap.
Spark plug gap
0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
3 - 19
CHECKING THE SPARK PLUG/
CHECKING THE IGNITION TIMING
T.
7. Install:
• spark plug
CHK
ADJ
R.
13 Nm (1.3 m · kg, 9.4 ft · lb)
NOTE:
Before installing the spark plug, clean the
spark plug and gasket surface.
_
8. Connect:
• spark plug cap
EAS00064
CHECKING THE IGNITION TIMING
NOTE:
Prior to checking the ignition timing, check the
wiring connections of the entire ignition system. Make sure all connections are tight and
free of corrosion.
_
1
1.
•
2.
•
Remove:
timing mark accessing screw 1
Connect:
timing light
(onto the spark plug lead)
Timing light
90890-03141
a
b
3. Check:
• ignition timing
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a. Start the engine, warm it up for several minutes, and then let it run at the specified
engine idling speed.
Engine idling speed
1,300 ~ 1,500 r/min
b. Check that the stationary pointer a is within
the firing range b on the A.C. magneto
rotor.
Incorrect firing range → Check the ignition
system.
NOTE:
The ignition timing is not adjustable.
_
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3 - 20
CHECKING THE IGNITION TIMING/
MEASURING THE COMPRESSION PRESSURE
4.
•
5.
•
CHK
ADJ
Detach:
timing light
Install:
timing mark accessing screw
EAS00067
MEASURING THE COMPRESSION
PRESSURE
NOTE:
Insufficient compression pressure will result in
a loss of performance.
_
1. Measure:
• valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE
CLEARANCE”.
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Disconnect:
• spark plug cap
4. Remove:
• spark plug
CAUTION:
_
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
with compressed air to prevent it from falling into the cylinder.
1
2
5. Install:
• compression gauge 1
• adaptor (compression gauge) 2
Compression gauge
90890-03081
Adaptor (compression gauge)
90890-04082
3 - 21
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
6. Measure:
• compression pressure
Out of specification → Refer to steps (c)
and (d).
Compression pressure (at sea
level)
Minimum
600 kPa (6.0 kg/cm2, 85.3 psi)
Standard
650 kPa (6.5 kg/cm2, 92.4 psi)
Maximum
700 kPa (7.0 kg/cm2, 99.6 psi)
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a. Set the main switch to “ON” and the engine
stop switch to “ ”.
b. With the throttle wide open, crank the
engine until the reading on the compression
gauge stabilizes.
WARNING
_
To prevent sparking, ground the spark plug
lead before cranking the engine.
c. If the compression pressure is above the
maximum specification, check the cylinder
head, valve surfaces, and piston crown for
carbon deposits.
Carbon deposits → Eliminate.
d. If the compression pressure is below the
minimum specification, pour a teaspoonful
of engine oil into the spark plug bore and
measure it again.
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
Reading
Diagnosis
Higher than without oil
Piston ring(s) worn
or damaged →
Repair.
Same as without
oil
Piston, valves, cylinder head gasket
or piston possibly
defective → Repair.
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3 - 22
MEASURING THE COMPRESSION PRESSURE/
CHECKING THE ENGINE OIL LEVEL
R.
Install:
spark plug
Connect:
spark plug cap
T.
7.
•
8.
•
CHK
ADJ
13 Nm (1.3 m · kg, 9.4 ft · lb)
EAS00069
CHECKING THE ENGINE OIL LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable stand.
• Make sure the motorcycle is upright.
_
2. Start the engine, warm it up for 10 ~ 15 minutes, and then turn it off.
3. Check:
• engine oil level
The engine oil level should be between the
minimum level mark a and maximum level
mark b.
Below the minimum level mark → Add the
recommended engine oil to the proper level.
NOTE:
• Before checking the engine oil level, wait a
few minutes until the oil has settled.
• Do not screw the dipstick 1 in when checking the oil level.
_
-20 -10 0 10 20 30 40 50 ˚C
Recommended oil
Refer to the chart for the engine
oil grade which is best suited
for certain atmospheric temperatures.
API standard
SE, SF, SG or higher grade
SAE 10W-30
SAE 10W-40
SAE 15W-40
SAE 20W-40
SAE 20W-50
CAUTION:
_
• Engine oil also lubricates the clutch and
the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives or use engine
oils with a grade of CD c or higher and
do not use oils labeled “ENERGY CONSERVING II” d or higher.
• Do not allow foreign materials to enter the
crankcase.
3 - 23
CHECKING THE ENGINE OIL LEVEL/
CHANGING THE ENGINE OIL
CHK
ADJ
4. Start the engine, warm it up for several minutes, and then turn it off.
5. Check the engine oil level again.
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
_
EAS00076
CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several minutes, and then turn it off.
2. Place a container under the engine.
3. Remove:
• engine oil filler cap 1
• camshaft sprocket cover 2
4. Install the engine oil drain attachment 1
under the engine oil drain bolt of the crankcase.
NOTE:
“engine oil drain attachment” is a part of the
owner’s tool kit.
5. Remove:
• engine oil drain bolt (crankcase) 2
(along with the gasket)
6. Remove:
• engine oil drain bolt (oil tank) 1
(along with the gasket)
7.
•
8.
•
3 - 24
Remove:
oil filter element drain bolt 1
Drain:
engine oil
(completely from the crankcase and the oil
tank)
CHANGING THE ENGINE OIL
CHK
ADJ
9. If the oil filter element is also to be replaced,
perform the following procedure.
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a. Remove the oil filter element cover 1 and
oil filter element 2.
b. Check the O-rings 3 and replace them if
they are cracked or damaged.
c. Install the new oil filter element and the oil
filter element cover.
T.
Oil filter element cover bolt
10 Nm (1.0 m · kg, 7.2 ft · lb)
R.
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10.Check:
• engine oil drain bolt gasket
Damage → Replace.
11.Install:
• engine oil drain bolt (crankcase)
(along with the gasket)
T.
R.
30 Nm (3.0 m · kg, 22 ft · lb)
• engine oil drain bolt (oil tank)
(along with the gasket)
T.
R.
18 Nm (1.8 m · kg, 13 ft · lb)
• oil filter element drain bolt
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
12.Fill:
• oil tank
(with the specified amount of the recommended engine oil)
CAUTION:
_
The engine oil tank must be filled with
engine oil in two steps. First, fill the engine
oil tank with 1.9 L (1.67 Imp qt, 2.00 US qt)
of the recommended engine oil. Then, start
the engine, race it five or six times, turn it
off, and then add the remainder of the
engine oil.
Quantity
Total amount
2.90 L (2.55 Imp qt, 3.07 US qt)
Without oil filter element
replacement
2.50 L (2.20 Imp qt, 2.64 US qt)
With oil filter element replacement
2.60 L (2.29 Imp qt, 2.75 US qt)
3 - 25
CHANGING THE ENGINE OIL
CHK
ADJ
13.Install:
• engine oil filler cap
• camshaft sprocket cover
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
14.Start the engine, warm it up for several minutes, and then turn it off.
15.Check:
• engine
(for engine oil leaks)
16.Check:
• engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
17.Check:
• engine oil pressure
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a. Slightly loosen the bleed bolt 1.
b. Start the engine and keep it idling until
engine oil starts to seep from the bleed bolt.
If no engine oil comes out after one minute,
turn the engine off so that it will not seize.
c. Check the engine oil passages, the oil filter
element, and the oil pump for damage or
leakage. Refer to “OIL PUMP” in chapter 5.
d. Start the engine after correcting the problem(s) and check the engine oil pressure
again.
e. Tighten the bleed bolt to the specified
torque.
T.
Bleed bolt
5 Nm (0.5 m · kg, 3.6 ft · lb)
R.
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3 - 26
ADJUSTING THE CLUTCH CABLE FREE PLAY
CHK
ADJ
EAS00078
ADJUSTING THE CLUTCH CABLE FREE
PLAY
1. Check:
• clutch cable free play a
Out of specification → Adjust.
Clutch cable free play (at the end
of the clutch lever)
10.0 ~ 15.0 mm (0.39 ~ 0.59 in)
2. Adjust:
• clutch cable free play
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Handlebar end
a. Slide back the rubber cover 1.
b. Loosen the locknut 2.
c. Turn the adjusting bolt 3 in direction b or
c until the specified clutch cable free play
is obtained.
Direction b
Clutch cable free play is
increased.
Direction c
Clutch cable free play is
decreased.
d. Tighten the locknut.
e. Slide the rubber cover to its original position.
NOTE:
If the specified clutch cable free play cannot be
obtained on the handlebar end of the cable,
adjust the free play at the engine end of the
cable using the adjusting nut.
_
Engine end
a. Loosen the locknut 1.
b. Turn the adjusting nut 2 in direction a or
b until the specified clutch cable free play
is obtained.
Direction a
Clutch cable free play is
increased.
Direction b
Clutch cable free play is
decreased.
c. Tighten the locknuts.
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3 - 27
CHECKING THE AIR FILTER ELEMENT
CHK
ADJ
EAS00086
CHECKING THE AIR FILTER ELEMENT
NOTE:
There is a check hose 1 at the bottom of the
air filter case. If dust and/or water collects in
this hose, clean the air filter element and air filter case.
1. Remove:
• seat
• right side panel
Refer to “COWLING AND COVER”.
2. Remove:
• air filter case cover (right) 1
3.
•
4.
•
Remove:
air filter element 1
Check:
air filter element
Damage → Replace.
5. Install:
• air filter element 1
• air filter case cover (right)
CAUTION:
_
Never operate the engine without the air filter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the throttle body tuning, leading to poor
engine performance and possible overheating.
NOTE:
Insert the air filter element into the air filter
case as shown.
_
3 - 28
CHECKING THE AIR FILTER ELEMENT/
CHECKING THE THROTTLE BODY JOINT/
CHECKING THE FUEL HOSE
CHK
ADJ
6. Install:
• right side panel
• seat
Refer to “COWLING AND COVER”.
EAS00094
1
CHECKING THE THROTTLE BODY JOINT
1. Check:
• throttle body joint 1
Cracks/damage → Replace.
Refer to “FUEL INJECTION SYSTEM” in
chapter 7.
EAS00096
CHECKING THE FUEL HOSE
1. Remove:
• seat
• side panels (left and right)
Refer to “COWLING AND COVER”.
• fuel tank
Refer to “FUEL TANK”.
1
2. Check:
• fuel hose 1
Cracks/damage → Replace.
Loose connection → Connect properly.
3. Install:
• fuel tank
Refer to “FUEL TANK”.
• side panels (left and right)
• seat
Refer to “COWLING AND COVER”.
3 - 29
CHECKING THE BREATHER HOSE/
CHECKING THE EXHAUST SYSTEM
CHK
ADJ
EAS00098
CHECKING THE BREATHER HOSE
1. Check:
• crankcase-to-crankcase-breather-chamber
hose 1
• air-filter-to-crankcase-breather-chamber
hose 2
Cracks/damage → Replace.
Loose connection → Connect properly.
2
1
CAUTION:
_
Make sure the breather hoses are routed
correctly.
EAS00099
6
2
6
2
3
3
5
4
3
3
9
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the
exhaust pipes and gaskets.
1. Check:
• exhaust pipes 1
• mufflers 2
Cracks/damage → Replace.
• gaskets 3
Exhaust gas leaks → Replace.
2. Check:
• tightening torques
LT
LT
T.
7
R.
1
LT
5
74
1
938
3 - 30
Exhaust pipe nut 4
20 Nm (2.0 m · kg, 14 ft · lb)
Exhaust pipe bolt 5
27 Nm (2.7 m · kg, 19 ft · lb)
Muffler bolt 6
27 Nm (2.7 m · kg, 19 ft · lb)
Exhaust pipe and muffler bolt 7
20 Nm (2.0 m · kg, 14 ft · lb)
Exhaust pipe bolt 8
12 Nm (1.2 m · kg, 8.7 ft · lb)
Exhaust pipe bracket bolt 9
23 Nm (2.3 m · kg, 17 ft · lb)
CHECKING THE COOLANT LEVEL/
CHECKING THE COOLING SYSTEM
CHK
ADJ
EAS00102
CHECKING THE COOLANT LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable stand.
• Make sure the motorcycle is upright.
_
2. Check:
• coolant level
The coolant level should be between the
maximum level mark a and minimum level
mark b.
Below the minimum level mark → Add the
recommended coolant to the proper level.
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 distilled water is not available, soft water
may be used.
3. Start the engine, warm it up for several minutes, and then turn it off.
4. Check:
• coolant level
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.
_
EAS00104
CHECKING THE COOLING SYSTEM
1. Remove:
• seat
• side panels (left and right)
Refer to “COWLING AND COVER”.
• fuel tank
Refer to “FUEL TANK”.
3 - 31
CHECKING THE COOLING SYSTEM/
CHANGING THE COOLANT
2.
•
•
•
•
•
•
3
3
3.
•
1
•
•
CHK
ADJ
Check:
radiator 1
radiator outlet hose 2
radiator inlet hose 3
water pump assembly 4
water pump outlet pipe 5
water pump outlet hose 6
Cracks/damage → Replace.
Refer to “COOLING SYSTEM” in chapter 6.
Install:
fuel tank
Refer to “FUEL TANK”.
side panels (left and right)
seat
Refer to “COWLING AND COVER”.
2
6
4
5
(3)
EAS00105
CHANGING THE COOLANT
1. Remove:
• seat
• right side panel
Refer to “COWLING AND COVER”.
• fuel tank right side cover
Refer to “FUEL TANK”.
3 - 32
CHANGING THE COOLANT
CHK
ADJ
2. Remove:
• radiator cap retainer 1
• radiator cap 2
WARNING
_
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the
engine is hot. Scalding hot fluid and steam
may be blown out, which could cause serious injury. When the engine has cooled,
open the radiator cap as follows:
Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap
counterclockwise toward the detent to
allow any residual pressure to escape.
When the hissing sound has stopped,
press down on the radiator cap and turn it
counterclockwise to remove.
3.
•
•
4.
•
Remove:
coolant reservoir cap 3
coolant reservoir 4
Drain:
coolant
(from the coolant reservoir)
5. Install:
• coolant reservoir
T.
R.
5 Nm (0.5 m · kg, 3.6 ft · lb)
6. Remove:
• coolant drain bolt 1
(along with the copper washer)
7. Drain:
• coolant
(from the engine and radiator)
8. Check:
• copper washer 1 New
• coolant drain bolt 2
Damage → Replace.
9. Install:
• coolant drain bolt
T.
R.
3 - 33
10 Nm (1.0 m · kg, 7.2 ft · lb)
CHANGING THE COOLANT
CHK
ADJ
10.Fill:
• cooling system
(with the specified amount of the recommended coolant)
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Quantity
Total amount
1.00 L (0.88 Imp qt, 1.06 US qt)
Coolant reservoir capacity
0.25 L (0.22 Imp qt, 0.26 US qt)
From minimum to maximum
level mark
0.15 L (0.13 Imp qt, 0.16 US qt)
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
WARNING
_
• If coolant splashes in your eyes, thoroughly wash them with water and consult
a doctor.
• If coolant splashes on your clothes,
quickly wash it away with water and then
with soap and water.
• If coolant is swallowed, induce vomiting
and get immediate medical attention.
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 distilled water is not available, soft water
may be used.
• If coolant comes into contact with painted
surfaces, immediately wash them with
water.
• Do not mix different types of antifreeze.
3 - 34
CHANGING THE COOLANT
CHK
ADJ
11.Install:
• radiator cap
• radiator cap retainer
T.
R.
a
7 Nm (0.7 m · kg, 5.1 ft · lb)
12.Fill:
• coolant reservoir
(with the recommended coolant to the maximum level mark a)
13.Install:
• coolant reservoir cap
14.Start the engine, warm it up for several minutes, and then turn it off.
15.Check:
• coolant level
Refer to “CHECKING THE COOLANT
LEVEL”.
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant has settled.
_
16.Install:
• fuel tank right side cover
Refer to “FUEL TANK”.
• right side panel
• seat
Refer to “COWLING AND COVER”.
3 - 35
ADJUSTING THE REAR BRAKE PEDAL
CHK
ADJ
EAS00110
CHASSIS
ADJUSTING THE REAR BRAKE PEDAL
1. Check:
• brake pedal position
(distance a from the top of the rider footrest to the top of the brake pedal)
Out of specification → Adjust.
Brake pedal position (below the
top of the rider footrest)
12.0 mm (0.47 in)
2. Adjust:
• brake pedal position
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut 1.
b. Turn the adjusting bolt 2 in direction a or
b until the specified brake pedal position is
obtained.
1
b
2
a
Direction a
Brake pedal is raised.
Direction b
Brake pedal is lowered.
c. Tighten the locknut 1 to the specified
torque.
T.
Locknut
18 Nm (1.8 m · kg, 13 ft · lb)
R.
WARNING
_
A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will considerably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, check and, if necessary, bleed the brake system.
CAUTION:
_
After adjusting the brake pedal position,
make sure there is no brake drag.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 36
ADJUSTING THE REAR BRAKE PEDAL/
CHECKING THE BRAKE FLUID LEVEL
CHK
ADJ
3. Adjust:
• rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH”.
EAS00115
CHECKING THE BRAKE FLUID LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable stand.
• Make sure the motorcycle is upright.
_
È
2. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Recommended brake fluid
DOT 4
É
È Front brake
É Rear brake
WARNING
_
• Use only the designated brake fluid.
Other brake fluids may cause the piston
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 fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
CAUTION:
_
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the
brake fluid level, make sure the top of the
brake fluid reservoir is horizontal.
_
3 - 37
CHECKING THE FRONT AND REAR BRAKE PADS AND BRAKE PAD
PINS/ADJUSTING THE REAR BRAKE LIGHT SWITCH
CHK
ADJ
EAS00118
È
CHECKING THE FRONT AND REAR BRAKE
PADS AND BRAKE PAD PINS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check:
• front brake pads
XT660R
Wear indicator grooves 1 have almost disappeared → Replace the brake pads as a
set.
XT660X
Wear limit 2 reached → Replace the brake
pads as a set.
Refer to “REPLACING THE FRONT
BRAKE PADS” in chapter 4.
3. Measure:
• rear brake pads
Wear limit 3 reached → Replace the brake
pads as a set.
Refer to “REPLACING THE REAR BRAKE
PADS” in chapter 4.
É
Ê
3
Rear brake pad wear limit
1.0 mm (0.04 in)
4. Check:
• brake pad pins
Damage/wear → Replace.
È Front brake (XT660R)
É Front brake (XT660X)
Ê Rear brake (XT660R/XT660X)
EAS00128
ADJUSTING THE REAR BRAKE LIGHT
SWITCH
NOTE:
The rear brake light switch is operated by
movement of the brake pedal. The rear brake
light switch is properly adjusted when the
brake light comes on just before the braking
effect starts.
_
3 - 38
ADJUSTING THE REAR BRAKE LIGHT SWITCH/
CHECKING THE FRONT AND REAR BRAKE HOSES
CHK
ADJ
1. Check:
• rear brake light operation timing
Incorrect → Adjust.
2. Adjust:
• rear brake light operation timing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the main body 1 of the rear brake light
switch so that it does not rotate and turn the
adjusting nut 2 in direction a or b until the
rear brake light comes on at the proper
time.
Direction a
Brake light comes on
sooner.
Direction b
Brake light comes on
later.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00131
1
1
2
2
CHECKING THE FRONT AND REAR BRAKE
HOSES
The following procedure applies to all of the
brake hoses and brake hose clamps.
1. Check:
• front brake hose 1
• rear brake hoses 2
Cracks/damage/wear → Replace.
2. Check:
• brake hose clamp
Loose → Tighten the clamp bolt.
3. Hold the motorcycle upright and apply the
brake several times.
4. Check:
• brake hoses
Brake fluid leakage → Replace the damaged hose.
Refer to “FRONT AND REAR BRAKES” in
chapter 4.
3 - 39
BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHK
ADJ
EAS00134
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNING
_
Bleed the hydraulic brake system whenever:
• the system is disassembled.
• a brake hose is loosened, disconnected
or replaced.
• the brake fluid level is very low.
• brake operation is faulty.
NOTE:
• Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir or brake
fluid reservoir to overflow.
• When bleeding the hydraulic brake system,
make sure there is always enough brake
fluid before applying the brake. Ignoring this
precaution could allow air to enter the
hydraulic brake system, considerably lengthening the bleeding procedure.
• If bleeding is difficult, it may be necessary to
let the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the hose have disappeared.
_
È
2
1
1. Bleed:
• hydraulic brake system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
É
a. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
b. Install the diaphragm (brake master cylinder
reservoir or brake fluid reservoir).
c. Connect a clear plastic hose 1 tightly to the
bleed screw 2.
È Front (XT660R)
É Front (XT660X)
Ê Rear (XT660R/XT660X)
Ê
2
1
d. Place the other end of the hose into a container.
e. Slowly apply the brake several times.
f. Fully pull the brake lever or fully press down
the brake pedal and hold it in position.
3 - 40
BLEEDING THE HYDRAULIC BRAKE SYSTEM/
ADJUSTING THE SHIFT PEDAL
CHK
ADJ
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release the
pressure and cause the brake lever to contact
the throttle grip or the brake pedal to fully
extend.
_
h. Tighten the bleed screw, and then release
the brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Tighten the bleed screw to the specified
torque.
T.
Bleed screw
14 Nm (1.4 m · kg, 10 ft · lb)
R.
k. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.
WARNING
_
After bleeding the hydraulic brake system,
check the brake operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ADJUSTING THE SHIFT PEDAL
1. Check:
• shift pedal position
(distance a from the top of the rider footrest to the top of the shift pedal)
Out of specification → Adjust.
Shift pedal position
(from the top of the rider footrest
to the top of the shift pedal)
15.0 mm (0.59 in)
3 - 41
ADJUSTING THE SHIFT PEDAL/
ADJUSTING THE DRIVE CHAIN SLACK
CHK
ADJ
2. Adjust:
• shift pedal position
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a.
b.
c.
d.
2
1
Remove the bolt 1.
Remove the shift pedal 2.
Install the shift pedal at the correct position.
Install the bolt, and then tighten it to the
specified torque.
T.
Shift pedal bolt
16 Nm (1.6 m · kg, 11 ft · lb)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00140
ADJUSTING THE DRIVE CHAIN SLACK
NOTE:
The drive chain slack must be checked at the
tightest point on the chain.
_
CAUTION:
_
A drive chain that is too tight will overload
the engine and other vital parts, and one
that is too loose can skip and damage the
swingarm or cause an accident. Therefore,
keep the drive chain slack within the specified limits.
1. Stand the motorcycle on a level surface.
WARNING
_
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so
that the rear wheel is elevated.
_
2. Spin the rear wheel several times and find
the tightest position of the drive chain.
3 - 42
ADJUSTING THE DRIVE CHAIN SLACK
CHK
ADJ
3. Check:
• drive chain slack a
Out of specification → Adjust.
Drive chain slack
40.0 ~ 55.0 mm (1.57 ~ 2.17 in)
4. Adjust:
• drive chain slack
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the wheel axle nut 1.
b. Loosen both locknuts 2.
c. Turn both adjusting nuts 3 in direction a or
b until the specified drive chain slack is
obtained.
Direction a
Drive chain is tightened.
Direction b
Drive chain is loosened.
NOTE:
To maintain the proper wheel alignment, adjust
both sides evenly.
_
d. Tighten both locknuts to the specified
torque.
T.
Locknut
16 Nm (1.6 m · kg, 11 ft · lb)
R.
e. Tighten the wheel axle nut to the specified
torque.
T.
Wheel axle nut
105 Nm (10.5 m · kg, 75 ft · lb)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 43
LUBRICATING THE DRIVE CHAIN/
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
EAS00142
LUBRICATING THE DRIVE CHAIN
The drive chain consists of many interacting
parts. If the drive chain is not maintained properly, it will wear out quickly. Therefore, the
drive chain should be serviced, especially
when the motorcycle is used in dusty areas.
This motorcycle has a drive chain with small
rubber O-rings between each side plate.
Steam cleaning, high-pressure washing, certain solvents, and the use of a coarse brush
can damage these O-rings. Therefore, use
only kerosene to clean the drive chain. Wipe
the drive chain dry and thoroughly lubricate it
with engine oil or chain lubricant that is suitable for O-ring chains. Do not use any other
lubricants on the drive chain since they may
contain solvents that could damage the Orings.
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
EAS00146
CHECKING AND ADJUSTING THE
STEERING HEAD
1. Stand the motorcycle on a level surface.
WARNING
_
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so
that the front wheel is elevated.
_
2. Check:
• steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness → Adjust the steering
head.
3 - 44
CHECKING AND ADJUSTING THE STEERING HEAD
1
1
2
1
2
3
CHK
ADJ
3.
•
•
•
•
•
Remove:
handlebar protector cover (XT660X)
handlebar protector (XT660X)
handlebar holder caps
upper handlebar holders 1
handlebar 2
4.
•
5.
•
•
•
Loosen:
upper bracket pinch bolts 1
Remove:
steering stem nut 2
washer
upper bracket 3
6. Adjust:
• steering head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the lock washer 1, the upper ring
nut 2, and the rubber washer 3.
b. Loosen the lower ring nut 4, and then
tighten it to the specified torque with a
steering nut wrench 5.
NOTE:
Set the torque wrench at a right angle to the
steering nut wrench.
_
Steering nut wrench
90890-01403
T.
R.
Lower ring nut (initial tightening
torque)
43 Nm (4.3 m · kg, 31 ft · lb)
c. Loosen the lower ring nut completely, and
then tighten it to the specified torque.
WARNING
_
Do not overtighten the lower ring nut.
T.
R.
3 - 45
Lower ring nut (final tightening
torque)
7 Nm (0.7 m · kg, 5.1 ft · lb)
CHECKING AND ADJUSTING THE STEERING HEAD/
CHECKING THE FRONT FORK
CHK
ADJ
d. Check the steering head for looseness or
binding by turning the front fork all the way
in both directions. If any binding is felt,
remove the lower bracket and check the
upper and lower bearings.
Refer to “STEERING HEAD” in chapter 4.
e. Install the rubber washer 2.
f. Install the upper ring nut 3.
g. Finger tighten the upper ring nut 3, and
then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten
the upper ring nut until their slots are
aligned.
h. Install the lock washer 1.
NOTE:
Make sure the lock washer tabs a sit correctly
in the ring nut slots b.
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7.
•
•
•
Install:
upper bracket
washer
steering stem
T.
R.
130 Nm (13.0 m · kg, 94 ft · lb)
8. Tighten:
• upper bracket pinch bolts
T.
R.
23 Nm (2.3 m · kg, 17 ft · lb)
9. Install:
• handlebar
• upper handlebar holders
T.
R.
23 Nm (2.3 m · kg, 17 ft · lb)
• handlebar holder caps
• handlebar protector (XT660X)
• handlebar protector cover (XT660X)
Refer to “HANDLEBAR” in chapter 4.
EAS00149
CHECKING THE FRONT FORK
1. Stand the motorcycle on a level surface.
WARNING
_
Securely support the motorcycle so that
there is no danger of it falling over.
1
2
2. Check:
• inner tubes 1
Damage/scratches → Replace.
• oil seals 2
Oil leakage → Replace.
3 - 46
CHECKING THE FRONT FORK/ADJUSTING THE REAR
SHOCK ABSORBER ASSEMBLY
CHK
ADJ
3. Hold the motorcycle upright and apply the
front brake.
4. Check:
• front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Rough movement → Repair.
Refer to “FRONT FORK” in chapter 4.
EAS00156
ADJUSTING THE REAR SHOCK
ABSORBER ASSEMBLY
WARNING
_
Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload
CAUTION:
_
Never go beyond the maximum or minimum adjustment positions.
1. Adjust:
• spring preload
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Adjust the spring preload with the special
wrench provided in the owner’s tool kit.
b. Turn the adjusting ring 1 in direction a or
b.
c. Align the desired position on the adjusting
ring with the stopper 2.
Direction a
Spring preload is
increased (suspension
is harder).
Direction b
Spring preload is
decreased (suspension
is softer).
Adjusting positions
Minimum: 1
Standard: 2
Maximum: 5
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 47
CHECKING THE TIRES
CHK
ADJ
EAS00166
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Check:
• tire pressure
Out of specification → Regulate.
WARNING
_
• The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.
• The tire pressure and the suspension
must be adjusted according to the total
weight (including cargo, rider, passenger
and accessories) and the anticipated
riding speed.
• Operation of an overloaded motorcycle
could cause tire damage, an accident or
an injury.
NEVER OVERLOAD THE MOTORCYCLE.
XT660R
Basic weight
(with oil and a
full fuel tank)
181.0 kg (399 lb)
Maximum
load*
186.0 kg (410 lb)
Cold tire
pressure
3 - 48
Front
Rear
Up to 90 kg
load*
200 kPa
200 kPa
(2.00 kgf/cm2, (2.00 kgf/cm2,
29 psi)
29 psi)
90 kg ~ maximum load*
200 kPa
225 kPa
2
(2.00 kgf/cm , (2.25 kgf/cm2,
29 psi)
33 psi)
Off-road
riding
200 kPa
200 kPa
2
(2.00 kgf/cm , (2.00 kgf/cm2,
29 psi)
29 psi)
CHECKING THE TIRES
CHK
ADJ
XT660X
Basic weight
(with oil and a
full fuel tank)
186.0 kg (410 lb)
Maximum
load*
186.0 kg (410 lb)
Cold tire
pressure
Front
Rear
Up to 90 kg
load*
210 kPa
210 kPa
(2.10 kgf/cm2, (2.10 kgf/cm2,
30 psi)
30 psi)
90 kg ~ maximum load*
230 kPa
220 kPa
(2.20 kgf/cm2, (2.30 kgf/cm2,
31 psi)
33 psi)
* Total weight of rider, passenger, cargo and
accessories
WARNING
_
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.
2. Check:
• tire surfaces
Damage/wear → Replace the tire.
Minimum tire tread depth
1.6 mm (0.063 in)
1 Tire tread depth
2 Sidewall
3 Wear indicator
WARNING
_
• Do not use a tubeless tire on a wheel
designed only for tube tires to avoid tire
failure and personal injury from sudden
deflation.
• When using tube tires, be sure to install
the correct tube.
• Always replace a new tube tire and a new
tube as a set.
• To avoid pinching the tube, make sure the
wheel rim band and tube are centered in
the wheel groove.
3 - 49
CHECKING THE TIRES
È
É
CHK
ADJ
• Patching a punctured tube is not recommended. If it is absolutely necessary to
do so, use great care and replace the tube
as soon as possible with a good quality
replacement.
È Tire
É Wheel
Tube wheel
Tube tire only
Tubeless wheel
Tube or tubeless
tire
• After extensive tests, the tires listed
below have been approved by Yamaha
Motor Co., Ltd. for this model. The front
and rear tires should always be by the
same manufacturer and of the same
design. No guarantee concerning handling characteristics can be given if a tire
combination other than one approved by
Yamaha is used on this motorcycle.
Front tire (XT660R)
Manufacturer
Model
Size
METZELER
TOURANCE
FRONT
90/9021M/C 54S
MICHELIN
SIRAC
90/9021M/C 54T
Manufacturer
Model
Size
METZELER
TOURANCE
130/8017M/C 65S
MICHELIN
SIRAC A
130/8017M/C 65T
Manufacturer
Model
Size
PIRELLI
DRAGON
120/70R
17M/C 58H
Manufacturer
Model
Size
PIRELLI
DRAGON
160/60R
17M/C 69H
Rear tire (XT660R)
Front tire (XT660X)
Rear tire (XT660X)
3 - 50
CHECKING THE TIRES/
CHECKING AND TIGHTENING THE SPOKES
CHK
ADJ
WARNING
_
New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed before
any high-speed riding is done.
NOTE:
For tires with a direction of rotation mark 1:
• Install the tire with the mark pointing in the
direction of wheel rotation.
• Align the mark 2 with the valve installation
point.
_
EAS00169
CHECKING AND TIGHTENING THE
SPOKES
The following procedure applies to all of the
spokes.
1. Check:
• spoke 1
Bends/damage → Replace.
Loose → Tighten.
Tap the spokes with a screwdriver.
NOTE:
A tight spoke will emit a clear, ringing tone; a
loose spoke will sound flat.
_
2. Tighten:
• spoke
(with a spoke wrench 2)
T.
R.
3 Nm (0.3 m · kg, 2.2 ft · lb)
NOTE:
Be sure to tighten the spokes before and after
break in.
_
3 - 51
CHECKING AND LUBRICATING THE CABLES/
LUBRICATING THE LEVERS AND BRAKE PEDAL/
LUBRICATING THE SIDESTAND
CHK
ADJ
EAS00170
CHECKING AND LUBRICATING THE
CABLES
The following procedure applies to all of the
inner and outer cables.
WARNING
_
Damaged outer cable may cause the cable
to corrode and interfere with its movement.
Replace damaged outer cable and inner
cables as soon as possible.
1. Check:
• outer cable
Damage → Replace.
2. Check:
• cable operation
Rough movement → Lubricate.
Recommended lubricant
Engine oil or a suitable cable
lubricant
NOTE:
Hold the cable end upright and pour a few
drops of lubricant into the cable sheath or use
a suitable lubricating device.
_
EAS00171
LUBRICATING THE LEVERS AND BRAKE
PEDAL
Lubricate the pivoting point and metal-to-metal
moving parts of the levers and brake pedal.
Recommended lubricant
Lithium-soap-based grease
EAS00172
LUBRICATING THE SIDESTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.
Recommended lubricant
Lithium-soap-based grease
3 - 52
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
EAS00178
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE
BATTERY
WARNING
_
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
• Wear protective eye gear when handling
or working near batteries.
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
• DO NOT SMOKE when charging or handling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk followed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
CAUTION:
_
• This is a sealed battery. Never remove the
sealing caps because the balance
between cells will not be maintained and
battery performance will deteriorate.
• Charging time, charging amperage and
charging voltage for an MF battery are different from those of conventional batteries. The MF battery should be charged as
explained in the charging method illustrations. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging the battery.
3 - 53
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
NOTE:
Since MF batteries are sealed, it is not possible to check the charge state of the battery by
measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to
be checked by measuring the voltage at the
battery terminals.
_
1. Remove:
• seat
Refer to “COWLING AND COVER”.
• battery cover
Refer to “AIR FILTER CASE”.
2. Disconnect:
• battery leads
(from the battery terminals)
1
2
CAUTION:
_
First, disconnect the negative battery lead
1, then the positive battery lead 2.
3.
•
4.
•
Remove:
battery
Check:
battery charge
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Open-circuit voltage (V)
a. Connect a pocket tester to the battery terminals.
Positive tester probe →
positive battery terminal
Negative tester probe →
negative battery terminal
Relationship between the open-circuit voltage and the
charging time at 20 °C (68 °F)
NOTE:
• The charge state of an MF battery can be
checked by measuring its open-circuit voltage (i.e., the voltage when the positive battery terminal is disconnected).
• No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.
_
Charging time (hours)
These values vary with the temperature, the condition of the battery
plates, and the electrolyte level.
b. Check the charge of the battery, as shown
in the charts and the following example.
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20 ~ 30%
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3 - 54
CHECKING AND CHARGING THE BATTERY
Ambient temperature
Open-circuit voltage (V)
Charging
CHK
ADJ
5. Charge:
• battery
(refer to the appropriate charging method
illustration)
WARNING
_
Do not quick charge a battery.
Time (minutes)
Check the open-circuit
voltage.
CAUTION:
_
Open-circuit voltage (V)
Ambient
temperature
Charging condition of the battery (%)
• Never remove the MF battery sealing
caps.
• Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause
battery overheating and battery plate
damage.
• If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
• When charging a battery, be sure to
remove it from the motorcycle. (If charging has to be done with the battery
mounted on the motorcycle, disconnect
the negative battery lead from the battery
terminal.)
• To reduce the chance of sparks, do not
plug in the battery charger until the battery charger leads are connected to the
battery.
• Before removing the battery charger lead
clips from the battery terminals, be sure
to turn off the battery charger.
• Make sure the battery charger lead clips
are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may
generate heat in the contact area and a
weak clip spring may cause sparks.
• If the battery becomes hot to the touch at
any time during the charging process,
disconnect the battery charger and let the
battery cool before reconnecting it. Hot
batteries can explode!
• As shown in the illustration, the open-circuit voltage of an MF battery stabilizes
about 30 minutes after charging has been
completed. Therefore, wait 30 minutes
after charging is completed before measuring the open-circuit voltage.
3 - 55
CHK
ADJ
CHECKING AND CHARGING THE BATTERY
Charging method using a variable-current (voltage) charger
Charger
Ammeter
Measure the open-circuit
voltage prior to charging.
Connect a charger and
ammeter to the battery and
start charging.
YES
Is the amperage higher
than the standard charging
amperage written on the
battery?
NOTE:
Leave the battery unused for
more than 30 minutes before
measuring its open-circuit voltage.
NOTE:
Set the charging voltage to 16 ~
17 V. (If the charging voltage is
lower, charging will be insufficient,
if it is higher, the battery will be
over-charged.)
NO
Adjust the charging voltage to
20 ~ 25 V.
Adjust the voltage to obtain the
standard charging amperage.
YES
Monitor the amperage for
3 ~ 5 minutes. Is the standard
charging amperage exceeded?
NO
If the amperage does not
exceed the standard charging
amperage after 5 minutes,
replace the battery.
Set the timer to the charging
time determined by the opencircuit voltage.
Refer to “CHECKING AND
CHARGING THE BATTERY”.
If the required charging time exceeds 5 hours, it is advisable to check the
charging amperage after 5 hours. If there is any change in the amperage,
readjust the voltage to obtain the standard charging amperage.
Leave the battery unused for more than 30 minutes before measuring its
open-circuit voltage.
12.8 V → Charging is complete.
12.0 ~ 12.7 V → Recharging is required.
Under 12.0 V → Replace the battery.
3 - 56
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
Charging method using a constant voltage charger
NOTE:
Leave the battery unused for
more than 30 minutes before
measuring its open-circuit voltage.
Measure the open-circuit
voltage prior to charging.
Connect a charger and
ammeter to the battery
and start charging.
YES
Is the amperage higher
than the standard charging amperage written on
the battery?
Charge the battery until the charging
voltage reaches 15 V.
NO
This type of battery charger cannot
charge an MF battery. A variable-voltage charger is recommended.
NOTE:
Set the charging time to a maximum of 20 hours.
Charger
Leave the battery unused for more than
30 minutes before measuring its open-circuit voltage.
12.8 V → Charging is complete.
12.0 ~ 12.7 V → Recharging is required.
Under 12.0 V → Replace the battery.
Ammeter
Voltmeter
CAUTION:
Constant amperage chargers are not
suitable for charging MF batteries.
3 - 57
CHECKING AND CHARGING THE BATTERY/
CHECKING THE FUSES
6.
•
7.
•
2
1
CHK
ADJ
Install:
battery
Connect:
battery leads
(to the battery terminals)
CAUTION:
_
First, connect the positive battery lead 1,
then the negative battery lead 2.
8. Check:
• battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
9. Lubricate:
• battery terminals
Recommended lubricant
Dielectric grease
10.Install:
• battery cover
Refer to “AIR FILTER CASE”.
• seat
Refer to “COWLING AND COVER”.
EAS00181
CHECKING THE FUSES
The following procedure applies to all of the
fuses.
CAUTION:
_
To avoid a short circuit, always set the
main switch to “OFF” when checking or
replacing a fuse.
1. Remove:
• seat
• left side panel
Refer to “COWLING AND COVER”.
3 - 58
CHECKING THE FUSES
3
2
2.
•
•
•
CHK
ADJ
Check:
fuse 1
fuse box 1 2
fuse box 2 3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and
check the continuity.
1
NOTE:
Set the pocket tester selector to “Ω × 1”.
_
Pocket tester
90890-03112
b. If the pocket tester indicates “∞”, replace
the fuse.
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3. Replace:
• blown fuse
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a. Set the main switch to “OFF”.
b. Install a new fuse of the correct amperage
rating.
c. Set on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.
Fuses
Amperage
Q’ty
rating
Main
30 A
1
Headlight
20 A
1
Signaling system
10 A
1
Ignition
10 A
1
Fuel injection system
10 A
1
Parking lighting system
10 A
1
Radiator fan motor
7.5 A
1
Backup (immobilizer
unit, meter assembly)
10 A
1
Reserve
30 A
1
Reserve
20 A
1
Reserve
10 A
1
Reserve
7.5 A
1
3 - 59
CHECKING THE FUSES/
REPLACING THE HEADLIGHT BULB
CHK
ADJ
WARNING
_
Never use a fuse with an amperage rating
other than that specified. Improvising or
using a fuse with the wrong amperage rating may cause extensive damage to the
electrical system, cause the lighting and
ignition systems to malfunction and could
possibly cause a fire.
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4. Install:
• left side panel
• seat
Refer to “COWLING AND COVER”.
EAS00182
REPLACING THE HEADLIGHT BULB
1. Remove:
• front fender
• front fork protector
• front cowling
Refer to “COWLING AND COVER”.
2.
•
3.
•
Disconnect:
headlight coupler 1
Remove:
headlight bulb holder cover 2
4. Remove:
• headlight bulb holder 1
• headlight bulb 2
WARNING
_
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
3 - 60
REPLACING THE HEADLIGHT BULB/
ADJUSTING THE HEADLIGHT BEAM
5.
•
•
•
CHK
ADJ
Install:
headlight bulb New
headlight bulb holder
headlight bulb holder cover
CAUTION:
_
Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be
adversely affected. If the headlight bulb
gets soiled, thoroughly clean it with a cloth
moistened with alcohol or lacquer thinner.
6.
•
7.
•
•
•
Connect:
headlight coupler
Install:
front cowling
front fork protector
front fender
Refer to “COWLING AND COVER”.
EAS00186
b
ADJUSTING THE HEADLIGHT BEAM
1. Adjust:
• headlight beam (vertically)
a
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1
a. Turn the adjusting screw 1 in direction a
or b.
Direction a
Headlight beam is lowered.
Direction b
Headlight beam is
raised.
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3 - 61
SETTING THE DIGITAL CLOCK
CHK
ADJ
EAS00187
SETTING THE DIGITAL CLOCK
1. Set:
• digital clock 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “ON”.
b. Push the “SELECT” button 2 and “RESET”
button 3 together for at least two seconds.
c. When the hour digits start flashing, push
the “RESET” button to set the hours.
d. Push the “SELECT” button and the minute
digits will start flashing.
e. Push the “RESET” button to set the minutes.
f. Push the “SELECT” button to start the
clock.
NOTE:
After reconnecting the battery, the clock indication is 1:00 and must be set to the correct
time.
_
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3 - 62
CHAS
4
CHAS
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISC............................................................... 4-1
FRONT WHEEL ........................................................................................4-2
REMOVING THE FRONT WHEEL............................................................ 4-3
CHECKING THE FRONT WHEEL ............................................................ 4-3
CHECKING THE FRONT BRAKE DISC ................................................... 4-6
INSTALLING THE FRONT WHEEL .......................................................... 4-7
ADJUSTING THE FRONT WHEEL STATIC BALANCE ........................... 4-8
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET............... 4-10
REAR WHEEL......................................................................................... 4-10
BRAKE DISC AND REAR WHEEL SPROCKET..................................... 4-12
REMOVING THE REAR WHEEL ............................................................ 4-14
CHECKING THE REAR WHEEL............................................................. 4-14
CHECKING THE REAR BRAKE DISC....................................................4-15
CHECKING THE REAR WHEEL DRIVE HUB ........................................ 4-16
CHECKING AND REPLACING THE REAR WHEEL SPROCKET .........4-17
INSTALLING THE REAR WHEEL........................................................... 4-17
ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-18
FRONT AND REAR BRAKES....................................................................... 4-19
FRONT BRAKE PADS (XT660R)............................................................ 4-19
FRONT BRAKE PADS (XT660X)............................................................ 4-20
REAR BRAKE PADS............................................................................... 4-21
REPLACING THE FRONT BRAKE PADS .............................................. 4-22
REPLACING THE REAR BRAKE PADS................................................. 4-24
FRONT BRAKE MASTER CYLINDER....................................................4-26
REAR BRAKE MASTER CYLINDER ......................................................4-29
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER ............. 4-32
DISASSEMBLING THE REAR BRAKE MASTER CYLINDER................ 4-32
CHECKING THE FRONT AND REAR BRAKE MASTER
CYLINDERS ........................................................................................... 4-33
ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER
CYLINDER ............................................................................................. 4-34
ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................4-36
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-36
FRONT BRAKE CALIPER (XT660R) ......................................................4-39
FRONT BRAKE CALIPER (XT660X) ......................................................4-41
REAR BRAKE CALIPER .........................................................................4-43
REMOVING THE FRONT BRAKE CALIPER..........................................4-45
REMOVING THE REAR BRAKE CALIPER ............................................4-45
CHECKING THE FRONT AND REAR BRAKE CALIPERS ....................4-46
INSTALLING THE FRONT BRAKE CALIPER ........................................ 4-47
INSTALLING THE REAR BRAKE CALIPER...........................................4-49
CHAS
FRONT FORK................................................................................................4-51
REMOVING THE FRONT FORK LEGS.................................................. 4-55
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-55
CHECKING THE FRONT FORK LEGS .................................................. 4-57
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-58
INSTALLING THE FRONT FORK LEGS ................................................ 4-62
HANDLEBAR ................................................................................................4-63
REMOVING THE HANDLEBAR..............................................................4-65
CHECKING THE HANDLEBAR ..............................................................4-65
INSTALLING THE HANDLEBAR ............................................................ 4-65
STEERING HEAD.......................................................................................... 4-69
LOWER BRACKET ................................................................................. 4-69
REMOVING THE LOWER BRACKET.....................................................4-71
CHECKING THE STEERING HEAD .......................................................4-71
INSTALLING THE STEERING HEAD .....................................................4-72
REAR SHOCK ABSORBER ASSEMBLY ....................................................4-74
HANDLING THE REAR SHOCK ABSORBER ........................................ 4-76
DISPOSING OF A REAR SHOCK ABSORBER ..................................... 4-76
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY................... 4-77
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-78
CHECKING THE CONNECTING ARMS AND RELAY ARM .................. 4-78
INSTALLING THE RELAY ARM..............................................................4-78
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ................. 4-79
SWINGARM AND DRIVE CHAIN.................................................................. 4-80
REMOVING THE SWINGARM................................................................4-82
REMOVING THE DRIVE SPROCKET ....................................................4-83
REMOVING THE DRIVE CHAIN............................................................. 4-83
CHECKING THE SWINGARM ................................................................4-83
CHECKING THE DRIVE CHAIN ............................................................. 4-84
INSTALLING THE SWINGARM ..............................................................4-86
FRONT WHEEL AND BRAKE DISC
CHAS
EAS00512
CHASSIS
FRONT WHEEL AND BRAKE DISC
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib)
T.
