Page 1 Manuals by Motomatrix / www.motomatrix.co.uk 2005 MT-01(T