R.
59 Nm (5.9 m • kg, 43 ft • Ib)
3
1
2
6
T.
R.
40 Nm (4.0 m • kg, 29 ft • Ib)
7
5
4
(6)
LT
T.
R.
Order
Job/Part
Removing the front wheel and brake
disc
Q’ty
23 Nm (2.3 m • kg, 17 ft • Ib)
Remarks
Remove the parts in the order listed.
NOTE:
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
_
1
2
3
4
5
6
7
Brake caliper
Wheel axle pinch bolt
Front wheel axle
Front wheel
Spacer (left)
Spacer (right)
Front brake disc
1
2
1
1
1
1
1
Loosen.
Refer to “REMOVING
THE FRONT WHEEL” and
“INSTALLING THE
FRONT WHEEL”.
For installation, reverse the removal procedure.
4-1
FRONT WHEEL AND BRAKE DISC
CHAS
EAS00518
FRONT WHEEL
LS
New 1
2
3
2
1 New
LS
Order
1
2
3
Job/Part
Disassembling the front wheel
Oil seal
Bearing
Spacer
Q’ty
Remarks
Remove the parts in the order listed.
2
2
1
For assembly, reverse the disassembly
procedure.
4-2
FRONT WHEEL AND BRAKE DISC
CHAS
EAS00519
REMOVING THE FRONT WHEEL
1. Stand the motorcycle on a level surface.
WARNING
_
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so
that the front wheel is elevated.
_
2. Remove:
• brake caliper
NOTE:
Do not apply the brake lever when removing
the brake caliper.
_
3. Elevate:
• front wheel
NOTE:
Place the motorcycle on a suitable stand so
that the front wheel is elevated.
_
EAS00526
CHECKING THE FRONT WHEEL
1. Check:
• wheel axle
Roll the wheel axle on a flat surface.
Bends → Replace.
WARNING
_
Do not attempt to straighten a bent wheel
axle.
2. Check:
• tire
• front wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” in chapter 3.
4-3
FRONT WHEEL AND BRAKE DISC
CHAS
3. Check:
• spokes
Bends/damage → Replace.
Loose → Tighten.
Tap the spokes with a screwdriver.
NOTE:
A tight spoke will emit a clear, ringing tone, a
loose spoke will sound flat.
_
4. Tighten:
• spokes 1
(with a spoke wrench 2)
T.
R.
3 Nm (0.3 m · kg, 2.2 ft · lb)
NOTE:
After tightening the spokes, measure the front
wheel runout.
_
5. Measure:
• radial wheel runout 1
• lateral wheel runout 2
Over the specified limits → Replace.
radial wheel runout limit
2.0 mm (0.08 in)
lateral wheel runout limit
2.0 mm (0.08 in)
6. Check:
• collars
Damage/wear → Replace.
WARNING
_
After mounting a new tire, ride conservatively for a while to become accustomed to
the “feel” of the new tire and to allow the
tire to seat itself properly in the rim. Failure
to do so could lead to an accident with possible injury to the rider or damage to the
motorcycle.
4-4
FRONT WHEEL AND BRAKE DISC
CHAS
7. Check:
• wheel bearings
Front wheel turns roughly or is loose →
Replace the wheel bearings.
• oil seals
Damage/wear → Replace.
8. Replace:
• oil seals New
• wheel bearings
2
1
New
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a. Clean the outside of the front wheel hub.
b. Remove the oil seals 1 with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag 2
between the screwdriver and the wheel surface.
_
c. Remove the wheel bearings 3 with a general bearing puller.
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
CAUTION:
_
Do not contact the wheel bearing inner race
4 or balls 5. Contact should be made only
with the outer race 6.
NOTE:
Use a socket 7 that matches the diameter of
the wheel bearing outer race and oil seal.
_
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4-5
FRONT WHEEL AND BRAKE DISC
CHAS
EAS00527
CHECKING THE FRONT BRAKE DISC
1. Check:
• brake disc
Damage/galling → Replace.
2. Measure:
• brake disc deflection
Out of specification → Correct the brake
disc deflection or replace the brake disc.
Brake disc deflection limit (maximum)
0.15 mm (0.006 in)
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a. Place the motorcycle on a suitable stand so
that the front wheel is elevated.
b. Before measuring the front brake disc
deflection, turn the handlebar to the left or
right to ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 3.0 mm (0.12 in)
below the edge of the brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Measure:
• brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification → Replace.
Brake disc thickness limit (minimum)
4.0 mm (0.16 in)
4-6
FRONT WHEEL AND BRAKE DISC
CHAS
4. Adjust:
• brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages and in a
crisscross pattern.
_
T.
R.
Brake disc bolt
23 Nm (2.3 m · kg, 17 ft · lb)
LOCTITE®
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be
brought within specification, replace the
brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00542
INSTALLING THE FRONT WHEEL
1. Lubricate:
• oil seal lips
Recommended lubricant
Lithium-soap-based grease
4-7
FRONT WHEEL AND BRAKE DISC
CHAS
T.
2. Tighten:
• wheel axle 1
59 Nm (5.9 m · kg, 43 ft · lb)
• wheel axle pinch bolts 2
R.
T.
R.
18 Nm (1.8 m · kg, 13 ft · lb)
CAUTION:
_
Before tightening the wheel axle nut, push
down hard on the handlebar several times
and check if the front fork rebounds
smoothly.
NOTE:
To tighten the wheel axle pinch bolt, tighten
the outer and inner bolts to the specified
torque, and then tighten the outer bolt to the
specified torque again.
3. Install:
• brake caliper bolts
T.
R.
40 Nm (4.0 m · kg, 29 ft · lb)
WARNING
_
Make sure the brake hose is routed properly.
EAS00548
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
NOTE:
• After replacing the tire, wheel or both, the
front wheel static balance should be
adjusted.
• Adjust the front wheel static balance with the
brake disc installed.
_
1. Remove:
• balancing weight(s)
4-8
FRONT WHEEL AND BRAKE DISC
CHAS
2. Find:
• front wheel’s heavy spot
NOTE:
Place the front wheel on a suitable balancing
stand.
_
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Spin the front wheel.
b. When the front wheel stops, put an “X1”
mark at the bottom of the wheel.
c. Turn the front wheel 90° so that the “X1”
mark is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X2” mark at
the bottom of the wheel.
f. Repeat steps (d) through (f) several times
until all the marks come to rest at the same
spot.
g. The spot where all the marks come to rest
is the front wheel’s heavy spot “X”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
• front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a balancing weight 1 onto the rim
exactly opposite the heavy spot “X”.
NOTE:
Start with the lightest weight.
_
b. Turn the front wheel 90° so that the heavy
spot is positioned as shown.
c. If the heavy spot does not stay in that position, install a heavier weight.
d. Repeat steps (b) and (c) until the front
wheel is balanced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the front wheel and make sure it stays
at each position shown.
b. If the front wheel does not remain stationary
at all of the positions, rebalance it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-9
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
CHAS
EAS00550
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET
REAR WHEEL
T.
R.
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
105 Nm (10.5 m • kg, 75 ft • lb)
13
T.
R.
3
16 Nm (1.6 m • kg, 11 ft • Ib)
6
8
7
9
LS
14
5
14
4
4
5
12
T.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
R.
1
11
10
R.
T.
R.
Order
T.
2
16 Nm (1.6 m • kg, 11 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Job/Part
Removing the rear wheel
Q’ty
Remarks
Remove the parts in the order listed.
NOTE:
Place the motorcycle on a suitable stand
so that the rear wheel is elevated.
_
1
2
3
4
5
6
7
8
9
Stabilizer
Chain cover
Chain cover
Locknut
Adjusting nut
Wheel axle nut
Washer (N)
Rear wheel axle
Washer (O)
1
1
1
2
2
1
1
1
1
4 - 10
XT660X
XT660X
XT660R
Loosen.
Loosen.
Refer to “INSTALLING THE REAR
WHEEL”.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
T.
R.
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
CHAS
105 Nm (10.5 m • kg, 75 ft • lb)
13
T.
R.
3
16 Nm (1.6 m • kg, 11 ft • Ib)
6
8
7
9
LS
14
5
14
4
4
5
12
T.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
R.
1
11
10
R.
T.
R.
Order
10
T.
2
16 Nm (1.6 m • kg, 11 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Job/Part
Rear wheel
11
12
13
Spacer (left)
Spacer (right)
Brake caliper
14
Chain puller
Q’ty
Remarks
1
Refer to “REMOVING THE REAR
WHEEL” and “INSTALLING THE REAR
WHEEL”.
1
1
1
Refer to “REMOVING THE REAR
WHEEL” and “INSTALLING THE REAR
WHEEL”.
2
For installation, reverse the removal procedure.
4 - 11
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
CHAS
BRAKE DISC AND REAR WHEEL SPROCKET
T.
R.
13 Nm (1.3 m • kg, 9.4 ft • Ib)
7
LT
(6)
6
4
5
LS
3
New
1
2
6
LS
(6)
T.
R.
Order
1
2
3
4
5
6
7
69 Nm (6.9 m • kg, 50 ft • Ib)
Job/Part
Removing the brake disc and rear
wheel sprocket
Oil seal
Rear wheel sprocket
Bearing
Rear wheel drive hub
Spacer
Rear wheel drive hub damper
Rear brake disc
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1
1
1
4
1
For installation, reverse the removal procedure.
4 - 12
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
Order
1
2
3
Job/Part
Disassembling the rear wheel
Bearing
Oil seal
Spacer
Q’ty
CHAS
Remarks
Remove the parts in the order listed.
2
1
1
For assembly, reverse the disassembly
procedure.
4 - 13
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
CHAS
EAS00561
REMOVING THE REAR WHEEL
1. Stand the motorcycle on a level surface.
WARNING
_
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so
that the rear wheel is elevated.
_
2.
•
•
3.
•
•
•
•
•
•
•
Loosen:
locknut 1
adjusting nut 2
Remove:
stabilizer (XT660X)
chain cover
wheel axle nut 3
washer (N)
wheel axle
washer (O)
rear wheel
NOTE:
Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
_
4. Remove:
• brake caliper
NOTE:
Do not depress the brake pedal when removing the brake caliper.
_
EAS00566
CHECKING THE REAR WHEEL
1. Check:
• wheel axle
• rear wheel
• wheel bearings
• oil seals
Refer to “CHECKING THE
WHEEL”.
4 - 14
FRONT
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
CHAS
2. Check:
• tire
• rear wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” in chapter 3.
3. Check:
• spokes
Refer to “CHECKING THE FRONT
WHEEL”.
4. Measure:
• radial wheel runout
• lateral wheel runout
Refer to “CHECKING THE FRONT
WHEEL”.
EAS00527
CHECKING THE REAR BRAKE DISC
1. Check:
• brake disc
Damage/galling → Replace.
2. Measure:
• brake disc deflection
Out of specification → Correct the brake
disc deflection or replace the brake disc.
Brake disc deflection limit (maximum)
0.15 mm (0.006 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the motorcycle on a suitable stand so
that the rear wheel is elevated.
b. Remove the brake caliper.
c. Hold the dial gauge at a right angle against
the brake disc surface.
d. Measure the deflection 1.5 mm (0.06 in)
below the edge of the brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 15
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
CHAS
3. Measure:
• brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification → Replace.
Brake disc thickness limit (minimum)
4.5 mm (0.18 in)
4. Adjust:
• brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages and in a
crisscross pattern.
_
T.
R.
Brake disc bolt
13 Nm (1.3 m · kg, 9.4 ft · lb)
LOCTITE®
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be
brought within specification, replace the
brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00567
1
2
CHECKING THE REAR WHEEL DRIVE HUB
1. Check:
• rear wheel drive hub 1
Cracks/damage → Replace.
• rear wheel drive hub dampers 2
Damage/wear → Replace.
4 - 16
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
CHAS
EAS00568
CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
1. Check:
• rear wheel sprocket
More than 1/4 tooth a wear → Replace the
rear wheel sprocket.
Bent teeth → Replace the rear wheel
sprocket.
b Correct
1 Drive chain roller
2 Rear wheel sprocket
2. Replace:
• rear wheel sprocket
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the self-locking nuts and the rear
wheel sprocket.
b. Clean the rear wheel drive hub with a clean
cloth, especially the surfaces that contact
the sprocket.
c. Install the new rear wheel sprocket.
T.
R.
Rear wheel sprocket self-locking
nut
69 Nm (6.9 m · kg, 50 ft · lb)
NOTE:
Tighten the self-locking nuts in stages and in a
crisscross pattern.
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00571
INSTALLING THE REAR WHEEL
1. Lubricate:
• wheel axle
• oil seal lips
Recommended lubricant
Lithium-soap-based grease
4 - 17
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
2.
•
•
•
•
•
CHAS
Install:
rear wheel
washer (O)
rear axle
washer (N)
rear axle nut
NOTE:
Install the washer with the “N” mark on the
right-hand side of the vehicle and the washer
with the “O” mark on the left-hand side of the
vehicle. Be sure to install both washers with
the marks facing outward.
3. Adjust:
• drive chain slack
Drive chain slack
40.0 ~ 55.0 mm (1.57 ~ 2.17 in)
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
4. Tighten:
• wheel axle nut
T.
R.
105 Nm (10.5 m · kg, 75 ft · lb)
5. Install:
• chain cover
• chain cover bolts
T.
R.
7 Nm (0.7 m · kg, 5.1 ft · lb)
• stabilizer (XT660X)
T.
R.
7 Nm (0.7 m · kg, 5.1 ft · lb)
EAS00575
ADJUSTING THE REAR WHEEL STATIC
BALANCE
NOTE:
• After replacing the tire, wheel or both, the
rear wheel static balance should be adjusted.
• Adjust the rear wheel static balance with the
brake disc and rear wheel drive hub
installed.
_
1. Adjust:
• rear wheel static balance
Refer to “ADJUSTING THE
WHEEL STATIC BALANCE”.
4 - 18
FRONT
CHAS
FRONT AND REAR BRAKES
EAS00577
FRONT AND REAR BRAKES
FRONT BRAKE PADS (XT660R)
T.
R.
14 Nm (1.4 m • kg, 10 ft • Ib)
5
4
6
3
1
5
2
1
T.
R.
Order
1
2
3
4
5
6
40 Nm (4.0 m • kg, 29 ft • Ib)
Job/Part
Removing the front brake pads
Brake caliper bolt
Brake pad clip
Brake pad pin
Brake pad
Brake pad spring
Bleed screw
Q’ty
2
1
1
2
2
1
Remarks
Remove the parts in the order listed.
Refer to “REPLACING THE FRONT
BRAKE PADS”.
For installation, reverse the removal procedure.
4 - 19
FRONT AND REAR BRAKES
CHAS
FRONT BRAKE PADS (XT660X)
T.
R.
14 Nm (1.4 m • kg, 10 ft • Ib)
6
4
1
1
5
T.
R.
40 Nm (4.0 m • kg, 29 ft • Ib)
2
2
3
Order
1
2
3
4
5
6
Job/Part
Removing the front brake pads
Brake caliper bolt
Brake pad clip
Brake pad pin
Brake pad spring
Brake pad
Bleed screw
Q’ty
2
2
2
1
2
1
Remarks
Remove the parts in the order listed.
Refer to “REPLACING THE FRONT
BRAKE PADS”.
For installation, reverse the removal procedure.
4 - 20
FRONT AND REAR BRAKES
CHAS
EAS00578
REAR BRAKE PADS
T.
R.
14 Nm (1.4 m • kg, 10 ft • Ib)
1
2
5
4
3
4
Order
1
2
3
4
5
Job/Part
Removing the rear brake pads
Rear wheel
Brake pad pin
Retaining bolt
Brake pad
Brake pad spring
Bleed screw
Q’ty
1
1
2
2
1
Remarks
Remove the parts in the order listed.
Refer to “REAR WHEEL, BRAKE DISC,
AND REAR WHEEL SPROCKET”.
Refer to “REPLACING THE REAR
BRAKE PADS”.
For installation, reverse the removal procedure.
4 - 21
FRONT AND REAR BRAKES
CHAS
EAS00579
CAUTION:
_
Disc brake components rarely require disassembly.
Therefore, always follow these preventive
measures:
• Never disassemble brake components
unless absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly.
• Never use solvents on internal brake
components.
• Use only clean or new brake fluid for
cleaning brake components.
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact
with the eyes as it can cause serious
injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.
EAS00581
È
REPLACING THE FRONT BRAKE PADS
NOTE:
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
_
1
2
3
5 4
5
É
2
1
6
1. Remove:
• brake caliper bolts 1
• brake caliper 2
• brake pad clip(s) 3
• brake pad pin(s) 4
• brake pads 5
• brake pad springs (XT660R)
• brake pad spring 6 (XT660X)
È XT660R
É XT660X
4 3
4
4 - 22
FRONT AND REAR BRAKES
CHAS
2. Measure:
• brake pad wear limit a
Out of specification → Replace the brake
pads as a set.
È
Brake pad wear limit
1.0 mm (0.04 in)
È XT660R
É XT660X
3. Check:
• brake pad pin(s)
Damage/wear → Replace.
É
È
2
1
4. Install:
• brake pad springs
• brake pads
NOTE:
Always replace the brake pads and brake pad
springs as a set.
_
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
É
a. Connect a clear plastic hose 1 tightly to the
bleed screw 2. Put the other end of the
hose into an open container.
1
È XT660R
É XT660X
2
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
T.
R.
4 - 23
Bleed screw
14 Nm (1.4 m · kg, 1.0 ft · lb)
FRONT AND REAR BRAKES
CHAS
d. Install new brake pads and new brake pad
springs.
È
NOTE:
The arrow a on the brake pad spring must
point in the direction of rotation.
_
a
È XT660R
É XT660X
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
É
R.
Install:
brake pad pin
brake pad clip
brake caliper
T.
5.
•
•
•
40 Nm (4.0 m · kg, 29 ft · lb)
a
6. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00583
REPLACING THE REAR BRAKE PADS
NOTE:
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
_
1
2
3
1. Remove:
• rear wheel
• brake caliper
Refer to “REAR WHEEL, BRAKE DISC,
AND REAR WHEEL SPROCKET”.
2. Remove:
• brake pad clip 1
• brake pad pin 2
• brake pads 3
• brake pad springs
4 - 24
FRONT AND REAR BRAKES
a
CHAS
3. Measure:
• brake pad wear limit a
Out of specification → Replace the brake
pads as a set.
Brake pad wear limit
1.0 mm (0.04 in)
4. Install:
• brake pad springs
• brake pads
1
2
NOTE:
Always replace the brake pads and brake pad
springs as a set.
_
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose 1 securely to
the bleed screw 2. Put the other end of the
hose into an open container.
b. Loosen the bleed screw and push the brake
caliper piston into the brake caliper with
your finger.
c. Tighten the bleed screw.
T.
Bleed screw
14 Nm (1.4 m · kg, 10 ft · lb)
R.
d. Install new brake pads and new brake pad
springs.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5.
•
•
•
•
6.
•
7.
•
4 - 25
Install:
brake pad pin
brake pad clip
brake caliper
rear wheel
Refer to “REAR WHEEL, BRAKE DISC,
AND REAR WHEEL SPROCKET”.
Check:
brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
Check:
brake pedal operation
Soft or spongy feeling →Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
CHAS
FRONT AND REAR BRAKES
EAS00584
FRONT BRAKE MASTER CYLINDER
1
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
2
11
3
4
12
8
T.
R.
6 Nm (0.6 m • kg, 4.3 ft • Ib)
LS
10
6
New 7
9
5
T.
R.
Order
1
2
3
4
Job/Part
Removing the front brake master
cylinder
Brake fluid
Rearview mirror (right)
Brake master cylinder reservoir cap
Brake master cylinder reservoir diaphragm holder
Brake master cylinder reservoir diaphragm
Q’ty
Remarks
Remove the parts in the order listed.
Drain.
1
1
1
1
4 - 26
30 Nm (3.0 m • kg, 22 ft • Ib)
CHAS
FRONT AND REAR BRAKES
1
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
2
11
3
4
12
8
T.
R.
6 Nm (0.6 m • kg, 4.3 ft • Ib)
LS
10
6
New 7
9
5
T.
R.
Order
5
6
7
8
9
10
11
12
Job/Part
Front brake light switch
Union bolt
Copper washer
Brake hose
Brake lever
Spring
Brake master cylinder holder
Brake master cylinder
Q’ty
1
Disconnect.
1
2
1
Disconnect.
30 Nm (3.0 m • kg, 22 ft • Ib)
Remarks
Refer to “DISASSEMBLING THE FRONT
BRAKE MASTER CYLINDER” and “ASSEMBLING
AND INSTALLING THE
FRONT BRAKE MASTER
CYLINDER”.
1
1
1
1
For installation, reverse the removal procedure.
4 - 27
FRONT AND REAR BRAKES
CHAS
EAS00585
Order
1
2
3
4
Job/Part
Disassembling the front brake master cylinder
Dust boot
Circlip
Brake master cylinder kit
Brake master cylinder
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1
1
For assembly, reverse the disassembly
procedure.
4 - 28
FRONT AND REAR BRAKES
CHAS
EAS00586
REAR BRAKE MASTER CYLINDER
1
2
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
3
4
6
7
New
5
8
9
10 New
13
11
12
LS
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib)
T.
R.
Order
1
2
3
4
5
6
7
8
9
23 Nm (2.3 m • kg, 17 ft • Ib)
Job/Part
Q’ty
Remarks
Removing the rear brake master cylRemove the parts in the order listed.
inder
Brake fluid
Drain.
Brake fluid reservoir cap
1
Brake fluid reservoir diaphragm holder
1
Brake fluid reservoir diaphragm
1
Brake fluid reservoir
1
Brake fluid reservoir hose
1
Union bolt
1
Refer to “DISASSEMBLING THE REAR
Copper washer
2
Brake hose
1
Disconnect. BRAKE MASTER CYLINDER” and “INSTALLING
Right side heel plate
1
THE REAR BRAKE MASTER CYLINDER”.
4 - 29
FRONT AND REAR BRAKES
CHAS
1
2
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
3
4
6
7
New
5
8
9
10 New
13
11
12
LS
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib)
T.
R.
Order
10
11
12
13
23 Nm (2.3 m • kg, 17 ft • Ib)
Job/Part
Cotter pin
Washer
Pin
Master cylinder
Q’ty
1
1
1
1
Remarks
Refer to “INSTALLING THE REAR
BRAKE MASTER CYLINDER”.
For installation, reverse the removal procedure.
4 - 30
FRONT AND REAR BRAKES
CHAS
EAS00587
Order
1
2
3
Job/Part
Disassembling the rear brake master cylinder
Hose joint
Brake master cylinder kit
Brake master cylinder
Q’ty
1
1
1
4 - 31
Remarks
Remove the parts in the order listed.
Refer to “ASSEMBLING THE REAR
BRAKE MASTER CYLINDER”.
For assembly, reverse the disassembly
procedure.
FRONT AND REAR BRAKES
CHAS
EAS00588
DISASSEMBLING THE FRONT BRAKE
MASTER CYLINDER
NOTE:
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire
brake system.
_
1. Disconnect:
• front brake light switch 1
NOTE:
Push the fastener to remove the front brake
light switch from the brake master cylinder.
2.
•
•
•
3
Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
_
2
1
EAS00589
1
3
2
DISASSEMBLING THE REAR BRAKE
MASTER CYLINDER
1. Remove:
• union bolt 1
• copper washers 2
• brake hose 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
_
2. Remove:
• right side heel plate
4 - 32
FRONT AND REAR BRAKES
CHAS
EAS00592
È
CHECKING THE FRONT AND REAR BRAKE
MASTER CYLINDERS
The following procedure applies to both of the
brake master cylinders.
1. Check:
• brake master cylinder 1
Damage/scratches/wear → Replace.
• brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed
air.
É
È Front
É Rear
1
È
2. Check:
• brake master cylinder kit
Damage/scratches/wear → Replace as a
set.
É
È Front
É Rear
1
3
2
1
2
3
3. Check:
• front brake master cylinder reservoir 1
Cracks/damage → Replace.
• front brake master cylinder reservoir diaphragm 2
Damage/wear → Replace.
• front brake master cylinder reservoir diaphragm holder 3
Damage/wear → Replace.
4. Check:
• rear brake fluid reservoir 1
Cracks/damage → Replace.
• rear brake fluid reservoir diaphragm 2
Cracks/damage → Replace.
• rear brake fluid reservoir diaphragm holder
3
Damaged/wear → Replace.
4 - 33
FRONT AND REAR BRAKES
CHAS
5. Check:
• brake hoses
Cracks/damage/wear → Replace.
EAS00598
ASSEMBLING AND INSTALLING THE
FRONT BRAKE MASTER CYLINDER
WARNING
_
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake
components.
Recommended brake fluid
DOT 4
1. Install:
• brake master cylinder 1
• brake master cylinder holder
1
T.
R.
7 Nm (0.7 m · kg, 5.1 ft · lb)
NOTE:
• Install the brake master cylinder holder with
the “UP” mark a facing up.
• Align the end of the brake master cylinder
holder with the punch mark b on the handlebar.
• First, tighten the upper bolt, then the lower
bolt.
_
b
a
Install:
copper washers New
brake hose
union bolt
30 Nm (3.0 m · kg, 22 ft · lb)
T.
R.
2.
•
•
•
WARNING
_
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING” in chapter 2.
NOTE:
• Install the brake hose within the range
shown.
• Turn the handlebar to the left and right to
make sure the brake hose does not touch
other parts (e.g., wire harness, cables,
leads). Correct if necessary.
_
40˚±10˚
4 - 34
FRONT AND REAR BRAKES
CHAS
3. Fill:
• brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
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 fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake master cylinder reservoir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
CAUTION:
_
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
6. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4 - 35
FRONT AND REAR BRAKES
CHAS
EAS00608
ASSEMBLING THE REAR BRAKE MASTER
CYLINDER
WARNING
_
• All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.
Recommended brake fluid
DOT 4
• Whenever a master cylinder is disassembled, replace the piston seals and dust
seals.
1. Install:
• brake master cylinder kit
• joint 1
NOTE:
Turn the adjusting bolt 2 until the clearance a
is within the specified limits when install the
joint 1.
_
Clearance
2.1 mm (0.08 in)
2
a
R.
2. Tighten:
• nut 3
T.
3
1
18 Nm (1.8 m · kg, 13 ft · lb)
INSTALLING THE REAR BRAKE MASTER
CYLINDER
1. Install:
• brake master cylinder
• pin 1
• washer 2
• cotter pin 3 New
1
2
3 New
NOTE:
Install the cotter pin and bend the ends as
shown.
4 - 36
FRONT AND REAR BRAKES
2
CHAS
2. Install:
• right side heel plate
T.
R.
23 Nm (2.3 m · kg, 17 ft · lb)
• copper washers New
• brake hose 1
• union bolt 2
30 Nm (3.0 m · kg, 22 ft · lb)
1
T.
R.
WARNING
a
_
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING” in chapter 2.
CAUTION:
_
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection a as shown.
3. Fill:
• brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
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 fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
CAUTION:
_
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4 - 37
FRONT AND REAR BRAKES
CHAS
4. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
6. Adjust:
• brake pedal position a
Refer to “ADJUSTING THE REAR BRAKE
PEDAL” in chapter 3.
Brake pedal position (below the
top of the rider footrest)
12.0 mm (0.47 in)
7. Adjust:
• rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” in chapter 3.
4 - 38
FRONT AND REAR BRAKES
CHAS
EAS00612
FRONT BRAKE CALIPER (XT660R)
T.
R.
40 Nm (4.0 m • kg, 29 ft • Ib)
4
3
2 New
1
5
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
New 2
Order
1
2
3
4
5
Job/Part
Removing the front brake caliper
Brake fluid
Union bolt
Copper washer
Brake hose
Front brake caliper bolt
Brake caliper
Q’ty
1
2
1
2
1
Remarks
Remove the parts in the order listed.
Drain.
Disconnect.
Refer to “INSTALLING
THE FRONT BRAKE
CALIPER”.
For installation, reverse the removal procedure.
4 - 39
FRONT AND REAR BRAKES
CHAS
EAS00614
LS
4
LS
3
4
2
1
5
T.
R.
Order
1
2
3
4
5
Job/Part
Disassembling the front brake caliper
Brake pad clip
Brake pad pin
Brake pad
Brake pad spring
Bleed screw
14 Nm (1.4 m • kg, 10 ft • Ib)
Q’ty
1
1
2
2
1
Remarks
Remove the parts in the order listed.
Refer to “INSTALLING THE FRONT
BRAKE CALIPER”.
For assembly, reverse the disassembly
procedure.
4 - 40
FRONT AND REAR BRAKES
CHAS
FRONT BRAKE CALIPER (XT660X)
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
3
1
2 New
4
5
T.
R.
40 Nm (4.0 m • kg, 29 ft • Ib)
Order
1
2
3
4
5
Job/Part
Removing the front brake caliper
Brake fluid
Union bolt
Copper washer
Brake hose
Front brake caliper bolt
Brake caliper
Q’ty
1
2
1
2
1
Remarks
Remove the parts in the order listed.
Drain.
Disconnect.
Refer to “INSTALLING
THE FRONT BRAKE
CALIPER”.
For installation, reverse the removal procedure.
4 - 41
FRONT AND REAR BRAKES
T.
R.
14 Nm (1.4 m • kg, 10 ft • Ib)
CHAS
5
3
1
2
1
4
Order
1
2
3
4
5
Job/Part
Disassembling the front brake caliper
Brake pad clip
Brake pad pin
Brake pad spring
Brake pad
Bleed screw
Q’ty
2
2
1
2
1
Remarks
Remove the parts in the order listed.
Refer to “INSTALLING THE FRONT
BRAKE CALIPER”.
For assembly, reverse the disassembly
procedure.
4 - 42
FRONT AND REAR BRAKES
CHAS
EAS00616
REAR BRAKE CALIPER
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
2
New 3
T.
4
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
5
1
T.
R.
Order
1
2
3
4
5
Job/Part
Removing the rear brake caliper
Brake fluid
Rear wheel
Brake caliper protector
Union bolt
Copper washer
Brake hose
Brake caliper
Q’ty
1
1
2
1
1
4 Nm (0.4 m • kg, 2.9 ft • Ib)
Remarks
Remove the parts in the order listed.
Drain.
Refer to “REAR WHEEL, BRAKE DISC,
AND REAR WHEEL SPROCKET”.
Disconnect.
Refer to “INSTALLING
THE REAR BRAKE CALIPER”.
For installation, reverse the removal procedure.
4 - 43
FRONT AND REAR BRAKES
CHAS
EAS00617
2
T.
R.
3
14 Nm (1.4 m • kg, 10 ft • Ib)
6
5
4
5
1
LS
Order
1
2
3
4
5
6
Job/Part
Disassembling the rear brake caliper
Brake caliper bracket
Brake pad clip
Brake pad pin
Brake pad
Brake pad spring
Bleed screw
Q’ty
1
1
1
2
2
1
Remarks
Remove the parts in the order listed.
Refer to “INSTALLING THE REAR
BRAKE CALIPER”.
For assembly, reverse the disassembly
procedure.
4 - 44
FRONT AND REAR BRAKES
CHAS
EAS00619
È
REMOVING THE FRONT BRAKE CALIPER
4
NOTE:
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
_
3
1
2
É
3
1.
•
•
•
•
Remove:
union bolt 1
copper washers 2
brake hose 3
brake caliper 4
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
1
_
2
4
È XT660R
É XT660X
EAS00626
REMOVING THE REAR BRAKE CALIPER
NOTE:
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
_
1. Remove:
• brake caliper protector
4
2
1
2.
•
•
•
•
•
3
Remove:
union bolt 1
copper washers 2
brake hose 3
brake caliper 4
rear wheel
Refer to “REAR WHEEL, BRAKE DISC,
AND REAR WHEEL SPROCKET”.
_
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
4 - 45
CHAS
FRONT AND REAR BRAKES
EAS00633
CHECKING THE FRONT AND REAR BRAKE
CALIPERS
Recommended brake component
replacement schedule
È
Brake pads
If necessary
Brake hoses
Every four years
Brake fluid
Every two years
and whenever the
brake is disassembled
1. Check:
• brake caliper pistons 1
Rust/scratches/wear → Replace the brake
caliper.
• brake caliper body 2
Cracks/damage → Replace the brake caliper.
• brake caliper
Brake fluid leakage → Replace the brake
caliper.
1
2
È Front (XT660R)
É Front (XT660X)
Ê Rear (XT660R/XT660X)
É
2
1
2. Check:
• brake caliper bracket
Cracks/damage → Replace.
Ê
1
2
4 - 46
FRONT AND REAR BRAKES
CHAS
EAS00634
INSTALLING THE FRONT BRAKE CALIPER
1. Install:
• brake pad springs
• brake pads
• brake pad pin(s)
• brake pad clip(s)
Refer to “FRONT BRAKE PADS”.
2. Install:
• brake caliper 1
• brake caliper bolts 2
È
2
T.
R.
3
40 Nm (4.0 m · kg, 29 ft · lb)
• copper washers New
• brake hose 3
• union bolt 4
30 Nm (3.0 m · kg, 22 ft · lb)
4
T.
R.
1
WARNING
_
É
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING” in chapter 2.
3
4
CAUTION:
_
1
XT660R
When installing the brake hose onto the
brake caliper 1, make sure the brake pipe
a touches the brake caliper body b.
XT660X
When installing the brake hose onto the
brake caliper 1, make sure the brake pipe
a touches the projection c on the brake
caliper.
2
È
b
a
È XT660R
É XT660X
É
a
c
4 - 47
FRONT AND REAR BRAKES
CHAS
3. Fill:
• brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
_
• Use only the designated brake fluid.
Other brake fluids may cause the piston
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 fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake master cylinder reservoir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
CAUTION:
_
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
6. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4 - 48
FRONT AND REAR BRAKES
CHAS
EAS00642
INSTALLING THE REAR BRAKE CALIPER
1. Install:
• brake caliper springs
• brake pads
• brake pad pin
• brake pad clip
Refer to “REAR BRAKE PADS”.
3
2
b
1
T.
a
2. Install:
• brake caliper
• rear wheel
Refer to “REAR WHEEL, BRAKE DISC,
AND REAR WHEEL SPROCKET”.
• copper washers New
• brake hose 1
• union bolt 2
30 Nm (3.0 m · kg, 22 ft · lb)
R.
WARNING
_
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING” in chapter 2.
CAUTION:
_
When installing the brake hose onto the
brake caliper 3, make sure the brake pipe
a touches the projection b on the brake
caliper.
1
3. Install:
• brake caliper protector
• brake caliper protector bolt 1
T.
R.
7 Nm (0.7 m · kg, 5.1 ft · lb)
• brake caliper protector bolt 2
T.
R.
4 Nm (0.4 m · kg, 2.9 ft · lb)
2
4. Fill:
• brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
4 - 49
FRONT AND REAR BRAKES
CHAS
WARNING
_
• Use only the designated brake fluid.
Other brake fluids may cause the piston
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 fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
CAUTION:
_
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
5. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
6. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7. Check:
• brake pedal operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4 - 50
FRONT FORK
CHAS
EAS00646
FRONT FORK
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib)
7
6
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
8
5
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
1
2
2
10
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
9
R.
T.
R.
3
T.
(4)
16 Nm (1.6 m • kg, 11 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
4
Order
Job/Part
Removing the front fork legs
Q’ty
Front fender
Front fork protector
Front cowling assembly
Front wheel
1
2
3
4
5
Front mud guard
Front mud guard stay
Stabilizer
Front mud guard
Brake hose holder
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front fork legs.
Refer to “COWLING AND COVER” in
chapter 3.
1
2
1
1
2
4 - 51
Refer to “FRONT WHEEL AND BRAKE
DISC”.
XT660R
XT660R
XT660X
XT660X
Refer to “INSTALLING THE FRONT
FORK LEGS”.
FRONT FORK
CHAS
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib)
7
6
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
8
5
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
1
2
2
10
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
9
R.
T.
R.
3
T.
(4)
16 Nm (1.6 m • kg, 11 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
4
Order
6
7
8
9
10
Job/Part
Upper bracket pinch bolt
Cap bolt
Lower bracket pinch bolt
Front fork leg
Front fork leg
Q’ty
2
Loosen.
1
Loosen.
2
Loosen.
1
1
4 - 52
Remarks
Refer to “REMOVING
THE FRONT FORK
LEGS” and “INSTALLING
THE FRONT FORK
LEGS”.
XT660R
XT660X
For installation, reverse the removal procedure.
FRONT FORK
CHAS
EAS00648
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib)
1
New 2
LS
3
5 New
6
A New
0
B
4
F
C New
8
New
E New
9
D
R.
Job/Part
Disassembling the front fork legs
7
LT
T.
Order
G
Q’ty
30 Nm (3.0 m • kg, 22 ft • Ib)
Remarks
Remove the parts in the order listed.
NOTE:
The following the procedure applies to
both of the front fork legs.
1
2
3
4
5
6
7
8
9
0
Cap bolt
O-ring
Spring seat
Fork spring
Dust seal
Oil seal clip
Damper rod bolt/copper washer
Damper rod
Rebound spring
Inner tube
1
1
1
1
1
1
1/1
1
1
1
4 - 53
Refer to “DISASSEMBLING THE
FRONT FORK LEGS” and “ASSEMBLING THE FRONT FORK LEGS”.
FRONT FORK
CHAS
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib)
1
New 2
LS
3
5 New
6
A New
0
B
4
F
C New
8
New
E New
9
D
R.
Job/Part
Oil seal
Washer
Outer tube bushing
Oil flow stopper
Inner tube bushing
Outer tube
Outer tube
7
LT
T.
Order
A
B
C
D
E
F
G
G
30 Nm (3.0 m • kg, 22 ft • Ib)
Q’ty
Remarks
1
1
Refer to “ASSEMBLING THE FRONT
1
FORK LEGS”.
1
1
1
XT660R
1
XT660X
For assembly, reverse the disassembly
procedure.
4 - 54
FRONT FORK
CHAS
EAS00649
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Stand the motorcycle on a level surface.
WARNING
_
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so
that the front wheel is elevated.
_
2. Remove:
• brake hose holders 1
1
2
1
3.
•
•
•
Loosen:
upper bracket pinch bolts 1
cap bolt 2
lower bracket pinch bolts 3
WARNING
_
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
4. Remove:
• front fork leg
3
EAS00652
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Remove:
• cap bolt
• spring seat
• fork spring
4 - 55
FRONT FORK
CHAS
2. Drain:
• fork oil
NOTE:
Stroke the outer tube several times while
draining the fork oil.
3. Remove:
• dust seal 1
• oil seal clip 2
(with a flat-head screwdriver)
CAUTION:
_
Do not scratch the inner tube.
4. Remove:
• damper rod bolt 1
• copper washer
NOTE:
While holding the damper rod assembly with
the damper rod holder 2 and T-handle 3,
loosen the damper rod bolt 1.
_
Damper rod holder
90890-01460
T-handle
90890-01326
5. Remove:
• inner tube
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the front fork leg horizontally.
b. Securely clamp the brake caliper bracket in
a vise with soft jaws.
c. Separate the inner tube from the outer tube
by pulling the inner tube forcefully but carefully.
CAUTION:
_
• Excessive force will damage the oil seal
and the inner tube bushing. A damaged
oil seal or inner tube bushing must be
replaced.
4 - 56
FRONT FORK
CHAS
• Avoid bottoming the inner tube into the
outer tube during the above procedure,
as the oil flow stopper will be damaged.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00657
È
1
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Check:
• inner tube 1
• outer tube 2
Bends/damage/scratches → Replace.
2
WARNING
_
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
É
1
È XT660R
É XT660X
2
2. Measure:
• spring free length a
Out of specification → Replace.
Spring free length
XT660R
633.0 mm (24.92 in)
<Limit>: 620 mm (24.41 in)
XT660X
593.0 mm (23.35 in)
<Limit>: 581 mm (22.87 in)
4 - 57
FRONT FORK
CHAS
3. Check:
• damper rod 1
Damage/wear → Replace.
Obstruction → Blow out all of the oil passages with compressed air.
• oil flow stopper 2
Damage → Replace.
1
2
CAUTION:
_
• The front fork leg has a built-in damper
adjusting rod and a very sophisticated
internal construction, which are particularly sensitive to foreign material.
• When disassembling and assembling the
front fork leg, do not allow any foreign
material to enter the front fork.
EAS00659
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
WARNING
_
• Make sure the oil levels in both front fork
legs are equal.
• Uneven oil levels can result in poor handling and a loss of stability.
NOTE:
• When assembling the front fork leg, be sure
to replace the following parts:
- inner tube bushing
- outer tube bushing
- oil seal
- dust seal
• Before assembling the front fork leg, make
sure all of the components are clean.
_
1
1. Install:
• damper rod 1
• rebound spring 2
3
CAUTION:
_
2
Allow the damper rod assembly to slide
slowly down the inner tube 3 until it protrudes from the bottom of the inner tube.
Be careful not to damage the inner tube.
4 - 58
FRONT FORK
CHAS
2. Lubricate:
• inner tube’s outer surface
Recommended lubricant
Fork oil 10 W or equivalent
3. Tighten:
• damper rod bolt 1
New
T.
1
R.
Damper rod bolt
30 Nm (3.0 m · kg, 22 ft · lb)
LOCTITE®
NOTE:
While holding the damper rod with the damper
rod holder 2 and T-handle 3, tighten the
damper rod bolt.
_
LT
Damper rod holder
90890-01460
T-handle
90890-01326
4. Install:
• outer tube bushing 1 New
(with the fork seal driver weight 3 and fork
seal driver attachment 4)
• washer 2
Fork seal driver weight
90890-01367
Fork seal driver attachment (ø43)
90890-01374
4 - 59
FRONT FORK
CHAS
5. Install:
• oil seal 1 New
(with the fork seal driver weight 2 and fork
seal driver attachment 3)
CAUTION:
_
Make sure the numbered side of the oil seal
faces up.
NOTE:
• Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.
• Lubricate the outer surface of the inner tube
with fork oil.
• Before installing the oil seal, cover the top of
the front fork leg with a plastic bag 4 to protect the oil seal during installation.
_
6. Install:
• oil seal clip 1
NOTE:
Adjust the oil seal clip so that it fits into the
outer tube’s groove.
_
7. Install:
• dust seal 1
(with the fork seal driver weight 2)
Fork seal driver weight
90890-01367
4 - 60
FRONT FORK
CHAS
8. Fill:
• front fork leg
(with the specified amount of the recommended fork oil)
Quantity (each front fork leg)
XT660R
640.0 cm3
(22.53 Imp oz, 21.64 US oz)
XT660X
600.0 cm3
(21.12 Imp oz, 20.29 US oz)
Recommended oil
Fork oil 10 W or equivalent
9. Measure:
• front fork leg oil level a
Out of specification → Correct.
Front fork leg oil level (from the
top of the inner tube, with the
inner tube fully compressed and
without the fork spring)
125.0 mm (4.92 in)
NOTE:
• While filling the front fork leg, keep it upright.
• After filling, slowly pump the front fork leg up
and down to distribute the fork oil.
_
2
1
10.Install:
• spring 1
• spring seat 2
• O-ring New
• cap bolt
NOTE:
• Install the spring with the smaller pitch facing
up.
• Before installing the cap bolt, lubricate its Oring with lithium-soap-based grease.
• Temporarily tighten the cap bolt.
_
4 - 61
FRONT FORK
CHAS
EAS00662
b
a
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Install:
• front fork leg
Temporarily tighten the lower bracket pinch
bolts.
NOTE:
To install the front fork leg, align the inner tube
a with the lower edge b of the bevel on the
upper bracket as shown.
_
2. Tighten:
• lower bracket pinch bolts 1
T.
R.
23 Nm (2.3 m · kg, 17 ft · lb)
T.
18 Nm (1.8 m · kg, 13 ft · lb)
• cap bolt 2
• upper bracket pinch bolts 3
R.
T.
R.
23 Nm (23 m · kg, 17 ft · lb)
1
WARNING
_
Make sure the brake hose is routed properly.
2
3. Install:
• brake hose holders
T.
3
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
• front mud guard
WARNING
_
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING” in chapter 2.
4 - 62
HANDLEBAR
CHAS
EAS00664
HANDLEBAR
T.
R.
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
13
1
5
3
16
14
11
8
16
9
LS
6
2
17
12
4
2
10
6
15
LS
7
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Order
1
2
3
Job/Part
Removing the handlebar
Rearview mirror (left and right)
Plastic band
Front brake light switch
4
5
6
7
8
9
10
11
12
Brake master cylinder holder
Brake master cylinder
Grip end
Throttle cable holder
Right handlebar switch
Throttle cable
Throttle grip
Clutch switch
Clutch lever holder
Q’ty
2
2
1
1
1
2
1
1
2
1
1
1
4 - 63
Remarks
Remove the parts in the order listed.
Disconnect.
Refer to “REMOVING THE HANDLEBAR”.
Refer to “INSTALLING
THE HANDLEBAR”.
Disconnect.
HANDLEBAR
T.
R.
1
CHAS
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
13
1
5
3
16
14
11
8
16
9
LS
6
2
17
12
2
4
10
6
15
LS
7
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Order
13
14
15
Job/Part
Clutch lever
Left handlebar switch
Handlebar grip
16
17
Upper handlebar holder
Handlebar
Q’ty
Remarks
1
Refer to “INSTALLING THE HANDLEBAR”.
1
1
Refer to “REMOVING THE HANDLEBAR” and “INSTALLING THE HANDLEBAR”.
2
Refer to “INSTALLING THE HANDLEBAR”.
1
For installation, reverse the removal procedure.
4 - 64
HANDLEBAR
CHAS
EAS00666
REMOVING THE HANDLEBAR
1. Stand the motorcycle on a level surface.
WARNING
_
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:
• front brake light switch 1
• clutch switch
NOTE:
• Push the fastener to remove the front brake
light switch from the brake master cylinder.
• Push the fastener to remove the clutch
switch from the clutch lever.
3. Remove:
• handlebar grip 1
NOTE:
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
_
EAS00668
1
CHECKING THE HANDLEBAR
1. Check:
• handlebar 1
Bends/cracks/damage → Replace.
WARNING
_
Do not attempt to straighten a bent handlebar as this may dangerously weaken it.
EAS00671
INSTALLING THE HANDLEBAR
1. Stand the motorcycle on a level surface.
WARNING
_
Securely support the motorcycle so that
there is no danger of it falling over.
4 - 65
HANDLEBAR
a
2. Install:
• handlebar 1
• upper handlebar holders 2
2
2
T.
R.
23 Nm (2.3 m · kg, 17 ft · lb)
• handlebar protector (XT660X)
• handlebar protector cover (XT660X)
1
b
CHAS
CAUTION:
_
• First, tighten the bolts on the front side of
the upper handlebar holder, then the
bolts on the rear side.
• Turn the handlebar all the way to the left
and right. If there is any contact with the
fuel tank, adjust the handlebar position.
NOTE:
• The upper handlebar holders should be
installed with the arrow marks a facing forward.
• Align the match mark b on the handlebar
with the upper surface of the lower handlebar
holders.
_
T.
3. Install:
• handlebar grip 1
7 Nm (0.7 m · kg, 5.1 ft · lb)
• grip end 2
R.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of rubber adhesive onto
the left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
WARNING
_
Do not touch the handlebar grip until the
rubber adhesive has fully dried.
NOTE:
There should be 1 ~ 3 mm (0.04 ~ 0.12 in) of
clearance a between the handlebar grip and
the grip end.
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 66
HANDLEBAR
1
CHAS
4. Install:
• left handlebar switch 1
b
NOTE:
Align the projection a on the left handlebar
switch with the hole b in the handlebar.
_
a
5. Install:
• clutch lever
• clutch lever holder 1
1
T.
a
R.
7 Nm (0.7 m · kg, 5.1 ft · lb)
NOTE:
Align the mating surfaces of the clutch lever
holder with the punch mark a on the handlebar.
_
1
Install:
throttle grip 1
throttle cables 2
right handlebar switch 3
7 Nm (0.7 m · kg, 5.1 ft · lb)
grip end
T.
R.
2
6.
•
•
•
•
NOTE:
• Lubricate the inside of the throttle grip with a
thin coat of lithium-soap-based grease and
install it onto the handlebar.
• Route the throttle cables through the slot in
the right handlebar switch, and then install
the cables.
• Align the projection a on the right handlebar
switch with the hole b in the handlebar.
• There should be 1 ~ 3 mm (0.04 ~ 0.12 in) of
clearance c between the throttle grip and
the grip end.
_
3
b
a
7. Install:
• throttle cable holder
WARNING
_
C
Make sure
smoothly.
4 - 67
the
throttle
grip
operates
HANDLEBAR
CHAS
8. Install:
• brake master cylinder
• brake master cylinder holder
Refer to “FRONT AND REAR BRAKES”.
9. Adjust:
• clutch cable free play
Refer to “ADJUSTING THE CLUTCH
CABLE FREE PLAY” in chapter 3.
Clutch cable free play (at the end
of the clutch lever)
10.0 ~ 15.0 mm (0.39 ~ 0.59 in)
10.Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
Throttle cable free play (at the
flange of the throttle grip)
3.0 ~ 5.0 mm (0.12 ~ 0.20 in)
4 - 68
CHAS
STEERING HEAD
EAS00675
STEERING HEAD
LOWER BRACKET
T.
T.
R.
32 Nm (3.2 m • kg, 23 ft • Ib)
R.
.
T
.
R
23 Nm (2.3 m • kg, 17 ft • Ib)
130 Nm (13.0 m • kg, 94 ft • lb)
1
4
1
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
15
LS
13
5
16
2
6
10
3
32 Nm (3.2 m • kg, 23 ft • Ib)
T.
R.
.
R.
T.
R.
Order
1
2
3
4
5
6
7
8
9
10
R
T.
LS
14
.
T
7
8
9
11
23 Nm (2.3 m • kg, 17 ft • Ib)
1st 43 Nm (4.3 m • kg, 31 ft • lb)
2nd 7 Nm (0.7 m • kg, 5.1 ft • lb)
12
23 Nm (2.3 m • kg, 17 ft • Ib)
Job/Part
Removing the lower bracket
Front wheel
Front fork legs
Handlebar
Lower handlebar holder
Immobilizer unit coupler
Main switch coupler
Steering stem nut
Upper bracket
Lock washer
Upper ring nut
Rubber washer
Lower ring nut
Lower bracket
Q’ty
2
1
2
1
1
1
1
1
1
1
4 - 69
Remarks
Remove the parts in the order listed.
Refer to “FRONT WHEEL AND BRAKE
DISC”.
Refer to “FRONT FORK”.
Refer to “HANDLEBAR”.
Disconnect.
Disconnect.
Refer to “REMOVING THE LOWER
BRACKET” and “INSTALLING THE
STEERING HEAD”.
CHAS
STEERING HEAD
T.
T.
R.
32 Nm (3.2 m • kg, 23 ft • Ib)
R.
.
T
.
R
23 Nm (2.3 m • kg, 17 ft • Ib)
130 Nm (13.0 m • kg, 94 ft • lb)
1
4
1
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
15
LS
13
5
16
2
6
10
3
32 Nm (3.2 m • kg, 23 ft • Ib)
T.
R.
.
R.
T.
R.
Order
11
12
13
14
15
16
R
T.
LS
14
.
T
7
8
9
11
23 Nm (2.3 m • kg, 17 ft • Ib)
1st 43 Nm (4.3 m • kg, 31 ft • lb)
2nd 7 Nm (0.7 m • kg, 5.1 ft • lb)
12
23 Nm (2.3 m • kg, 17 ft • Ib)
Job/Part
Bearing cover
Upper bearing
Lower bearing
Upper bearing outer race
Lower bearing outer race
Dust seal
Q’ty
1
1
1
1
1
1
Remarks
Refer to “INSTALLING THE STEERING
HEAD”.
For installation, reverse the removal procedure.
4 - 70
STEERING HEAD
CHAS
EAS00679
REMOVING THE LOWER BRACKET
1. Stand the motorcycle on a level surface.
WARNING
_
Securely support the motorcycle so that
there is no danger of it falling over.
3
4
2.
•
•
•
•
Remove:
upper ring nut 1
rubber washer
lower ring nut 2
lower bracket
NOTE:
Hold the lower ring nut with the steering nut
wrench 3, and then remove the upper ring nut
with the ring nut wrench 4.
_
2
1
Steering nut wrench
90890-01403
Ring nut wrench
90890-01268
WARNING
_
Securely support the lower bracket so that
there is no danger of it falling.
EAS00681
CHECKING THE STEERING HEAD
1. Wash:
• bearings
• bearing races
Recommended cleaning solvent
Kerosene
2. Check:
• bearings
• bearing races
Damage/pitting → Replace.
4 - 71
STEERING HEAD
CHAS
3. Replace:
• bearings
• bearing races
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bearing races from the steering
head pipe with a long rod 1 and hammer.
b. Remove the bearing race from the lower
bracket with a floor chisel 2 and hammer.
c. Install a new dust seal and new bearing
races.
CAUTION:
_
If the bearing race is not installed properly,
the steering head pipe could be damaged.
NOTE:
• Always replace the bearings and bearing
races as a set.
• Whenever the steering head is disassembled, replace the dust seal.
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• upper bracket
• lower bracket
(along with the steering stem)
Bends/cracks/damage → Replace.
EAS00683
INSTALLING THE STEERING HEAD
1. Lubricate:
• upper bearing
• lower bearing
• bearing races
Recommended lubricant
Lithium-soap-based grease
2.
•
•
•
•
4 - 72
Install:
lower ring nut 1
rubber washer 2
upper ring nut 3
lock washer 4
Refer to “CHECKING THE STEERING
HEAD” in chapter 3.
STEERING HEAD
CHAS
3. Install:
• upper bracket
• steering stem nut
NOTE:
Temporarily tighten the steering stem nut.
_
4. Install:
• front fork legs
Refer to “INSTALLING THE FRONT FORK
LEGS”.
NOTE:
Temporarily tighten the lower bracket pinch
bolts.
_
5. Tighten:
• steering stem nut
T.
R.
130 Nm (13.0 m · kg, 94 ft · lb)
6. Install:
• lower handlebar holders
• lower handlebar holder nuts
NOTE:
Temporarily tighten the lower handlebar nuts.
7. Install:
• handlebar
• upper handlebar holder
Refer to “HANDLEBAR”.
8. Tighten:
• lower handlebar holder nuts
T.
R.
4 - 73
32 Nm (3.2 m · kg, 23 ft · lb)
CHAS
REAR SHOCK ABSORBER ASSEMBLY
EAS00685
REAR SHOCK ABSORBER ASSEMBLY
T.
R.
59 Nm (5.9 m • kg, 43 ft • Ib)
T.
R.
7
59 Nm (5.9 m • kg, 43 ft • Ib)
T.
R.
42 Nm (4.2 m • kg, 30 ft • Ib)
T.
R.
8
59 Nm (5.9 m • kg, 43 ft • Ib)
LS
4
7
6
LS
4
5
LS
1
6
3
9
1
11
9
10
2
LS
11
LS
3
LS
10
2
1
LS
Order
Job/Part
Removing the rear shock absorber
assembly
Seat/side panels (left and right)/rear
cover
Fuel tank
Rear fender/air filter case
Rear wheel
1
2
3
Self-locking nut/washer/bolt
Connecting arm
Oil seal/bearing/spacer
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “COWLING AND COVER” in
chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “AIR FILTER CASE” in chapter
3.
Refer to “REAR WHEEL, BRAKE DISC,
AND REAR WHEEL SPROCKET”.
2/2/2 Refer to “REMOVING THE REAR
SHOCK ABSORBER ASSEMBLY” and
2
“INSTALLING
THE REAR SHOCK
2/1/1
ABSORBER ASSEMBLY”.
4 - 74
CHAS
REAR SHOCK ABSORBER ASSEMBLY
T.
R.
59 Nm (5.9 m • kg, 43 ft • Ib)
T.
R.
7
59 Nm (5.9 m • kg, 43 ft • Ib)
T.
R.
42 Nm (4.2 m • kg, 30 ft • Ib)
T.
R.
8
59 Nm (5.9 m • kg, 43 ft • Ib)
LS
4
7
6
LS
4
5
LS
1
6
3
9
1
11
9
10
2
LS
11
LS
3
LS
10
2
1
LS
Order
4
5
6
7
8
9
10
11
Job/Part
Self-locking nut/washer/nut
Relay arm
Self-locking nut/washer/bolt
Self-locking nut/washer/bolt
Rear shock absorber assembly
Oil seal/bearing/spacer
Oil seal/bearing/spacer
Oil seal/bearing/spacer
Q’ty
1/1/1
1
1/2/1
1/1/1
1
2/1/2
2/1/1
2/1/1
Remarks
Refer to “REMOVING THE REAR
SHOCK ABSORBER ASSEMBLY” and
“INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY”.
Refer to “INSTALLING THE RELAY
ARM”.
For installation, reverse the removal procedure.
4 - 75
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00686
HANDLING THE REAR SHOCK ABSORBER
WARNING
_
This rear shock absorber contains highly
compressed nitrogen gas. Before handling
the rear shock absorber, read and make
sure you understand the following information. The manufacturer cannot be held
responsible for property damage or personal injury that may result from improper
handling of the rear shock absorber.
• Do not tamper or attempt to open the rear
shock absorber.
• Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion
due to excessive gas pressure.
• Do not deform or damage the rear shock
absorber in any way. Rear shock
absorber damage will result in poor
damping performance.
EAS00688
a
DISPOSING OF A REAR SHOCK
ABSORBER
Gas pressure must be released before disposing of a rear shock absorber. To release the
gas pressure, drill a 2 ~ 3 mm hole through the
rear shock absorber at a point a 30 ~ 60 mm
from its end as shown.
WARNING
_
Wear eye protection to prevent eye damage
from released gas or metal chips.
4 - 76
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00690
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Stand the motorcycle on a level surface.
WARNING
_
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so
that the rear wheel is elevated.
_
2. Remove:
• connecting arm bolt 1
• rear shock absorber assembly lower bolt 2
NOTE:
While removing the rear shock absorber
assembly lower bolt, hold the swingarm so that
it does not drop down.
2
1
3. Remove:
• rear shock absorber assembly upper bolt 1
• rear shock absorber assembly 2
1
2
NOTE:
Raise the swingarm, and then remove the rear
shock absorber assembly from between the
swingarm and relay arm.
4 - 77
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00695
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:
• rear shock absorber rod
Bends/damage → Replace the rear shock
absorber assembly.
• rear shock absorber
Gas leaks/oil leaks → Replace the rear
shock absorber assembly.
• spring
Damage/wear → Replace the rear shock
absorber assembly.
• bolts
Bends/damage/wear → Replace.
CHECKING THE CONNECTING ARMS AND
RELAY ARM
1. Check:
• connecting arms 1
• relay arm 2
Damage/wear → Replace.
2. Check:
• spacers
• oil seals
• bearings
Damage/pitting/scratches → Replace.
2
1
1
a
3
2
INSTALLING THE RELAY ARM
1. Install:
• bearings 1
(to the relay arm and swingarm)
b
Installed depth a
7.2 ~ 8.2 mm (0.28 ~ 0.32 in)
4
5
• bearing 2
(to the relay arm)
6
Installed depth b
4.0 ~ 5.0 mm (0.16 ~ 0.20 in)
1
a
7
1
3 Swingarm
4 Rear shock absorber
5 Relay arm
6 Connecting arm
7 Frame
a
4 - 78
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00697
INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY
1. Lubricate:
• bearings
• bolts
Recommended lubricant
Lithium-soap-based grease
2. Install:
• rear shock absorber assembly
NOTE:
When installing the rear shock absorber
assembly, lift up the swingarm.
_
3. Tighten:
• rear shock absorber assembly upper nut
T.
R.
59 Nm (5.9 m · kg, 43 ft · lb)
• rear shock absorber assembly lower nut
T.
R.
42 Nm (4.2 m · kg, 30 ft · lb)
• relay-arm-to-frame nut
T.
R.
59 Nm (5.9 m · kg, 43 ft · lb)
• relay-arm-to-connecting-arm nuts
T.
R.
59 Nm (5.9 m · kg, 43 ft · lb)
• connecting-arm-to-swingarm nut
T.
R.
59 Nm (5.9 m · kg, 43 ft · lb)
4. Adjust:
• drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
Drive chain slack
40.0 ~ 55.0 mm (1.57 ~ 2.17 in)
4 - 79
CHAS
SWINGARM AND DRIVE CHAIN
EAS00700
SWINGARM AND DRIVE CHAIN
R.
R.
T.
T.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
3
59 Nm (5.9 m • kg, 43 ft • Ib)
T.
R.
T.
R.
120 Nm (12.0 m • kg, 85 ft • lb)
2
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
92Nm (9.2 m • kg, 66 ft • Ib)
LS
1
New
LS
11
T.
R.
48 Nm (4.8 m • kg, 35 ft • Ib)
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
6
9
7
LS
8
New
17
18
11
10
15
14
18
14
10
4
15
16
LS
LS
5
19
12
13
LS
LS
T.
R.
T.
R.
T.
R.
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Order
1
2
3
4
5
6
7
8
9
23 Nm (2.3 m • kg, 17 ft • Ib)
Job/Part
Removing the swingarm and drive
chain
Rear wheel
Q’ty
Right side heel plate
Brake master cylinder
Rear brake light switch
Right footrest/brake pedal assembly
Left side heel plate
Drive sprocket cover
Drive chain guard
Nut/lock washer
Drive sprocket
1
1
1
1
1
1
1
1/1
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “REAR WHEEL, BRAKE DISC,
AND REAR WHEEL SPROCKET”.
4 - 80
Refer to “REMOVING THE DRIVE
SPROCKET” and “INSTALLING THE
SWINGARM”.
CHAS
SWINGARM AND DRIVE CHAIN
R.
R.
T.
T.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
3
59 Nm (5.9 m • kg, 43 ft • Ib)
T.
R.
T.
R.
120 Nm (12.0 m • kg, 85 ft • lb)
2
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
92Nm (9.2 m • kg, 66 ft • Ib)
LS
1
New
LS
11
T.
R.
48 Nm (4.8 m • kg, 35 ft • Ib)
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
6
9
7
LS
8
New
17
18
11
10
15
14
18
14
10
4
15
16
LS
LS
5
19
12
13
LS
LS
T.
R.
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
Job/Part
Nut/washer/bolt
Cap/pivot shaft nut/pivot shaft
12
Swingarm
13
14
15
16
17
18
19
Drive chain guide
Dust cover/oil seal
Bearing
Spacer
Spacer
Oil seal/bushing
Drive chain
R.
R.
Order
10
11
T.
T.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Q’ty
1/1/1
2/1/1
1
1
2/2
2
1
1
2/2
1
4 - 81
7 Nm (0.7 m • kg, 5.1 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
Refer to “REMOVING THE DRIVE
SPROCKET” and “INSTALLING THE
SWINGARM”.
Refer to “REMOVING THE SWINGARM”
and “INSTALLING THE SWINGARM”.
Refer to “INSTALLING THE SWINGARM”.
Refer to “REMOVING THE DRIVE
CHAIN”.
For installation, reverse the removal procedure.
SWINGARM AND DRIVE CHAIN
CHAS
EAS00703
REMOVING THE SWINGARM
1. Stand the motorcycle on a level surface.
WARNING
_
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so
that the rear wheel is elevated.
_
2. Measure:
• swingarm side play
• swingarm vertical movement
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the tightening torque of the pivot
shaft nut.
T.
Pivot shaft nut
92 Nm (9.2 m · kg, 66 ft · lb)
R.
b. Measure the swingarm side play È by moving the swingarm from side to side.
c. If the swingarm side play is out of specification, check the spacers, bearings, and dust
covers.
È
Swingarm side play (at the end of
the swingarm)
1.0 mm (0.04 in)
É
d. Check the swingarm vertical movement É
by moving the swingarm up and down.
If swingarm vertical movement is not
smooth or if there is binding, check the
spacers, bearings, and dust covers.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3.
•
•
•
4 - 82
Remove:
swingarm shaft nut
pivot shaft
swingarm
SWINGARM AND DRIVE CHAIN
CHAS
REMOVING THE DRIVE SPROCKET
NOTE:
Loosen the drive sprocket nut before removing
the rear wheel.
2
1
3
1.
•
•
2.
3.
•
•
•
Remove:
drive sprocket cover
chain guard
Straighten the lock washer tab a
Remove:
drive sprocket nut 1
lock washer 2
drive sprocket 3
a
EAS00704
REMOVING THE DRIVE CHAIN
1. Stand the motorcycle on a level surface.
WARNING
_
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so
that the rear wheel is elevated.
_
2. Remove:
• drive chain
EAS00707
CHECKING THE SWINGARM
1. Check:
• swingarm
Bends/cracks/damage → Replace.
4 - 83
SWINGARM AND DRIVE CHAIN
CHAS
2. Check:
• pivot shaft
Roll the pivot shaft on a flat surface.
Bends → Replace.
WARNING
_
Do not attempt to straighten a bent pivot
shaft.
3.
•
•
•
•
•
Wash:
pivot shaft
dust covers
spacer
bushing
bearings
Recommended cleaning solvent
Kerosene
4.
•
•
•
Check:
dust covers
spacers
oil seals
Damage/wear → Replace.
• bearings
• bushings
Damage/pitting → Replace.
EAS00709
CHECKING THE DRIVE CHAIN
1. Measure:
• a 15-link section a of the drive chain
Out of specification → Replace the drive
chain.
15-link drive chain section limit
(maximum)
240.5 mm (9.47 in)
NOTE:
• While measuring the 15-link section, push
down on the drive chain to increase its tension.
• Measure the length between drive chain
roller 1 and F as shown.
• Perform this measurement at two or three
different places.
_
4 - 84
SWINGARM AND DRIVE CHAIN
CHAS
2. Check:
• drive chain
Stiffness → Clean and lubricate or replace.
3. Clean:
• drive chain
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
CAUTION:
_
• This motorcycle has a drive chain with
small rubber O-rings 1 between the drive
chain side plates. Never use high-pressure water or air, steam, gasoline, certain
solvents (e.g., benzine), or a coarse brush
to clean the drive chain. High-pressure
methods could force dirt or water into the
internal sections of the drive chain, and
solvents will deteriorate the O-rings. A
coarse brush can also damage the Orings. Therefore, use only kerosene to
clean the drive chain.
• Don’t soak the drive chain in kerosine for
more than ten minutes, otherwise the Orings can be damaged.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• O-rings 1
Damage → Replace the drive chain.
• drive chain rollers 2
Damage/wear → Replace the drive chain.
• drive chain side plates 3
Damage/wear → Replace the drive chain.
Cracks → Replace the drive chain and
make sure the battery breather hose is
properly routed away from the drive chain
and below the swingarm.
4 - 85
SWINGARM AND DRIVE CHAIN
CHAS
5. Lubricate:
• drive chain
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
6. Check:
• drive sprocket
• rear wheel sprocket
More than 1/4 tooth a wear → Replace the
drive chain sprockets as a set.
Bent teeth → Replace the drive chain
sprockets as a set.
b Correct
1 Drive chain roller
2 Drive chain sprocket
EAS00711
INSTALLING THE SWINGARM
1. Lubricate:
• spacers
• dust covers
• pivot shaft
Recommended lubricant
Lithium-soap-based grease
2 31
a
2.
•
•
•
13 2
Installed depth of bearing a
4 mm (0.16 in)
Installed depth of bushing b
8 mm (0.31 in)
b
b
Install:
bushings 1
bearings 2
spacers 3
(to swingarm)
a
4 - 86
SWINGARM AND DRIVE CHAIN
3.
•
•
•
Install:
swingarm
pivot shaft
pivot shaft nut
T.
R.
4.
•
•
•
R.
3
1
1
59 Nm (5.9 m · kg, 43 ft · lb)
• rear wheel
Refer to “INSTALLING
WHEEL”.
5. Install:
• drive sprocket 1
• lock washer 2 New
• drive sprocket nut 3
T.
R.
a
92 Nm (9.2 m · kg, 66 ft · lb)
Install:
connecting arm bolt
washer
connecting arm nut
T.
New 2
3
CHAS
THE
REAR
120 Nm (12.0 m · kg, 85 ft · lb)
NOTE:
• Install the drive sprocket 1 and drive
sprocket nut 3 in the direction shown.
• While applying the rear brake, tighten the
drive sprocket nut.
6. Bend the lock washer tab a along a flat
side of the nut.
7. Adjust:
• drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
Drive chain slack
40.0 ~ 55.0 mm (1.57 ~ 2.17 in)
8. Adjust:
• brake pedal position
Refer to “ADJUSTING THE REAR BRAKE
PEDAL” in chapter 3.
Brake pedal position (below the
top of the rider footrest)
12.0 mm (0.47 in)
9. Adjust:
• rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” in chapter 3.
4 - 87
ENG
5
ENG
CHAPTER 5
ENGINE
ENGINE REMOVAL ........................................................................................5-1
EXHAUST PIPES AND MUFFLERS .........................................................5-1
LEADS, CABLES, HOSES, AND IGNITION COIL ....................................5-2
ENGINE..................................................................................................... 5-5
INSTALLING THE ENGINE....................................................................... 5-7
CYLINDER HEAD............................................................................................ 5-8
REMOVING THE CYLINDER HEAD.......................................................5-10
CHECKING THE CYLINDER HEAD .......................................................5-11
CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET
COVER ................................................................................................... 5-12
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-12
CHECKING THE CAMSHAFT SPROCKET............................................5-12
INSTALLING THE CYLINDER HEAD .....................................................5-12
ROCKER ARMS AND CAMSHAFT ..............................................................5-16
REMOVING THE ROCKER ARMS AND CAMSHAFT............................ 5-18
CHECKING THE CAMSHAFT.................................................................5-18
CHECKING THE DECOMPRESSION SYSTEM..................................... 5-19
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 5-20
INSTALLING THE CAMSHAFT AND ROCKER ARMS .......................... 5-21
VALVES AND VALVE SPRINGS.................................................................. 5-23
REMOVING THE VALVES...................................................................... 5-24
CHECKING THE VALVES AND VALVE GUIDES ..................................5-25
CHECKING THE VALVE SEATS ............................................................ 5-27
CHECKING THE VALVE SPRINGS........................................................ 5-29
INSTALLING THE VALVES .................................................................... 5-30
CYLINDER AND PISTON.............................................................................. 5-32
REMOVING THE CYLINDER AND PISTON...........................................5-34
CHECKING THE CYLINDER AND PISTON ...........................................5-34
CHECKING THE PISTON RINGS........................................................... 5-36
CHECKING THE PISTON PIN ................................................................5-37
INSTALLING THE PISTON AND CYLINDER .........................................5-38
ENG
CLUTCH ........................................................................................................5-40
CLUTCH COVER ....................................................................................5-40
PULL LEVER SHAFT .............................................................................. 5-41
CLUTCH .................................................................................................. 5-42
REMOVING THE CLUTCH ..................................................................... 5-44
CHECKING THE FRICTION PLATES.....................................................5-44
CHECKING THE CLUTCH PLATES .......................................................5-45
CHECKING THE CLUTCH SPRINGS.....................................................5-45
CHECKING THE CLUTCH HOUSING ....................................................5-46
CHECKING THE CLUTCH BOSS........................................................... 5-46
CHECKING THE PRESSURE PLATE ....................................................5-46
CHECKING THE PULL LEVER SHAFT AND PULL ROD ......................5-46
CHECKING THE PRIMARY DRIVEN GEAR ..........................................5-47
INSTALLING THE CLUTCH.................................................................... 5-47
OIL PUMP...................................................................................................... 5-50
CHECKING THE OIL PUMP ................................................................... 5-53
CHECKING THE OIL DELIVERY PIPES AND HOSES .......................... 5-54
ASSEMBLING THE OIL PUMP...............................................................5-54
INSTALLING THE OIL PUMP .................................................................5-55
BALANCER DRIVEN GEAR .........................................................................5-56
REMOVING THE BALANCER DRIVEN GEAR
AND BALANCER DRIVE GEAR ............................................................ 5-58
CHECKING THE BALANCER DRIVEN GEAR,
WATER PUMP DRIVE GEAR, PRIMARY DRIVE GEAR,
AND BALANCER DRIVE GEAR ............................................................ 5-58
INSTALLING THE BALANCER DRIVEN GEAR
AND BALANCER DRIVE GEAR ............................................................ 5-59
SHIFT SHAFT................................................................................................5-60
SHIFT SHAFT AND STOPPER LEVER.................................................. 5-60
CHECKING THE SHIFT SHAFT ............................................................. 5-62
CHECKING THE STOPPER LEVER ......................................................5-62
INSTALLING THE SHIFT SHAFT ........................................................... 5-62
STARTER CLUTCH AND A.C. MAGNETO .................................................. 5-63
REMOVING THE A.C. MAGNETO ROTOR............................................5-65
CHECKING THE STATOR COIL AND CRANKSHAFT POSITION
SENSOR ................................................................................................5-66
CHECKING THE STARTER CLUTCH ....................................................5-66
CHECKING THE TORQUE LIMITER......................................................5-67
INSTALLING THE A.C. MAGNETO ROTOR ..........................................5-67
ENG
CRANKCASE ................................................................................................5-69
CRANKCASE BEARINGS....................................................................... 5-71
SEPARATING THE CRANKCASE.......................................................... 5-72
CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE 3 ............. 5-72
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDES ..........5-73
CHECKING THE BEARINGS AND OIL SEALS...................................... 5-73
CHECKING THE CRANKCASE ..............................................................5-73
ASSEMBLING THE CRANKCASE.......................................................... 5-74
CRANKSHAFT ..............................................................................................5-76
CRANKSHAFT AND BALANCER ........................................................... 5-76
REMOVING THE CRANKSHAFT ASSEMBLY ....................................... 5-77
CHECKING THE CRANKSHAFT ............................................................ 5-77
INSTALLING THE CRANKSHAFT .......................................................... 5-78
TRANSMISSION............................................................................................ 5-79
MAIN AXLE ............................................................................................. 5-80
DRIVE AXLE ........................................................................................... 5-81
CHECKING THE SHIFT FORKS............................................................. 5-82
CHECKING THE SHIFT DRUM ASSEMBLY..........................................5-82
CHECKING THE TRANSMISSION ......................................................... 5-82
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ..............................5-83
INSTALLING THE TRANSMISSION .......................................................5-84
ENG
ENGINE REMOVAL
ENG
EAS00188
ENGINE
ENGINE REMOVAL
EXHAUST PIPES AND MUFFLERS
R.
R.
27 Nm (2.7 m • kg, 19 ft • Ib)
T.
T.
27 Nm (2.7 m • kg, 19 ft • Ib)
1
1
LS
LS
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
3 New
3 New
New
3
New
3
LT
LT
4
2
T.
R.
T.
R.
T.
R.
27 Nm (2.7 m • kg, 19 ft • Ib)
LT
T.
R.
R.
R.
Job/Part
Removing the exhaust pipes and
mufflers
Muffler (left and right)
Exhaust pipe (left and right)
Gasket
Exhaust pipe bracket
T.
T.
1
2
3
4
20 Nm (2.0 m • kg, 14 ft • Ib)
3 New
R.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
T.
Order
2
20 Nm (2.0 m • kg, 14 ft • Ib)
23 Nm (2.3 m • kg, 17 ft • Ib)
27 Nm (2.7 m • kg, 19 ft • Ib)
12 Nm (1.2 m • kg, 8.7 ft • Ib)
23 Nm (2.3 m • kg, 17 ft • Ib)
Q’ty
Remarks
Remove the parts in the order listed.
2
2
5
1
For installation, reverse the removal procedure.
5-1
ENG
ENGINE REMOVAL
LEADS, CABLES, HOSES, AND IGNITION COIL
* Apply sealant
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Yamaha bond No. 1215
90890-85505
5
New
LS
2
LT
8
9
7 6
13
11
∗
8
7
New
1
6
12
4
R.
LS
T.
3
10
7 Nm (0.7 m • kg, 5.1 ft • Ib)
14
T.
R.
16 Nm (1.6 m • kg, 11 ft • Ib)
Order
Job/Part
Removing the leads, cables, hoses,
and ignition coil
Engine oil
Q’ty
Coolant
Seat/side panels (left and right)/rear
cover
Fuel tank side covers (left and right)/
fuel tank
Rear wheel
Remarks
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Refer to “COWLING AND COVER” in
chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “REAR WHEEL, BRAKE DISC,
AND REAR WHEEL SPROCKET” in
chapter 4.
5-2
ENG
ENGINE REMOVAL
* Apply sealant
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Yamaha bond No. 1215
90890-85505
5
New
LS
2
LT
8
9
7 6
13
11
∗
8
7
New
1
6
12
4
R.
LS
T.
3
10
7 Nm (0.7 m • kg, 5.1 ft • Ib)
14
T.
R.
16 Nm (1.6 m • kg, 11 ft • Ib)
Order
Job/Part
Q’ty
Starter motor
Air filter case
Throttle body/fast idle plunger inlet
hose
Thermostat/thermo sensor
Radiator
Water pump assembly/water pump
outlet hose
Air cut-off valve assembly/air-filter-toair-cut-off-valve hose
Swingarm
1
2
Shift pedal
Oil delivery hose 1
Remarks
Refer to “STARTER MOTOR” in chapter
8.
Refer to “AIR FILTER CASE” in chapter
3.
Refer to “THROTTLE BODY ASSEMBLY” in chapter 7.
Refer to “THERMOSTAT” in chapter 6.
Refer to “RADIATOR” in chapter 6.
Refer to “WATER PUMP” in chapter 6.
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
Refer to “SWINGARM AND DRIVE
CHAIN” in chapter 4.
1
1
5-3
Disconnect.
ENG
ENGINE REMOVAL
* Apply sealant
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Yamaha bond No. 1215
90890-85505
5
New
LS
2
LT
8
9
7 6
13
11
∗
8
7
New
1
6
12
4
R.
LS
T.
3
10
7 Nm (0.7 m • kg, 5.1 ft • Ib)
14
T.
R.
16 Nm (1.6 m • kg, 11 ft • Ib)
Order
3
4
5
6
7
8
9
10
11
12
13
14
Job/Part
Oil delivery hose 2
Oil tank breather hose
Crankcase-to-crankcase-breatherchamber hose
A.C. magneto coupler
Neutral switch connector
Speed sensor coupler
Ignition coil lead
Ignition coil
Intake air pressure sensor coupler
Vacuum hose
Intake air pressure sensor
Clutch cable
Q’ty
1
Disconnect.
1
Disconnect.
1
2
1
1
2
1
1
1
1
1
Remarks
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
5-4
ENG
ENGINE REMOVAL
EAS00191
ENGINE
T.
R.
5
6
73 Nm (7.3 m • kg, 53 ft • lb)
5
5
7
8
6
4
2
5
4
1
2
T.
R.
55 Nm (5.5m • kg, 40 ft • Ib)
T.
R.
73 Nm (7.3 m • kg, 53 ft • lb)
1
3
9
1
T.
R.
Order
1
Job/Part
Removing the engine
Q’ty
73 Nm (7.3 m • kg, 53 ft • lb)
Remarks
Remove the parts in the order listed.
NOTE:
Place a suitable stand under the frame
and engine.
_
CAUTION:
Install all of the nuts and bolt, and then
tighten them to specified torques.
1
2
3
4
5
6
Engine front mounting bracket bolt/nut
Engine front bracket bolt/nut
Engine front bracket
Engine rear mounting bolt/nut
Engine upper bracket bolt/nut
Engine upper mounting bolt/nut
2/2
2/2
1
1/1
2/2
1/1
5-5
Refer to “INSTALLING THE ENGINE”.
ENG
ENGINE REMOVAL
T.
R.
5
6
73 Nm (7.3 m • kg, 53 ft • lb)
5
5
7
8
6
4
2
5
4
1
2
T.
R.
55 Nm (5.5m • kg, 40 ft • Ib)
T.
R.
73 Nm (7.3 m • kg, 53 ft • lb)
1
3
9
1
T.
R.
Order
7
8
9
Job/Part
Engine upper bracket (right)
Engine upper bracket (left)
Engine
1
73 Nm (7.3 m • kg, 53 ft • lb)
Q’ty
Remarks
1
1
1
NOTE:
Remove
the Refer to “INSTALLengine from the ING THE ENGINE”.
right side of the
motorcycle.
For installation, reverse the removal procedure.
5-6
ENGINE REMOVAL
ENG
EAS00192
INSTALLING THE ENGINE
1. Install:
• engine front bracket 1
• engine front bracket bolt/nut 2
• engine front mounting bolt/nut 3
• engine rear mounting bolt/nut 4
• engine front bracket bolt/nut 5
• engine front mounting bolt/nut 6
• engine upper bracket (left) 7
• engine upper bracket (right) 8
• engine upper bracket bolts/nuts 9
• engine upper mounting bolt/nut 0
9
0
98
7
4
0
9
2
5
9
4 2
3
5
NOTE:
Do not fully tighten the bolts.
3
6 1
6
2. Tighten:
• engine front bracket bolts/nuts 2, 5
T.
R.
73 Nm (7.3 m · kg, 53 ft · lb)
• engine front mounting bolts/nuts 3, 6
T.
R.
73 Nm (7.3 m · kg, 53 ft · lb)
• engine rear mounting bolt/nut 4
T.
R.
73 Nm (7.3 m · kg, 53 ft · lb)
• engine upper bracket bolts/nuts 9
T.
R.
73 Nm (7.3 m · kg, 53 ft · lb)
• engine upper mounting bolt/nut 0
T.
R.
5-7
55 Nm (5.5 m · kg, 40 ft · lb)
ENG
CYLINDER HEAD
EAS00221
CYLINDER HEAD
T.
20 Nm (2.0 m • kg, 14 ft • Ib)
R.
T.
R.
13 Nm (1.3 m • kg, 9.4 ft • Ib)
T.
R.
50 Nm (5.0 m • kg, 36 ft • Ib)
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
E
T.
1
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
New
New
3
(4)
7
LS
New
8
New
New
New
12
3
E
New
3
6
10
11
(4)
3
9
LS
2
New
4
New
5 New
New
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
E
LS
T.
R.
T.
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
R.
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the cylinder head
Engine
Timing mark accessing screw/crankshaft end accessing screw
Spark plug
Camshaft sprocket cover/O-ring
Tappet cover/O-ring
Air cut-off valve outlet pipe
Gasket
Oil delivery pipe 1
Timing chain tensioner cap bolt
Timing chain tensioner/gasket
Camshaft sprocket
Cylinder head
Q’ty
1
1/1
2/2
1
1
1
1
1/1
1
1
5-8
45 Nm (4.5 m • kg, 32 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “ENGINE REMOVAL”.
Refer to “ADJUSTING THE VALVE
CLEARANCE” in chapter 3.
Refer to “REMOVING THE CYLINDER
HEAD” and “INSTALLING THE CYLINDER HEAD”.
ENG
CYLINDER HEAD
T.
20 Nm (2.0 m • kg, 14 ft • Ib)
R.
T.
R.
13 Nm (1.3 m • kg, 9.4 ft • Ib)
T.
R.
50 Nm (5.0 m • kg, 36 ft • Ib)
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
E
T.
1
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
New
New
3
(4)
7
LS
New
8
New
New
New
12
3
E
New
3
6
10
11
(4)
3
9
LS
2
New
4
New
5 New
New
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
E
LS
T.
R.
T.
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
R.
Order
11
12
Job/Part
Cylinder head gasket
Dowel pin
Q’ty
1
2
45 Nm (4.5 m • kg, 32 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
For installation, reverse the removal procedure.
5-9
CYLINDER HEAD
ENG
EAS00225
b
a
REMOVING THE CYLINDER HEAD
1. Align:
• “I” mark a on the A.C. magneto rotor
(with the stationary pointer b on the A.C.
magneto cover)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise.
b. When the piston is at top dead center (TDC)
on the compression stroke, align the “I”
mark c on the camshaft sprocket with the
stationary pointer d on the cylinder head.
d
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c
2. Loosen:
• camshaft sprocket bolts 1
NOTE:
While holding the A.C. magneto rotor nut with
a wrench, remove the bolt.
1
3.
•
4.
•
Loosen:
timing chain tensioner cap bolt
Remove:
timing chain tensioner
(along with the gasket)
• camshaft sprocket
• timing chain
NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire.
_
5. Remove:
• cylinder head
3
1
2
4
NOTE:
• Loosen the bolts in the proper sequence as
shown.
• Loosen each bolt 1/2 of a turn at a time. After
all of the bolts are fully loosened, remove
them.
_
5 - 10
CYLINDER HEAD
ENG
EAS00229
CHECKING THE CYLINDER HEAD
1. Eliminate:
• combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damaging or scratching:
• spark plug bore threads
• valve seats
_
2. Check:
• cylinder head
Damage/scratches → Replace.
• cylinder head water jacket
Mineral deposits/rust → Eliminate.
3. Measure:
• cylinder head warpage
Out of specification → Resurface the cylinder head.
Maximum cylinder head warpage
0.03 mm (0.0012 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
2
a. Place a straightedge 1 and a thickness
gauge 2 across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder head as follows.
d. Place 400 ~ 600 grit wet sandpaper on the
surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
NOTE:
To ensure an even surface, rotate the cylinder
head several times.
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 11
CYLINDER HEAD
ENG
EAS00212
2
1
3
3
CHECKING THE TAPPET COVERS AND
CAMSHAFT SPROCKET COVER
1. Check:
• tappet covers 1
• camshaft sprocket cover 2
• O-rings 3
Damage/wear → Replace the defective
part(s).
EAS00210
CHECKING THE TIMING CHAIN
TENSIONER
1. Check:
• timing chain tensioner
Cracks/damage → Replace.
2. Check:
• one-way cam operation
Rough movement → Replace the timing
chain tensioner housing.
3. Check:
• timing chain tensioner cap bolt
• copper washer New
• spring
• one-way cam
• gasket New
• timing chain tensioner rod
Damage/wear → Replace the defective
part(s).
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
1. Install:
• dowel pins
• cylinder head gasket New
5 - 12
CYLINDER HEAD
2.
•
•
•
ENG
Install:
cylinder head
washers New
cylinder head bolts
NOTE:
• Lubricate the cylinder head bolt threads and
muting surface with engine oil.
• Install the washers with their blunt surface
facing the bolt seat.
3. Tighten:
• cylinder head bolts 1
4
T.
3
R.
2
• cylinder head bolts 2
1
T.
R.
2
= 145 mm (5.71 in)
50 Nm (5.0 m · kg, 36 ft · lb)
• cylinder head bolts 3
1
4
T.
R.
4
= 135 mm (5.31 in)
50 Nm (5.0 m · kg, 36 ft · lb)
45 Nm (4.5 m · kg, 32 ft · lb)
• cylinder head bolts 4
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
NOTE:
Tighten the cylinder head bolts in the proper
tightening sequence as shown and torque
them in two stages.
_
3
3
4. Install:
• camshaft sprocket
(onto the camshaft)
a
NOTE:
Make sure that the projection a on the decompressor lever is in the position shown in the
illustration.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
c
a. Turn the primary pulley counterclockwise.
b. Align the “I” mark b on the A.C. magneto
rotor with the stationary pointer c on the
A.C. magneto cover.
b
5 - 13
CYLINDER HEAD
e
3
d
1
2
ENG
c. Install the timing chain 1 onto the camshaft
sprocket 2, then the camshaft sprocket
onto the camshaft, and then finger tighten
the camshaft sprocket bolts.
NOTE:
To install the camshaft sprocket sprocket,
install the projection 3 on the camshaft
sprocket into the slot a in the decompression
lever.
d. Make sure the “I” mark d on the camshaft
sprocket with the stationary pointer e on
the cylinder head.
NOTE:
• When installing the camshaft sprocket, be
sure to keep the timing chain as tight as possible at the exhaust end of the chain.
• Align the projection on the camshaft with the
slot in the camshaft sprocket.
_
CAUTION:
_
Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
e. Remove the wire from the timing chain.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• timing chain tensioner
6 New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3
2 New
1
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 tensioner housing.
c. Install the timing chain tensioner and gasket
6 onto the cylinder.
R.
5
T.
4
Timing chain tensioner bolt
10 Nm (1.0 m · kg, 7.2 ft · lb)
NOTE:
Install the gasket with its beaded side facing
the timing chain tensioner end.
5 - 14
CYLINDER HEAD
ENG
d. Install the spring and timing chain tensioner
cap bolt.
T.
Timing chain tensioner cap bolt
20 Nm (2.0 m · kg, 14 ft · lb)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b
a
6. Turn:
• crankshaft
(several turns counterclockwise)
7. Check:
• “I” mark a
NOTE:
Check that the “I” mark on the A.C. magneto
rotor is aligned with the stationary pointer b
on the A.C. magneto cover.
• “I” mark c
d
c
NOTE:
Check that the “I” mark on the camshaft
sprocket is aligned with the stationary pointer
d on the cylinder head.
Out of alignment → Correct.
Repeat steps 4-7, if necessary.
8. Tighten:
• camshaft sprocket bolts
T.
R.
20 Nm (2.0 m · kg, 14 ft · lb)
CAUTION:
_
Be sure to tighten the camshaft sprocket
bolts to the specified torque to avoid the
possibility of the bolts coming loose and
damaging the engine.
9. Measure:
• valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE
CLEARANCE” in chapter 3.
5 - 15
VALVE
ROCKER ARMS AND CAMSHAFT
ENG
ROCKER ARMS AND CAMSHAFT
T.
R.
14 Nm (1.4 m • kg, 10 ft • Ib)
4
4
3
T.
R.
4
14 Nm (1.4 m • kg, 10 ft • Ib)
2
4
3
E
8
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
7
M
5
E
1
M
2
E
M
Order
1
2
3
4
5
6
6
LT
Job/Part
Q’ty
Remarks
Removing the rocker arms and camRemove the parts in the order listed.
shaft
Cylinder head
Refer to “CYLINDER HEAD”.
Bearing retainer
1
Rocker arm shaft
2
Refer to “REMOVRocker arm
2
ING THE ROCKER
Locknut/valve adjuster
4/4
ARMS AND CAMCAUTION:
Camshaft
1
SHAFT” and
Do not disas- “INSTALLING THE
semble the cam- CAMSHAFT AND
shaft assembly.
ROCKER ARMS”.
Decompressor lever
1
5 - 16
ROCKER ARMS AND CAMSHAFT
ENG
T.
R.
14 Nm (1.4 m • kg, 10 ft • Ib)
4
4
3
T.
R.
4
14 Nm (1.4 m • kg, 10 ft • Ib)
2
4
3
E
8
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
7
M
5
E
1
M
2
E
M
Order
7
8
Job/Part
Decompressor lever pin
Bearing
Q’ty
1
1
5 - 17
6
LT
Remarks
Refer to “REMOVING THE ROCKER
ARMS AND CAMSHAFT” and
“INSTALLING THE CAMSHAFT AND
ROCKER ARMS”.
For installation, reverse the removal procedure.
ROCKER ARMS AND CAMSHAFT
ENG
EAS00202
1
2 1
REMOVING THE ROCKER ARMS AND
CAMSHAFT
1. Loosen:
• locknuts
• adjusting screws
2. Remove:
• camshaft retainer 1
3.
•
•
•
•
Remove:
intake rocker arm shaft
exhaust rocker arm shaft
intake rocker arm
exhaust rocker arm
NOTE:
Remove the rocker arm shafts with the slide
hammer bolt 1 and weight 2.
_
Slide hammer bolt
90890-01083
Weight
90890-01084
4. Remove:
• camshaft
EAS00205
CHECKING THE CAMSHAFT
1. Check:
• camshaft lobes
Blue discoloration/pitting/scratches →
Replace the camshaft and camshaft
sprocket.
5 - 18
ROCKER ARMS AND CAMSHAFT
ENG
2. Measure:
• camshaft lobe dimensions a and b
Out of specification → Replace the camshaft.
Camshaft lobe dimensions
Intake
a 43.488 ~ 43.588 mm
(1.7121 ~ 1.7161 in)
<Limit>:
43.388 mm (1.7062 in)
b 36.959 ~ 37.059 mm
(1.4551 ~ 1.4590 in)
<Limit>:
36.840 mm (1.4504 in)
Exhaust
a 43.129 ~ 43.229 mm
(1.6980 ~ 1.7019 in)
<Limit>:
42.983 mm (1.6922 in)
b 37.007 ~ 37.107 mm
(1.4570 ~ 1.4609 in)
<Limit>:
36.886 mm (1.4522 in)
3. Measure:
• camshaft runout
Out of specification → Replace.
Camshaft runout limit
0.040 mm (0.0016 in)
CHECKING THE DECOMPRESSION
SYSTEM
1. Check:
• decompression system
1
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the decompression system with the
camshaft sprocket installed on and the
decompressor pin installed in the camshaft.
b. Check that the decompressor lever pin 1
projects from the camshaft.
c. Check that the decompressor cam 2
moves smoothly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 19
ROCKER ARMS AND CAMSHAFT
ENG
EAS00206
CHECKING THE ROCKER ARMS AND
ROCKER ARM SHAFTS
The following procedure applies to both of the
rocker arms and rocker arm shafts.
1. Check:
• rocker arm
Damage/wear → Replace.
2. Check:
• rocker arm shaft
Blue discoloration/excessive wear/pitting/
scratches → Replace or check the lubrication system.
3. Measure:
• rocker arm inside diameter
Out of specification → Replace.
Rocker arm inside diameter
12.000 ~ 12.018 mm
(0.4724 ~ 0.4731 in)
<Limit>: 12.036 mm (0.4739 in)
4. Measure:
• rocker arm shaft outside diameter
Out of specification → Replace.
Rocker arm shaft outside diameter
11.981 ~ 11.991 mm
(0.4717 ~ 0.4721 in)
<Limit>: 11.955 mm (0.4707 in)
5 - 20
ROCKER ARMS AND CAMSHAFT
ENG
5. Calculate:
• rocker-arm-to-rocker-arm-shaft clearance
NOTE:
Calculate the clearance by subtracting the
rocker arm shaft outside diameter from the
rocker arm inside diameter.
_
Above 0.081 mm (0.0032 in) → 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
1
a
b
INSTALLING THE CAMSHAFT AND
ROCKER ARMS
1. Install:
• bearing 1
(onto the camshaft)
NOTE:
• Apply engine oil to the bearing.
• Install the bearing so that the seal is facing
a the camshaft.
Installed depth b
0 mm (0 in)
2.
•
•
•
Lubricate:
camshaft
decompressor lever pin
decompressor lever
Recommended lubricant
Camshaft
Molybdenum disulfide oil
Camshaft bearing
Engine oil
5 - 21
ROCKER ARMS AND CAMSHAFT
ENG
3. Install:
• decompressor lever pin 1
• decompressor lever 2
1
2
NOTE:
Install the decompressor lever pin 1 and
decompressor lever 2 in the camshaft 3 as
shown in the illustration.
_
3
a
4. Install:
• camshaft 1
NOTE:
Install the camshaft on the slot a facing up.
5. Lubricate:
• rocker arm shafts
1
Recommended lubricant
Engine oil
1
2
3
6.
•
•
•
•
Install:
exhaust rocker arm 1
exhaust rocker arm shaft 2
intake rocker arm
intake rocker arm shaft
NOTE:
• Use a slide hammer bolt 3 to install the
rocker arm shaft.
• Make sure the rocker arm shaft (intake and
exhaust) is completely pushed into the cylinder head.
_
Slide hammer bolt
90890-01083
7. Install:
• camshaft retainer
• camshaft retainer bolts
LT
T.
R.
5 - 22
10 Nm (1.0 m · kg, 7.2 ft · lb)
ENG
VALVES AND VALVE SPRINGS
EAS00236
VALVES AND VALVE SPRINGS
1
3
3
2
1
2
2
2
6
3
M
6
M
7
6
7
New
7
M
7
3
6
New
M
New
5
4
4
5
M
Order
1
2
3
4
5
6
7
Job/Part
Removing the valves and valve
springs
Cylinder head
Rocker arms/rocker arm shafts/camshaft
Valve cotter
Valve spring retainer
Valve spring
Exhaust valve
Intake valve
Valve stem seal
Valve spring seat
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
Refer to “ROCKER ARMS AND CAMSHAFT”.
8
4
4
2
2
4
4
Refer to “REMOVING THE VALVES”
and “INSTALLING THE VALVES”.
For installation, reverse the removal procedure.
5 - 23
VALVES AND VALVE SPRINGS
ENG
EAS00237
REMOVING THE VALVES
The following procedure applies to all of the
valves and related components.
NOTE:
Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve
seats), make sure the valves properly seal.
_
1. Check:
• valve sealing
Leakage at the valve seat → Check the
valve face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pour a clean solvent a into the intake and
exhaust ports.
b. Check that the valves properly seal.
NOTE:
There should be no leakage at the valve seat
1.
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Remove:
• valve cotters
NOTE:
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
1 and the valve spring compressor attachment 2.
_
Valve spring compressor
90890-04019
Valve spring compressor attachment
90890-01243
5 - 24
VALVES AND VALVE SPRINGS
3.
•
•
•
•
•
ENG
Remove:
valve spring retainer 1
valve spring 2
valve stem seal 3
valve spring seat 4
valve 5
NOTE:
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
_
EAS00239
CHECKING THE VALVES AND VALVE
GUIDES
The following procedure applies to all of the
valves and valve guides.
1. Measure:
• valve-stem-to-valve-guide clearance
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter a –
Valve stem diameter b
Out of specification → Replace the valve
guide.
Valve-stem-to-valve-guide clearance
Intake
0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
<Limit>: 0.08 mm (0.0031 in)
Exhaust
0.025 ~ 0.052 mm
(0.0010 ~ 0.0020 in)
<Limit>: 0.10 mm (0.0039 in)
5 - 25
VALVES AND VALVE SPRINGS
ENG
2. Replace:
• valve guide
NOTE:
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100 °C (212 °F) in an oven.
_
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve guide with the valve
guide remover 1.
b. Install the new valve guide with the valve
guide installer 2 and valve guide remover
1.
c. After installing the valve guide, bore the
valve guide with the valve guide reamer 3
to obtain the proper valve-stem-to-valveguide clearance.
NOTE:
After replacing the valve guide, reface the
valve seat.
_
Valve guide remover (ø6)
90890-04064
Valve guide installer (ø6)
90890-04065
Valve guide reamer (ø6)
90890-04066
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
• carbon deposits
(from the valve face and valve seat)
4. Check:
• valve face
Pitting/wear → Grind the valve face.
• valve stem end
Mushroom shape or diameter larger than
the body of the valve stem → Replace the
valve.
5. Measure:
• valve margin thickness a
Out of specification → Replace the valve.
Valve margin thickness
0.80 ~ 1.20 mm
(0.0315 ~ 0.0472 in)
5 - 26
VALVES AND VALVE SPRINGS
ENG
6. Measure:
• valve stem runout
Out of specification → Replace the valve.
NOTE:
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always
replace the valve stem seal.
_
Valve stem runout
0.010 mm (0.0004 in)
EAS00240
CHECKING THE VALVE SEATS
The following procedure applies to all of the
valves and valve seats.
1. Eliminate:
• carbon deposits
(from the valve face and valve seat)
2. Check:
• valve seat
Pitting/wear → Replace the cylinder head.
3. Measure:
• valve seat width a
Out of specification → Replace the cylinder
head.
Valve seat width
Intake
1.00 ~ 1.20 mm
(0.0394 ~ 0.0472 in)
Exhaust
1.00 ~ 1.20 mm
(0.0394 ~ 0.0472 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply Mechanic’s blueing dye (Dykem) onto
the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
d. Measure the valve seat width.
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been
removed.
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 27
VALVES AND VALVE SPRINGS
ENG
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.
CAUTION:
_
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil onto the
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all
of the lapping compound.
NOTE:
For the best lapping results, lightly tap the
valve seat while rotating the valve back and
forth between your hands.
_
e. Apply a fine lapping compound to the valve
face and repeat the steps above.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) b
onto the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
j. Measure the valve seat width again. If the
valve seat width is out of specification,
reface and lap the valve seat.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 28
VALVES AND VALVE SPRINGS
ENG
EAS00241
CHECKING THE VALVE SPRINGS
The following procedure applies to all of the
valve springs.
1. Measure:
• valve spring free length a
Out of specification → Replace the valve
spring.
Valve spring free length
Intake
40.38 mm (1.59 in)
<Limit>: 38.36 mm (1.51 in)
Exhaust
40.38 mm (1.59 in)
<Limit>: 38.36 mm (1.51 in)
2. Measure:
• compressed valve spring force a
Out of specification → Replace the valve
spring.
b Installed length
Compressed valve spring force
(installed)
171 ~ 197 N at 35.00 mm
(17.44 ~ 20.09 kg at 35.00 mm,
38.44 ~ 44.29 lb at 1.38 in)
3. Measure:
• valve spring tilt a
Out of specification → Replace the valve
spring.
Spring tilt limit
2.5°/1.8 mm (2.5°/0.071 in)
5 - 29
VALVES AND VALVE SPRINGS
ENG
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. Lubricate:
• valve stem 1
• valve stem seal 2
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
3.
•
•
•
•
•
Install:
valve 1
valve spring seat 2
valve stem seal 3
valve spring 4
valve spring retainer 5
(into the cylinder head)
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
5 - 30
VALVES AND VALVE SPRINGS
ENG
4. Install:
• valve cotters
NOTE:
Install the valve cotters by compressing the
valve spring with the valve spring compressor
1 and the valve spring compressor attachment 2.
_
Valve spring compressor
98090-04019
Valve spring compressor attachment
90890-01243
5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a soft-face
hammer.
CAUTION:
_
Hitting the valve tip with excessive force
can damage the valve.
5 - 31
ENG
CYLINDER AND PISTON
EAS00251
CYLINDER AND PISTON
New
R.
E
T.
1
1st 15 Nm (1.5 m • kg, 11 ft • lb)
2nd 50 Nm (5.0 m • kg, 36 ft • lb)
New
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
New
E
New
LS
3 New
4
10
11
12
E
9
5 New
2
UP
6
New 7
6
8
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
E
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the cylinder and piston
Cylinder head
Timing chain guide (exhaust)
Water jacket joint
O-ring
Cylinder
Cylinder gasket
Dowel pin
Piston pin clip
Piston pin
Piston
Top ring
7 New
Q’ty
1
1
1
1
1
2
2
1
1
1
5 - 32
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
Refer to “INSTALLING THE PISTON
AND CYLINDER”.
Refer to “REMOVING THE CYLINDER
AND PISTON” and “INSTALLING THE
PISTON AND CYLINDER”.
ENG
CYLINDER AND PISTON
New
R.
E
T.
1
1st 15 Nm (1.5 m • kg, 11 ft • lb)
2nd 50 Nm (5.0 m • kg, 36 ft • lb)
New
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
New
E
New
LS
3 New
4
10
11
12
E
9
5 New
2
UP
6
New 7
6
8
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
E
Order
11
12
Job/Part
2nd ring
Oil ring
7 New
Q’ty
1
1
5 - 33
Remarks
Refer to “REMOVING THE CYLINDER
AND PISTON” and “INSTALLING THE
PISTON AND CYLINDER”.
For installation, reverse the removal procedure.
CYLINDER AND PISTON
ENG
EAS00253
2
1
REMOVING THE CYLINDER AND PISTON
1. Remove:
• piston pin clips 1
• piston pin 2
• piston 3
CAUTION:
_
3
Do not use a hammer to drive the piston
pin out.
NOTE:
• Before removing the piston pin clip, cover the
crankcase opening with a clean rag to prevent the piston pin clip from falling into the
crankcase.
• Before removing the piston pin, deburr the
piston pin clip’s groove and the piston’s pin
bore area. If both areas are deburred and the
piston pin is still difficult to remove, remove it
with the piston pin puller set 4.
_
Piston pin puller set
90890-01304
2.
•
•
•
Remove:
top ring
2nd ring
oil ring
NOTE:
When removing a piston ring, open the end
gap with your fingers and lift the other side of
the ring over the piston crown.
_
EAS00255
CHECKING THE CYLINDER AND PISTON
1. Check:
• piston wall
• cylinder wall
Vertical scratches → Replace the cylinder
and the piston and piston rings as a set.
5 - 34
CYLINDER AND PISTON
ENG
2. Measure:
• piston-to-cylinder clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore “C” with the cylinder
bore gauge.
NOTE:
Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the
cylinder. Then, find the average of the measurements.
_
Cylinder bore “C”
100.000 ~ 100.010 mm
(3.9370 ~ 3.9374 in)
Taper limit “T”
0.05 mm (0.002 in)
Out-of-round “R”
0.05 mm (0.002 in)
“C” = maximum of D1 ~ D2
“T” = maximum of D1 or D2 – maximum of
D5 or D6
“R” = maximum of D1, D3 or D5 – minimum of D2, D4 or D6
b. If out of specification, replace the cylinder
and the piston and piston rings as a set.
c. Measure piston skirt diameter “P” with the
micrometer.
a 10 mm (0.39 in) from the bottom edge of the piston
d. If out of specification, replace the piston and
piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” Piston skirt diameter “P”
Piston-to-cylinder clearance
0.030 ~ 0.055 mm
(0.0012 ~ 0.0022 in)
<Limit>: 0.13 mm (0.0051 in)
f. If out of specification, replace the cylinder
and the piston and piston rings as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 35
CYLINDER AND PISTON
ENG
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 clearance, eliminate any carbon deposits from the
piston ring grooves and piston rings.
_
Piston ring side clearance
Top ring
0.030 ~ 0.080 mm
(0.0012 ~ 0.0031 in)
<Limit>: 0.13 mm (0.0051 in)
2nd ring
0.030 ~ 0.070 mm
(0.0012 ~ 0.0028 in)
<Limit>: 0.11 mm (0.0043 in)
2. Install:
• piston ring
(into the cylinder)
NOTE:
Level the piston ring into the cylinder with the
piston crown.
_
a 40 mm (1.57 in)
3. Measure:
• piston ring end gap
Out of specification → Replace the piston
ring.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is excessive, replace all three piston rings.
_
Piston ring end gap
Top ring
0.20 ~ 0.35 mm
(0.0079 ~ 0.0138 in)
<Limit>: 0.60 mm (0.0236 in)
2nd ring
0.35 ~ 0.50 mm
(0.0138 ~ 0.0197 in)
<Limit>: 0.85 mm (0.0335 in)
Oil ring
0.20 ~ 0.70 mm
(0.0079 ~ 0.0276 in)
5 - 36
CYLINDER AND PISTON
ENG
EAS00265
CHECKING THE PISTON PIN
1. Check:
• piston pin
Blue discoloration/grooves → Replace the
piston pin, and then check the lubrication
system.
2. Measure:
• piston pin outside diameter a
Out of specification → Replace the piston
pin.
Piston pin outside diameter
22.991 ~ 23.000 mm
(0.9052 ~ 0.9055 in)
<Limit>: 22.971 mm (0.9044 in)
3. Measure:
• piston pin bore inside diameter b
Out of specification → Replace the piston.
Piston pin bore inside diameter
23.004 ~ 23.015 mm
(0.9057 ~ 0.9061 in)
<Limit>: 23.045 mm (0.9073 in)
4. Calculate:
• piston-pin-to-piston-pin-bore clearance
Out of specification → Replace the piston
pin and piston as a set.
Piston-pin-to-piston-pin-bore clearance =
Piston pin bore inside diameter b –
Piston pin outside diameter a
Piston-pin-to-piston clearance
0.004 ~ 0.024 mm
(0.0002 ~ 0.0009 in)
<Limit>: 0.074 mm (0.0029 in)
5 - 37
CYLINDER AND PISTON
ENG
EAS00267
INSTALLING THE PISTON AND CYLINDER
1. Install:
• top ring 1
• 2nd ring 2
• oil ring expander 3
• lower oil ring rail 4
• upper oil ring rail 5
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up.
_
2.
•
•
•
1
a
Install:
piston 1
piston pin 2
piston pin clips 3 New
NOTE:
• Apply engine oil to the piston pin.
• Make sure the punch mark a on the piston
points towards the exhaust side of the cylinder.
• Before installing the piston pin clips, cover
the crankcase opening with a clean rag to
prevent the clip from falling into the crankcase.
_
2
3 New
3.
•
•
4.
•
•
•
Install:
cylinder gasket New
dowel pins
Lubricate:
piston
piston rings
cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
5 - 38
CYLINDER AND PISTON
120˚
e
120˚
5. Offset:
• piston ring end gaps
a
a Top ring
b Upper oil ring rail
c Oil ring expander
d Lower oil ring rail
e 2nd ring
f 20 mm (0.79 in)
È Exhaust side
120˚
f f
d
c
È
ENG
b
6. Install:
• cylinder 1
• timing chain guide (exhaust)
1
NOTE:
• While compressing the piston rings with one
hand, install the cylinder with the other hand.
• Pass the timing chain and timing chain guide
(exhaust side) through the timing chain cavity.
_
7. Install:
• washers New
• cylinder bolts
NOTE:
• Lubricate the cylinder bolt threads and muting surface with engine oil.
• Install the washers with their blunt surface
facing up.
8. Tighten:
• cylinder bolts
• cylinder bolts
3
E
2
1
E
T.
R.
3
= 116 mm (4.57 in) 1
= 109 mm (4.29 in) 2
Cylinder bolt
1st
15 Nm (1.5 m · kg, 11 ft · lb)
2nd
50 Nm (5.0 m · kg, 36 ft · lb)
• cylinder bolts (timing chain side) 3
T.
R.
5 - 39
10 Nm (1.0 m · kg, 7.2 ft · lb)
CLUTCH
ENG
EAS00273
CLUTCH
CLUTCH COVER
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
2
1
5
5
4 New
(7)
3
T.
R.
Order
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Part
Removing the clutch cover
Engine oil
Q’ty
1
2
3
Clutch cable
Clutch cable holder
Clutch cover
1
1
1
4
5
Gasket
Dowel pin
1
2
Remarks
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “REMOVING THE CLUTCH” and
“INSTALLING THE CLUTCH”.
For installation, reverse the removal procedure.
5 - 40
ENG
CLUTCH
PULL LEVER SHAFT
1 New
3
E
7 New
8
8
6
E
5
Order
1
2
3
4
5
6
7
8
Job/Part
Removing the pull lever shaft
Circlip
Circlip
Washer
Pull lever
Pull lever spring
Pull lever shaft
Oil seal
Bearing
Q’ty
4
3 2 New
Remarks
Remove the parts in the order listed.
1
1
2
1
1
1
1
2
For installation, reverse the removal procedure.
5 - 41
CLUTCH
ENG
EAS00274
CLUTCH
E
14
12
13
9
E
8
4
56
56
7
5
5 4
4
5
5
E
4
New 11
2
10
3
M
E
(5)
T.
R.
R.
Order
1
E
E
T.
90 Nm (9.0 m • kg, 65 ft • Ib)
(5)
1
2
3
4
Job/Part
Removing the clutch
Clutch spring
Pressure plate
Pull rod
Friction plate 1
Q’ty
5
6
Clutch plate
Friction plate 2
6
2
7
Friction plate 3
1
8
9
Clutch damper spring
Clutch damper spring seat
1
1
5
1
1
4
5 - 42
9 Nm (0.9 m • kg, 6.5 ft • Ib)
Remarks
Remove the parts in the order listed.
Inside diameter (plate
with notched tabs) =
119 mm (4.69 in)
Inside diameter (plate
with no notched tabs)
= 119 mm (4.69 in)
Inside diameter (plate
with notched tabs) =
128 mm (5.04 in)
Refer to
“INSTALLING
THE CLUTCH”.
CLUTCH
ENG
E
14
12
13
9
E
8
4
56
56
7
5
5 4
4
5
5
E
4
New 11
2
10
3
M
E
(5)
T.
R.
R.
Order
10
11
12
13
14
Job/Part
Clutch boss nut
Lock washer
Clutch boss
Thrust washer
Clutch housing
1
E
E
T.
90 Nm (9.0 m • kg, 65 ft • Ib)
(5)
Q’ty
1
1
1
1
1
9 Nm (0.9 m • kg, 6.5 ft • Ib)
Remarks
Refer to “REMOVING THE CLUTCH”
and “INSTALLING THE CLUTCH”.
For installation, reverse the removal procedure.
5 - 43
CLUTCH
ENG
EAS00275
1
REMOVING THE CLUTCH
1. Remove:
• clutch cover 1
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
2. Straighten the lock washer tab.
3. Loosen:
• clutch boss nut 1
3
2
1
NOTE:
While holding the clutch boss 2 with the universal clutch holder 3, loosen the clutch boss
nut.
_
Universal clutch holder
90890-04086
4.
•
•
•
Remove:
clutch boss nut
lock washer
clutch boss
EAS00280
CHECKING THE FRICTION PLATES
The following procedure applies to all of the
friction plates.
1. Check:
• friction plate 1
• friction plate 2
• friction plate 3
Damage/wear → Replace the friction plates
as a set.
5 - 44
CLUTCH
2.
•
•
•
ENG
Measure:
friction plate 1 thickness
friction plate 2 thickness
friction plate 3 thickness
Out of specification → Replace the friction
plates as a set.
NOTE:
Measure the friction plate at four places.
_
Friction plate 1 thickness
2.90 ~ 3.10 mm (0.114 ~ 0.122 in)
<Limit>: 2.80 mm (0.110 in)
Friction plate 2 thickness
2.92 ~ 3.08 mm
(0.115 ~ 0.121 in)
<Limit>: 2.80 mm (0.110 in)
Friction plate 3 thickness
2.90 ~ 3.10 mm (0.114 ~ 0.122 in)
<Limit>: 2.80 mm (0.110 in)
EAS00281
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the
clutch plates.
1. Check:
• clutch plate
Damage → Replace the clutch plates as a
set.
2. Measure:
• clutch plate warpage
(with a surface plate and thickness gauge
1)
Out of specification → Replace the clutch
plates as a set.
Clutch plate warpage limit
0.20 mm (0.0079 in)
EAS00282
CHECKING THE CLUTCH SPRINGS
The following procedure applies to all of the
clutch springs.
1. Check:
• clutch spring
Damage → Replace the clutch springs as a
set.
5 - 45
CLUTCH
ENG
2. Measure:
• clutch spring free length a
Out of specification → Replace the clutch
springs as a set.
Clutch spring free length
55.6 mm (2.19 in)
<Limit>: 52.82 mm (2.08 in)
EAS00284
CHECKING THE CLUTCH HOUSING
1. Check:
• clutch housing dogs
Damage/pitting/wear → Deburr the clutch
housing dogs or replace the clutch housing.
NOTE:
Pitting on the clutch housing dogs will cause
erratic clutch operation.
_
EAS00285
CHECKING THE CLUTCH BOSS
1. Check:
• clutch boss splines
Damage/pitting/wear → Replace the clutch
boss.
NOTE:
Pitting on the clutch boss splines will cause
erratic clutch operation.
_
EAS00286
2
1
CHECKING THE PRESSURE PLATE
1. Check:
• pressure plate 1
Cracks/damage → Replace.
• bearing 2
Damage/wear → Replace.
EAS00287
2
1
CHECKING THE PULL LEVER SHAFT AND
PULL ROD
1. Check:
• pull lever shaft pinion gear teeth 1
• pull rod teeth 2
Damage/wear → Replace the pull rod and
pull lever shaft pinion gear as a set.
5 - 46
CLUTCH
ENG
2. Check:
• pull rod bearing
Damage/wear → Replace.
EAS00292
CHECKING THE PRIMARY DRIVEN GEAR
1. Check:
• primary driven gear
Damage/wear → Replace the primary drive
gear and clutch housing as a set.
Excessive noise during operation →
Replace the primary drive gear and clutch
housing as a set.
EAS00299
3
2
1
INSTALLING THE CLUTCH
1. Install:
• clutch boss
• lock washer New
• clutch boss nut 1
NOTE:
Lubricate the crankshaft end threads with
engine oil.
2. Tighten:
• clutch boss nut
T.
R.
90 Nm (9.0 m · kg, 65 ft · lb)
NOTE:
While holding the clutch boss 2 with the universal clutch holder 3, tighten the clutch boss
nut.
_
Universal clutch holder
90890-04086
3. Bend the lock washer tab along a flat side of
the nut.
5 - 47
CLUTCH
ENG
4. Lubricate:
• friction plates
• clutch plates
(with the recommended lubricant)
Recommended lubricant
Engine oil
12
5.
•
•
•
•
•
•
4
Install:
clutch damper spring seat 1
clutch damper spring 2
friction plate 3 3
clutch plates 4
friction plates 1 5, 7
friction plates 2 6
NOTE:
• Install the clutch damper spring 2 with the
“OUTSIDE” mark facing out.
• First, install a friction plate and then alternate
between a clutch plate and a friction plate.
• Install friction plate 3 3 and friction plate 1
5 so that the tab with two notches a is
between the two punch marks b on the
clutch housing as shown.
• Install friction plate 1 7 so that the tab with
two notches c is between the two punch
marks d on the clutch housing as shown.
_
35 6 57
c
7 d
a
b
35
6. Install:
• clutch springs
• clutch spring bolts
T.
R.
9 Nm (0.9 m · kg, 6.5 ft · lb)
NOTE:
• Lubricate the clutch spring threads with
engine oil.
• Tighten the clutch spring bolts in stages and
in a crisscross pattern.
_
Install:
dowel pins
gasket New
10 Nm (1.0 m · kg, 7.2 ft · lb)
clutch cover
clutch cable holder
T.
R.
7.
•
•
•
•
T.
R.
5 - 48
10 Nm (1.0 m · kg, 7.2 ft · lb)
CLUTCH
ENG
NOTE:
• To install the clutch cover, position the pull
rod so that the teeth face towards that rear of
the motorcycle.
• Tighten the clutch cover bolts in stages and
in a crisscross pattern.
_
8.
•
•
•
•
1
2
b
a
b
NOTE:
• Install the pull lever with the “UP” mark facing
up.
• Align the punch mark a on the pull lever with
the punch mark b on the clutch cover.
• Install the pull lever spring 1 as shown.
_
a
1
c
Install:
pull lever spring 1
pull lever 2
washer
circlip New
9. Install:
• clutch cable 1
10.Check:
• clutch cable length a
Out of specification → Adjust.
NOTE:
• Push the pull lever in direction b and check
the cable length a.
• Bend the tab c on the pull lever to secure
the clutch cable.
Clutch cable length
65.6 ~ 73.9 mm (2.58 ~ 2.91 in)
11.Adjust:
• clutch cable length
NOTE:
Move the pull lever a notch until the cable
length is within specification.
12.Adjust:
• clutch cable free play
Refer to “ADJUSTING THE CLUTCH
CABLE FREE PLAY” in chapter 3.
5 - 49
OIL PUMP
ENG
OIL PUMP
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib)
4
3
New
T.
R.
1
3
New
3
New
5
10 Nm (1.0 m • kg, 7.2 ft • Ib)
New
New
7
New
2
6 New
New
7
LS
LS
(9)
12
13 New
LS
11
14 New
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
New
LT
R.
10
T.
9
10 Nm (1.0 m • kg, 7.2 ft • Ib)
8
T.
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib)
Order
Job/Part
Removing the oil pump
Engine oil
Q’ty
Coolant
Water pump assembly
Clutch cable holder/clutch housing
Right footrest/brake pedal assembly
1
2
3
4
Oil filter element cover
Oil filter element
Union bolt
Oil delivery pipe 2
1
1
3
1
5 - 50
Remarks
Remove the parts in the order listed.
Drain.
Refer to “CHECKING AND CHANGING
THE ENGINE OIL” in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Refer to “WATER PUMP” in chapter 6.
Refer to “CLUTCH”.
Refer to “SWINGARM AND DRIVE
CHAIN” in chapter 4.
OIL PUMP
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib)
4
3
New
T.
R.
1
New
New
7
3
New
3
New
5
10 Nm (1.0 m • kg, 7.2 ft • Ib)
ENG
New
2
6 New
New
7
LS
LS
(9)
12
13 New
LS
11
14 New
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
New
LT
R.
10
T.
9
10 Nm (1.0 m • kg, 7.2 ft • Ib)
8
T.
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib)
Order
5
6
7
8
9
10
11
12
13
14
Job/Part
Crankcase cover (right)
Gasket
Dowel pin
Oil baffle plate 1
Circlip
Oil pump driven gear
Oil baffle plate 2
Oil pump
Oil pump gasket
O-ring
Q’ty
1
1
2
1
1
1
1
1
1
2
Remarks
Refer to “INSTALLING THE OIL PUMP”.
For installation, reverse the removal procedure.
5 - 51
OIL PUMP
ENG
EAS00360
Order
1
2
3
4
5
6
7
8
9
0
A
Job/Part
Disassembling the oil pump
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
Q’ty
1/1
1
1
1
1/1
2
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “ASSEMBLING THE OIL
PUMP”.
For assembly, reverse the disassembly
procedure.
5 - 52
OIL PUMP
ENG
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 defective part(s).
2. Measure:
• inner-rotor-to-outer-rotor-tip clearance a
• outer-rotor-to-oil-pump-housing clearance
b
• oil-pump-housing-to-inner-rotor-and-outerrotor clearance c
Out of specification → Replace the oil
pump.
1 Inner rotor
2 Outer rotor
3 Oil pump housing
Inner-rotor-to-outer-rotor-tip
clearance
0.07 ~ 0.12 mm
(0.0028 ~ 0.0047 in)
<Limit>: 0.2 mm (0.008 in)
Outer-rotor-to-oil-pump-housing
clearance
0.03 ~ 0.08 mm
(0.0012 ~ 0.0031 in)
<Limit>: 0.15 mm (0.0059 in)
Oil-pump-housing-to-inner-rotorand-outer-rotor clearance
0.03 ~ 0.08 mm
(0.0012 ~ 0.0031 in)
<Limit>: 0.15 mm (0.0059 in)
3. Check:
• oil pump operation
Rough movement → Repeat steps (1) and
(2) or replace the defective part(s).
5 - 53
OIL PUMP
ENG
EAS00367
CHECKING THE OIL DELIVERY PIPES AND
HOSES
The following procedure applies to all of the oil
delivery pipes and hoses.
1. Check:
• oil delivery pipe
• oil delivery hose
Damage → Replace.
Obstruction → Wash and blow out with
compressed air.
EAS00375
ASSEMBLING THE OIL PUMP
1. Lubricate:
• oil pump inner rotor 1
• oil pump inner rotor 2
• oil pump outer rotor 1
• oil pump outer rotor 2
• oil pump shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Install:
• oil pump outer rotor 2 1
• oil pump inner rotor 2 2
(to the oil pump housing 2)
• oil pump housing
T.
R.
7 Nm (0.7 m · kg, 5.1 ft · lb)
NOTE:
• Install oil pump inner rotor 2 and outer rotor 2
with the alignment marks a facing up.
• When installing the inner rotor, align the pin
in the oil pump shaft with the groove in the
inner rotor.
_
3. Check:
• oil pump operation
Refer to “CHECKING THE OIL PUMP”.
5 - 54
OIL PUMP
ENG
EAS00376
INSTALLING THE OIL PUMP
1. Install:
• oil pump gasket New
• oil pump
• oil baffle plate 2
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
• oil pump driven gear 1
• oil pump driven gear circlip New
• oil baffle plate 1
1
T.
LT
R.
4 Nm (0.4 m · kg, 2.9 ft · lb)
CAUTION:
_
After tightening the bolts, make sure the oil
pump turns smoothly.
NOTE:
• Install the oil pump driven gear 1 in the
direction shown.
• Install the circlip with its blunt surface facing
the engine.
_
5 - 55
BALANCER DRIVEN GEAR
ENG
BALANCER DRIVEN GEAR
T.
70 Nm (7.0 m • kg, 50 ft • Ib)
R.
11
12
New 3
1
E
5
New 4
6
9
10
M
2
8
7
M
T.
R.
Order
80 Nm (8.0 m • kg, 58 ft • lb)
1
2
3
Job/Part
Removing the balancer driven gear
Water pump assembly
Clutch housing
Crankcase cover (right)
Balancer driven gear nut
Primary drive gear nut
Lock washer
Q’ty
4
Lock washer
1
5
Washer
1
1
1
1
5 - 56
Remarks
Remove the parts in the order listed.
Refer to “WATER PUMP” in chapter 6.
Refer to “CLUTCH”.
Refer to “OIL PUMP”.
Refer to “REMOVING THE BALANCER
DRIVEN GEAR AND BALANCER
DRIVE GEAR” and “INSTALLING THE
BALANCER DRIVEN GEAR AND BALANCER DRIVE GEAR.
Refer to “REMOVING THE BALANCER
DRIVEN GEAR AND BALANCER DRIVE
GEAR” and “INSTALLING THE BALANCER DRIVEN GEAR AND BALANCER DRIVE GEAR.
BALANCER DRIVEN GEAR
ENG
T.
R.
70 Nm (7.0 m • kg, 50 ft • Ib)
11
12
New 3
1
E
New 4
5
6
9
10
M
2
8
7
M
T.
R.
Order
6
7
8
80 Nm (8.0 m • kg, 58 ft • lb)
Job/Part
Water pump drive gear
Primary drive gear
Balancer drive gear
9
10
11
Straight key
Washer
Balancer driven gear
12
Straight key
Q’ty
Remarks
1
1
1
Refer to “INSTALLING THE BALANCER
DRIVEN GEAR AND BALANCER DRIVE
GEAR”.
1
1
1
Refer to “INSTALLING THE BALANCER
DRIVEN GEAR AND BALANCER DRIVE
GEAR”.
1
For installation, reverse the removal procedure.
5 - 57
BALANCER DRIVEN GEAR
3
1
4
REMOVING THE BALANCER DRIVEN
GEAR AND BALANCER DRIVE GEAR
1. Straighten the lock washer tab.
2. Loosen:
• balancer driven gear nut 1
• primary drive gear nut 2
NOTE:
Place an aluminum plate a between the teeth
of the balancer driven gear 3 and balancer
drive gear 4.
a
3
ENG
a
4
3.
•
•
•
•
Remove:
balancer driven gear
water pump drive gear
primary drive gear
balancer drive gear
2
CHECKING THE BALANCER DRIVEN
GEAR, WATER PUMP DRIVE GEAR,
PRIMARY DRIVE GEAR, AND BALANCER
DRIVE GEAR
1. Check:
• balancer driven gear
• balancer drive gear
• water pump drive gear
• primary drive gear
Damage/wear → Replace.
5 - 58
BALANCER DRIVEN GEAR
3
1
b
a
2
ENG
INSTALLING THE BALANCER DRIVEN
GEAR AND BALANCER DRIVE GEAR
1. Install:
• washer
• balancer drive gear 1
• straight key 2
• balancer driven gear 3
• straight key
• primary drive gear
• water pump drive gear
NOTE:
• Align the punch mark a on the balancer
drive gear with the punch mark b on the balancer driven gear.
• Install the key with its blunt surface facing c
the crankshaft.
2
c
2. Install:
• lock washer 1 New
• primary drive gear nut 2
T.
1
R.
• lock washer 3 New
• balancer driven gear nut 4
2
T.
R.
a
3
4
a
80 Nm (8.0 m · kg, 58 ft · lb)
70 Nm (7.0 m · kg, 50 ft · lb)
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 - 59
ENG
SHIFT SHAFT
EAS00327
SHIFT SHAFT
SHIFT SHAFT AND STOPPER LEVER
2 New
4
1
3
5
LS
E
14
T.
R.
16 Nm (1.6 m • kg, 11 ft • Ib)
LT
LT
T.
E
R.
22 Nm (2.2 m • kg, 16 ft • Ib)
14
1113
8 7 12
5
13
6
10 New
9
E
Order
1
2
3
4
5
6
Job/Part
Removing the shift shaft and stopper lever
Water pump assembly
Clutch housing
Crankcase cover (right)
Shift pedal
Circlip
Washer
Oil seal
Bearing
Shift shaft
7
8
Shift shaft spring
Spacer
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “WATER PUMP” in chapter 6.
Refer to “CLUTCH”.
Refer to “OIL PUMP”.
1
1
1
1
2
1
1
1
5 - 60
Refer to “INSTALLING THE SHIFT
SHAFT”.
ENG
SHIFT SHAFT
2 New
4
1
3
5
LS
E
14
T.
R.
16 Nm (1.6 m • kg, 11 ft • Ib)
LT
LT
T.
E
R.
22 Nm (2.2 m • kg, 16 ft • Ib)
14
1113
8 7 12
5
13
6
10 New
9
E
Order
9
Job/Part
Stopper lever spring
10
11
Circlip
Stopper lever
12
13
14
Spacer
Washer
Shift shaft spring stopper
Q’ty
Remarks
1
Refer to “INSTALLING THE SHIFT
SHAFT”.
1
1
Refer to “INSTALLING THE SHIFT
SHAFT”.
1
2
1
For installation, reverse the removal procedure.
5 - 61
SHIFT SHAFT
ENG
EAS00329
1
CHECKING THE SHIFT SHAFT
1. Check:
• shift shaft 1
• shift shaft pawl 2
Bends/damage/wear → Replace.
• shift shaft spring 3
Damage/wear → Replace.
3
2
EAS00330
CHECKING THE STOPPER LEVER
1. Check:
• stopper lever 1
Bends/damage → Replace.
Roller turns roughly → Replace the stopper
lever.
• stopper lever spring 2
Damage/wear → Replace.
2
1
EAS00331
4
INSTALLING THE SHIFT SHAFT
1. Install:
• shift shaft spring stopper
LT
T.
R.
1
5
3
2
2.
•
•
•
22 Nm (2.2 m · kg, 16 ft · lb)
Install:
stopper lever 1
stopper lever spring 2
shift shaft 3
_
NOTE:
• Hook the ends of the stopper lever spring
onto the stopper lever and the crankcase
boss 4.
• Mesh the stopper lever with the shift drum
segment assembly.
• Lubricate the oil seal lips with lithium-soapbased grease.
• Hook the end of the shift shaft spring onto
the shift shaft spring stopper 5.
T.
3. Install:
16 Nm (1.6 m · kg, 11 ft · lb)
• shift pedal
Refer to “ADJUSTING THE SHIFT PEDAL”
in chapter 3.
R.
5 - 62
ENG
STARTER CLUTCH AND A.C. MAGNETO
EAS00341
STARTER CLUTCH AND A.C. MAGNETO
* Apply sealant
Yamaha bond No. 1215
90890-85505
7
11
14
E
E
10
7
R.
2
T.
E
80 Nm (8.0 m • kg, 58 ft • Ib)
T.
15
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
7
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
E
LT
7
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
17
16
∗
8
LT
(3)
9
2
1
5 13
LT
E
LT
3
12
4
4
New (3)
New
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
New
Job/Part
Removing the starter clutch and
A.C. magneto
Engine oil
(6)
R.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Q’ty
Seat/left side panel
Starter motor
Drive sprocket cover
1
2
3
Shift pedal
A.C. magneto coupler
Neutral switch connector/lead
Torque limiter cover/gasket
LS
T.
T.
Order
6
2
1/1
1/1
5 - 63
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
Remove the parts in the order listed.
Drain.
Refer to “CHECKING AND CHANGING
THE ENGINE OIL” in chapter 3.
Refer to “COWLING AND COVER” in
chapter 3.
Refer to “STARTER MOTOR” in chapter
8.
Refer to “SWINGARM AND DRIVE
CHAIN” in chapter 4.
Refer to “SHIFT SHAFT”.
Disconnect.
Disconnect.
Refer to “REMOVING THE A.C. MAGNETO ROTOR”.
ENG
STARTER CLUTCH AND A.C. MAGNETO
* Apply sealant
Yamaha bond No. 1215
90890-85505
7
11
14
E
E
10
7
R.
2
T.
E
80 Nm (8.0 m • kg, 58 ft • Ib)
T.
15
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
7
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
E
LT
7
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
17
16
∗
8
LT
(3)
9
2
1
5 13
LT
E
LT
3
12
4
4
New (3)
New
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
New
Job/Part
Torque limiter/washer
Dowel pin
A.C. magneto cover/gasket
Dowel pin
Crankshaft position sensor
Stator coil
Starter clutch idle gear shaft
Starter clutch idle gear
A.C. magneto rotor
Starter clutch
Woodruff key
Starter clutch gear
Bearing
Washer
(6)
R.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LS
T.
T.
Order
4
5
6
7
8
9
10
11
12
13
14
15
16
17
6
Q’ty
1/2
1
1/1
4
1
1
1
1
1
1
1
1
1
1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
Refer to “REMOVING THE A.C. MAGNETO ROTOR” and “INSTALLING THE
A.C. MAGNETO ROTOR”.
For installation, reverse the removal procedure.
5 - 64
STARTER CLUTCH AND A.C. MAGNETO
ENG
EAS00346
REMOVING THE A.C. MAGNETO ROTOR
1. Remove:
• torque limiter cover
1
CAUTION:
Do not remove the bearing 1.
2. Remove:
• A.C. magneto cover
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
_
3. Remove:
• A.C. magneto rotor nut 1
• washer
3
a
1
2
NOTE:
• While holding the A.C. magneto rotor 2 with
the sheave holder 3, loosen the A.C. magneto rotor nut.
• Do not allow the sheave holder to touch the
projection a on the A.C. magneto rotor.
_
Sheave holder
90890-01701
4. Remove:
• A.C. magneto rotor 1
(with the flywheel puller 2)
• woodruff key
NOTE:
Use the rotor puller.
1
Flywheel puller
90890-01362
2
5 - 65
STARTER CLUTCH AND A.C. MAGNETO
ENG
CHECKING THE STATOR COIL AND
CRANKSHAFT POSITION SENSOR
1. Check:
• stator coil
• crankshaft position sensor
Damage → Replace the crankshaft position
sensor/stator assembly.
EAS00351
CHECKING THE STARTER CLUTCH
1. Check:
• starter clutch rollers 1
Damage/wear → Replace.
1
1
2
a
È
2. Check:
• starter clutch idle gear 1
• starter clutch gear 2
Burrs/chips/roughness/wear → Replace the
defective part(s).
3. Check:
• starter clutch gear’s contacting surfaces a
Damage/pitting/wear → Replace the starter
clutch gear.
4. Check:
• starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
É
a. Install the starter clutch gear onto the
starter clutch and hold the starter clutch.
b. When turning the starter clutch gear clockwise È, it should turn freely, otherwise the
starter clutch is faulty and must be
replaced.
c. When turning the starter clutch gear counterclockwise É, the starter clutch and the
starter clutch gear should engage, otherwise the starter clutch is faulty and must be
replaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 66
STARTER CLUTCH AND A.C. MAGNETO
ENG
CHECKING THE TORQUE LIMITER
1. Check:
• torque limiter
Damage/wear → Replace.
EAS00354
1
a
b
INSTALLING THE A.C. MAGNETO ROTOR
1. Install:
• stator coil 1
LT
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
• crankshaft position sensor
LT
T.
R.
7 Nm (0.7 m · kg, 5.1 ft · lb)
NOTE:
Align the projection a on the stator coil with
the slot b in the A.C. magneto cover.
_
1
2. Apply:
• Yamaha bond No. 1215 1
(into the slits)
Yamaha bond No. 1215
90890-85505
3. Install:
• starter clutch 1
(to A.C. magneto rotor)
• starter clutch bolts
LT
T.
R.
4.
•
•
•
•
30 Nm (3.0 m · kg, 22 ft · lb)
Install:
woodruff key
A.C. magneto rotor
washer
A.C. magneto rotor nut
NOTE:
• Clean the tapered portion of the crankshaft
and the A.C. magneto rotor hub.
• When installing the A.C. magneto rotor,
make sure the woodruff key is properly
seated in the keyway of the crankshaft.
• Lubricate crankshaft end threads with engine
oil.
_
5 - 67
STARTER CLUTCH AND A.C. MAGNETO
ENG
5. Tighten:
• A.C. magneto rotor nut 1
3
T.
R.
a
1
2
80 Nm (8.0 m · kg, 58 ft · lb)
NOTE:
• While holding the A.C. magneto rotor 2 with
the sheave holder 3, tighten the A.C. magneto rotor nut.
• Do not allow the sheave holder to touch the
projection a on the A.C. magneto rotor.
_
Sheave holder
90890-01701
6. Install:
• gasket New
• A.C. magneto cover
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
NOTE:
Tighten the A.C. magneto cover bolts in
stages, using a crisscross pattern.
7. Install:
• neutral switch lead 1
NOTE:
Route the neutral switch lead so that it is taut
and route it under the speed sensor lead 2 as
shown.
a 5 mm or more
5 - 68
ENG
CRANKCASE
CRANKCASE
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
New
LS
New
6
R.
9
T.
11
10 Nm (1.0 m • kg, 7.2 ft • Ib)
12
12
4
5
LS
8
New
2
LS
5
9
New
New
3
LS
1
7
(3)
10
New
T.
R.
LT
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
Order
1
2
3
4
Job/Part
Separating the crankcase
Engine
Cylinder head
Cylinder/piston
A.C. magneto
Clutch
Balancer driven gear/balancer drive
gear
Oil pump
Shift shaft
Timing chain guide (intake side)
Timing chain
Neutral switch
Speed sensor
Q’ty
8 Nm (0.8 m • kg, 5.8 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “ENGINE REMOVAL”.
Refer to “CYLINDER HEAD”.
Refer to “CYLINDER AND PISTON”.
Refer to “STARTER CLUTCH AND A.C.
MAGNETO”.
Refer to “CLUTCH”.
Refer to “BALANCER DRIVEN GEAR”.
Refer to “OIL PUMP”.
Refer to “SHIFT SHAFT”.
1
1
1
1
5 - 69
ENG
CRANKCASE
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
New
LS
New
6
R.
9
T.
11
10 Nm (1.0 m • kg, 7.2 ft • Ib)
12
12
4
5
LS
8
New
2
LS
5
9
New
New
3
LS
1
7
(3)
10
New
T.
R.
LT
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
Order
5
6
7
8
9
10
11
12
Job/Part
Lead holder
Crankcase (right)
Crankcase (left)
Dowel pin/O-ring
Dowel pin
Oil strainer
Oil delivery pipe 3
O-ring
Q’ty
2
1
1
1/1
2
1
1
2
8 Nm (0.8 m • kg, 5.8 ft • Ib)
Remarks
Refer to “SEPARATING THE CRANKCASE”.
For installation, reverse the removal procedure.
5 - 70
ENG
CRANKCASE
CRANKCASE BEARINGS
T.
* Apply sealant
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Yamaha bond No. 1215
90890-85505
∗
LS
2
1
2
4
E
4
4
3
E
LT
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
2
E
4
Order
1
2
3
4
Job/Part
Removing the crankcase bearings
Crankshaft/balancer
Transmission
Oil seal holder
Oil seal
Bearing retainer
Bearing
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CRANKSHAFT”.
Refer to “TRANSMISSION”.
1
3
1
7
For installation, reverse the removal procedure.
5 - 71
CRANKCASE
ENG
SEPARATING THE CRANKCASE
1. Separate:
• right crankcase 1
• left crankcase 2
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the crankcase bolts.
NOTE:
• Loosen each bolt 1/4 of a turn at a time and
after all the bolts are loosened, remove
them.
• Loosen the bolts in stages, using a crisscross pattern.
_
2
b. Remove the right crankcase.
NOTE:
Insert a screwdriver or pry bar into the pry
points in the crankcase and then carefully pry
apart the crankcase halves.
_
CAUTION:
_
Use a soft hammer to tap on one side of the
crankcase. Tap only on reinforced portions
of the crankcase. Do not tap on the crankcase mating surfaces. Work slowly and
carefully. Make sure that the crankcase
halves separate evenly.
c. Remove the dowel pins and O-ring.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE OIL STRAINER AND OIL
DELIVERY PIPE 3
1. Check:
• oil strainer
Damage → Replace.
Contaminants → Clean with engine oil.
5 - 72
CRANKCASE
ENG
2. Check:
• oil delivery pipe 3
Cracks/damage → Replace.
• oil delivery pipe holes 1
Clogged → Blow out with compressed air.
1
EAS00207
CHECKING THE TIMING CHAIN AND
TIMING CHAIN GUIDES
1. Check:
• timing chain
Damage/stiffness → Replace the timing
chain and camshaft sprocket as a set.
2. Check:
• timing chain guide (intake side)
Damage/wear → Replace.
EAS00401
CHECKING THE BEARINGS AND OIL
SEALS
1. Check:
• bearings
Clean and lubricate the bearings, and then
rotate the inner race with your finger.
Rough movement → Replace.
2. Check:
• oil seals
Damage/wear → Replace.
EAS00399
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces
and crankcase mating surfaces.
3. Check:
• crankcase
Cracks/damage → Replace.
• oil delivery passages
Obstruction → Blow out with compressed
air.
5 - 73
CRANKCASE
ENG
EAS00418
ASSEMBLING THE CRANKCASE
1. Lubricate:
• bearings
• oil seals
Recommended lubricant
Bearing
Engine oil
Oil seal
Lithium-soap-based grease
a
1
2. Install:
• bearings New
• bearing retainer 1
(to the right crankcase)
• bearing retainer bolts
T.
LT
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
NOTE:
Install the bearing retainer with the “OUT”
mark a facing up.
3. Thoroughly clean all the gasket mating surfaces and crankcase mating surfaces.
1
4. Apply:
• Yamaha bond No. 1215 1
(to the mating surfaces of both crankcase
halves)
Yamaha bond No. 1215
90890-85505
NOTE:
Do not allow any sealant to come into contact
with the oil gallery.
_
5. Install:
• dowel pins
• O-rings New
5 - 74
CRANKCASE
ENG
6. Fit the right crankcase onto the left crankcase. Tap lightly on the case with a soft
hammer.
CAUTION:
_
Before installing and torquing the crankcase bolts, be sure to check whether the
transmission is functioning properly by
manually rotating the shift drum in both
directions.
È
1
7. Install:
• lead holder 1
• crankcase bolts
È Left crankcase
É Right crankcase
8. Tighten:
• crankcase bolts
(follow the proper tightening sequence)
T.
R.
É
10 Nm (1.0 m · kg, 7.2 ft · lb)
NOTE:
Tighten the bolts in stages, using a crisscross
pattern.
_
9. Apply:
• 4-stroke engine oil
(to the crankshaft pin, bearing, and oil delivery hole)
10.Check:
• crankshaft and transmission operation
Unsmooth operation → Repair.
11.Install:
• speed sensor
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
• neutral switch
• neutral switch screw
LT
T.
R.
5 - 75
4 Nm (0.4 m · kg, 2.9 ft · lb)
CRANKSHAFT
ENG
EAS00381
CRANKSHAFT
CRANKSHAFT AND BALANCER
1
2
Order
1
2
Job/Part
Removing the crankshaft and balancer
Crankcase
Balancer
Crankshaft
Q’ty
Remarks
Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.
1
1
5 - 76
Refer to “REMOVING THE CRANKSHAFT ASSEMBLY” and “INSTALLING
THE CRANKSHAFT”.
For installation, reverse the removal procedure.
CRANKSHAFT
ENG
EAS00388
REMOVING THE CRANKSHAFT
ASSEMBLY
1. Remove:
• crankshaft 1
1
NOTE:
• Remove the crankshaft with the crankcase
separating tool 2.
• Make sure the crankcase separating tool is
centered over the crankshaft.
_
2
Crankcase separating tool
90890-01135
EAS00394
CHECKING THE CRANKSHAFT
1. Measure:
• big end side clearance D
Out of specification → Replace the big end
bearing, crankshaft pin, or connecting rod.
D
C
Big end side clearance
0.350 ~ 0.650 mm
(0.0138 ~ 0.0256 in)
C
2. Measure:
• crankshaft width A
Out of specification → Replace the crankshaft.
Crankshaft width
74.95 ~ 75.00 mm
(2.9508 ~ 2.9528 in)
A
3. Measure:
• crankshaft runout C
Out of specification → Replace the crankshaft, bearing or both.
NOTE:
Turn the crankshaft slowly.
_
Maximum crankshaft runout
0.04 mm (0.0016 in)
5 - 77
CRANKSHAFT
ENG
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. The crankshaft 1 and the crankshaft pin 2
oil passages must be properly interconnected with a tolerance of less than 1 mm
(0.04 in).
1
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• crankshaft sprocket
Damage/wear → Replace the crankshaft.
• bearing
Cracks/damage/wear → Replace the crankshaft.
5. Check:
• crankshaft journal
Scratches/wear → Replace the crankshaft.
• crankshaft journal oil passage
Obstruction → Blow out with compressed
air.
EAS00408
INSTALLING THE CRANKSHAFT
1. Install:
• crankshaft 1
NOTE:
Install the crankshaft with the crankshaft
installer pot, crankshaft installer bolt, adapter
and spacer (crankshaft installer).
5
1
_
4
2
3
Crankshaft installer pot 2
90890-01274
Crankshaft installer bolt 3
90890-01275
Adapter 4
90890-04130
Spacer (crankshaft installer) 5
90890-04144
CAUTION:
_
To avoid scratching the crankshaft and to
ease the installation procedure, lubricate
the oil seal lips with lithium-soap-based
grease and each bearing with engine oil.
NOTE:
Hold the connecting rod at the top dead center
(TDC) on the compression stroke with one
hand while turning the nut of the crankshaft
installer bolt with the other. Turn the crankshaft
installer bolt until the crankshaft bottoms
against the bearing.
_
5 - 78
TRANSMISSION
ENG
EAS00419
TRANSMISSION
7
6
3
E
E
2
1
5
E
4
E
E
E
Order
1
2
3
4
5
6
7
Job/Part
Removing the transmission, shift
drum, and shift forks
Crankcase
Shift fork “C”
Shift fork “R”
Shift fork “L”
Shift drum
Main axle assembly
Spacer
Drive axle assembly
Q’ty
Remarks
Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.
1
1
1
1
1
1
1
Refer to “INSTALLING THE TRANSMISSION”.
For installation, reverse the removal procedure.
5 - 79
ENG
TRANSMISSION
MAIN AXLE
7
8
9
8
7
0
A
New
M
New
1
2
M
3
4
5
New
6
M
M
Order
1
2
3
4
5
6
7
8
9
0
A
Job/Part
Disassembling the main axle
Circlip
2nd pinion gear
Toothed lock washer
Toothed washer retainer
5th pinion gear
Toothed spacer
Toothed washer
Circlip
3rd pinion gear
4th pinion gear
Main axle/1st pinion gear
Q’ty
1
1
1
1
1
1
2
2
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “ASSEMBLING THE MAIN
AXLE AND DRIVE AXLE”.
For assembly, reverse the disassembly
procedure.
5 - 80
TRANSMISSION
ENG
DRIVE AXLE
8
M
6
5
4
7
M
New A
New
1
LS
2
0
3
9
New
6
5
M
New
Order
1
2
3
4
5
6
7
8
9
0
A
Job/Part
Disassembling the drive axle
Circlip
Washer
1st wheel gear
4th wheel gear
Circlip
Toothed washer
3rd wheel gear
5th wheel gear
2nd wheel gear
Drive axle
O-ring
Q’ty
1
1
1
1
2
2
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “ASSEMBLING THE MAIN
AXLE AND DRIVE AXLE”.
For assembly, reverse the disassembly
procedure.
5 - 81
TRANSMISSION
ENG
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.
2. Check:
• shift fork movement
Rough movement → Replace the shift
forks.
EAS00422
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
• shift drum grooves
Damage/scratches/wear → Replace the
shift drum assembly.
• shift drum segment 1
Damage/wear → Replace the shift drum
assembly.
• shift drum bearing 2
Damage/pitting → Replace the shift drum
assembly.
EAS00425
CHECKING THE TRANSMISSION
1. Measure:
• main axle runout
(with a centering device and dial gauge 1)
Out of specification → Replace the main
axle.
Main axle runout limit
0.08 mm (0.0031 in)
5 - 82
TRANSMISSION
ENG
2. Measure:
• drive axle runout
(with a centering device and dial gauge 1)
Out of specification → Replace the drive
axle.
Drive axle runout limit
0.08 mm (0.0031 in)
3. 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)
Incorrect → Reassemble the transmission
axle assemblies.
5. Check:
• transmission gear movement
Rough movement → Replace the defective
part(s).
6. Check:
• circlips
Bends/damage/looseness → Replace.
ASSEMBLING THE MAIN AXLE AND DRIVE
AXLE
1. Install:
• toothed washer 1
• circlip 2 New
NOTE:
• Be sure the circlip shape-edged corner a is
positioned opposite side to the toothed
washer and gear.
• Install the circlip so that both ends b are
positioned in the center of each axle spline
c.
_
5 - 83
TRANSMISSION
ENG
INSTALLING THE TRANSMISSION
1. Install:
• shift fork “L” 1 (to drive axle)
• shift fork “C” 2 (to main axle)
• shift fork “R” 3 (to drive axle)
• shift drum 4
• transmission assembly
3
1
4
2
NOTE:
• The embossed marks on the shift forks
should face towards the right side of the
engine and be in the following sequence:
“R”, “C”, and “L”.
• Make sure that the shift fork cam follower is
properly seated in the shift drum groove.
_
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 - 84
COOL
6
COOL
CHAPTER 6
COOLING SYSTEM
RADIATOR ...................................................................................................... 6-1
CHECKING THE RADIATOR.................................................................... 6-3
INSTALLING THE RADIATOR..................................................................6-4
THERMOSTAT ................................................................................................6-5
CHECKING THE THERMOSTAT.............................................................. 6-6
INSTALLING THE THERMOSTAT............................................................ 6-6
WATER PUMP.................................................................................................6-8
DISASSEMBLING THE WATER PUMP.................................................. 6-11
CHECKING THE WATER PUMP ............................................................ 6-11
ASSEMBLING THE WATER PUMP........................................................ 6-12
INSTALLING THE WATER PUMP .......................................................... 6-14
COOL
RADIATOR
COOL
EAS00454
COOLING SYSTEM
RADIATOR
8
New
New
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
1
9
12
2
5
3
3
4
11
6
10
New
7
New
T.
R.
Order
5 Nm (0.5 m • kg, 3.6 ft • Ib)
Job/Part
Removing the radiator
Seat/side panels (left and right)
Q’ty
Fuel tank side covers (left and right)/
fuel tank
Coolant
1
2
3
4
5
6
Radiator cap retainer
Radiator cap
Coolant reservoir hose/cap
Coolant reservoir breather hose
Fast idle plunger outlet hose
Coolant reservoir
Remarks
Remove the parts in the order listed.
Refer to “COWLING AND COVER” in
chapter 3.
Refer to “FUEL TANK” in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
2
1
1/1
1
1
1
6-1
Disconnect.
RADIATOR
COOL
8
New
New
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
1
9
12
2
5
3
3
4
11
6
10
New
7
New
T.
R.
Order
7
8
9
10
11
12
5 Nm (0.5 m • kg, 3.6 ft • Ib)
Job/Part
Radiator outlet hose
Radiator inlet hose
Radiator fan motor coupler
Radiator guard
Radiator
Radiator fan
Q’ty
Remarks
1
Refer to “INSTALLING THE RADIATOR”.
1
1
Disconnect.
1
1
1
For installation, reverse the removal procedure.
6-2
RADIATOR
COOL
EAS00455
CHECKING THE RADIATOR
1. Check:
• radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the radiator.
Damage → Repair or replace.
NOTE:
Straighten any flattened fins with a thin, flathead screwdriver.
_
2. Check:
• radiator hoses
Cracks/damage → Replace.
3. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Radiator cap opening pressure
110.0 ~ 140.0 kPa
(1.10 ~ 1.40 kg/cm2,
16.0 ~ 20.3 psi)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the radiator cap tester 1 and radiator
cap tester adaptor 2 and radiator cap
tester adaptor 3 to the radiator cap 4.
Radiator cap tester
90890-01325
Radiator cap tester adaptor
90890-01352
Radiator cap tester adaptor
90890-01497
b. Apply the specified pressure for ten seconds and make sure there is no drop in
pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” in chapter 8.
6-3
RADIATOR
COOL
EAS00456
2
1
INSTALLING THE RADIATOR
1. Install:
• radiator inlet hose 1
• radiator outlet hose 2
• hose clamps 3 New
New 3
a
a
3
New
NOTE:
Install the radiator inlet hose and radiator outlet hose so that each hose contacts the
respective projection a.
_
2. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
3. Check:
• cooling system
Leaks → Repair or replace any faulty part.
2
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Attach the radiator cap tester 1 and radiator tester adapter 2 to the radiator.
Radiator cap tester
90890-01325
Radiator tester adapter
90890-01496
b. Apply 100 kPa (1.0 kg/cm, 14.2233 psi) of
pressure and make sure there is no drop in
pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Measure:
• radiator cap opening pressure
Bellow the specified pressure → Replace
the radiator cap.
Refer to “CHECKING THE RADIATOR”.
6-4
THERMOSTAT
COOL
EAS00460
THERMOSTAT
3
8 New
1
2 New
7
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib)
4
6
5 New
LS
T.
R.
Order
1
2
3
4
5
6
7
8
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Part
Removing the thermostat
Coolant
Coolant temperature sensor coupler
Hose clamp
Radiator inlet hose
Thermostat cover
O-ring
Thermostat
Coolant temperature sensor
Copper washer
Q’ty
1
1
1
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Disconnect.
Refer to “INSTALLING
THE THERMOSTAT”.
For installation, reverse the removal procedure.
6-5
THERMOSTAT
COOL
EAS00462
CHECKING THE THERMOSTAT
1. Check:
• thermostat 1
Does not open at 71 ~ 85 °C (159.8 ~
185 °F) → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Suspend the thermostat in a container filled
with water.
b. Slowly heat the water.
c. Place a thermometer in the water.
d. While stirring the water, observe the thermostat and thermometer’s indicated temperature.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1 Thermostat
2 Thermometer
3 Water
4 Container
È Fully closed
É Fully open
NOTE:
If the accuracy of the thermostat is in doubt,
replace it. A faulty thermostat could cause serious overheating or overcooling.
Opening (mm)
_
2. Check:
• thermostat cover
• thermostat housing (cylinder head)
Cracks/damage → Replace.
Temperature
EAS00466
INSTALLING THE THERMOSTAT
1. Install:
• thermostat 1
• O-ring 2 New
• thermostat cover 3
a
2
R.
3
T.
1
10 Nm (1.0 m · kg, 7.2 ft · lb)
NOTE:
• Install the thermostat with its breather hole
a facing up.
• Lubricate the O-ring with a thin coat of lithium-soap-based grease.
New
_
6-6
THERMOSTAT
New 2
COOL
2. Install:
• radiator inlet hose 1
• hose clamp 2 New
1
a
NOTE:
Install the radiator inlet hose 1 so that it contacts the projection on the thermostat cover a.
3. Install:
• copper washer New
• coolant temperature sensor
T.
R.
18 Nm (1.8 m · kg, 13 ft · lb)
CAUTION:
_
Use extreme care when handling the coolant temperature sensor. Replace the sensor if it is dropped or subjected to a strong
impact.
4. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
5. Check:
• cooling system
Leaks → Repair or replace any faulty part.
6. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Refer to “CHECKING THE RADIATOR”.
6-7
WATER PUMP
COOL
EAS00468
WATER PUMP
New 1
LS
8
2
T.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R.
New 7
5
New 4
6
T.
3
R.
New
10 Nm (1.0 m • kg, 7.2 ft • Ib)
1 New
LS
New
(3)
T.
R.
Order
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Part
Removing the water pump
Q’ty
Remarks
Remove the parts in the order listed.
NOTE:
It is not necessary to remove the water
pump unless the coolant level is
extremely low or the coolant contains
engine oil.
Coolant
1
2
3
4
Hose clamp
Radiator outlet hose
Water pump cover
Gasket
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
3
1
1
1
6-8
Disconnect.
Refer to “INSTALLING
THE WATER PUMP”.
WATER PUMP
COOL
New 1
LS
8
2
T.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R.
New 7
5
New 4
6
T.
3
R.
New
10 Nm (1.0 m • kg, 7.2 ft • Ib)
1 New
LS
New
(3)
T.
R.
Order
5
6
7
8
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Part
Water pump assembly
Water pump outlet pipe
O-ring
Water pump outlet hose
Q’ty
1
1
1
1
Remarks
Refer to “INSTALLING THE WATER
PUMP”.
For installation, reverse the removal procedure.
6-9
WATER PUMP
COOL
9 New
LS
0
New 7
5
New 6
LS
3
1 New
4
2
8
E
Order
1
2
3
4
5
6
7
8
9
0
Job/Part
Disassembling the water pump
Circlip
Impeller shaft gear
Pin
Washer
Impeller shaft assembly
Water pump seal
Oil seal
Bearing
O-ring
Water pump housing
Q’ty
1
1
1
1
1
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “ASSEMBLING THE WATER
PUMP”.
Refer to “DISASSEMBLING THE
WATER PUMP” and “ASSEMBLING
THE WATER PUMP”.
For assembly, reverse the disassembly
procedure.
6 - 10
WATER PUMP
COOL
EAS00470
DISASSEMBLING THE WATER PUMP
1. Remove:
• water pump seal 1
NOTE:
Tap out the water pump seal from water pump
housing in the direction of the arrow shown.
_
2 Water pump housing
2. Remove:
• bearing 1
• oil seal 2
NOTE:
Tap out the bearing and oil seal from water
pump housing in the direction of the arrow
shown.
_
3 Water pump housing
3. Remove:
• rubber damper holder 1
• rubber damper 2
(from the impeller, with a thin, flat-head
screwdriver)
NOTE:
Do not scratch the impeller shaft.
_
EAS00474
2
1
3
5
4
CHECKING THE WATER PUMP
1. Check:
• water pump housing cover 1
• water pump housing 2
• impeller 3
• rubber damper 4
• rubber damper holder 5
Cracks/damage/wear → Replace.
2. Check:
• water pump seal
• oil seal
Cracks/damage/wear → Replace.
3. Check:
• bearing
Rough movement → Replace.
4. Check:
• impeller shaft gear
Pitting/wear → Replace.
6 - 11
WATER PUMP
5.
•
•
•
COOL
Check:
water pump outlet pipe
radiator outlet hose
water jacket inlet housing
Cracks/damage/wear → Replace.
EAS00475
ASSEMBLING THE WATER PUMP
1. Install:
• oil seal 1 New
(into the water pump housing 2)
• bearing 3
NOTE:
• Before installing the oil seal, apply tap water
or coolant onto its outer surface.
• Install the oil seal with a socket that matches
its outside diameter.
_
2. Install:
• water pump seal 1 New
CAUTION:
_
Never lubricate the water pump seal surface with oil or grease.
NOTE:
• Install the water pump seal with the special
tools.
• Before installing the water pump, apply
Yamaha bond No.1215 2 to the water pump
housing 3.
_
Mechanical seal installer 4
90890-04132
Middle driven shaft bearing driver
5
90890-04058
Yamaha bond No.1215
90890-85505
È Push down.
6 - 12
WATER PUMP
COOL
3. Install:
• rubber damper 1 New
• rubber damper holder 2 New
NOTE:
Before installing the rubber damper, apply tap
water or coolant onto its outer surface.
_
4. Measure:
• impeller shaft tilt
Out of specification → Repeat steps (3) and
(4).
CAUTION:
_
Make sure the rubber damper and rubber
damper holder are flush with the impeller.
Impeller shaft tilt limit
0.15 mm (0.006 in)
1 Straightedge
2 Impeller
5.
•
•
•
•
•
1
Install:
impeller shaft assembly 1
washer
pin
impeller shaft gear
circlip New
NOTE:
After installation, check that the impeller shaft
rotates smoothly.
_
6 - 13
WATER PUMP
COOL
EAS00478
New 2
a
INSTALLING THE WATER PUMP
1. Install:
• water pump outlet hose 1
• O-rings New
• water pump outlet pipe
(to the water pump assembly)
T.
1
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
• hose clamps 2 New
WARNING
_
Always use new O-rings.
NOTE:
• Install the water pump outlet hose so that it
contacts the projection a on the water jacket
joint.
• Before installing the water pump outlet pipe,
lubricate the O-rings with a thin coat of lithium-soap-based grease.
_
2. Install:
• gasket New
• water pump cover
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
• water pump assembly
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
3. Install:
• radiator outlet hose 1
• hose clamp 2 New
1
2 New
a
NOTE:
Install the radiator outlet hose 1 so that it contacts the projection a on the water pump
cover.
4. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
5. Check:
• cooling system
Leaks → Repair or replace the faulty part.
6. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Refer to “CHECKING THE RADIATOR”.
6 - 14
FI
7
FI
CHAPTER 7
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM............................................................................7-1
WIRING DIAGRAM ................................................................................... 7-2
ECU SELF-DIAGNOSTIC FUNCTION......................................................7-3
ALTERNATE OPERATION CONTROL (FAIL-SAFE ACTION) ................ 7-4
FAIL-SAFE ACTION TABLE ..................................................................... 7-4
TROUBLESHOOTING CHART .................................................................7-6
DIAGNOSTIC MODE ................................................................................ 7-7
TROUBLESHOOTING DETAILS ............................................................ 7-12
THROTTLE BODY ASSEMBLY.................................................................... 7-23
CHECKING THE FUEL INJECTOR ........................................................ 7-26
CHECKING THE THROTTLE BODY ......................................................7-26
INSTALLING THE THROTTLE BODY ASSEMBLY................................7-27
CHECKING THE FUEL PUMP................................................................7-28
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR ................................................................................................7-29
AIR INDUCTION SYSTEM ............................................................................7-32
AIR INJECTION....................................................................................... 7-32
AIR CUT-OFF VALVE ............................................................................. 7-32
AIR INDUCTION SYSTEM DIAGRAMS.................................................. 7-33
AIR CUT-OFF VALVE ASSEMBLY......................................................... 7-34
CHECKING THE AIR INDUCTION SYSTEM..........................................7-36
FI
FI
FUEL INJECTION SYSTEM
EAS00894
FUEL INJECTION SYSTEM
EAS00895
FUEL INJECTION SYSTEM
1 Air cut-off valve
2 Air induction system solenoid
3 Engine trouble warning light
4 Fuel tank
5 Fuel pump (include fuel pressure regulator)
6 Fuel hose
7 Fuel injector
8 Throttle position sensor
1
2
9 Intake air temperature sensor
0 Air filter case
A Fuel injection system relay
B Battery
C Catalytic converter
D ECU
E Lean angle cut-off switch
F Fast idle plunger
G Crankshaft position sensor
3
4
5
6 7
H Coolant temperature sensor
I Spark plug
J Intake air pressure sensor
K Ignition coil
8
9
0
K
J
I
H
G
7-1
F
E
D
C
B
A
W
G/W L/Y
W
Gy G/W
ON
OFF
P
4
W W
W W
3
Br/L
Br/R
R
L
2
B BB R/G
W
W
W
B1 BB
B
B
B
R
5
7-2
BB4 BB1
BB
B1
BB3
BB4
BB2
BB1
R/G
G/L
R/W
BB
Y/L
B
W W W
BB3 BB2
B
B
{
B2 B1
È
z
R/W Lg Y/L
R/G B2 B
Y/L G/L R/W
Br/L
Br/R
Br/L
Sb
R
W
W
W
R
Br/R
1
Gy G/W
B
R
Br/R
Br/L
Br/L
Br/L
y
x
w
v
R
R
R
Br
R/L
Br
R
B
A
0
Br
R/G
Br
B
L/R
B
6
B
R
B
B
B
R
R
B
B
L G/Y
R/W
Br
B
L
q
9
L
R R
7
8
R
R
R
L
Br
L/W
R/W
R/W
R
L/R Y
G/Y
R/W L/W
Br
B
s
B R/B
R/B B
D
G Y L/W Br/W R/L
Ch
P Lg Br
L/W R/W
R L/B
C
d
R
R/B
A
B
L/R
L/R
L/R B
t
B
r
B L/R
(BLACK)
B
Y
u
B L Y
Y L/R B
Br Y
B
k
B
P
Y
G
B
-
-
(BLACK)
Br Y
f
P
Br
B
B
B
A
B
l
Y G
Y Lg
A A
Y G
R/L
L/W
Y/B
g
R/Y
R/L
Y
Br
B
Ch
Y
I
B
Ch
Ch
A
Ch
-
h
b
n
G
Br/W
Br/W
c
Br
Br/W
B
Dg
G
A
Dg
o
-
i
B B
(BLUE)
J
B
G
K
p
B/Y
L/Y
B
j
B
B
B
R/L G/W
L/Y B/Y
R/L B
(DARK GREEN)
G/W B
R/B L/B R/L
L/W L/R R/W L/G L/Y Sb B/Y Lg
(BLUE)
L/G B
Br L/W
Lg
Br
Ch
B
L/G
Sb L/Y L/G
m
Lg
L/W
L/W
Y/B
R/L
R/Y
R/W B/Y R/L L/R
L/B
H
(BLACK)
B
F
e
B
R/Y Br/W L/B Y Dg
Ch
Br G P
1 Crankshaft position sensor
3 Neutral switch
4 Main switch
6 Battery
7 Main fuse
0 Fuel injection system fuse
D Engine stop switch
I Fuel injection system relay
J Sidestand switch
K Fuel pump
L ECU
M Ignition coil
N Spark plug
O Fuel injector
P Air induction system solenoid
Q Intake air temperature sensor
R Coolant temperature sensor
S Speed sensor
T Throttle position sensor
U Intake air pressure sensor
V Lean angle cut-off switch
Y Multifunction meter
[ Engine trouble warning light
v Ignition fuse
(BLACK)
-
E
L/B
G
L/W R/B
L/W
Br
A
L/R G Ch
B Y Dg
G/L
G
Ch
Y
R/W
R/G
G/W
W
Ch R/G Y
G G/L R/W
Y R/G Ch
R/W G/L Dg
Y
G/W Y/L
B/W Lg
Y/L G/W
Lg B/W
Z
[
\
]
_
a
X
MAIN HARNESS SUB-WIRE HARNESS
Ch Lg L/R
G Y B
Y/L
B/W
Lg
Y/B
G/Y
Y/L
L/R
B/Y
L/B
R
Gy
L/W
R/L
B/W
L
B
Y/G
P/W
Y
L
W
B/L
G/R
Br/W
Br/R
R/B
O
Br/W
G/R
O
P
(GRAY)
(BLACK)
L
Y/G
B/L
L
P/W
B/L
B/L
B/L
R/W
R/L
V
U
T
G/R B/L
Br/W B/L
Br/R R/W
R/LR/B
M
N
L
Y
B/L
R
(BLACK)
Q
(DARK BLUE)
Br/R
R/B
O
R/B
L Br/R R R/B O
L/W Y/L Y/G
W Gy B/W
B
B/Y L/B G/R Br/W P/W Y B/L L/R G/Y Y/B R/L
L Y/G B/L
(BLACK)
B/L P/W L
(BLACK)
L Y B/L
L
W
B/L
S
L
W
B/L
P O/R
B/W
FUEL INJECTION SYSTEM
FI
EAS00898
WIRING DIAGRAM
FI
FUEL INJECTION SYSTEM
EAS00899
ECU SELF-DIAGNOSTIC FUNCTION
The ECU is equipped with a self-diagnostic function to ensure the normal operation of the fuel injection system. If a malfunction is detected in the fuel injection system, the self-diagnostic function
immediately operates the engine with alternate operating instructions and the engine trouble warning light comes on to alert the rider of the malfunction. Once a malfunction has been detected, its
corresponding fault code is stored in the memory of the ECU.
• To alert the rider that the fuel injection system is not functioning, the engine trouble warning light
flashes when the start switch is pushed to start the engine.
• If a malfunction is detected in the fuel injection system, the ECU provides the proper alternate
operating instructions necessary to operate the engine and the engine trouble warning light
comes on to alert the rider of the malfunction.
• After the engine has been turned off, the lowest fault code appears on the odometer/fuel reserve
tripmeter/tripmeter 2 LCD. Once a fault code has been displayed, it remains stored in the memory of the ECU until it is deleted.
EAS00900
Engine trouble warning light indication and FI system operation
Engine trouble
warning light
ECU operation
FI operation
Vehicle operation
Flashes*
Warning provided
when unable to start
engine
Operation stopped
Cannot be operated
Remains on
Malfunction detected
Operated with alternate characteristics in
accordance with the
description of the malfunction
Can or cannot be
operated depending
on the fault code
* The warning light flashes if any one of the following conditions is present and the start switch is
pushed:
12: Crankshaft position sensor
19: Sidestand switch
(open circuit in the wire to the ECU)
30: Lean angle cut-off switch
(latch up detected)
41: Lean angle cut-off switch
(open or short circuit)
50: ECU internal malfunction
(faulty ECU memory)
7-3
FI
FUEL INJECTION SYSTEM
EAS00901
Checking for a defective engine trouble warning light bulb
The engine trouble warning light comes on for 1.4 seconds after the main switch is turned to “ON” or
when the start switch is pushed. If the warning light does not come on under these conditions, the
warning light bulb may be defective.
Main switch Main switch
on
off
Engine trouble
warning light
Light
off
Light on for 1.4
seconds
Light
off
Initialized
EAS00902
ALTERNATE OPERATION CONTROL (FAIL-SAFE ACTION)
If the ECU detects an abnormal signal from a sensor while the motorcycle is being driven, the ECU
illuminates the engine trouble warning light and it provides the engine with alternate operating
instructions, according to the malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that
are programmed for each sensor in order to provide the engine with the alternate operating instructions that enable the engine to continue to operate or stop operating, depending on the conditions.
The ECU applies the fail-safe actions in two ways: one in which the sensor output is set to a prescribed value, and the other in which the ECU directly operates an actuator. Details on the fail-safe
actions are given in the table below.
FAIL-SAFE ACTION TABLE
Self-diagnostic function
Fault
code No.
Item
Symptom
Fail-safe action
Startability
Driveability
—
No
No
Yes
Yes
Yes
Yes
12
Crankshaft position
sensor
No normal signals are
received from the sensor.
13
Intake air pressure
sensor (open or short
circuit)
Open or short circuit is
detected.
• Fixes the intake air pressure to 101 kPa
(760 mmHg, 29.9 inHg).
Intake air pressure
sensor
Intake air pressure sensor
hose is clogged or disconnected, causing the constant
application of atmospheric
pressure to the sensor.
• Fixes the intake air pressure to 101 kPa
(760 mmHg, 29.9 inHg).
14
15
Throttle position sensor
(open or short circuit)
Open or short circuit is
detected.
• Fixes the throttle position
sensor to fully open.
Yes
Yes
16
Throttle position sensor
(stuck)
The throttle position sensor is
detected stuck.
• Fixes the throttle position
sensor to fully open.
Yes
Yes
19
Broken or disconnected blue/black lead
of the ECU
Open circuit in the input line
(blue/black) of the ECU is
detected.
—
No
No
21
Coolant temperature
sensor
Open or short circuit is
detected.
• Fixes the coolant temperature to 80 °C (176 °F).
Yes
Yes
22
Intake air temperature
sensor
Open or short circuit is
detected.
• Fixes the intake air temperature to 20 °C (68 °F).
Yes
Yes
7-4
FI
FUEL INJECTION SYSTEM
Fault
code No.
30
Item
Lean angle cut-off
switch (latch up
detected)
The motorcycle has overturned.
Faulty ignition
Open circuit is detected in the
primary lead of the ignition
coil.
33
41
44
46
50
Fail-safe action
Startability
Driveability
—
No
No
—
No
No
—
No
No
Yes
Yes
Yes
Yes
Lean angle cut-off
switch (open or short
circuit)
Open or short circuit is
detected.
Speed sensor, neutral
switch
No normal signals are
received from the speed sensor or an open or short circuit
is detected in the neutral
switch.
• Fixes the gear to the top
gear.
Fuel system voltage
(monitor voltage)
The ECU is unable to monitor
the battery voltage (open circuit in the wire to the ECU).
• Fixes the battery voltage
to 12 V.
Error in writing the
amount of CO adjustment on EEPROM
An error is detected while
reading or writing on
EEPROM (CO adjustment
value).
—
Yes
Yes
Vehicle system power
supply (monitor voltage)
Power supply to the fuel injection system relay is not normal.
—
Yes
Yes
ECU internal malfunction (memory check
error)
Faulty ECU memory. When
this malfunction is detected,
the code number might not
appear on the meter.
—
No
Yes
Start unable warning
Relay is not turned ON even if
the crank signal is input while
the start switch is turned ON.
When the start switch is turned
ON while an error is detected
with the fault code of No. 12,
19, 33, 41 or 50.
No
No
Fail-safe action
Startability
Driveability
—
No
No
—
No
No
—
No
No
—
No
No
42
43
Symptom
—
• Engine trouble warning
light flashes when the start
switch is turned ON.
Communication error with the meter
Fault
code No.
Item
Er-1
ECU internal malfunction (output signal
error)
No signals are received from
the ECU.
Er-2
ECU internal malfunction (output signal
error)
No signals are received from
the ECU within the specified
duration.
Er-3
ECU internal malfunction (output signal
error)
Data from the ECU cannot be
received correctly.
Er-4
ECU internal malfunction (input signal error)
Non-registered data has been
received from the meter.
Symptom
7-5
FI
FUEL INJECTION SYSTEM
EAS00904
TROUBLESHOOTING CHART
Engine operation is not normal or the engine trouble warning light is on.
The engine trouble warning light may not come on even if the engine operation is not normal.
The engine trouble warning light comes on.
The engine trouble warning light does not come on.
Check the fault code number displayed on the meter.
Check the operation of the following sensors and
actuators in the diagnostic mode. Refer to “Diagnostic
mode table”.
01: Throttle position sensor (throttle angle)
07: Vehicle speed pulse
09: Fuel system voltage
21: Neutral switch
30: Ignition coil
36: Fuel injector
48: Air induction system solenoid
Identify the system with the malfunction.
Refer to “FAIL-SAFE ACTION TABLE”.
Identify the probable cause of the malfunction.
Refer to “Diagnostic monitoring code table”.
OK
Check and repair the probable cause of the malfunction.
Fault code No. is indicated.
Fault code No. is not
indicated.
Check and repair. Refer
to “TROUBLESHOOTING DETAILS”. Monitor the operation of the
sensors and the actuators in the diagnostic
mode. Refer to “Diagnostic mode table”.
Check
and
repair.
Refer to “FAIL-SAFE
ACTION TABLE”.
Malfunction
engine
of
NG
the
Defective sensor or
actuator
Check and repair the
inner parts of the
engine. Refer to
chapter 5.
Check and repair the
corresponding sensor or actuator.
OK
NG
OK
Check the engine condition.
Perform the ECU reinstatement action.
Refer to “Restore method” in “TROUBLESHOOTING
DETAILS”.
Fault code number
displayed
OK
Set the main switch to “OFF”, set it back to “ON”, and
then check if the fault code number is still displayed
on the meter.
No fault code number displayed
Repairs completed
Erase the malfunction history.*
The malfunction history is stored even if the main switch is set to “OFF”. The malfunction history must be erased in the
diagnostic mode. Refer to “Diagnostic mode table (Diagnostic code No. 62)”.
*
Operated when the engine trouble warning light is on.
7-6
FUEL INJECTION SYSTEM
FI
EAS00905
DIAGNOSTIC MODE
Setting the diagnostic mode
1. Set the main switch to “OFF” and set the
engine stop switch to “ ”.
2. Disconnect the wire harness coupler from
the fuel pump.
3. Simultaneously press and hold the
“SELECT” and “RESET” buttons, turn the
main switch to “ON”, and continue to press
the buttons for 8 seconds or more.
NOTE:
All displays on the meter disappear “dIAG”
appears on the odometer/fuel reserve tripmeter/tripmeter 2 LCD.
_
4. Press the “SELECT” button to select the CO
adjustment mode “Co” or the diagnostic
mode “dIAG”.
5. After selecting “dIAG”, simultaneously press
the “SELECT” and “RESET” buttons for 2
seconds or more to execute the selection.
6. Set the engine stop switch to “ ”.
7. Select the diagnostic code number that
applies to the item that was verified with the
fault code number by pressing the
“SELECT” and “RESET” buttons.
NOTE:
The diagnostic code number appears on the
odometer/fuel reserve tripmeter/tripmeter 2
LCD (01-70).
• To decrease the selected diagnostic code
number, press the “SELECT” button. Press
the “SELECT” button for 1 second or longer
to automatically decrease the diagnostic
code numbers.
• To increase the selected diagnostic code
number, press the “RESET” button. Press
the “RESET” button for 1 second or longer to
automatically increase the diagnostic code
numbers.
_
7-7
FUEL INJECTION SYSTEM
FI
8. Verify the operation of the sensor or actuator.
• Sensor operation
The data representing the operating conditions of the sensor appears on the odometer/fuel reserve tripmeter/tripmeter 2 LCD.
• Actuator operation
Set the engine stop switch to “ ” to operate the actuator.
NOTE:
If the engine stop switch is set to “
“ ”, and then set it to “ ” again.
_
”, set it to
9. Set the main switch to “OFF” to cancel the
diagnostic mode.
7-8
FUEL INJECTION SYSTEM
FI
EAS00906
Diagnostic monitoring code table
Fault
code No.
Symptom
No normal signals are received from
the crankshaft position sensor.
14
Open or short circuit in wire harness
Defective crankshaft position sensor
Disconnected crankshaft position sensor coupler
Malfunction in A.C. magneto rotor
Malfunction in ECU
Improperly installed crankshaft position sensor
—
Open or short circuit is detected in the
intake air pressure sensor.
•
•
•
•
Open or short circuit in wire harness
Defective intake air pressure sensor
Disconnected intake air pressure sensor coupler
Malfunction in ECU
03
Faulty intake air pressure sensor
hose system.
• detected hose
• clogged hose
• Disconnected, clogged, kinked, or pinched intake air
pressure sensor hose
• Defective intake air pressure sensor
• Malfunction in ECU
03
Open or short circuit is detected in the
throttle position sensor.
•
•
•
•
•
01
15
16
19
• Stuck throttle position sensor
• Improperly installed throttle position sensor
• Malfunction in ECU
Open circuit in the input line (blue/
black lead) of ECU is detected when
the start switch is pushed.
• Open circuit in wire harness (ECU coupler)
• Malfunction in ECU
Open or short circuit is detected in the
coolant temperature sensor.
•
•
•
•
•
Open or short circuit in wire harness
Defective coolant temperature sensor
Disconnected coolant temperature sensor coupler
Malfunction in ECU
Improperly installed coolant temperature sensor
06
•
•
•
•
•
Open or short circuit in wire harness
Defective intake air temperature sensor
Disconnected intake air temperature sensor coupler
Malfunction in ECU
Improperly installed intake air temperature sensor
05
Open or short circuit is detected in the
intake air temperature sensor.
22
42
43
01
20
The motorcycle has overturned.
• Overturned motorcycle
• Malfunction in ECU
Open circuit is detected in the primary
lead of the ignition coil.
•
•
•
•
Open circuit in wire harness
Malfunction in ignition coil
Malfunction in ECU
Malfunction in a component of ignition cut-off circuit system
30
Open or short circuit is detected in the
lean angle cut-off switch.
•
•
•
•
Open or short circuit in wire harness
Defective lean angle cut-off switch
Disconnected lean angle cut-off switch coupler
Malfunction in ECU
08
No normal signals are received from
the speed sensor or an open or short
circuit is detected in the neutral
switch.
•
•
•
•
•
•
•
•
Open or short circuit in wire harness
Defective speed sensor
Disconnected speed sensor coupler
Malfunction in vehicle speed sensor detected unit
Defective neutral switch
Disconnected neutral switch connector
Malfunction in the engine side of the neutral switch
Malfunction in ECU
07
21
Power supply to the injector and fuel
pump is not normal. (The ECU is
unable to monitor the battery voltage.)
• Open circuit in wire harness
• Malfunction in ECU
• Defective fuel injection system relay
33
41
Open or short circuit in wire harness
Defective throttle position sensor
Disconnected throttle position sensor coupler
Malfunction in ECU
Improperly installed throttle position sensor
Stuck throttle position sensor is
detected.
21
30
Diagnostic code
•
•
•
•
•
•
12
13
Probable cause of malfunction
7-9
08
09, 50
FUEL INJECTION SYSTEM
Fault
code No.
44
46
50
Er-1
Er-2
Er-3
Er-4
Symptom
Probable cause of malfunction
FI
Diagnostic code
An error is detected while reading or
writing on EEPROM.
• Malfunction in ECU (The CO adjustment value is not
properly written on or read from the internal memory.)
60
Power supply to the fuel injection system relay is not normal.
• Open circuit in wire harness
• Malfunction in rectifier/regulator
• Malfunction in A.C. magneto rotor
Refer to “CHARGING SYSTEM” in chapter 8.
09
Faulty ECU memory. When this malfunction is detected, the code number
might not appear on the meter.
• Malfunction in ECU (The program and data are not properly written on or read from the internal memory.)
No signals are received from the
ECU.
•
•
•
•
Open or short circuit in sub-wire harness
Disconnected ECU coupler
Malfunction in meter
Malfunction in ECU
—
No signals are received from the ECU
within the specified duration.
•
•
•
•
Improper connection in sub-wire harness
Disconnected ECU coupler
Malfunction in meter
Malfunction in ECU
—
Data from the ECU cannot be
received correctly.
•
•
•
•
Improper connection in sub-wire harness
Disconnected ECU coupler
Malfunction in meter
Malfunction in ECU
—
Non-registered data has been
received from the meter.
•
•
•
•
Improper connection in sub-wire harness
Disconnected ECU coupler
Malfunction in meter
Malfunction in ECU
—
—
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
temperature sensor and the coolant temperature sensor respectively.
• If it is not possible to check the intake air temperature, use the ambient temperature as reference.
_
Diagnostic
code
Item
Displays the throttle angle.
• Check with throttle fully closed.
• Check with throttle fully open.
0 ~ 125 degrees
• Fully closed (15 ~ 17 degrees)
• Fully open (97 ~ 100 degrees)
Intake air pressure
Displays the intake air pressure.
Set the engine stop switch to “ ”.
• Generate the pressure difference by cranking the
engine with the start switch, but do not start the
engine.
When the engine is stopped:
Atmospheric pressure 101.3 kPa
(760 mmHg, 30 inHg)
When cranking the engine with start
switch:
1.3 ~ 26.6 kPa
(10 ~ 200 mmHg, 0.4 ~ 7.9 inHg)
Intake air temperature
Displays the intake air temperature.
• Check the temperature in the air filter case.
Compare the temperature in the air
filter case to the value displayed on
the meter.
Coolant temperature
Displays the coolant temperature.
• Check the coolant temperature.
Compare the coolant temperature to
the value displayed on the meter.
Vehicle speed pulse
Displays the accumulation of the vehicle speed
pulses that are generated when the tire is spun.
(0 ~ 199; resets to 0 after 199)
OK if the numbers appear on the
meter.
03
05
07
Data displayed on meter
(reference value)
Throttle angle
01
06
Action
7 - 10
FUEL INJECTION SYSTEM
Diagnostic
code
08
09
20
21
Item
Displays the lean angle cut-off switch values.
Upright: 0.4 ~ 1.4 V
Overturned: 3.7 ~ 4.4 V
Fuel system voltage (battery voltage)
Displays the fuel system voltage (battery voltage).
Set the engine stop switch to “ ”.
Approximately 12.0 V
Sidestand switch
Displays that the switch is on or off. (When the gear
is in a position other than neutral.)
Stand retracted: On
Stand extended: Off
Neutral switch
Displays that the switch is on or off.
Neutral: On
In gear: Off
Ignition coil
The engine stop switch is set to “ ”, the ignition
coil operates 5 times every second and the engine
trouble warning light comes on.
• Connect an ignition checker to the spark plug cap.
• If the engine stop switch is set to “ ”, set it to
“ ”, and then set it to “ ” again.
Check that sparks are generated 5
times with the engine stop switch is
set to “ ”.
Fuel injector
The engine stop switch is set to “ “, the fuel injector operates 5 times every second and the engine
trouble warning light comes on.
• If the engine stop switch is set to “ ”, set it to
“ ”, and then set it to “ ” again.
Check that the operating sound of the
fuel injector is generated 5 times
when the engine stop switch is set to
“ ”.
Air induction system
The engine stop switch is set to “ ”, the air induction system solenoid operates 5 times every second
and the engine trouble warning light comes on.
• If the engine stop switch is set to “ ”, set it to
“ ”, and then set it to “ ” again.
Check that the operating sound of the
air induction system solenoid is generated 5 times when the engine stop
switch is set to “ ”.
Fuel injection system
relay
The engine stop switch is set to “ ”, the fuel injection system relay operates 5 times every second
and the engine trouble warning light comes on (on
when relay is operating, off when relay is not operating).
• If the engine stop switch is set to “ ”, set it to
“ ”, and then set it to “ ” again.
Check that the operating sound of the
fuel injection system relay is generated 5 times when the engine stop
switch is set to “ ”.
Radiator fan motor relay
The engine stop switch is set to “ “, the radiator
fan motor relay operates 5 times, 5 seconds each
time (2 seconds on, 3 seconds off), and the engine
trouble warning light comes on.
• If the engine stop switch is set to “ ”, set it to
“ ”, and then set it to “ ” again.
Check that the operating sound of the
radiator fan motor relay is generated
and that the radiator fan motor is
operated 5 times when the engine
stop switch is set to “ ”.
Headlight relay 1
The engine stop switch is set to “ ”, the headlight
relay operates 5 times, 5 seconds each time (2 seconds on, 3 seconds off), and the engine trouble
warning light comes on.
• If the engine stop switch is set to “ ”, set it to
“ ”, and then set it to “ ” again.
Check that the operating sound of the
headlight relay is generated and that
the headlight comes on 5 times when
the engine stop switch is set to “ ”.
E2PROM fault code display
• Transmits the abnormal portion of the data in the
E2PROM that has been detected as fault code 44.
01
“00” is displayed when there is no
malfunction.
Malfunction history code
display
• Displays the codes of the history of the self-diagnosis malfunctions (i.e., a code of a malfunction
that occurred once and which has been corrected).
• If multiple malfunctions have been detected, different codes are displayed at 2-second intervals, and
this process is repeated.
12 ~ 61
“00” is displayed when there is no
malfunction.
Malfunction history code
erasure
• Displays the total number of codes that are being
detected through self diagnosis and the fault codes
in the past history.
• Erases only the history codes when the engine
stop switch is set to “ ”. If the engine stop switch
is set to “ ”, set it to “ ”, and then set it to “ ”
again.
00 ~ 17
“00” is displayed when there is no
malfunction.
Control number
• Displays the program control number.
00 ~ 255
36
48
50
51
52
61
62
70
Data displayed on meter
(reference value)
Lean angle cut-off switch
30
60
Action
FI
7 - 11
FUEL INJECTION SYSTEM
FI
EAS00908
TROUBLESHOOTING DETAILS
This section describes the countermeasures per fault code number displayed on the meter. Check
and service the items or components that are the probable cause of the malfunction following the
order in the “TROUBLESHOOTING CHART”.
After the checking and servicing the malfunctioning part, reset the meter display. Refer to “Restore
method”.
Fault code No.:
Fault code number displayed on the meter when the engine failed to work normally. Refer to
“Diagnostic monitoring code table”.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOSTIC MODE”.
Fault code No.
12
Symptom
No normal signals are received from the crankshaft position sensor.
Used diagnostic code No. – –
Order
Item/components
Check or maintenance job
Restore method
1
Crankshaft position sensor installation
Check the sensor for looseness or pinching.
Reinstated by cranking the engine.
2
Coupler connections
Crankshaft position sensor coupler
ECU coupler
Check the couplers for any pins that may have
pulled out.
Check that the couplers are securely locked.
If necessary, repair the coupler or securely connect it.
3
Open or short circuit in the wire har- Repair or replace if there is an open or short cirness
cuit between the wire harnesses.
Gray - Gray
Green/White - Black/Blue
4
Defective crankshaft position sensor
Replace the sensor if it is defective.
Refer to “IGNITION SYSTEM” in chapter 8.
7 - 12
FUEL INJECTION SYSTEM
Fault code No.
13
Symptom
FI
Open or short circuit is detected from the intake air pressure sensor.
Used diagnostic code No. 03 (intake air pressure sensor)
Order
1
Item/components
Check or maintenance job
Restore method
Coupler connections
Intake air pressure sensor coupler
ECU coupler
Sub-wire harness coupler
Check the couplers for any pins that may have
pulled out.
Check that the couplers are securely locked.
Reinstated by cranking the engine.
If necessary, repair the coupler or securely connect it.
2
Open or short circuit in the wire har- Repair or replace if there is an open or short cirness
cuit between the wire harnesses.
Black/Blue - Black/Blue
Pink/White - Pink/White
Blue - Blue
3
Defective intake air pressure sensor
Execute the diagnostic mode. (Code No. 03)
Replace the sensor if it is defective.
1. Connect the pocket tester (DC 20 V) to the
intake air pressure sensor coupler (wire harness end) as shown.
Positive tester probe → pink/white 1
Negative tester probe → black/blue 2
1
2
L P/W B/L
2. Set the main switch to “ON”.
3. Measure the intake air pressure sensor output
voltage.
Intake air pressure sensor output voltage
3.4 ~ 3.8 V
4. Is the intake air pressure sensor OK?
7 - 13
FI
FUEL INJECTION SYSTEM
Fault code No.
14
Symptom
Intake air pressure sensor hose is disconnected or clogged.
Used diagnostic code No. 03 (intake air pressure sensor)
Order
1
Item/components
Check or maintenance job
Restore method
Disconnected, clogged, kinked, or
pinched intake air pressure sensor
hose
Repair or replace the hose.
Reinstated by starting the engine and
operating it at idle.
Intake air pressure sensor malfunc- Check and repair the connection.
tion at intermediate electrical potential
Replace the sensor if there is a malfunction.
2
Coupler connections
Check the couplers for any pins that may have
Intake air pressure sensor coupler pulled out.
ECU coupler
Check that the couplers are securely locked.
If necessary, repair the coupler or securely connect it.
3
Defective intake air pressure sensor
Fault code No.
15
Symptom
Execute the diagnostic mode. (Code No. 03)
Replace the sensor if it is defective.
Refer to “Fault code No. 13”.
Open or short circuit is detected from the throttle position senor.
Used diagnostic code No. 01 (throttle position sensor)
Order
Item/components
Check or maintenance job
Restore method
1
Throttle position sensor installation
Check the sensor for looseness or pinching.
Check that the sensor is installed in the specified
position.
Reinstated by setting the main switch
to “ON”.
2
Coupler connections
Throttle position sensor coupler
ECU coupler
Check the connections of the couplers.
Check that the couplers are securely locked.
If necessary, repair the coupler or securely connect it.
3
Open or short circuit in the wire har- Repair or replace if there is an open or short cirness
cuit between the wire harnesses.
Black/Blue - Black/Blue
Yellow - Yellow
Blue - Blue
4
Check the throttle position sensor
lead open circuit output voltage.
Check for an open circuit and replace the throttle
position sensor, if necessary.
Black/Blue - Yellow
Open circuit item
Output voltage
Ground wire open circuit
5V
Output wire open circuit 0 V
Power supply wire
open circuit
5
Defective throttle position sensor
0V
Execute the diagnostic mode. (Code No. 01)
Replace the sensor if it is defective.
Refer to “THROTTLE BODY ASSEMBLY”.
7 - 14
FUEL INJECTION SYSTEM
Fault code No.
16
Symptom
FI
The throttle position sensor is detected stuck.
Used diagnostic code No. 01 (throttle position sensor)
Order
Item/components
Check or maintenance job
Restore method
1
Defective throttle position sensor
Replace the sensor if it is defective.
Refer to “THROTTLE BODY ASSEMBLY”.
2
Throttle position sensor installation
Execute the diagnostic mode. (Code No. 01)
Check the sensor for looseness or pinching.
Check that the sensor is installed in the specified
position. Refer to “THROTTLE BODY ASSEMBLY”.
Reinstated by starting the engine, operating it at idle, and
then racing it.
Fault code No.
19
Symptom
Open circuit is detected in the input wire from the sidestand switch to the ECU.
Used diagnostic code No. 20 (sidestand switch)
Order
1
Item/components
Check or maintenance job
Restore method
Coupler connections
ECU coupler
Blue/Black connector
Check the couplers for any pins that may have
pulled out.
Check that the couplers are securely locked.
If the transmission is
in gear, it is reinstated by retracting
the sidestand.
If the transmission is
in neutral, it is reinstated by reconnecting the wiring.
If necessary, repair the coupler or securely connect it.
2
Open or short circuit in the wire har- Repair or replace if there is an open or short cirness
cuit between the ECU and sidestand switch.
Blue/Black
3
Defective sidestand switch
Fault code No.
21
Symptom
Execute the diagnostic mode. (Code No. 20)
Replace the switch if it is defective.
Refer to “CHECKING THE SWITCHES” in chapter 8.
Open or short circuit is detected from the coolant temperature sensor.
Used diagnostic code No. 06 (coolant temperature sensor)
Order
Item/components
Check or maintenance job
Restore method
1
Coolant temperature sensor installation
Check the sensor for looseness or pinching.
2
Coupler connections
Coolant temperature sensor coupler
ECU coupler
Check the coupler for any pins that may have
pulled out.
Check that the couplers are securely locked.
Reinstated by setting the main switch
to “ON’.
If necessary, repair the coupler or securely connect it.
3
Open or short circuit in the wire har- Repair or replace if there is an open or short cirness
cuit between the wire harnesses.
Black/Blue - Black/Blue
Green/Red - Green/Red
4
Defective coolant temperature sensor
Execute the diagnostic mode. (Code No. 06)
Replace the sensor if it is defective.
Refer to “COOLING SYSTEM” in chapter 8.
7 - 15
FUEL INJECTION SYSTEM
Fault code No.
22
Symptom
FI
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
1
Intake air temperature sensor
installation
Check the sensor looseness or pinching.
2
Coupler connections
Check the couplers for any pins that may have
Intake air temperature sensor cou- pulled out.
pler
Check that the couplers are securely locked.
ECU coupler
If necessary, repair the coupler or securely connect it.
Reinstated by setting the main switch
to “ON”.
3
Open or short circuit in the wire har- Repair or replace if there is an open or short cirness
cuit between the wire harnesses.
Black/Blue - Black/Blue
Brown/White - Brown/White
4
Defective intake air temperature
sensor
Execute the diagnostic mode. (Code No. 05)
Replace the sensor if it is defective.
1. Remove the intake air temperature sensor
from the air filter case.
2. Connect the pocket tester (Ω × 100) to the
intake air temperature sensor terminal as
shown.
Positive tester probe → brown/white 1
Negative tester probe → black/blue 2
Br/W B/L
2
1
3. Measure the intake air temperature sensor
resistance.
Intake air temperature sensor
resistance
2.21 ~ 2.69 Ω at 20 °C (68 °F)
WARNING
• Handle the intake air temperature sensor
with special care.
• Never subject the intake air temperature
sensor to strong shocks. If the intake air
temperature sensor is dropped, replace it.
4. Is the intake air temperature sensor OK?
7 - 16
FI
FUEL INJECTION SYSTEM
Fault code No.
30
Symptom
The motorcycle has overturned.
Used diagnostic code No. 08 (lean angle cut-off switch)
Order
Item/components
Check or maintenance job
Restore method
1
The motorcycle has overturned.
Raise the motorcycle upright.
2
Lean angle cut-off switch installation
Check the switch for looseness or pinching.
3
Coupler connections
Lean angle cut-off switch coupler
ECU coupler
Check the coupler for any pins that may have
pulled out.
Check that the couplers are securely locked.
Reinstated by setting the main switch
to “ON” (the engine
cannot be started
unless the main
switch is first set to
“OFF”).
If necessary, repair the coupler or securely connect it.
4
Defective lean angle cut-off switch
Fault code No.
33
Symptom
Execute the diagnostic mode. (Code No. 08)
Replace the switch if it is defective.
Refer to “IGNITION SYSTEM” in chapter 8.
Malfunction detected in the primary lead of the ignition coil.
Used diagnostic code No. 30 (ignition coil)
Order
1
Item/components
Check or maintenance job
Restore method
Coupler and connector connections
Ignition coil primary connector
(Orange)
ECU coupler
Check the coupler and connector for any pins
that may have pulled out.
Check the connector and coupler are securely
locked.
Reinstated by starting the engine and
operating it at idle.
If necessary, repair the coupler or securely connect it.
2
Open or short circuit in the wire har- Repair or replace if there is an open or short cirness
cuit between the wire harnesses.
Orange - Orange
3
Defective ignition coil
Fault code No.
41
Symptom
Execute the diagnostic mode. (Code No. 30)
Test the primary and secondary coils for continuity.
Replace the coil if it is defective.
Refer to “IGNITION SYSTEM” in chapter 8.
Open or short circuit is detected in the lean angle cut-off switch.
Used diagnostic code No. 08 (lean angle cut-off switch)
Order
1
Item/components
Check or maintenance job
Restore method
Coupler connections
Lean angle cut-off switch coupler
ECU coupler
Check the couplers for any pins that may have
pulled out.
Check that the couplers are securely locked.
Reinstated immediately when it
becomes normal.
If necessary, repair the coupler or securely connect it.
2
Open or short circuit in the wire har- Repair or replace if there is an open or short cirness
cuit between the wire harnesses.
Black/Blue - Black/Blue
Yellow/Green - Yellow/Green
Blue - Blue
3
Defective lean angle cut-off switch
Execute the diagnostic mode. (Code No. 08)
Replace the switch if it is defective.
Refer to “Fault code No. 30”.
7 - 17
FUEL INJECTION SYSTEM
Fault code No.
42
Symptom
FI
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
A-1
Item/components
Check or maintenance job
Restore method
Coupler connections
Speed sensor coupler
ECU coupler
Check the couplers for any pins that may have
pulled out.
Check that the couplers are securely locked.
Reinstated by starting
the engine, and inputting the vehicle speed
signals by operating
the motorcycle at 20
to 30 km/h (12.4 to
18.6 mi/h).
If necessary, repair the coupler or securely connect it.
A-2
Open or short circuit in the wire har- Repair or replace if there is an open or short cirness
cuit between the wire harnesses.
Blue - Blue
White - White
Black/Blue - Black/Blue
A-3
Gear for detecting vehicle speed
has broken.
Replace the gear if it is defective.
Refer to “TRANSMISSION” in chapter 5.
A-4
Defective speed sensor
Execute the diagnostic mode. (Code No. 07)
Replace the sensor if it is defective.
1. Measure the speed sensor output voltage.
2. Connect the pocket tester (DC 20 V) to the
speed sensor coupler as shown.
Positive tester probe → pink 1
Negative tester probe → black/white 2
1
P O/R
B/W
L
W
B/L
2
3. Set the main switch to “ON”.
4. Elevate the rear wheel and slowly rotate it.
5. Measure the speed sensor output voltage.
Speed sensor output voltage
When sensor is on
DC 4.8 V or more
When sensor is off
DC 0.6 V or less
6. Is the speed sensor OK?
7 - 18
FUEL INJECTION SYSTEM
Fault code No.
42
Symptom
FI
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
B-1
Item/components
Check or maintenance job
Restore method
Coupler connections
Neutral switch connector
Wiring harness ECU coupler
Check the couplers for any pins that may have
pulled out.
Check that the couplers are securely locked.
Reinstated by starting
the engine, and inputting the vehicle speed
signals by operating
the motorcycle at 20
to 30 km/h (12.4 to
18.6 mi/h).
If necessary, repair the coupler or securely connect it.
B-2
Open or short circuit in the wire har- Repair or replace if there is an open or short cirness
cuit between the wire harnesses.
between neutral switch and relay unit
Sky blue - Sky blue
between relay unit and ECU
Blue/Yellow - Blue/Black
B-3
Faulty shift drum (neutral detection
area)
Replace if defective.
Refer to “TRANSMISSION” in chapter 5.
B-4
Defective neutral switch
Execute the diagnostic mode. (Code No. 21)
Replace the switch if it is defective.
Refer to “CHECKING THE SWITCHES” in chapter 8.
7 - 19
FUEL INJECTION SYSTEM
Fault code No.
43
Symptom
FI
The ECU is unable to monitor the battery voltage.
Used diagnostic code No. 09, 50 (fuel system voltage)
Order
1
Item/components
Check or maintenance job
Restore method
Coupler connections
Fuel injection system relay coupler
Wiring harness ECU coupler
Check the couplers for any pins that may have
pulled out.
Check that the couplers are securely locked.
Reinstated by starting the engine and
operating it at idle.
If necessary, repair the coupler or securely connect it.
2
Defective main relay
Replace the relay if it is defective.
3
Open or short circuit in the wire har- Execute the diagnostic mode. (Code No. 09)
ness
Repair or replace if there is an open or short circuit:
between battery and fuel injection system fuse
Red - Red
between fuel injection system fuse and fuel injection system relay
Brown - Brown
between fuel injection system relay and ECU
Red/Blue - Red/Blue
between battery and main switch
Red - Red
between main switch and ignition fuse
Brown/Blue - Brown/Blue
between ignition fuse and engine stop switch
Red - Red
between engine stop switch and fuel injection
system relay
Red/Black - Red/Black
between fuel injection system relay and ECU
Blue/Red - Blue/Red
4
Malfunction or open circuit in the
fuel injection system relay
Execute the diagnostic mode. (Code No. 50)
Replace if defective.
1. Remove the relay unit.
2. Connect the pocket tester (Ω × 1) and battery
(12 V) to the relay terminals as shown.
Positive battery terminal → red/black 1
Negative battery terminal → blue/red 2
Positive tester probe → brown 3
Negative tester probe → red/blue 4
3. Does the diode have continuity between
brown and red/blue?
If there is no malfunction with the fuel injection
system relay, replace the ECU.
7 - 20
FUEL INJECTION SYSTEM
Fault code No.
44
Symptom
FI
Error is detected while reading or writing on EEPROM
(CO adjustment value).
Used diagnostic code No. 60 (EEPROM improper cylinder indication)
Order
1
Item/components
Check or maintenance job
Restore method
Malfunction in ECU
Execute the diagnostic mode. (Code No. 60)
• Check the faulty cylinder.
• Readjust the CO of the displayed cylinder.
Refer to “ADJUSTING THE EXHAUST GAS
VOLUME” in chapter 3.
Replace the ECU if it is defective.
Reinstated by setting the main switch
to “ON”.
Fault code No.
46
Symptom
Power supply to the FI system relay is not normal.
Used diagnostic code No. 09
Order
Item/components
Check or maintenance job
Restore method
1
Faulty battery
Replace or change the battery.
Refer to “CHECKING AND CHARGING THE
BATTERY” in chapter 3.
Reinstated by starting the engine and
operating it at idle.
2
Open or short circuit in the wire har- Excute the diagnostic mode. (Code No. 09)
ness.
Repair or replace if there is an open or short circuit:
between battery and fuel injection system fuse
Red - Red
between the fuel injection system fuse and fuel
injection system relay
Brown - Brown
between the fuel injection system relay and ECU
Red/Blue - Red/Blue
3
Coupler connections ECU coupler
Fault code No.
50
Symptom
Check the coupler for any pins that may have
pulled out.
Check that the coupler is securely locked.
If necessary, repair the coupler or securely connect it.
Faulty ECU memory. (When this malfunction is detected in the ECU, the fault
code number might not appear on the meter.)
Used diagnostic code No. – –
Order
1
Item/components
Check or maintenance job
Restore method
Malfunction in ECU
Replace the ECU.
Reinstated by setting the main switch
to “ON”.
7 - 21
FUEL INJECTION SYSTEM
Fault code No.
Er-1
Symptom
FI
No signals are received from the ECU.
Used diagnostic code No. – –
Order
1
Item/components
Check or maintenance job
Restore method
Coupler connections
ECU coupler
Meter couplers
Check the couplers for any pins that may have
pulled out.
Check that the couplers are securely locked.
Reinstated automatically when it receives
a normal signal.
If there is a malfunction, repair it and connect it
securely.
2
Malfunction in meter assembly
Replace the meter assembly.
3
Malfunction in ECU
Replace the ECU.
Fault code No.
Er-2
Symptom
Reinstated automatically when it receives
a normal signal.
No signals are received from the ECU within the specified duration.
Used diagnostic code No. – –
Order
1
Item/components
Check or maintenance job
Restore method
Coupler connections
ECU coupler
Meter couplers
Check the couplers for any pins that may have
pulled out.
Check that the couplers are securely locked.
Reinstated automatically when it receives
a normal signal.
If there is a malfunction, repair it and connect it
securely.
2
Malfunction in meter assembly
Replace the meter assembly.
3
Malfunction in ECU
Replace the ECU.
Fault code No.
Er-3
Symptom
Data from the ECU cannot be received correctly.
Used diagnostic code No. – –
Order
1
Item/components
Check or maintenance job
Restore method
Coupler connections
ECU coupler
Meter couplers
Check the couplers for any pins that may have
pulled out.
Check that the couplers are securely locked.
Reinstated automatically when it receives
a normal signal.
If there is a malfunction, repair it and connect it
securely.
2
Malfunction in meter assembly
Replace the meter assembly.
3
Malfunction in ECU
Replace the ECU.
Fault code No.
Er-4
Symptom
Non-registered data has been received from the meter.
Used diagnostic code No. – –
Order
1
Item/components
Check or maintenance job
Restore method
Coupler connections
ECU coupler
Meter couplers
Check the couplers for any pins that may have
pulled out.
Check that the couplers are securely locked.
Reinstated automatically when it receives
a normal signal.
If there is a malfunction, repair it and connect it
securely.
2
Malfunction in meter assembly
Replace the meter assembly.
3
Malfunction in ECU
Replace the ECU.
7 - 22
THROTTLE BODY ASSEMBLY
FI
EAS00909
THROTTLE BODY ASSEMBLY
3
1
5
4
2
6
9
8 11
10 10
8
R.
Order
T.
7
Job/Part
Removing the throttle body assembly
Seat
6 Nm (0.6 m • kg, 4.3 ft • Ib)
Q’ty
Fuel tank
Air filter case
Coolant
1
2
3
Fuel injector coupler
Throttle position sensor coupler
Throttle cable
1
1
2
4
Vacuum hose
1
7 - 23
Remarks
Remove the parts in the order listed.
Refer to “COWLING AND COVER” in
chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “AIR FILTER CASE” in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Disconnect.
Disconnect.
Disconnect.
Refer to “INSTALLING THE THROTTLE
BODY ASSEMBLY”.
Disconnect.
THROTTLE BODY ASSEMBLY
FI
3
1
5
4
2
6
9
8 11
10 10
8
Job/Part
Fast idle plunger outlet hose
Fast idle plunger inlet hose
Pilot air hose
Throttle body joint clamp screw
Throttle body assembly
Throttle body joint clamp
Throttle body joint
R.
Order
5
6
7
8
9
10
11
T.
7
6 Nm (0.6 m • kg, 4.3 ft • Ib)
Q’ty
Remarks
1
Disconnect.
1
1
2
Loosen.
1
Refer to “INSTALLING THE THROT2
TLE BODY ASSEMBLY”.
1
For installation, reverse the removal procedure.
7 - 24
FI
THROTTLE BODY ASSEMBLY
New
3
New
4
2
1
Order
1
2
3
4
Job/Part
Disassembling the throttle body
assembly
Throttle position sensor
Fuel injection pipe
Fuel injector
Throttle body
Q’ty
1
1
1
1
Remarks
Remove the parts in the order listed.
CAUTION:
Do not disassemble the throttle body.
For assembly, reverse the disassembly
procedure.
7 - 25
THROTTLE BODY ASSEMBLY
FI
EAS00912
1
2
R/L R/B
CHECKING THE FUEL INJECTOR
1. Check:
• fuel injector
Damage → Replace.
2. Check:
• fuel injector resistance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the injection wire harness coupler from the fuel injector.
b. Connect the pocket tester (Ω × 1) to the fuel
injector terminal as shown.
Positive tester probe → red/black 1
Negative tester probe → red/blue 2
c. Measure the fuel injector resistance.
Out of specification → Replace the fuel
injector.
Fuel injector resistance
12 Ω at 20 °C (68 °F)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00913
CHECKING THE THROTTLE BODY
1. Check:
• throttle body
Cracks/damage → Replace the throttle
body.
2. Check:
• fuel passages
Obstructions → Clean.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the throttle body in a petroleumbased solvent
CAUTION:
Do not use any caustic carburetor cleaning
solution.
b. Blow out all of the passages with compressed air.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 26
THROTTLE BODY ASSEMBLY
INSTALLING THE THROTTLE BODY
ASSEMBLY
1. Install:
• throttle body joint clamps
b
b
NOTE:
Align the projection a on the throttle body joint
with the slot b in the throttle body joint clamp.
a
a
2. Install:
• throttle body joint
a
NOTE:
Align the projection a on the cylinder head
with the slot b in the throttle body joint.
b
a
FI
b
3. Install:
• throttle body assembly
NOTE:
Align the projection a on the throttle body
assembly with the slot b throttle body joint.
4.
•
5.
•
6.
•
7.
•
7 - 27
Install:
throttle cable
Adjust:
throttle lever free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
Adjust:
engine idling speed
Refer to “ADJUSTING THE ENGINE
IDLING SPEED” in chapter 3.
Check:
throttle position sensor
Refer to “CHECKING AND ADJUSTING
THE THROTTLE POSITION SENSOR”.
THROTTLE BODY ASSEMBLY
FI
EAS00819
CHECKING THE FUEL PUMP
WARNING
_
Gasoline is extremely flammable and under
certain circumstances there can be a danger of an explosion or fire. Be extremely
careful and note the following points:
• Stop the engine before refueling.
• Do not smoke, and keep away from open
flames, sparks, or any other source of
fire.
• If you do accidentally spill gasoline, wipe
it up immediately with dry rags.
• If gasoline touches the engine when it is
hot, a fire may occur. Therefore, make
sure the engine is completely cool before
performing the following test.
1. Check:
• fuel pump operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the fuel tank.
b. Put the end of the fuel hose into an open
container.
c. Connect a battery (DC 12 V) to the fuel
pump coupler as shown.
Positive battery lead → red/blue 1
Negative battery lead → black 2
G/W B
d. If fuel flows out of the fuel hose, the fuel
pump is OK. If fuel does not flow, replace
the fuel pump.
B R/L
12
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
+
7 - 28
THROTTLE BODY ASSEMBLY
1
4
2
3
FI
2. Check:
• fuel pressure
5
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the fuel tank.
Refer to “FUEL TANK” in chapter 3.
b. Connect the pressure gauge 1 to the
adapter 2.
c. Connect the fuel pressure adapter to the
fuel pump and fuel hose 3.
Pressure gauge
90890-03153
Fuel pressure adapter
90890-03176
d. Connect the fuel pump coupler 4 and fuel
sender coupler 5 to the fuel pump.
Refer to “FUEL TANK” in chapter 3.
e. Set the main switch to “ON” and the engine
stop switch to “ ”.
f. Start the engine.
g. Measure the fuel pressure.
Fuel pressure
324 kPa (3.24 kg/cm2, 46.1 psi)
Out of specification → Replace the fuel
pump.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00502
CHECKING AND ADJUSTING THE
THROTTLE POSITION SENSOR
NOTE:
Before adjusting the throttle position sensor,
the engine idling speed should be properly
adjusted.
7 - 29
THROTTLE BODY ASSEMBLY
2 3 1
FI
1. Check:
• throttle position sensor
(removed from the throttle body)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
B/L Y L
a. Disconnect the throttle position sensor coupler from the throttle position sensor.
b. Remove the throttle position sensor from
the throttle body.
c. Connect the pocket tester (Ω × 1k) to the
throttle position sensor.
Positive tester probe → blue terminal 1
Negative tester probe →
black/blue terminal 2
d. Measure the maximum throttle position sensor resistance.
Out of specification → Replace the throttle
position sensor.
Maximum throttle position sensor
resistance
4.0 ~ 6.0 kΩ at 20 °C (68 °F)
(blue — black/blue)
e. Connect the pocket tester (Ω × 1k) to the
throttle position sensor.
Positive tester probe →
yellow terminal 3
Negative tester probe →
black/blue terminal 2
f. While slowly opening the throttle, check that
the throttle position sensor resistance is
within the specified range.
The resistance does not change or it
changes abruptly → Replace the throttle
position sensor.
The slot is worn or broken → Replace the
throttle position sensor.
NOTE:
Check mainly that the resistance changes
gradually when turning the throttle, since the
readings (from closed to wide-open throttle)
may differ slightly from those specified.
7 - 30
THROTTLE BODY ASSEMBLY
FI
Throttle position sensor resistance
0 ~ 5 ± 1.0 kΩ at 20 °C (68 °F)
(yellow — black/blue)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
• throttle position sensor angle
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
2
B/L Y L
a. Connecting the throttle position sensor coupler to the wire harness.
b. Connect the digital circuit tester to the throttle position sensor.
Positive tester probe →
yellow terminal 1
Negative tester probe →
black/blue terminal 2
Digital circuit tester
90890-03174
c. Measure the throttle position sensor voltage.
d. Adjust the throttle position sensor angle so
the measured voltage is within the specified
range.
Throttle position sensor voltage
0.63 ~ 0.73 V
(yellow — black/blue)
e. After adjusting the throttle position sensor
angle, tighten the throttle position sensor
screws.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 31
AIR INDUCTION SYSTEM
FI
EAS00507
AIR INDUCTION SYSTEM
AIR INJECTION
The air induction system burns unburned
exhaust gases by injecting fresh air (secondary air) into the exhaust port, reducing the
emission of hydrocarbons.
When there is negative pressure at the
exhaust port, the reed valve opens, allowing
secondary air to flow into the exhaust port. The
required temperature for burning the unburned
exhaust gases is approximately 600 to 700 °C
(1,112 to 1,292 °F).
EAS00917
È
1
AIR CUT-OFF VALVE
The air cut-off valve is controlled by the signals
from the ECU in accordance with the combustion conditions. Ordinarily, the air cut-off valve
opens to allow the air to flow during idle and
closes to cut-off the flow when the vehicle is
being driven. However, if the coolant temperature is below the specified value, the air cut-off
valve remains open and allows the air to flow
into the exhaust pipe until the temperature
becomes higher than the specified value.
È From the air filter case
É To the cylinder head
1 The air cut-off valve is closed.
2 The air cut-off valve is open.
É
È
2
7 - 32
AIR INDUCTION SYSTEM
FI
EAS00509
AIR INDUCTION SYSTEM DIAGRAMS
1 Air filter case
2 Reed valve
3 Air cut-off valve
4 Exhaust port
1
4
3
2
4
7 - 33
FI
AIR INDUCTION SYSTEM
AIR CUT-OFF VALVE ASSEMBLY
4
1
3
2
Order
1
2
3
4
Job/Part
Removing the air cut-off valve
assembly
Right side panel
Q’ty
Fuel tank right side cover
Air induction system solenoid coupler
Air cut-off valve outlet hose
Air-filter-to-air-cut-off-valve hose
Air cut-off valve assembly
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “COWLING AND COVER” in
chapter 3.
Refer to “FUEL TANK” in chapter 3.
Disconnect.
For installation, reverse the removal procedure.
7 - 34
AIR INDUCTION SYSTEM
FI
LT
LT
3
2
1
Order
1
2
3
Job/Part
Disassembling the air cut-off valve
assembly
Air cut-off valve cover
Reed valve assembly
Air cut-off valve
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1
For assembly, reverse the disassembly
procedure.
7 - 35
AIR INDUCTION SYSTEM
FI
EAS00918
CHECKING THE AIR INDUCTION SYSTEM
1. Check:
• hoses
Loose connections → Connect properly.
Cracks/damage → Replace.
• pipe
Cracks/damage → Replace.
Refer to “CYLINDER HEAD” in chapter 5.
2. Check:
• reed valve
• reed valve stopper
• reed valve seat
Cracks/damage → Replace the reed valve
assembly.
3. Check:
• air cut-off valve
Cracks/damage → Replace.
4. Check
• Air induction system solenoid
2
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Br/R R/W
a. Remove the air induction system solenoid
coupler from the air cut-off valve assembly.
b. Connect the pocket tester (Ω × 1) to the air
induction system solenoid terminal as
shown.
Positive tester probe → brown/red 1
Negative tester probe → red/white 2
c. Measure the air induction system solenoid
resistance.
Out of specification → Replace the air cutoff valve assembly.
Air induction system solenoid
resistance
18 ~ 22 Ω at 20 °C (68 °F)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 36
–
ELEC
+
8
ELEC
CHAPTER 8
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS........................................................................ 8-1
CHECKING SWITCH CONTINUITY................................................................8-3
CHECKING THE SWITCHES..........................................................................8-5
CHECKING THE BULBS AND BULB SOCKETS .......................................... 8-7
TYPES OF BULBS .................................................................................... 8-7
CHECKING THE CONDITION OF THE BULBS ....................................... 8-8
CHECKING THE CONDITION OF THE BULB SOCKETS .......................8-9
CHECKING THE LEDs..............................................................................8-9
IGNITION SYSTEM ....................................................................................... 8-12
CIRCUIT DIAGRAM ................................................................................ 8-12
TROUBLESHOOTING ............................................................................8-13
ELECTRIC STARTING SYSTEM .................................................................. 8-17
CIRCUIT DIAGRAM ................................................................................ 8-17
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ........................ 8-18
TROUBLESHOOTING ............................................................................8-19
STARTER MOTOR........................................................................................ 8-23
CHECKING THE STARTER MOTOR .....................................................8-25
ASSEMBLING THE STARTER MOTOR................................................. 8-27
CHARGING SYSTEM....................................................................................8-28
CIRCUIT DIAGRAM ................................................................................ 8-28
TROUBLESHOOTING ............................................................................8-29
LIGHTING SYSTEM ......................................................................................8-31
CIRCUIT DIAGRAM ................................................................................ 8-31
TROUBLESHOOTING ............................................................................8-32
CHECKING THE LIGHTING SYSTEM....................................................8-34
SIGNALING SYSTEM ...................................................................................8-37
CIRCUIT DIAGRAM ............................................................................... 8-37
TROUBLESHOOTING ............................................................................8-39
CHECKING THE SIGNALING SYSTEM ................................................. 8-40
COOLING SYSTEM....................................................................................... 8-49
CIRCUIT DIAGRAM ................................................................................ 8-49
TROUBLESHOOTING ............................................................................8-50
–
+
ELEC
IMMOBILIZER SYSTEM................................................................................ 8-52
CIRCUIT DIAGRAM ................................................................................ 8-52
GENERAL INFORMATION ..................................................................... 8-53
KEY CODE REGISTRATION .................................................................. 8-54
SELF-DIAGNOSIS MALFUNCTION CODES..........................................8-57
TROUBLESHOOTING ............................................................................8-58
CHECKING THE IMMOBILIZER SYSTEM ............................................. 8-59
SELF-DIAGNOSIS......................................................................................... 8-63
TROUBLESHOOTING ............................................................................8-64
–
+
–
ELEC
ELECTRICAL COMPONENTS
+
EAS00729
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS
1 Spark plug
2 Spark plug cap
3 Ignition coil
4 Intake air pressure sensor
5 Front brake light switch
6 Right handlebar switch
7 Immobilizer unit
8 Main switch
9 Fuel pump
0 Clutch switch
A Left handlebar switch
B Throttle position sensor
C Coolant temperature sensor
D Fuel injector
9
6
3
E Lean angle cut-off switch
F Turn signal/hazard relay
G Headlight relay
H Radiator fan motor relay
I Relay unit
J Battery
K Fuse box 1
0
A
B
8
7
D
4
C
E
5
2
H
G
1
I
Z
F
[
J
K
L
Y
W
M
X
N
V
O
T
U
S
8-1
R
Q
P
L Fuse box 2
M Starter relay
N Main fuse
O Rectifier/regulator
P ECU
Q Intake air temperature sensor
R Sidestand switch
S Neutral switch
T Crankshaft position sensor
U Stator coil
V Rear brake light switch
3
+
W Speed sensor
X Starter motor
Y Radiator fan motor
Z Horn
[ Air induction system solenoid
9
6
–
ELEC
ELECTRICAL COMPONENTS
0
A
B
8
7
D
4
C
E
5
2
H
G
1
I
Z
F
[
J
K
L
Y
W
M
X
N
V
O
T
U
S
8-2
R
Q
P
CHECKING SWITCH CONTINUITY
ELEC
–
+
EAS00730
CHECKING SWITCH CONTINUITY
Check each switch for continuity with the
pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch.
CAUTION:
_
Never insert the tester probes into the coupler terminal slots 1. Always insert the
probes from the opposite end of the coupler, taking care not to loosen or damage
the leads.
Pocket tester
90890-03112
NOTE:
• Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back
and forth between the switch positions a few
times.
_
b
R Br/L Br/R
a
ON
OFF
P
R
Br/L
The terminal connections for switches (e.g.,
main switch, engine stop switch) are shown in
an illustration similar to the one on the left.
The switch positions a are shown in the far
left column and the switch lead colors b are
shown in the top row in the switch illustration.
Br/R
NOTE:
“
” indicates a continuity of electricity
between switch terminals (i.e., a closed circuit
at the respective switch position).
_
The example illustration on the left shows
that:
There is continuity between red, brown/blue,
and brown/red when the switch is set to “ON”.
There is continuity between red and brown/red
when the switch is set to “P”.
8-3
CHECKING SWITCH CONTINUITY
8-4
ELEC
–
+
CHECKING THE SWITCHES
ELEC
–
+
EAS00731
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear → Repair or replace.
Improperly connected → Properly connect.
Incorrect continuity reading → Replace the switch.
1
R Br/L Br/R
8
Br/R
ON
OFF
P
R/W R/B
L/W R/W
B R/B
R
Br/L
9
B L/W
-
2
Br P
-
3
R/Y Br/W L/B Y Dg
Br G P
Ch
0
R/Y Y
-
B
B
(BLACK)
4
Y L/B G
5
Ch Br/W Dg
A
B
B
(BLUE)
6
Ch Br/W Dg
-
B
7
Sb
B
B
C
D
B
8-5
B
CHECKING THE SWITCHES
1 Main switch
2 Horn switch
3 Pass switch
4 Dimmer switch
5 Turn signal switch
6 Hazard switch
7 Clutch switch
8 Engine stop switch
9 Start switch
0 Front brake light switch
A Sidestand switch
B Neutral switch
C Rear brake light switch
D Fuses
8-6
ELEC
–
+
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
EAS00732
CHECKING THE BULBS AND
BULB SOCKETS
Check each bulb and bulb socket for damage
or wear, proper connections, and also for continuity between the terminals.
Damage/wear → Repair or replace the
bulb, bulb socket or both.
Improperly connected → Properly connect.
No continuity → Repair or replace the bulb,
bulb socket or both.
TYPES OF BULBS
The bulbs used on this motorcycle are shown
in the illustration on the left.
• Bulbs A and B are used for the headlights
and usually use a bulb holder that must be
detached before removing the bulb. The
majority of these types of bulbs can be
removed from their respective socket by
turning them counterclockwise.
• Bulb C is used for turn signal and tail/brake
lights and can be removed from the socket
by pushing and turning the bulb counterclockwise.
• Bulbs D and E are used for meter and indicator lights and can be removed from their
respective socket by carefully pulling them
out.
8-7
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:
• bulb
WARNING
_
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
CAUTION:
_
• Be sure to hold the socket firmly when
removing the bulb. Never pull the lead,
otherwise it may be pulled out of the terminal in the coupler.
• Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the
life of the bulb, and the luminous flux will
be adversely affected. If the headlight
bulb gets soiled, thoroughly clean it with
a cloth moistened with alcohol or lacquer
thinner.
2. Check:
• bulb (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
90890-03112
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
_
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 2, and check the continuity.
b. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 3, and check the continuity.
c. If either of the readings indicate no continuity, replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-8
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the
bulb sockets.
1. Check:
• bulb socket (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
90890-03112
NOTE:
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
_
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the
respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any
of the readings indicate no continuity,
replace the bulb socket.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE LEDs
The following procedures applies to all of the
LEDs.
1. Check:
• LED (for proper operation)
Improper operation → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the meter assembly coupler
(meter assembly end).
8-9
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
b. Connect two jumper leads 1 from the battery terminals to the respective coupler terminal as shown.
Turn signal indicator
light (left)
Positive battery terminal → chocolate
Negative battery terminal → black/white
Turn signal indicator
light (right)
Positive battery terminal → dark green
Negative battery terminal → black/white
High beam indicator
light
Positive battery terminal → red/white or
yellow
Negative battery terminal →black/white
Neutral indicator
light
Positive battery terminal → red/white
Negative battery terminal → black/white
or light green
Back light
Positive battery terminal → red/white or
red/green
Negative battery terminal → black/white
Coolant temperature
warning light
Engine trouble warning light
Fuel level warning
light
Positive battery terminal → red/white
Negative battery terminal → black/white
Immobilizer system indicator LED
Connect the pocket tester (kΩ × 1) to the
meter coupler.
8 - 10
Positive tester probe →
black/white
Negative tester probe →
green/blue
Continuity
Positive tester probe →
green/blue
Negative tester probe →
black/white
No continuity
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
WARNING
_
• A wire that is used as a jumper lead must
have at least the same capacity of the battery lead, otherwise the jumper lead may
burn.
• This check is likely to produce sparks,
therefore, make sure no flammable gas or
fluid is in the vicinity.
CAUTION:
Do not connect the jumper lead (battery
voltage) to the terminals (green/blue and
black/white) for the immobilizer system
indicator light (LED). The LED could be
damaged.
c. When the jumper leads are connected to
the terminals, the respective LED should
illuminate.
Does not light → Replace the meter assembly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8 - 11
W
G/W L/Y
W
Gy G/W
8 - 12
3
Br/L
Br/R
R
L
2
B BB R/G
W
W
W
B1 BB
B
B
B
R
5
BB4 BB1
BB
B1
BB3
BB4
BB2
BB1
R/G
G/L
R/W
BB
Y/L
B
W W W
BB3 BB2
B
B
{
B2 B1
È
z
R/W Lg Y/L
R/G B2 B
Y/L G/L R/W
Br/L
Br/R
Br/L
Sb
R
W
W
W
R
Br/R
1
B
R
1 Crankshaft position
sensor
4 Main switch
6 Battery
7 Main fuse
D Engine stop switch
L ECU
M Ignition coil
N Spark plug
V Lean angle cut-off
switch
v Ignition fuse
ON
OFF
P
4
W W
W W
Gy G/W
Br/R
Br/L
Br/L
Br/L
y
x
w
v
R
R
R
Br
R/L
Br
R
B
A
0
Br
R/G
Br
B
L/R B
t
(BLACK)
B
R
B
B
B
B
B
L G/Y
B
r
R
R
L
Br
L/W
B
L/R Y
G/Y
R/W L/W
R/W
R/W
(BLACK)
B
L
q
B L/R
R/W
Br
9
L
R R
7
8
R
R
Y
B
Br Y
B
s
u
B L Y
Y L/R B
Br
B R/B
R/B B
B
P
Y
G
B
-
-
P
Br
(BLACK)
Br Y
B
Y/B
B
Ch
Y
B
Ch
Ch
A
Ch
-
h
b
m
Lg
L/W
L/W
Y/B
R/L
R/Y
n
G
Br/W
Br/W
c
Br
Br/W
B
Dg
G
A
Dg
o
-
i
B B
(BLUE)
J
B
G
K
p
B/Y
L/Y
B
j
B
B
B
R/L G/W
L/Y B/Y
R/L B
(DARK GREEN)
G/W B
R/B L/B R/L
L/W L/R R/W L/G L/Y Sb B/Y Lg
(BLUE)
L/G B
Br L/W
Lg
Br
Ch
B
L/G
Sb L/Y L/G
I
G/L
G
Ch
Y
R/W
R/G
G/W
W
Ch R/G Y
G G/L R/W
Y R/G Ch
R/W G/L Dg
Y
G/W Y/L
B/W Lg
Y/L G/W
Lg B/W
Z
[
\
]
_
a
X
Y/L
B/W
Lg
Y/B
G/Y
Y/L
L/R
B/Y
L/B
R
Gy
L/W
R/L
B/W
L
B
Y/G
P/W
Y
L
W
B/L
G/R
Br/W
Br/R
R/B
O
Br/W
G/R
O
P
(GRAY)
(BLACK)
L
Y/G
B/L
L
P/W
B/L
B/L
B/L
R/W
R/L
V
U
T
G/R B/L
Br/W B/L
Br/R R/W
R/LR/B
M
N
L
Y
B/L
R
(BLACK)
Q
(DARK BLUE)
Br/R
R/B
O
R/B
L Br/R R R/B O
L/W Y/L Y/G
W Gy B/W
B
B/Y L/B G/R Br/W P/W Y B/L L/R G/Y Y/B R/L
L Y/G B/L
(BLACK)
B/L P/W L
(BLACK)
L Y B/L
L
W
B/L
S
L
W
B/L
P O/R
B/W
–
B
A
B
l
Y G
Y Lg
A A
Y G
R/L
L/W
g
R/Y
R/L
Y
Br
R/W B/Y R/LL/R
L/B
H
(BLACK)
B
f
B
B
F
e
-
E
L/B
R/Y Br/W L/B Y Dg
Ch
Br G P
d
R
R/B
k
D
G Y L/W Br/W R/L
Ch
P Lg Br
L/W R/W
R L/B
C
G
L/W R/B
L/W
Br
L/R G Ch
B Y Dg
ELEC
B
L/R
L/R
A
L/R
B
6
R
R
A
MAIN HARNESS SUB-WIRE HARNESS
Ch Lg L/R
G Y B
IGNITION SYSTEM
+
EAS00734
IGNITION SYSTEM
CIRCUIT DIAGRAM
IGNITION SYSTEM
EAS00736
ELEC
–
+
EAS00739
TROUBLESHOOTING
2. Battery
The ignition system fails to operate (no
spark or intermittent spark).
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main and ignition fuses
2. battery
3. spark plug
4. ignition spark gap
5. spark plug cap resistance
6. ignition coil resistance
7. crankshaft position sensor resistance
8. main switch
9. engine stop switch
10.lean angle cut-off switch
11.wiring connections (of the entire ignition
system)
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
YES
NO
• Clean the battery
terminals.
• Recharge or
replace the battery.
EAS00740
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. battery cover
3. side panels (left and right)
4. fuel tank side covers (left and right)
5. fuel tank
• Troubleshoot with the following special
tool(s).
_
3. Spark plug
Pocket tester
90890-03112
Ignition checker
90890-06754
• Check the condition of the spark plug.
• Check the spark plug type.
• Measure the spark plug gap.
Refer to “CHECKING THE SPARK PLUG”
in chapter 3.
Standard spark plug
CR7E (NGK)
Spark plug gap
0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
• Is the spark plug in good condition, is it of
the correct type, and is its gap within specification?
YES
EAS00738
NO
1. Main and ignition fuses
• Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and ignition fuses OK?
YES
NO
Replace the fuse(s).
8 - 13
Re-gap or replace
the spark plug.
IGNITION SYSTEM
EAS00742
ELEC
–
+
EAS00744
4. Ignition spark gap
5. Spark plug cap resistance
• Disconnect the spark plug cap 1 from the
spark plug.
• Connect the ignition checker 2 as shown.
• Set the main switch to “ON”.
• Measure the ignition spark gap a.
• Crank the engine by pushing the start
switch and gradually increase the spark
gap until a misfire occurs.
• Remove the spark plug cap from the spark
plug lead.
• Connect the pocket tester (Ω × 1k) to the
spark plug cap as shown.
• Measure the spark plug cap resistance.
Spark plug cap resistance
10.0 kΩ at 20 °C (68 °F)
• Is the spark plug cap OK?
Minimum ignition spark gap
6.0 mm (0.24 in)
• Is there a spark and is the spark gap within
specification?
YES
NO
YES
NO
The ignition system
is OK.
8 - 14
Replace the
plug cap.
spark
IGNITION SYSTEM
EAS00746
ELEC
–
+
EAS00748
7. Crankshaft position sensor resistance
6. Ignition coil resistance
• Disconnect the crankshaft position sensor
coupler from the wire harness.
• Connect the pocket tester (Ω × 100) to the
crankshaft position sensor terminal as
shown.
• Disconnect the ignition coil connectors
from the ignition coil terminals.
• Connect the pocket tester (Ω × 1) to the
ignition coil as shown.
Positive tester probe → red/black
Negative tester probe → orange
Positive tester probe → blue/yellow 1
Negative tester probe → green/white 2
G/W L/Y
2
• Measure the primary coil resistance.
1
• Measure the crankshaft position sensor
resistance.
Primary coil resistance
3.4 ~ 4.6 Ω at 20 °C (68 °F)
Crankshaft position sensor resistance
192 ~ 288 Ω at 20 °C (68 °F)
(between blue/yellow and green/
white)
• Connect the pocket tester (Ω × 1k) to the
ignition coil as shown.
Negative tester probe → spark plug lead 1
Positive tester probe → red/black 2
• Is the crankshaft position sensor OK?
YES
NO
Replace the crankshaft position sensor.
EAS00749
8. Main switch
• Measure the secondary coil resistance.
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
Secondary coil resistance
10.4 ~ 15.6 kΩ at 20 °C (68 °F)
• Is the ignition coil OK?
YES
YES
NO
NO
Replace the ignition
coil.
8 - 15
Replace the main
switch/immobilizer
unit.
IGNITION SYSTEM
EAS00750
ELEC
–
+
EAS00754
9. Engine stop switch
11.Wiring
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
• Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the ignition system’s wiring properly
connected and without defects?
NO
YES
YES
Replace the right
handlebar switch.
Replace the ECU.
10.Lean angle cut-off switch
• Connect the pocket tester (DC 20 V) to the
lean angle cut-off switch terminals as
shown.
Positive tester probe → yellow/green 1
Negative tester probe → black/blue 2
Lean angle cut-off switch voltage
Less than 65° a → 0.4 ~ 1.4 V
More than 65° b → 3.7 ~ 4.4 V
ON
a
a
ON
b
• Is the lean angle cut-off switch OK?
YES
NO
Replace the lean
angle cut-off switch.
8 - 16
NO
Properly connect or
repair the ignition
system’s wiring.
8 - 17
3
Br/L
Br/R
R
L
2
B BB R/G
W
W
W
B1 BB
B
B
B
R
5
BB4 BB1
BB
B1
BB3
BB4
BB2
BB1
R/G
G/L
R/W
BB
Y/L
B
W W W
BB3 BB2
B
B
{
B2 B1
È
z
R/W Lg Y/L
R/G B2 B
Y/L G/L R/W
Br/L
Br/R
Br/L
Sb
R
W
W
W
R
Br/R
1
3 Neutral switch
4 Main switch
6 Battery
7 Main fuse
8 Starter relay
9 Starter motor
D Engine stop switch
ON
OFF
P
4
W
G/W L/Y
W
W W
Gy G/W
W W
Gy G/W
B
R
y
x
w
v
Br
R/L
Br
R
B
A
0
Br
R/G
Br
B
B
R
B
B
B
R
B
B
(BLACK)
L G/Y
R/W
Br
B
R
R
L
Br
L/W
G/Y
R/W L/W
R/W
R/W
(BLACK)
B
L
q
9
L
R R
7
8
R
R
E Start switch
G Relay unit
H Starting circuit cut-off
r
relay
J Sidestand switch
j Clutch switch
v Ignition fuse
Br/R
Br/L
Br/L
Br/L
R
R
R
B
6
R
Br
s
B R/B
D
G Y L/W Br/W R/L
Ch
P Lg Br
L/W R/W
R L/B
R/B B
C
-
(BLACK)
Br Y
f
Br
B
(BLACK)
B
F
-
B
L/B
e
-
E
L/W
R/L
Y/B
g
R/Y
R/L
Y
Br
L/W
L/W
Y/B
R/L
R/Y
R/W B/Y R/LL/R
L/B
H
-
h
b
B
Br
Br/W
Br/W
Br
Br/W
-
i
B B
(BLUE)
J
K
B/Y
L/Y
B
j
B
B
B
R/L G/W
L/Y B/Y
R/L B
(DARK GREEN)
G/W B
R/B L/B R/L
L/W L/R R/W L/G L/Y Sb B/Y Lg
(BLUE)
L/G B
Br L/W
Lg
c
L/G
Sb L/Y L/G
I
L/R G Ch
B Y Dg
G/L
G
Ch
Y
R/W
R/G
G/W
W
Ch R/G Y
G G/L R/W
Y R/G Ch
R/W G/L Dg
Y
G/W Y/L
B/W Lg
Y/L G/W
Lg B/W
Z
[
\
]
_
a
X
Y
B
L
ELEC
R/Y Br/W L/B Y Dg
Ch
Br G P
d
R
R/B
G
L/W R/B
L/W
Br
A
MAIN HARNESS SUB-WIRE HARNESS
Ch Lg L/R
G Y B
ELECTRIC STARTING SYSTEM
–
+
EAS00755
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
ELECTRIC STARTING SYSTEM
ELEC
–
+
EAS00756
STARTING CIRCUIT CUT-OFF SYSTEM
OPERATION
If the engine stop switch is set to “ ” and the
main switch is set to “ON” (both switches are
closed), the starter motor can only operate if at
least one of the following conditions is met:
• The transmission is in neutral (the neutral
switch is closed).
• The clutch lever is pulled to the handlebar
(the clutch switch is closed) and the sidestand is up (the sidestand switch is closed).
The starting circuit cut-off relay prevents the
starter motor from operating when neither of
these conditions has been met. In this
instance, the starting circuit cut-off relay is
open so current cannot reach the starter
motor. When at least one of the above conditions has been met the starting circuit cut-off
relay is closed and the engine can be started
by pushing the start switch.
C
M
B
1
2
3
4
5
WHEN THE TRANSMISSION IS
IN NEUTRAL
WHEN THE SIDESTAND IS UP
AND THE CLUTCH LEVER IS
PULLED TO THE HANDLEBAR
6
A
7
8
9
0
1 Battery
2 Main fuse
3 Main switch
4 Ignition fuse
5 Engine stop switch
6 Relay unit (starting circuit cut-off relay)
7 Relay unit (diode)
8 Clutch switch
9 Sidestand switch
0 Neutral switch
A Start switch
B Starter relay
C Starter motor
8 - 18
ELECTRIC STARTING SYSTEM
EAS00757
ELEC
–
+
EAS00739
TROUBLESHOOTING
2. Battery
The starter motor fails to turn.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main and ignition fuses
2. battery
3. starter motor
4. relay unit (starting circuit cut-off relay)
5. relay unit (diode)
6. starter relay
7. main switch
8. engine stop switch
9. neutral switch
10.sidestand switch
11.clutch switch
12.start switch
13.wiring connections
(of the entire starting system)
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
NO
YES
• Clean the battery
terminals.
• Recharge or
replace the battery.
EAS00758
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. battery cover
3. side panels (left and right)
4. fuel tank side covers (left and right)
5. fuel tank
• Troubleshoot with the following special
tool(s).
3. Starter motor
_
• Connect the positive battery terminal 1
and starter motor lead 2 with a jumper
lead 3.
Pocket tester
90890-03112
WARNING
EAS00738
_
1. Main and ignition fuses
• Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and ignition fuses OK?
YES
• 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.
• This check is likely to produce sparks,
therefore make sure nothing flammable
is in the vicinity.
NO
• Does the starter motor turn?
YES
Replace the fuse(s).
NO
Repair or replace the
starter motor.
8 - 19
ELECTRIC STARTING SYSTEM
EAS00759
4. Relay unit (starting circuit cut-off relay)
• Disconnect the relay unit from the wire
harness.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the relay unit terminals as
shown.
Positive battery terminal → red/black 1
Negative battery terminal → black/yellow 2
–
ELEC
+
Positive tester probe →
sky blue 1
Negative tester probe →
black/yellow 2
Positive tester probe →
sky blue 1
Continuity
Negative tester probe →
blue/yellow 3
Positive tester probe →
blue/green 4
Negative tester probe →
blue/yellow 3
Positive tester probe → blue/white 3
Negative tester probe → blue/black 4
Positive tester probe →
black/yellow 2
Negative tester probe →
sky blue 1
Positive tester probe →
blue/yellow 3 No contiNegative tester probe →
nuity
sky blue 1
• Does the starting circuit cut-off relay have
continuity between blue/white and blue/
black?
NO
YES
Replace
unit.
the
Positive tester probe →
blue/yellow 3
Negative tester probe →
blue/green 4
relay
EAS00760
5. Relay unit (diode)
• Disconnect the relay unit from the wire
harness.
• Connect the pocket tester (Ω × 1) to the
relay unit terminals as shown.
• Measure the diode for continuity as follows.
NOTE:
When you switch the tester’s positive and
negative probes, the readings in the above
chart will be reversed.
_
• Are the testing readings correct?
NO
YES
Replace
unit.
8 - 20
the
relay
ELECTRIC STARTING SYSTEM
EAS00761
–
ELEC
+
EAS00750
6. Starter relay
8. Engine stop switch
• Disconnect the starter relay coupler from
the coupler.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the starter relay coupler as
shown.
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
YES
Positive battery terminal → red/white 1
Negative battery terminal → blue/white 2
NO
Replace the right
handlebar switch.
Positive tester probe → red 3
Negative tester probe → black 4
EAS00751
3
9. Neutral switch
R
R
• Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the neutral switch OK?
R
R/W L/W
B
2 1
YES
NO
4
Replace the neutral
switch.
• Does the starter relay have continuity
between red and black?
YES
EAS00752
NO
10.Sidestand switch
• Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the sidestand switch OK?
Replace the starter
relay.
EAS00749
YES
7. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES
NO
Replace the
stand switch.
side-
EAS00763
NO
11.Clutch switch
Replace the main
switch/immobilizer
unit.
• Check the clutch switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the clutch switch OK?
YES
NO
Replace the clutch
switch.
8 - 21
ELECTRIC STARTING SYSTEM
EAS00764
12.Start switch
• Check the start switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the start switch OK?
YES
NO
Replace the right
handlebar switch.
EAS00766
13. Wiring
• Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the starting system’s wiring properly
connected and without defects?
YES
The starting system
circuit is OK.
NO
Replace the relay
unit and properly
connect or repair the
starting system’s wiring.
8 - 22
ELEC
–
+
STARTER MOTOR
ELEC
–
+
EAS00767
STARTER MOTOR
3
.
T
R.
5 Nm (0.5 m • kg, 3.6 ft • Ib)
2
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
5
1
4
6
7
Order
1
2
3
4
5
6
7
Job/Part
Removing the starter motor
Crankcase-to-crankcase-breatherchamber hose
Air-filter-to-crankcase-breather-chamber hose
Crankcase breather chamber
Starter motor lead
Negative battery lead
Crankcase breather chamber bracket
Starter motor
Q’ty
1
Remarks
Remove the parts in the order listed.
Disconnect.
1
Disconnect.
1
1
1
1
1
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
8 - 23
STARTER MOTOR
Order
1
2
3
4
5
6
7
8
9
0
A
B
C
Job/Part
Disassembling the starter motor
Circlip
Starter motor gear
O-ring
Front bracket
Shims
Lock washer
Rear bracket
Shims
Brush holder assembly
Brush
Armature coil
O-ring
Starter motor yoke
Q’ty
ELEC
–
+
Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
1
1
1
2
1
For assembly, reverse the disassembly
procedure.
8 - 24
STARTER MOTOR
ELEC
–
+
EAS00770
CHECKING THE STARTER MOTOR
1. Check:
• commutator
Dirt → Clean with 600 grit sandpaper.
2. Measure:
• commutator diameter a
Out of specification → Replace the starter
motor.
Commutator wear limit
27 mm (1.06 in)
3. Measure:
• mica undercut a
Out of specification → Scrape the mica to
the proper measurement with a hacksaw
blade that has been grounded to fit the
commutator.
Mica undercut
0.70 mm (0.028 in)
NOTE:
The mica of the commutator must be undercut
to ensure proper operation of the commutator.
_
4. Measure:
• armature assembly resistances (commutator and insulation)
Out of specification → Replace the starter
motor.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the armature assembly resistances with the pocket tester.
8 - 25
STARTER MOTOR
ELEC
–
+
Pocket tester
90890-03112
Armature coil
Commutator resistance 1
0.025 ~ 0.035 Ω at 20 °C (68 °F)
Insulation resistance 2
Above 1 MΩ at 20 °C (68 °F)
b. If any resistance is out of specification,
replace the starter motor.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
• brush length a.
Out of specification → Replace the brushes
as a set.
Brush length wear limit
5.00 mm (0.20 in)
6. Measure:
• brush spring force
Out of specification → Replace the brush
springs as a set.
Brush spring force
7.65 ~ 10.01 N
(780 ~ 1,021 gf, 27.51 ~ 36.01 oz)
7. Check:
• gear teeth
Damage/wear → Replace the gear.
8. Check:
• bearing
• oil seal
Damage/wear → Replace the defective
part(s).
8 - 26
STARTER MOTOR
ELEC
–
+
EAS00772
ASSEMBLING THE STARTER MOTOR
1. Install:
• brush seat 1
NOTE:
Align the tab a on the brush seat with the slot
b in the starter motor yoke.
_
2. Install:
• lock washer
NOTE:
Align the tabs a on the lock washer with the
groves in the front bracket.
a
3. Install:
• rear bracket
a
NOTE:
Align the slot a in the rear bracket with the tab
b on the brush seat.
b
2
1
3
b
Install:
starter motor yoke 1
front bracket 2
rear bracket 3
O-rings 4 New
bolts
5 Nm (0.5 m · kg, 3.6 ft · lb)
T.
R.
b
4.
•
•
•
•
•
NOTE:
Align the alignment marks a on the starter
motor yoke with the alignment marks b on the
front and rear brackets.
_
New 4
a
4 New
5. Install:
• starter motor gear
• circlip
8 - 27
W
G/W L/Y
W
Gy G/W
8 - 28
ON
OFF
P
4
W W
W W
3
Br/L
Br/R
R
L
2
B BB R/G
W
W
W
R
R/G
G/L
R/W
BB
Y/L
B
W W W
B
5
B
R
R
R
R
B
A
0
Br
R/G
Br
B
B
6
B
B
B
R
R
R R
9
B
B
R
R
L/W
R/W
R/W L/W
2 A.C. magneto
5 Rectifier/regulator
6 Battery
7 Main fuse
7
8
R
R
R L/B
R/B B
ELEC
–
z
R/W Lg Y/L
R/G B2 B
Y/L G/L R/W
R
Br/R
Br/L
Sb
R
W
W
W
Br/L
Br/R
1
Gy G/W
CHARGING SYSTEM
+
EAS00773
CHARGING SYSTEM
CIRCUIT DIAGRAM
CHARGING SYSTEM
EAS00774
ELEC
–
+
EAS00738
TROUBLESHOOTING
1. Main fuse
The battery is not being charged.
• Check the main fuse for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main fuse OK?
Check:
1. main fuse
2. battery
3. charging voltage
4. stator coil resistance
5. wiring connections
(of the entire charging system)
YES
Replace the fuse.
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. battery cover
3. left side panel
• Troubleshoot with the following special
tool(s).
_
NO
EAS00739
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
Pocket tester
90890-03112
YES
NO
• Clean the battery
terminals.
• Recharge or
replace the battery.
8 - 29
CHARGING SYSTEM
EAS00775
ELEC
–
+
EAS00776
4. Stator coil resistance
3. Charging voltage
• Disconnect the A.C. magneto coupler from
the wire harness.
• Connect the pocket tester (Ω × 1) to the
charging coils as shown.
• Connect the pocket tester (DC 20 V) to the
battery as shown.
Positive tester probe →
positive battery terminal
Negative tester probe →
negative battery terminal
Positive tester probe → white 1
Negative tester probe → white 2
Positive tester probe → white 1
Negative tester probe → white 3
• Start the engine and let it run at approximately 5,000 r/min.
• Measure the charging voltage.
• Measure the stator coil resistances.
Charging voltage
14.0 V at 5,000 r/min
Stator coil resistance
0.224 ~ 0.336 Ω at 20 °C (68 °F)
(between white and white)
NOTE:
Make sure the battery is fully charged.
_
• Is the stator coil OK?
YES
• Is the charging voltage within specification?
NO
NO
Replace the crankshaft position sensor/
stator assembly.
YES
The charging circuit
is OK.
EAS00779
5. Wiring
• Check the wiring connections of the entire
charging system.
Refer to “CIRCUIT DIAGRAM”.
• Is the charging system’s wiring properly
connected and without defects?
YES
Replace the rectifier/
regulator.
8 - 30
NO
Properly connect or
repair the charging
system’s wiring.
W
G/W L/Y
W
Gy G/W
ON
OFF
P
4
W W
W W
3
Br/L
Br/R
R
L
2
B BB R/G
W
W
W
B1 BB
B
B
B
R
5
BB4 BB1
BB
B1
BB3
BB4
BB2
BB1
R/G
G/L
R/W
BB
Y/L
B
W W W
BB3 BB2
B
B
{
B2 B1
È
z
R/W Lg Y/L
R/G B2 B
Y/L G/L R/W
R
Br/R
Br/L
Sb
R
W
W
W
Br/L
Br/R
1
Gy G/W
B
R
8 - 31
Br/R
Br/L
Br/L
Br/L
y
x
w
v
R
R
R
Br
R/L
Br
R
B
A
0
Br
R/G
Br
B
L/R B
t
(BLACK)
B
R
B
B
B
B
B
L G/Y
B
r
R
R
L
Br
L/W
B
L/R Y
G/Y
R/W L/W
R/W
R/W
(BLACK)
B
L
q
B L/R
R/W
Br
9
L
R R
7
8
R
R
Y
B
Br Y
B
s
u
B L Y
Y L/R B
Br
B R/B
B
P
Y
G
B
-
(BLACK)
Br Y
f
P
Br
B
B
Y/B
B
Ch
Y
B
Ch
Ch
A
Ch
-
h
b
m
Lg
L/W
L/W
Y/B
R/L
R/Y
n
G
Br/W
Br/W
c
Br
Br/W
B
Dg
G
A
Dg
o
-
i
B B
(BLUE)
J
B
G
K
p
B/Y
L/Y
B
j
B
B
B
R/L G/W
L/Y B/Y
R/L B
(DARK GREEN)
G/W B
R/B L/B R/L
L/W L/R R/W L/G L/Y Sb B/Y Lg
(BLUE)
L/G B
Br L/W
Lg
Br
Ch
B
L/G
Sb L/Y L/G
I
G/L
G
Ch
Y
R/W
R/G
G/W
W
Ch R/G Y
G G/L R/W
Y R/G Ch
R/W G/L Dg
Y
G/W Y/L
B/W Lg
Y/L G/W
Lg B/W
Z
[
\
]
_
a
X
Y/L
B/W
Lg
Y/B
G/Y
Y/L
L/R
B/Y
L/B
R
Gy
L/W
R/L
B/W
L
B
Br/W
G/R
O
P
(GRAY)
(BLACK)
L
Y/G
B/L
L
P/W
B/L
B/L
B/L
R/W
R/L
V
U
T
G/R B/L
Br/W B/L
Br/R R/W
R/LR/B
M
N
L
Y
B/L
R
(BLACK)
Q
(DARK BLUE)
Br/R
R/B
O
R/B
L Y/G B/L
(BLACK)
B/L P/W L
(BLACK)
L Y B/L
L
W
B/L
S
L
W
B/L
P O/R
B/W
4 Main switch
6 Battery
7 Main fuse
L ECU
] High beam indicator light
b Headlight relay
f Pass switch
g Dimmer switch
l Headlight
t Auxiliary light
u Tail/brake light
x Headlight fuse
y Parking lighting
fuse
Y/G
P/W
Y
L
W
B/L
G/R
Br/W
Br/R
R/B
O
L Br/R R R/B O
L/W Y/L Y/G
W Gy B/W
B
B/Y L/B G/R Br/W P/W Y B/L L/R G/Y Y/B R/L
–
B
A
B
l
Y G
Y Lg
A A
Y G
R/L
L/W
g
R/Y
R/L
Y
Br
R/W B/Y R/LL/R
L/B
H
(BLACK)
B
F
-
B
L/B
e
-
E
R/Y Br/W L/B Y Dg
Br G P
Ch
d
R
R/B
k
D
G Y L/W Br/W R/L
Ch
P Lg Br
L/W R/W
R L/B
R/B B
C
G
L/W R/B
L/W
Br
L/R G Ch
B Y Dg
ELEC
B
L/R
L/R
A
L/R
B
6
R
R
A
MAIN HARNESS SUB-WIRE HARNESS
Ch Lg L/R
G Y B
LIGHTING SYSTEM
+
EAS00780
LIGHTING SYSTEM
CIRCUIT DIAGRAM
LIGHTING SYSTEM
EAS00781
ELEC
–
+
EAS00738
TROUBLESHOOTING
1. Main, headlight, and parking lighting fuses
Any of the following fail to come on:
headlight, high beam indicator light, tail/
brake light, on auxiliary light.
• Check the main, headlight, and parking
lighting fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, headlight, and parking lighting fuses OK?
Check:
1. main, headlight, and parking lighting fuses
2. battery
3. main switch
4. dimmer switch
5. pass switch
6. headlight relay
7. wiring connections
(of the entire lighting system)
YES
NO
Replace the fuse(s).
EAS00739
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. battery cover
3. side panels (left and right)
4. fuel tank side covers (left and right)
5. fuel tank
6. headlight assembly
• Troubleshoot with the following special
tool(s).
2. Battery
_
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
YES
NO
• Clean the battery
terminals.
• Recharge or
replace the battery.
Pocket tester
90890-03112
EAS00749
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES
NO
Replace the main
switch/immobilizer
unit.
8 - 32
LIGHTING SYSTEM
EAS00784
ELEC
–
+
6. Headlight relay
4. Dimmer switch
• Disconnect the headlight relay from the wire
harness.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the headlight relay terminal as
shown.
• Check the headlight relay for continuity.
• Check the dimmer switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the dimmer switch OK?
YES
NO
The dimmer switch is
faulty. Replace the
left handlebar switch.
EAS00786
Battery positive terminal → red/yellow 1
Battery negative terminal →
yellow/black 2
Positive tester probe → red/blue 3
Negative tester probe → blue/white 4
5. Pass switch
3
4
• Check the pass switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the pass switch OK?
YES
+
2
NO
1
Y/B
R/Y
L/W
The pass switch is
faulty. Replace the
left handlebar switch.
R/L
• Does the headlight relay have continuity
between red/blue and blue/white?
YES
NO
Replace the headlight relay.
EAS00787
7. Wiring
• Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the lighting system’s wiring properly
connected and without defects?
YES
Check the condition
of each of the lighting
system’s circuits.
Refer to “CHECKING THE LIGHTING
SYSTEM”.
8 - 33
NO
Properly connect or
repair the lighting
system’s wiring.
ELEC
LIGHTING SYSTEM
EAS00788
CHECKING THE LIGHTING SYSTEM
1. The headlight and the high beam indicator
light fail to come on.
1. Headlight bulb and socket
• Check the headlight bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the headlight bulb and socket OK?
–
+
Headlight
Positive tester probe →
yellow 1 or green 2
Negative tester probe → black 3
High beam indicator light
Positive tester probe → yellow 4
Negative tester probe → black/white 5
Meter assembly couplers (wire harness end)
NO
YES
Ch R/G Y
Dg G/L R/W
Replace the headlight bulb, socket or
both.
G/W Y/L
5
B/W Lg
G G/L R/W
B/W Lg
Ch R/G Y
G/W Y/L
4
2. High beam indicator light LED
•
•
•
•
Set the main switch to “ON”.
Start the engine.
Set the dimmer switch to “
” or “
”.
Measure the voltage (DC 12 V) of yellow
1 or green 2 at the headlight coupler
(wire harness end) and yellow 4 at the
meter assembly coupler (wire harness
end).
• Is the voltage within specification?
• Check the LED of the high beam indicator
light.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Is the high beam indicator light LED OK?
NO
YES
Replace the meter
assembly.
YES
This circuit is OK.
3. Voltage
• Connect the pocket tester (DC 20 V) to the
headlight and meter assembly couplers as
shown.
È When the dimmer switch is set to “
É When the dimmer switch is set to “
”
”
Headlight coupler (wire harness end)
È
2
DC 20 V
G
+
É
1
Y
B
3
8 - 34
NO
The wiring circuit
from the main switch
to the headlight coupler or meter assembly couplers is faulty
and
must
be
repaired.
ELEC
LIGHTING SYSTEM
EAS00790
EAS00791
2. The tail/brake light fails to come on.
3. The auxiliary light fails to come on.
1. Tail/brake light bulb and socket
1. Auxiliary light bulb and socket
–
+
• Check the auxiliary light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the auxiliary light bulb and socket OK?
• Check the tail/brake light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the tail/brake light bulb and socket
OK?
NO
YES
NO
YES
Replace the auxiliary
light bulb, socket or
both.
Replace the tail/
brake
light
bulb,
socket or both.
2. Voltage
2. Voltage
• Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness end)
as shown.
Positive tester probe → blue/red 1
Negative tester probe → black 2
• Connect the pocket tester (DC 20 V) to the
auxiliary light coupler (wire harness end)
as shown.
Positive tester probe → blue/red 1
Negative tester probe → black 2
1
2
B
L
Y
B
L/R
Y
B
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of blue/red
1 at the auxiliary light connectors (wire
harness end).
• Is the voltage within specification?
YES
NO
NO
This circuit is OK.
This circuit is OK.
L/R
B
2
1
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of blue/red
1 at the tail/brake light coupler (wire harness end).
• Is the voltage within specification?
YES
L/R
The wiring circuit
from the main switch
to the tail/brake light
coupler is faulty and
must be repaired.
8 - 35
The wiring circuit
from the main switch
to the auxiliary light
coupler is faulty and
must be repaired.
LIGHTING SYSTEM
8 - 36
ELEC
–
+
W
G/W L/Y
W
Gy G/W
ON
OFF
P
4
W W
W W
3
Br/L
Br/R
R
L
2
B BB R/G
W
W
W
B1 BB
B
B
B
R
5
BB4 BB1
BB
B1
BB3
BB4
BB2
BB1
R/G
G/L
R/W
BB
Y/L
B
W W W
BB3 BB2
B
B
{
B2 B1
È
z
R/W Lg Y/L
R/G B2 B
Y/L G/L R/W
Br/L
Br/R
Br/L
Sb
R
W
W
W
R
Br/R
1
Gy G/W
B
R
8 - 37
Br/R
Br/L
Br/L
Br/L
y
x
w
v
R
R
R
Br
R/L
Br
R
B
A
0
Br
R/G
Br
B
L/R B
t
(BLACK)
B
R
B
B
B
B
B
L G/Y
B
r
R
R
L
Br
L/W
B
L/R Y
G/Y
R/W L/W
R/W
R/W
(BLACK)
B
L
q
B L/R
R/W
Br
9
L
R R
7
8
R
R
Y
B
Br Y
B
s
u
B L Y
Y L/R B
Br
B R/B
R/B B
B
P
Y
G
B
-
-
P
Br
(BLACK)
Br Y
B
Y/B
B
Ch
Y
B
Ch
Ch
A
Ch
-
h
b
m
Lg
L/W
L/W
Y/B
R/L
R/Y
n
G
Br/W
Br/W
c
Br
Br/W
B
Dg
G
A
Dg
o
-
i
B B
(BLUE)
J
B
G
K
p
B/Y
L/Y
B
j
B
B
B
R/L G/W
L/Y B/Y
R/L B
(DARK GREEN)
G/W B
R/B L/B R/L
L/W L/R R/W L/G L/Y Sb B/Y Lg
(BLUE)
L/G B
Br L/W
Lg
Br
Ch
B
L/G
Sb L/Y L/G
I
G/L
G
Ch
Y
R/W
R/G
G/W
W
Ch R/G Y
G G/L R/W
Y R/G Ch
R/W G/L Dg
Y
G/W Y/L
B/W Lg
Y/L G/W
Lg B/W
Z
[
\
]
_
a
X
Y/L
B/W
Lg
Y/B
G/Y
Y/L
L/R
B/Y
L/B
R
Gy
L/W
R/L
B/W
L
B
Y/G
P/W
Y
L
W
B/L
G/R
Br/W
Br/R
R/B
O
Br/W
G/R
O
P
(GRAY)
(BLACK)
L
Y/G
B/L
L
P/W
B/L
B/L
B/L
R/W
R/L
V
U
T
G/R B/L
Br/W B/L
Br/R R/W
R/LR/B
M
N
L
Y
B/L
R
(BLACK)
Q
(DARK BLUE)
Br/R
R/B
O
R/B
L Br/R R R/B O
L/W Y/L Y/G
W Gy B/W
B
B/Y L/B G/R Br/W P/W Y B/L L/R G/Y Y/B R/L
L Y/G B/L
(BLACK)
B/L P/W L
(BLACK)
L Y B/L
L
W
B/L
S
L
W
B/L
P O/R
B/W
–
B
A
B
l
Y G
Y Lg
A A
Y G
R/L
L/W
g
R/Y
R/L
Y
Br
R/W B/Y R/LL/R
L/B
H
(BLACK)
B
f
B
B
F
e
-
E
L/B
R/Y Br/W L/B Y Dg
Br G P
Ch
d
R
R/B
k
D
G Y L/W Br/W R/L
Ch
P Lg Br
L/W R/W
R L/B
C
G
L/W R/B
L/W
Br
L/R G Ch
B Y Dg
ELEC
B
L/R
L/R
A
L/R
B
6
R
R
A
MAIN HARNESS SUB-WIRE HARNESS
Ch Lg L/R
G Y B
SIGNALING SYSTEM
+
EAS00793
SIGNALING SYSTEM
CIRCUIT DIAGRAM
SIGNALING SYSTEM
3 Neutral switch
4 Main switch
6 Battery
7 Main fuse
A Backup fuse (immobilizer unit, meter assembly)
F Front brake light switch
G Relay unit
K Fuel pump
L ECU
R Coolant temperature sensor
S Speed sensor
X Neutral indicator light
Y Multifunction meter
Z Coolant temperature warning light
[ Engine trouble warning light
\ Fuel level warning light
_ Turn signal indicator light
c Turn signal/hazard relay
e Horn switch
h Turn signal switch
i Hazard switch
k Horn
m Rear turn signal light (left)
n Front turn signal light (left)
o Front turn signal light (right)
p Rear turn signal light (right)
s Rear brake light switch
u Tail/brake light
v Ignition fuse
w Signaling system fuse
y Parking lighting fuse
8 - 38
ELEC
–
+
SIGNALING SYSTEM
EAS00794
ELEC
–
+
EAS00739
TROUBLESHOOTING
2. Battery
• Any of the following fail to come on: a
turn signal light, an indicator light, a
warning light, or the tail/brake light
• The horn fails to sound.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
Check:
1. main, ignition, signaling system, parking
lighting, and backup fuses
2. battery
3. main switch
4. wiring connections
(of the entire signaling system)
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. battery cover
3. side panels (left and right)
4. fuel tank side covers (left and right)
5. fuel tank
6. rear cover (left and right)
7. headlight assembly
• Troubleshoot with the following special
tool(s).
• Is the battery OK?
YES
NO
• Clean the battery
terminals.
• Recharge or
replace the battery.
_
EAS00749
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES
NO
Replace the main
switch/immobilizer
unit.
Pocket tester
90890-03112
EAS00795
EAS00738
1. Main, ignition, signaling system, parking
lighting, and backup fuses
• Check the main, ignition, signaling system,
parking lighting, and backup fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, ignition, signaling system,
parking lighting, and backup fuses OK?
YES
NO
Replace the fuse(s).
4. Wiring
• Check the entire signal system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the signaling system’s wiring properly
connected and without defects?
YES
Check the condition
of each of the signaling system’s circuits.
Refer to “CHECKING THE SIGNALING SYSTEM”.
8 - 39
NO
Properly connect or
repair the signaling
system’s wiring.
SIGNALING SYSTEM
EAS00796
• Disconnect the black connector at the horn
terminal.
• Connect a jumper lead 1 to the horn terminal and ground the jumper lead.
• Set the main switch to “ON”.
• Push the horn switch.
• Does the horn sound?
1. Horn switch
• Check the horn switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the horn switch OK?
NO
P
Replace the left handlebar switch.
1
2. Voltage
• Connect the pocket tester (DC 20 V) to the
horn connector at the horn terminal as
shown.
YES
Positive tester probe → pink 1
Negative tester probe → ground
The horn is OK.
P
B
1
• Set the main switch to “ON”.
• Push the horn switch.
• Measure the voltage (DC 12 V) of pink at
the horn terminal.
• Is the voltage within specification?
YES
+
3. Horn
CHECKING THE SIGNALING SYSTEM
1. The horn fails to sound.
YES
–
ELEC
NO
The wiring circuit
from the main switch
to the horn connector
is faulty and must be
repaired.
8 - 40
NO
Replace the horn.
SIGNALING SYSTEM
EAS00797
+
• Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness end)
as shown.
1. Tail/brake light bulb and socket
• Check the tail/brake light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the tail/brake light bulb and socket
OK?
Positive tester probe → yellow 1
Negative tester probe → black 2
2
NO
B
L
Y
Replace the tail/
brake
light
bulb,
socket or both.
• Set the main switch to “ON”.
• Pull in the brake lever or push down on the
brake pedal.
• Measure the voltage (DC 12 V) of yellow
1 at the tail/brake light coupler (wire harness end).
• Is the voltage within specification?
• Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the brake light switch OK?
NO
YES
Replace the brake
light switch.
B
L/R
Y
1
2. Brake light switches
YES
–
3. Voltage
2. The tail/brake light fails to come on.
YES
ELEC
This circuit is OK.
8 - 41
NO
The wiring circuit
from the main switch
to the tail/brake light
coupler is faulty and
must be repaired.
SIGNALING SYSTEM
EAS00799
3. The turn signal light, turn signal indicator
light or both fail to blink.
–
+
4. Hazard switch
• Check the hazard switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the hazard switch OK?
1. Turn signal indicator light bulb and socket
• Check the turn signal light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the turn signal light bulb and socket
OK?
NO
YES
Replace the left handlebar switch.
5. Voltage
NO
YES
ELEC
Replace the turn signal light bulb, socket
or both.
• Connect the pocket tester (DC 20 V) to the
turn signal/hazard relay coupler (wire harness end) as shown.
Positive tester probe → brown 1
Negative tester probe → ground
2. Turn signal indicator light LED
• Check the LED of the turn signal indicator
light.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Is the turn signal indicator light LED OK?
YES
NO
Replace the meter
assembly.
3. Turn signal switch
• Check the turn signal switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the turn signal switch OK?
YES
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of brown
1 at the turn signal/hazard relay coupler
(wire harness end).
• Is the voltage within specification?
YES
NO
Replace the left handlebar switch.
8 - 42
NO
The wiring circuit
from the main switch
to the turn signal/
hazard relay coupler
is faulty and must be
repaired.
SIGNALING SYSTEM
È
6. Voltage
• Connect the pocket tester (DC 20 V) to the
turn signal/hazard relay coupler (wire harness end) as shown.
ELEC
–
Ch
G
+
É
Ch
Dg
1
2
1
3
Positive tester probe → brown/white 1
Negative tester probe → ground
Ê
3
• Set the main switch to “ON”.
• Set the turn signal switch to “
” or “
”.
• Measure the voltage (DC 12 V) of brown/
white 1 at the turn signal/hazard relay
coupler (wire harness end).
• Is the voltage within specification?
G/W Y/L
B/W Lg
G G/L R/W
B/W Lg
Ch R/G Y
G/W Y/L
1
• Set the main switch to “ON”.
• Set the turn signal switch to “
” or “
”.
• Measure the voltage (DC 12 V) of chocolate 1 and dark green 2 or green 3 at
the turn signal light connectors or meter
assembly coupler (wire harness end).
• Is the voltage within specification?
NO
YES
Ch R/G Y
Dg G/L R/W
The turn signal/hazard relay is faulty and
must be replaced.
YES
This circuit is OK.
7. Voltage
• Connect the pocket tester (DC 20 V) to the
turn signal light connector or meter assembly coupler (wire harness end) as shown.
È Front turn signal light
É Rear turn signal light
Ê Turn signal indicator light
Left turn signal light
Positive tester probe → chocolate 1
Negative tester probe → ground
Right turn signal light
Positive tester probe →
dark green 2 or green 3
Negative tester probe → ground
8 - 43
NO
The wiring circuit
from the turn signal
switch to the turn signal light connectors
or meter assembly
coupler is faulty and
must be repaired.
SIGNALING SYSTEM
EAS00800
–
ELEC
+
EAS00753
4. The neutral indicator light fails to come on.
3. Relay unit (diode)
1. Neutral indicator light LED
• Check the LED of the neutral indicator
light.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Is the neutral indicator light LED OK?
YES
NO
Replace the meter
assembly.
2. Neutral switch
• Disconnect the relay unit from the wire
harness.
• Connect the pocket tester (Ω × 1) to the
relay unit terminals as shown.
• Check the diode for continuity.
Positive tester probe →
sky blue 1
Continuity
Negative tester probe →
light green 2
Positive tester probe →
light green 2 No continuity
Negative tester probe →
sky blue 1
• Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the neutral switch OK?
YES
NO
Replace the neutral
switch.
NOTE:
When you switch the positive and negative
tester probes, the readings in the above chart
will be reversed.
@
• Are the tester readings correct?
NO
YES
Replace
unit.
8 - 44
the
relay
SIGNALING SYSTEM
ELEC
–
+
EAS00803
4. Voltage
5. The fuel level warning light fails to come on.
• Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness
end) as shown.
1. Fuel level warning light LED
• Check the LED of the fuel level warning
light.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Is the fuel level warning light LED OK?
Positive tester probe → light green 1
Negative tester probe → ground
NO
YES
Ch R/G Y
G/W Y/L
Dg G/L R/W
B/W Lg
G G/L R/W
B/W Lg
Ch R/G Y
G/W Y/L
Replace the meter
assembly.
1
2. Fuel sender (thermistor)
• Set the main switch to “ON”.
• Shift the transmission to neutral.
• Measure the voltage (DC 12 V) of light
green 1 and ground at the meter assembly coupler.
• Is the voltage within specification?
YES
This circuit is OK.
• Disconnect the fuel sender coupler from
the fuel pump.
• Connect the pocket tester (kΩ × 1) to the
fuel sender as shown.
Positive tester probe → green/white 1
Negative tester probe → black 2
NO
The wiring circuit
from the main switch
to the meter assembly couplers is faulty
and
must
be
repaired.
• Check the fuel sender for continuity.
• Is the fuel sender OK?
YES
NO
Replace the fuel
pump assembly.
8 - 45
ELEC
SIGNALING SYSTEM
–
+
6. The speedometer fails to come on.
3. Voltage
• Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness
end) as shown.
Positive tester probe → green/white 1
Negative tester probe → black/white 2
Ch R/G Y
Dg G/L R/W
1. Voltage
• Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness
end) as shown.
Positive tester probe → yellow/blue 1
Negative tester probe → black/white 2
G/W Y/L
2
G G/L R/W
B/W Lg
Ch R/G Y
Dg G/L R/W
B/W Lg
Ch R/G Y
G/W Y/L
1
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of green/
white 1 and black/white 2 at the meter
assembly coupler.
• Is the voltage within specification?
YES
This circuit is OK.
NO
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and
must
be
repaired.
8 - 46
G/W Y/L
2
B/W Lg
G G/L R/W
B/W Lg
Ch R/G Y
G/W Y/L
1
• Set the main switch to “ON”.
• Elevate the rear wheel and slowly rotate it.
• Measure the voltage (DC 5 V) of yellow/
blue 1 at the meter assembly coupler
(wire harness end).
• Is the voltage within specification?
YES
NO
Replace the meter
assembly.
ELEC
SIGNALING SYSTEM
2. Speed sensor
• Connect the pocket tester (DC 20 V) to the
speed sensor coupler as shown.
1. Coolant temperature warning light LED
• Check the LED of the coolant temperature
warning light.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Is the coolant temperature warning light
LED OK?
1
B/W
L
W
Replace the meter
assembly.
• Set the main switch to “ON”.
• Elevate the rear wheel and slowly rotate it.
• Measure the voltage (DC 5 V) of pink and
black/white. With each full rotation of the
rear wheel, the voltage reading should
cycle from 0.6 V to 4.8 V to 0.6 V to 4.8 V.
• Does the voltage reading cycle correctly?
This circuit is OK.
NO
YES
B/L
2
YES
+
7. The coolant temperature warning light fails
to come on.
Positive tester probe → pink 1
Negative tester probe → black/white 2
P O/R
–
2. Voltage
• Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness
end) as shown.
Positive tester probe → yellow/blue 1
Negative tester probe → black/white 2
NO
Replace the speed
sensor.
Ch R/G Y
Dg G/L R/W
G/W Y/L
2
B/W Lg
G G/L R/W
B/W Lg
Ch R/G Y
G/W Y/L
1
• Set the main switch to “ON”.
• Measure the voltage (DC 5 V) of yellow/
blue 1 on the meter assembly coupler
(wire harness end).
• Is the voltage within specification?
YES
NO
The wiring circuit
from the ECU to the
meter assembly coupler is faulty and
must be repaired.
8 - 47
ELEC
SIGNALING SYSTEM
–
+
EAS00812
3. Coolant temperature sensor
• Remove the coolant temperature sensor
from the engine.
• Connect the pocket tester (Ω × 10) to the
coolant temperature sensor 1 as shown.
• Immerse the coolant temperature sensor
in a container filled with coolant 2.
3
NOTE:
Make sure that the coolant temperature sensor terminals do not get wet.
_
1
• Place a thermometer 3 in the coolant.
• Slowly heat the coolant, and then let it cool
to the specified temperature indicated in
the table.
• Check the coolant temperature sensor for
continuity at the temperatures indicated in
the table.
Test
step
Coolant
temperature
Resistance
1
20 °C (68 °F)
2.32 ~ 2.59 kΩ
2
80 °C (176 °F)
0.310 ~ 0.326 kΩ
3
110 °C (230 °F)
0.140 ~ 0.145 kΩ
2
• Does the coolant temperature sensor
operate properly?
YES
NO
Replace the coolant
temperature sensor.
WARNING
EAS00813
_
• Handle the coolant temperature sensor
with special care.
• Never subject the coolant temperature
sensor to strong shocks. If the coolant
temperature sensor is dropped, replace
it.
4. Wiring
• Check the entire cooling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the cooling system’s wiring properly
connected and without defects?
YES
T.
Coolant temperature sensor
18 Nm (1.8 m · kg, 13 ft · lb)
NO
R.
Replace the ECU.
8 - 48
Properly connect or
repair the cooling
system’s wiring.
W
G/W L/Y
W
Gy G/W
8 - 49
R
L
Br/L
Br/R
3
2
B BB R/G
W
W
W
B1 BB
B
B
B
R
5
BB4 BB1
BB
B1
BB3
BB4
BB2
BB1
R/G
G/L
R/W
BB
Y/L
B
W W W
BB3 BB2
B
B
{
B2 B1
È
z
R/W Lg Y/L
R/G B2 B
Y/L G/L R/W
Br/L
Br/R
Br/L
Sb
R
W
W
W
R
Br/R
1
B
R
4 Main switch
6 Battery
7 Main fuse
B Radiator fan motor fuse
L ECU
q Radiator fan motor relay
r Radiator fan motor
v Ignition fuse
ON
OFF
P
4
W W
W W
Gy G/W
Br/R
Br/L
Br/L
Br/L
y
x
w
v
R
R
R
Br
R/L
Br
R
B
A
0
Br
R/G
Br
B
L/R
t
B
r
L
L G/Y
R/W
Br
L
Br
L/W
R/W
R/W
(BLACK)
B
L
q
9
B
B
R
R
L/R Y
G/Y
R/W L/W
Y
B
Br Y
B
s
Y L/R B
Br
B R/B
D
G Y L/W Br/W R/L
Ch
P Lg Br
L/W R/W
R L/B
R/B B
C
Br Y
Y
G
B
-
(BLACK)
f
P
Br
B
Y G
Y Lg
A A
Y G
L/W
R/L
Y/B
g
R/Y
R/L
Y
Br
Ch
Y
I
Ch
Ch
A
Ch
-
h
b
n
G
Br/W
Br/W
c
Br
Br/W
Dg
G
A
Dg
o
-
i
B B
(BLUE)
J
G
K
p
B/Y
L/Y
B
j
B
B
B
R/L G/W
L/Y B/Y
R/L B
(DARK GREEN)
G/W B
R/B L/B R/L
L/W L/R R/W L/G L/Y Sb B/Y Lg
(BLUE)
L/G B
Br L/W
Lg
Br
Ch
B
L/G
Sb L/Y L/G
m
Lg
L/W
L/W
Y/B
R/L
R/Y
R/W B/Y R/LL/R
L/B
H
(BLACK)
B
F
-
B
L/B
e
-
E
R/Y Br/W L/B Y Dg
Ch
Br G P
d
R
R/B
G
L/W R/B
L/W
Br
G/L
G
Ch
Y
R/W
R/G
G/W
W
Ch R/G Y
G G/L R/W
Y R/G Ch
R/W G/L Dg
Y
G/W Y/L
B/W Lg
Y/L G/W
Lg B/W
Z
[
\
]
_
a
X
Y/L
B/W
Lg
Y/B
G/Y
Y/L
L/R
B/Y
L/B
R
Gy
L/W
R/L
B/W
L
B
Y/G
P/W
Y
L
W
B/L
G/R
Br/W
Br/R
R/B
O
Br/W
G/R
O
P
(GRAY)
(BLACK)
R
(BLACK)
Q
(DARK BLUE
Br/R
R/B
O
R/B
L/W Y/L Y/G
W Gy B/W
L Br/R R R/B O
B/Y L/B G/R Br/W P/W Y B/L L/R G/Y Y/B R/L
B
–
L/R
(BLACK)
B
R
B
B
B
R R
7
8
R
R
L/R G Ch
B Y Dg
ELEC
A
L/R
B
6
R
R
A
MAIN HARNESS SUB-WIRE HARNESS
Ch Lg L/R
G Y B
COOLING SYSTEM
+
EAS00807
COOLING SYSTEM
CIRCUIT DIAGRAM
COOLING SYSTEM
EAS00808
ELEC
–
+
EAS00739
TROUBLESHOOTING
2. Battery
The radiator fan motor fails to turn.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main, radiator fan motor, and ignition fuses
2. battery
3. main switch
4. radiator fan motor
5. radiator fan motor relay
6. wiring connections
(the entire cooling system)
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
YES
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. battery cover
3. side panels (left and right)
4. fuel tank side covers (left and right)
5. fuel tank
• Troubleshoot with the following special
tool(s).
• Clean the battery
terminals.
• Recharge or
replace the battery.
_
EAS00749
3. Main switch
Pocket tester
90890-03112
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES
EAS00738
1. Main, radiator fan motor, and ignition fuses
• Check the main, radiator fan motor, and
ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, radiator fan motor, and ignition fuses OK?
YES
NO
NO
Replace the fuse(s).
8 - 50
NO
Replace the main
switch/immobilizer
unit.
COOLING SYSTEM
EAS00809
ELEC
–
+
5. Radiator fan motor relay
4. Radiator fan motor
• Disconnect the radiator fan motor coupler
from the wire harness.
• Connect the battery (DC 12 V) as shown.
• Disconnect the radiator fan motor relay
from the wire harness.
• Connect the pocket tester (Ω × 1) and battery (DC 12 V) to the radiator fan motor terminal as shown.
• Check the radiator fan motor for continuity.
Battery positive terminal → red/white 1
Battery negative terminal →
green/yellow 2
Positive tester probe → brown 3
Negative tester probe → blue 4
3
Positive battery lead → red 1
Negative battery lead → black 2
4
• Does the radiator fan motor turn?
YES
+
2
NO
1
G/Y
R/W
L
Br
The
radiator
fan
motor is faulty and
must be replaced.
• Does the radiator fan motor relay have continuity between brown and blue?
YES
NO
Replace the radiator
fan motor relay.
EAS00813
6. Wiring
• Check the entire cooling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the cooling system’s wiring properly
connected and without defects?
YES
Replace the ECU.
8 - 51
NO
Properly connect or
repair the cooling
system’s wiring.
W
G/W L/Y
W
Gy G/W
8 - 52
3
Br/L
Br/R
R
L
2
B BB R/G
W
W
W
B1 BB
B
B
B
R
5
BB4 BB1
BB
B1
BB3
BB4
BB2
BB1
R/G
G/L
R/W
BB
Y/L
B
W W W
BB3 BB2
B
B
{
B2 B1
È
z
R/W Lg Y/L
R/G B2 B
Y/L G/L R/W
Br/L
Br/R
Br/L
Sb
R
W
W
W
R
Br/R
1
B
R
Br/R
Br/L
Br/L
Br/L
y
x
w
v
R
R
R
Br
R/L
Br
R
B
A
0
4 Main switch
6 Battery
7 Main fuse
A Backup fuse (immobilizer unit,
meter assembly)
L ECU
Y Multifunction meter
a Immobilizer system indicator light
v Ignition fuse
z Immobilizer unit
ON
OFF
P
4
W W
W W
Gy G/W
Br
R/G
Br
B
t
B
r
L
L G/Y
R/W
Br
L
Br
L/W
R/W
R/W
(BLACK)
B
L
q
9
B
B
R
R
L/R Y
G/Y
R/W L/W
Y
B
Br Y
B
s
Y L/R B
Br
B R/B
D
G Y L/W Br/W R/L
Ch
P Lg Br
L/W R/W
R L/B
R/B B
C
Br Y
Y
G
B
-
(BLACK)
f
P
Br
B
Y G
Y Lg
A A
Y G
L/W
R/L
Y/B
g
R/Y
R/L
Y
Br
Ch
Y
I
Ch
Ch
A
Ch
-
h
b
n
G
Br/W
Br/W
c
Br
Br/W
Dg
G
A
Dg
o
-
i
B B
(BLUE)
J
G
K
p
B/Y
L/Y
B
j
B
B
B
R/L G/W
L/Y B/Y
R/L B
(DARK GREEN)
G/W B
R/B L/B R/L
L/W L/R R/W L/G L/Y Sb B/Y Lg
(BLUE)
L/G B
Br L/W
Lg
Br
Ch
B
L/G
Sb L/Y L/G
m
Lg
L/W
L/W
Y/B
R/L
R/Y
R/W B/Y R/LL/R
L/B
H
(BLACK)
B
F
-
B
L/B
e
-
E
R/Y Br/W L/B Y Dg
Ch
Br G P
d
R
R/B
G
L/W R/B
L/W
Br
G/L
G
Ch
Y
R/W
R/G
G/W
W
Ch R/G Y
G G/L R/W
Y R/G Ch
R/W G/L Dg
Y
G/W Y/L
B/W Lg
Y/L G/W
Lg B/W
Z
[
\
]
_
a
X
Y/L
B/W
Lg
Y/B
G/Y
Y/L
L/R
B/Y
L/B
R
Gy
L/W
R/L
B/W
L
B
Y/G
P/W
Y
L
W
B/L
G/R
Br/W
Br/R
R/B
O
Br/W
G/R
O
P
(GRAY)
(BLACK)
R
(BLACK)
Q
(DARK BLUE)
Br/R
R/B
O
R/B
L/W Y/L Y/G
W Gy B/W
L Br/R R R/B O
B/Y L/B G/R Br/W P/W Y B/L L/R G/Y Y/B R/L
B
–
L/R
L/R
(BLACK)
B
R
B
B
B
R R
7
8
R
R
L/R G Ch
B Y Dg
ELEC
A
L/R
B
6
R
R
A
MAIN HARNESS SUB-WIRE HARNESS
Ch Lg L/R
G Y B
IMMOBILIZER SYSTEM
+
EB805000
IMMOBILIZER SYSTEM
CIRCUIT DIAGRAM
IMMOBILIZER SYSTEM
ELEC
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+
GENERAL INFORMATION
This motorcycle is equipped with an immobilizer system to help prevent theft by registering codes in
standard keys. This system consists of the following:
• a code re-registering key (with a red bow)
• two standard keys (with a black bow) that can be re-registered with new codes
• a transponder (which is installed in each key bow)
• an immobilizer unit
• an ECU
• an immobilizer system indicator light
The key with the red bow is used to register codes in each standard key. Do not use the key with the
red bow for driving. It should only be used for registering new codes in the standard keys. The
immobilizer system cannot be operated with a new key until a code is registered in the key. If you
lose the code re-registering key, the ECU, main switch, and immobilizer unit must be replaced.
Therefore, always use a standard key for driving.
NOTE:
Each standard key is registered during production, therefore, registering the keys at purchase is not
necessary.
CAUTION:
• DO NOT LOSE THE CODE RE-REGISTERING KEY! If the code re-registering key is lost, registering new codes in the standard keys is impossible. The standard keys can still be used
to start the motorcycle, however, if code re-registering is required (i.e., if a new standard
key is made or all keys are lost) the entire immobilizer system must be replaced. Therefore,
it is highly recommended to use either standard key and keep the code re-registering key
in a safe place.
• Do not submerse the keys in water.
• Do not expose the keys to excessively high temperatures.
• Do not place the keys close to magnets (this includes, but not limited to, products such as
speakers, etc.).
• Do not place heavy items on the keys.
• Do not grind the keys or alter their shape.
• Do not disassemble the key bows.
• Do not put two keys of any immobilizer system on the same key ring.
• Keep the standard keys as well as other immobilizer system keys away from the code reregistering key.
• Keep other immobilizer system keys away from the main switch as they may cause signal
interference.
8 - 53
IMMOBILIZER SYSTEM
ELEC
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KEY CODE REGISTRATION
The replacement of parts or code registration of a code re-registering key or standard key may be
required in the following conditions.
NOTE:
Each standard key is registered during production, therefore, registering the keys at purchase is not
necessary.
Parts to replace: replacing a lost key or system malfunction
Part to replace
Main
switch
Immobilizer
unit
Standard
key
ECU
Accessory
lock*2 and
key
Standard key is lost
All keys have been lost
(including code re-registering key)
Required key
registration
New standard key
Code re-registering
key and standard keys
*1
ECU is defective
Code re-registering
key
Immobilizer unit is
defective
Code re-registering
key and standard keys
Main switch is defective
Code re-registering
key and standard keys
*1
Accessory lock*2 is
defective
*1
*2
Not required
Replace as a set with the main switch.
Accessory locks include the seat lock, fuel tank cap, and helmet holder.
Code re-registering key registration:
When the immobilizer unit or ECU is replaced, the code re-registering key must be re-registered.
To register a code re-registering key:
1. Set the main switch to “ON” with the code re-registering key.
NOTE:
Check that the immobilizer system indicator light comes on for 1 second, then goes off. When the
indicator light goes off, the code re-registering key has been registered.
2. Check that the engine can be started.
3. Register the standard keys. Refer to “Standard key registration:”.
8 - 54
IMMOBILIZER SYSTEM
ELEC
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+
Standard key registration:
A standard key should be registered or the other standard key should be re-registered when a registered standard key has been lost. The standard keys must be re-registered when the immobilizer
unit or ECU has been replaced and the code re-registering key has been re-registered.
NOTE:
Do not start the engine with a standard key that has not been registered.
If the main switch is set to “ON” with a standard key that has not been registered, the immobilizer
system indicator light flashes to indicate malfunction code 52. (Refer to “SELF-DIAGNOSIS MALFUNCTION CODES”.)
1. Check that the immobilizer system indicator light flashes to indicate the standby mode. To activate the standby mode, set the main switch to “OFF”. The standby mode will be activated after 30
seconds. The indicator light stops flashing after 24 hours and the standby mode ends.
Main
switch
Standby mode
ON
OFF
On
LED
Off
On
Standby
mode
Off
2. Using the code re-registering key, set the main switch to “ON”, then to “OFF”, and then remove
the key within 5 seconds.
3. Insert the standard key to be registered into the main switch, and then set the main switch to
“ON” within 5 seconds to activate the key registration mode.
NOTE:
If the two standard key codes are stored in memory, they will be erased when the key registration
mode is activated. When the key registration mode is activated, the immobilizer system indicator
light flashes rapidly (i.e., off for 0.5 second and on for 0.5 second).
4. While the indicator light is flashing, set the main switch to “OFF”, remove the key, and then insert
the second standard key to be registered into the main switch within 5 seconds.
NOTE:
If the immobilizer system indicator light stops flashing 5 seconds after the first standard key is registered, the registration mode is complete. If this occurs, the second standard key cannot be registered, therefore, repeat steps 2 to 4 to register both standard keys.
5. Set the main switch to “ON”.
NOTE:
When the indicator light goes off, registration is complete.
8 - 55
IMMOBILIZER SYSTEM
ELEC
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6. Check that the engine can be started with the two registered standard keys.
less than 5.0 s
Standard key
registration
ON
Main
switch OFF
On
LED
Off
less than 5.0 s
less than 5.0 s
less than 5.0 s
First standard
key
Registration mode
Code re-registering key
Registration of the
second standard key
is complete.
Second standard key
Immobilizer system indicator light stops flashing when the registration of the second standard key is complete.
Voiding a standard key code:
If a registered standard key has been lost and you want to disable its use, register a new standard
key or re-register the other standard key. For registration of a standard key, refer to “Standard key
registration:”.
Standard key registration erases the stored standard key codes from memory, therefore, the lost
standard key is disabled.
less than 5.0 s
Standard key
code voiding
method
Main
switch
LED
ON
OFF
On
less than 5.0 s
less than 5.0 s
Remaining
standard key
Registration mode
Code re-registering key
Off
If the immobilizer system indicator light
stops flashing 5 seconds after the first
standard key is registered, the second
standard key cannot be registered.
8 - 56
IMMOBILIZER SYSTEM
ELEC
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SELF-DIAGNOSIS MALFUNCTION CODES
When a system malfunction occurs, the malfunction code number is displayed on the multifunction
display and is indicated by the immobilizer system indicator light flash patterns.
Malfunction
code
Part
Symptom
Cause
Action
Immobilizer unit
Code cannot be transmitted
between the key and immobilizer unit.
1) Objects that interrupt radio
waves exist around the keys
or antennas.
2) Immobilizer unit malfunction
3) Key malfunction
1) Keep magnets, metal,
and other immobilizer
system keys away from
the keys and antennas.
2) Replace the main
switch/immobilizer unit.
3) Replace the key.
Immobilizer unit
Codes transmitted between
the key and immobilizer unit
do not match.
1) Signal received from other
transponder (failed to recognize code after ten consecutive attempts).
2) Signal received from unregistered standard key.
1) Place the immobilizer
unit at least 50 mm
away from the transponder of other motorcycles.
2) Register the standard
key.
Immobilizer unit
Code cannot be transmitted
between the ECU and
immobilizer unit.
1) Noise interference or disconnected lead/cable.
2) Obstruction due to radio wave
noise.
3) Disconnected communication
harness.
4) Immobilizer unit malfunction
5) ECU malfunction
1) Check the wire harness
and connector.
2) Replace the main
switch/immobilizer unit.
3) Replace the ECU.
Immobilizer unit
Codes transmitted between
ECU and immobilizer unit
do not match.
1) Noise interference or disconnected lead/cable.
2) Obstruction due to radio wave
noise.
3) Immobilizer unit malfunction
4) ECU malfunction
(When used parts from other
motorcycles are used, the
code re-registering key is not
registered in the ECU.)
1) Register the code reregistering key.
2) Replace the main
switch/immobilizer unit.
3) Replace the ECU.
Immobilizer unit
Key code registration malfunction
Same standard key was
attempted to be registered two
consecutive times.
Register a new standard
key.
ECU
Unidentified code is
received.
Noise interference or disconnected lead/cable.
1) Check the wire harness
and connector.
2) Replace the main
switch/immobilizer unit.
3) Replace the ECU.
51
52
53
54
55
56
Immobilizer system indicator light malfunction code indication
Digits of 10: on for 1 second and off for 1.5 seconds.
Digits of 1: on for 0.5 second and off for 0.5 second.
Example: multifunction code 52
Light on
Light off
8 - 57
IMMOBILIZER SYSTEM
ELEC
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EAS00739
EAS00781
TROUBLESHOOTING
2. Battery
The immobilizer system fails to operate.
(The immobilizer system indicator light
starts to flash in the self-diagnosis code
sequence.)
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Minimum open-circuit voltage
12.8 V or more at 20 °C
Check:
1. main, ignition, and backup fuses
2. battery
3. main switch
4. wiring
(of the entire immobilizer system)
• Is the battery OK?
YES
NOTE:
• Before troubleshooting, remove the following
part(s).
1. seat
2. battery cover
3. side panels (left and right)
4. fuel tank side covers (left and right)
5. fuel tank
• Troubleshoot with the following special
tool(s).
• Clean the battery
terminals.
• Recharge or
replace the battery.
EAS00749
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES
Pocket tester
90890-03112
NO
Replace the main
switch/immobilizer
unit.
EAS00738
1. Main, ignition, and backup fuses
• Check the main, ignition, and backup
fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, ignition, and backup fuses
OK?
YES
NO
EAS00787
4. Wiring
• Check the entire immobilizer system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the immobilizer system’s wiring properly
connected and without defects?
NO
YES
Replace the fuse(s).
Check the condition
of each of the immobilizer system’s circuits.
Refer to “CHECKING THE IMMOBILIZER SYSTEM”.
8 - 58
NO
Properly connect or
repair the immobilizer
system’s wiring.
IMMOBILIZER SYSTEM
ELEC
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CHECKING THE IMMOBILIZER SYSTEM
1. Immobilizer system indicator light does not
go on when the main switch is set to “ON”.
3. Voltage
1. Immobilizer system indicator light LED
Positive tester probe → red/green 1
Negative tester probe → black 2
• Check the LED of the immobilizer system
indicator light.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Is the immobilizer system indicator light
LED OK?
YES
+
• Connect the pocket tester (DC 20 V) to the
immobilizer unit coupler as shown.
2
B
1
BB R/G
Y/L G/L R/W
NO
Replace the meter
assembly.
2. Voltage
• Connect the pocket tester (DC 20 V) to the
meter assembly couplers as shown.
Positive tester probe → green/blue 1
Negative tester probe → black/white 2
R/G B2 B
R/W Lg Y/L
• Set the main switch to “ON”.
• Measure the voltage (12 V) between red/
green and black on the immobilizer unit
coupler.
• Is the voltage within specification?
YES
NO
The wiring circuit
from the battery to
the immobilizer unit
is faulty and must be
repaired.
• Set the main switch to “ON”.
• Measure the voltage (2.6 V) between
green/blue and black/white on the meter
assembly couplers.
• Is the voltage within specification?
YES
NO
Replace the meter
assembly.
8 - 59
IMMOBILIZER SYSTEM
–
+
5. Voltage
4. Voltage
• Connect the pocket tester (DC 20 V) to the
immobilizer unit coupler as shown.
• Connect the pocket tester (DC 20 V) to the
immobilizer unit coupler as shown.
Positive tester probe → green/blue 1
Negative tester probe → black 2
Positive tester probe → red/white 1
Negative tester probe → black 2
2
B
ELEC
2
BB R/G
Y/L G/L R/W
R/G B2 B
B
Y/L G/L R/W
R/W Lg Y/L
R/G B2 B
R/W Lg Y/L
1
1
• Set the main switch to “ON”.
• Measure the voltage (2.6 V) between
green/blue and black on the immobilizer
unit coupler.
• Is the voltage within specification?
• Set the main switch to “ON”.
• Measure the voltage (12 V) between red/
white and black on the immobilizer unit
coupler.
• Is the voltage within specification?
YES
BB R/G
NO
YES
The wiring circuit
from the main switch
to the immobilizer
unit is faulty and
must be repaired.
The wiring circuit
from the immobilizer
unit to the meter
assembly is faulty
and
must
be
repaired.
8 - 60
NO
Replace the immobilizer unit.
IMMOBILIZER SYSTEM
2. The multifunction display is not indicated.
1. Voltage
• Connect the pocket tester (DC 20 V) to the
meter assembly couplers as shown.
Ch R/G Y
Dg G/L R/W
3
2
G/W Y/L
B/W Lg
G G/L R/W
B/W Lg
Ch R/G Y
G/W Y/L
1
Positive tester probe →
red/green 1 and red/white 3
Negative tester probe → black/white 2
• Turn the main switch to “ON”.
• Measure the voltage (DC 12 V) meter
assembly couplers (wire harness end).
• Is the voltage within specification?
YES
Replace the meter
assembly.
NO
The wiring circuit
from the main switch
to the meter assembly couplers is faulty
and
must
be
repaired.
8 - 61
ELEC
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IMMOBILIZER SYSTEM
ELEC
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3. When the main switch is set to “ON”, the immobilizer system indicator light flashes after 1 second.
• Check if metal or other immobilizer system keys exists near the immobilizer unit. If found, remove
the metal or keys, and then check the condition again.
Set the main switch to “ON” with
another standard key and check the
immobilizer system indicator. The indicator goes on for about 1 second, then
goes off.
Correct
First standard key (transponder) is
defective.
Correct
Second standard
key
(transponder) is defective.
Malfunction
Set the main switch to “ON” with the
code re-registering key and check the
immobilizer system indicator.
Malfunction
Re-register
the
standard key.
Malfunction
Replace the
standard
key.
Check if a self-diagnosis code is displayed.
Displayed
Read the malfunction code and check
the corresponding part.
Refer to “SELF-DIAGNOSIS MALFUNCTION CODES”.
Malfunction
Yellow/blue lead is disconnected or
short-circuited. Repair or replace the
circuit.
Not displayed
Immobilizer unit or ECU malfunction
Check the signal lead (yellow/blue)
between the immobilizer unit and ECU
connector.
Correct
Replace the immobilizer unit or ECU.
8 - 62
SELF-DIAGNOSIS
ELEC
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EAS00834
SELF-DIAGNOSIS
The XT660R/XT660X features a self-diagnosing system for the following circuit:
• Fuel sender (thermistor)
If the circuit is defective, the condition code will be displayed on the fuel level warning light when the
main switch is set to “ON” (irrespective of whether the engine is running or not).
Circuit
Fuel pump thermistor
Defect(-s)
• Open circuit
• Short circuit
System response
• The fuel warning light
indicate the condition
code.
*1 Condition code
Fuel level warning light
8 - 63
Condition code
Refer to *1
SELF-DIAGNOSIS
EAS00835
EAS00838
TROUBLESHOOTING
1. Fuel sender (thermistor)
CIRCUIT DIAGRAM
The fuel level warning light starts to indicates the self-diagnosis sequence.
L/G
(BLUE)
G/W B
J
B B
(BLUE)
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. side panels (left and right)
3. fuel tank side covers (left and right)
4. fuel tank
• Troubleshoot with the following special
tool(s).
_
+
R/L G/W
L/G B
Check:
1. fuel sender (thermistor)
–
ELEC
K
R/L B
(DARK GREEN)
B
B
B
X
W
Lg
R/W
R/G
G/W
Pocket tester
90890-03112
Z
[
\
]
_
a
Y
Ch
G
G/L
Br
Y/L
B/W
Y
R/W G/L Dg
Lg B/W
K Fuel pump
Y Multifunction meter
EAS00841
1. Fuel level warning light LED
• Check the LED of the fuel level warning
light.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Is the fuel level warning light LED OK?
YES
NO
Replace the meter
assembly.
EAS00843
2. Wire harness
• Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
• Is the wire harness OK?
YES
NO
Repair or replace the
wire harness.
8 - 64
SELF-DIAGNOSIS
EAS00842
3. Fuel sender (thermistor)
• Disconnect the fuel sender coupler from
the wire harness.
• Connect the pocket tester (kΩ × 1) to the
fuel sender as shown.
Positive tester probe → green/white 1
Negative tester probe → black 2
• Check the fuel sender for continuity.
• Is the fuel sender OK?
YES
Replace the meter
assembly.
NO
Replace the fuel
pump assembly.
8 - 65
ELEC
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TRBL
SHTG
9
TRBL
SHTG
CHAPTER 9
TROUBLESHOOTING
STARTING FAILURES.................................................................................... 9-1
ENGINE..................................................................................................... 9-1
FUEL SYSTEM.......................................................................................... 9-1
ELECTRICAL SYSTEMS ..........................................................................9-2
INCORRECT ENGINE IDLING SPEED........................................................... 9-2
ENGINE..................................................................................................... 9-2
FUEL SYSTEM.......................................................................................... 9-2
ELECTRICAL SYSTEMS ..........................................................................9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE .................................9-3
ENGINE..................................................................................................... 9-3
FUEL SYSTEM.......................................................................................... 9-3
FAULTY GEAR SHIFTING..............................................................................9-3
SHIFTING IS DIFFICULT ..........................................................................9-3
SHIFT PEDAL DOES NOT MOVE ............................................................ 9-3
JUMPS OUT OF GEAR.............................................................................9-3
FAULTY CLUTCH ........................................................................................... 9-3
CLUTCH SLIPS......................................................................................... 9-3
CLUTCH DRAGS ......................................................................................9-3
OVERHEATING............................................................................................... 9-4
ENGINE..................................................................................................... 9-4
COOLING SYSTEM .................................................................................. 9-4
FUEL SYSTEM.......................................................................................... 9-4
CHASSIS...................................................................................................9-4
ELECTRICAL SYSTEMS ..........................................................................9-4
OVERCOOLING .............................................................................................. 9-4
COOLING SYSTEM .................................................................................. 9-4
POOR BRAKING PERFORMANCE................................................................9-4
FAULTY FRONT FORK LEGS........................................................................ 9-5
LEAKING OIL ............................................................................................ 9-5
MALFUNCTION......................................................................................... 9-5
UNSTABLE HANDLING.................................................................................. 9-5
TRBL
SHTG
FAULTY LIGHTING OR SIGNALING SYSTEM..............................................9-6
HEADLIGHT DOES NOT COME ON ........................................................9-6
HEADLIGHT BULB BURNT OUT.............................................................. 9-6
TAIL/BRAKE LIGHT DOES NOT COME ON ............................................9-6
TAIL/BRAKE LIGHT BULB BURNT OUT.................................................. 9-6
TURN SIGNAL DOES NOT COME ON .................................................... 9-6
TURN SIGNAL FLASHES SLOWLY .........................................................9-6
TURN SIGNAL REMAINS LIT...................................................................9-6
TURN SIGNAL FLASHES QUICKLY ........................................................9-6
HORN DOES NOT SOUND ...................................................................... 9-6
STARTING FAILURES
TRBL
SHTG
EAS00844
TROUBLESHOOTING
NOTE:
The following guide for troubleshooting does not cover all the possible causes of trouble. It should
be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
_
STARTING FAILURES
FUEL SYSTEM
Fuel tank
• Empty fuel tank
• Clogged fuel tank drain hose
• Deteriorated or contaminated fuel
Fuel pump
• Faulty fuel pump
• Faulty relay unit
Throttle body
• Deteriorated or contaminated fuel
• Sucked-in air
ENGINE
Cylinder and cylinder head
• Loose spark plug
• Loose cylinder head or cylinder
• Damaged cylinder head gasket
• Damaged cylinder gasket
• Worn or damaged cylinder
• Incorrect valve clearance
• Improperly sealed valve
• Incorrect valve-to-valve-seat contact
• Incorrect valve timing
• Faulty valve spring
• Seized valve
Piston and piston ring(s)
• Improperly installed piston ring
• Damaged, worn or fatigued piston ring
• Seized piston ring
• Seized or damaged piston
Air filter
• Improperly installed air filter
• Clogged air filter element
Crankcase and crankshaft
• Improperly assembled crankcase
• Seized crankshaft
9-1
STARTING FAILURES/
INCORRECT ENGINE IDLING SPEED
ELECTRICAL SYSTEMS
Battery
• Discharged battery
• Faulty battery
Fuse(s)
• Blown, damaged or incorrect fuse
• Improperly installed fuse
Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
Ignition coil
• Cracked or broken ignition coil body
• Broken or shorted primary or secondary
coils
• Faulty spark plug lead
TRBL
SHTG
Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
• Broken A.C. magneto rotor woodruff key
Switches and wiring
• Faulty main switch
• Faulty engine stop switch
• Broken or shorted wiring
• Faulty neutral switch
• Faulty start switch
• Faulty sidestand switch
• Faulty clutch switch
• Improperly grounded circuit
• Loose connections
Starting system
• Faulty starter motor
• Faulty starter relay
• Faulty starting circuit cut-off relay
• Faulty starter clutch
EAS00846
INCORRECT ENGINE IDLING SPEED
ELECTRICAL SYSTEMS
Battery
• Discharged battery
• Faulty battery
Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
Ignition coil
• Broken or shorted primary or secondary
coils
• Faulty spark plug lead
• Cracked or broken ignition coil
Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
• Broken A.C. magneto rotor woodruff key
ENGINE
Cylinder and cylinder head
• Incorrect valve clearance
• Damaged valve train components
Air filter
• Clogged air filter element
FUEL SYSTEM
Throttle body
• Damaged or loose throttle body joint
• Improperly adjusted engine idling speed
(throttle stop screw)
• Improper throttle cable free play
• Flooded throttle body
• Faulty air induction system
9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/
FAULTY GEAR SHIFTING/FAULTY CLUTCH
TRBL
SHTG
EAS00848
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
Refer to “STARTING FAILURES”.
ENGINE
Air filter
• Clogged air filter element
FUEL SYSTEM
Fuel pump
• Faulty fuel pump
EAS00850
FAULTY GEAR SHIFTING
JUMPS OUT OF GEAR
Shift shaft
• Incorrect shift pedal position
• Improperly returned stopper lever
Shift forks
• Worn shift fork
Shift drum
• Incorrect axial play
• Worn shift drum groove
Transmission
• Worn gear dog
SHIFTING IS DIFFICULT
Refer to “CLUTCH DRAGS”.
SHIFT PEDAL DOES NOT MOVE
Shift shaft
• Improperly adjusted shift rod
• Bent shift shaft.
Shift drum and shift forks
• Foreign object in a shift drum groove
• Seized shift fork
• Bent shift fork guide bar
Transmission
• Seized transmission gear
• Foreign object between transmission gears
• Improperly assembled transmission
EAS00851
FAULTY CLUTCH
CLUTCH DRAGS
Clutch
• Unevenly tensioned clutch springs
• Warped pressure plate
• Bent clutch plate
• Swollen friction plate
• Bent clutch push rod
• Broken clutch boss
• Burnt primary driven gear bushing
• Match marks not aligned
Engine oil
• Incorrect oil level
• Incorrect oil viscosity (high)
• Deteriorated oil
CLUTCH SLIPS
Clutch
• Improperly assembled clutch
• Improperly adjusted clutch cable
• Loose or fatigued clutch spring
• Worn friction plate
• Worn clutch plate
Engine oil
• Incorrect oil level
• Incorrect oil viscosity (low)
• Deteriorated oil
9-3
OVERHEATING/OVERCOOLING/
POOR BRAKING PERFORMANCE
TRBL
SHTG
EAS00855
OVERHEATING
FUEL SYSTEM
Throttle body
• Faulty throttle body
• Damaged or loose throttle body joint
Air filter
• Clogged air filter element
CHASSIS
Brake(s)
• Dragging brake
ELECTRICAL SYSTEMS
Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
Ignition system
• Faulty ECU
ENGINE
Clogged coolant passages
• Cylinder head and piston
• Heavy carbon buildup
Engine oil
• Incorrect oil level
• Incorrect oil viscosity
• Inferior oil quality
COOLING SYSTEM
Coolant
• Low coolant level
Radiator
• Damaged or leaking radiator
• Faulty radiator cap
• Bent or damaged radiator fin
Water pump
• Damaged or faulty water pump
• Thermostat
• Thermostat stays closed
• Damaged hose
• Improperly connected hose
• Damaged pipe
• Improperly connected pipe
EAS00856
OVERCOOLING
COOLING SYSTEM
Thermostat
• Thermostat stays open
EAS00857
POOR BRAKING PERFORMANCE
•
•
•
•
•
•
•
•
•
•
Worn brake pad
Worn brake disc
Air in hydraulic brake system
Leaking brake fluid
Faulty brake caliper seal
Loose union bolt
Damaged brake hose
Oil or grease on the brake disc
Oil or grease on the brake pad
Incorrect brake fluid level
9-4
FAULTY FRONT FORK LEGS/
UNSTABLE HANDLING
TRBL
SHTG
EAS00861
FAULTY FRONT FORK LEGS
MALFUNCTION
• Bent or damaged inner tube
• Bent or damaged outer tube
• Damaged fork spring
• Worn or damaged outer tube bushing
• Bent or damaged damper rod
• Incorrect oil viscosity
• Incorrect oil level
LEAKING OIL
• Bent, damaged or rusty inner tube
• Cracked or damaged outer tube
• Improperly installed oil seal
• Damaged oil seal lip
• Incorrect oil level (high)
• Loose damper rod assembly bolt
• Damaged damper rod assembly bolt copper
washer
• Cracked or damaged cap bolt O-ring
EAS00864
UNSTABLE HANDLING
Rear shock absorber assembly
• Faulty rear shock absorber spring
• Leaking oil or gas
Tire(s)
• Uneven tire pressures (front and rear)
• Incorrect tire pressure
• Uneven tire wear
Wheel(s)
• Incorrect wheel balance
• Broken or loose spoke
• Damaged wheel bearing
• Bent or loose wheel axle
• Excessive wheel runout
Frame
• Bent frame
• Damaged steering head pipe
• Improperly installed bearing race
Handlebar
• Bent or improperly installed handlebar
Steering head components
• Improperly installed upper bracket
• Improperly installed lower bracket
(improperly tightened ring nut)
• Bent steering stem
• Damaged ball bearing or bearing race
Front fork leg(s)
• Uneven oil levels (both front fork legs)
• Unevenly tensioned fork spring (both front
fork legs)
• Broken fork spring
• Bent or damaged inner tube
• Bent or damaged outer tube
Swingarm
• Worn bearing or bushing
• Bent or damaged swingarm
9-5
FAULTY LIGHTING OR SIGNALING SYSTEM
TRBL
SHTG
EAS00866
FAULTY LIGHTING OR SIGNALING SYSTEM
TURN SIGNAL DOES NOT COME ON
• Faulty turn signal switch
• Faulty turn signal/hazard relay
• Burnt-out turn signal bulb
• Incorrect connection
• Damaged or faulty wire harness
• Improperly grounded circuit
• Faulty battery
• Blown, damaged or incorrect fuse
TURN SIGNAL FLASHES SLOWLY
• Faulty turn signal/hazard relay
• Faulty main switch
• Faulty turn signal switch
• Incorrect turn signal bulb
TURN SIGNAL REMAINS LIT
• Faulty turn signal/hazard relay
• Burnt-out turn signal bulb
TURN SIGNAL FLASHES QUICKLY
• Incorrect turn signal bulb
• Faulty turn signal/hazard relay
• Burnt-out turn signal bulb
HORN DOES NOT SOUND
• Improperly adjusted horn
• Damaged or faulty horn
• Faulty main switch
• Faulty horn switch
• Faulty battery
• Blown, damaged or incorrect fuse
• Faulty wire harness
HEADLIGHT DOES NOT COME ON
• Wrong headlight bulb
• Too many electrical accessories
• Hard charging
• Incorrect connection
• Improperly grounded circuit
• Poor contacts (main switch)
• Burnt-out headlight bulb
• Faulty headlight relay
• Faulty ECU
HEADLIGHT BULB BURNT OUT
• Wrong headlight bulb
• Faulty battery
• Faulty rectifier/regulator
• Improperly grounded circuit
• Faulty main switch
• Headlight bulb life expired
TAIL/BRAKE LIGHT DOES NOT COME ON
• Wrong tail/brake light bulb
• Too many electrical accessories
• Incorrect connection
• Burnt-out tail/brake light bulb
TAIL/BRAKE LIGHT BULB BURNT OUT
• Wrong tail/brake light bulb
• Faulty battery
• Incorrectly adjusted rear brake light switch
• Tail/brake light bulb life expired
9-6
XT660R(S)/XT660X(S) 2004 WIRING DIAGRAM
1 Crankshaft position sensor
2 A.C. magneto
3 Neutral switch
4 Main switch
5 Rectifier/regulator
6 Battery
7 Main fuse
8 Starter relay
9 Starter motor
0 Fuel injection system fuse
A Backup fuse (immobilizer unit, meter assembly)
B Radiator fan motor fuse
C Right handlebar switch
D Engine stop switch
E Start switch
F Front brake light switch
G Relay unit
H Starting circuit cut-off relay
I Fuel injection system relay
J Sidestand switch
K Fuel pump
L ECU
M Ignition coil
N Spark plug
O Fuel injector
P Air induction system solenoid
Q Intake air temperature sensor
R Coolant temperature sensor
S Speed sensor
T Throttle position sensor
U Intake air pressure sensor
V Lean angle cut-off switch
W Meter assembly
X Neutral indicator light
Y Multifunction meter
Z Coolant temperature warning light
[ Engine trouble warning light
\ Fuel level warning light
] High beam indicator light
_ Turn signal indicator light
a Immobilizer system indicator light
b Headlight relay
c Turn signal/hazard relay
d Left handlebar switch
e Horn switch
f Pass switch
g Dimmer switch
h Turn signal switch
i Hazard switch
j Clutch switch
k Horn
l Headlight
m Rear turn signal light (left)
n Front turn signal light (left)
o Front turn signal light (right)
p Rear turn signal light (right)
q Radiator fan motor relay
r Radiator fan motor
s Rear brake light switch
t Auxiliary light
u Tail/brake light
v Ignition fuse
w Signaling system fuse
x Headlight fuse
y Parking lighting fuse
z Immobilizer unit
{ Anti-theft alarm (optional)
È Optional
COLOR CODE
B ............ Black
Br........... Brown
Ch.......... Chocolate
Dg.......... Dark green
G ........... Green
Gy.......... Gray
L ............ Blue
Lg .......... Light green
O ........... Orange
P ............ Pink
R............ Red
Sb .......... Sky blue
W ........... White
Y ............ Yellow
B/L ......... Black/Blue
B/W ....... Black/White
B/Y ........ Black/Yellow
Br/L........ Brown/Blue
Br/R ....... Brown/Red
Br/W ...... Brown/White
G/L ........ Green/Blue
G/R ........ Green/Red
G/W ....... Green/White
G/Y ........ Green/Yellow
L/B ......... Blue/Black
L/G ........ Blue/Green
L/R......... Blue/Red
L/W ........ Blue/White
L/Y ......... Blue/Yellow
O/R ........ Orange/Red
P/W ....... Pink/White
R/B ........ Red/Black
R/G ........ Red/Green
R/L......... Red/Blue
R/W ....... Red/White
R/Y ........ Red/Yellow
Y/B ........ Yellow/Black
Y/G ........ Yellow/Green
Y/L ......... Yellow/Blue
XT660R(S)/XT660X(S) 2004 WIRING DIAGRAM
A
Ch Lg L/R
G Y B
L/R G Ch
B Y Dg
Gy G/W
MAIN HARNESS SUB-WIRE HARNESS
W W
1
W W
W
W
Gy G/W
G/W L/Y
W
W
W
2
5
W
W
W
R
B
Sb
R
R
R
R
R R
L
B
R
B
B
B
R
7
8
6
W W W
3
R/W
R/B
R
Gy
L/W
R/L
B
R
4
B
Br/R
ON
OFF
P
L/W R/B
L/W
Br
9
G
Br/R
R
R
Br/L
Br/L
O
O
R/B
R/B
O
Lg
I
H
Br L/W
R/W B/Y R/LL/R
L/B
Br/L
Br/R
R
B BB R/G
R/B L/B R/L
L/W L/R R/W L/G L/Y Sb B/Y Lg
A
Y/L G/L R/W
R/G B2 B
R/W Lg Y/L
R
B
R/B
D
R/G
R
R L/B
L/W R/W
R/B B
B R/B
L/B
Sb L/Y L/G
Br
E
L/G
(BLUE)
J
B
B
B
B
B
K
Br/W
B/L
L
Br/W B/L
R
G/R
B/L
(BLACK)
(DARK GREEN)
Br/R R/W
(BLACK)
R/L B
(BLUE)
Y
Br Y
P
Q
Br/W
G/R
(BLACK)
R
G/W B
R/LR/B
R/W
(DARK BLUE)
R/L G/W
L/G B
F
Br
R/G
G/L
R/W
BB
Y/L
B
z
Br/R
L/R
B/Y
L/B
C
Br
R/L
(GRAY)
Br/R
0
M
N
L/W
B
B
L/W Y/L Y/G
W Gy B/W
L Br/R R R/B O
B/Y L/B G/R Br/W P/W Y B/L L/R G/Y Y/B R/L
B
R
R/W L/W
B
G/R B/L
B
L
W
B/L
L
W
B/L
B
(BLACK)
Y/L
W
X
Y
L
Y
B/L
T
Lg
È
BB
B1
BB3
BB4
BB2
BB1
{
R/W
R/G
G/W
Br/L
B2 B1
B
B
B
B
v
Y
Z
[
\
]
_
a
R
w
Br
Br/L
B1 BB
BB3 BB2
BB4 BB1
Br/L
x
R/L
Y
Br/R
y
Ch
G
Br
R/W
Br
G/L
R/L
R/Y
q
Br
L
R/W
R/L
G/Y
R/Y
Y/B
L
r
L/W
Y/B
Br/W
d
B
Br
e
R/L
L/W
Br/W
f
-
g
h
B
G Y L/W Br/W R/L
Ch
P Lg Br
G G/L R/W
B/W Lg
G/W Y/L
L/Y
i
j
B
B/Y
P
Y
Lg
Ch
G
Y
Br Y
Y Lg
A A
Y G
L/R
A
L/R
L/R
L/R Y
Y
B L Y
B
B L/R
u
B
k
Ch
A
Ch
G
A
Dg
Ch
Dg
G
B
Y G
t
L/R B
Ch
G
Y L/R B
L/Y B/Y
-
R/Y Br/W L/B Y Dg
Ch
Br G P
B
m
n
o
p
P
l
B
B
B
B
A
B
B
Y/L G/W
Ch R/G Y
-
s
Lg B/W
Y R/G Ch
Br
-
Br
R/W G/L Dg
Br/W
B
L
(BLACK)
(BLACK)
c
L/W
L G/Y
B
R
Br
b
Y/L
B/W
B
B
B
P/W
L
P/W
B/L
Y/G
L
Y/G
B/L
L Y B/L
(BLACK)
U
B/L P/W L
(BLACK)
Y/B
G/Y
B/W
B
V
L Y/G B/L
S
P O/R
B/W
L
W
B/L
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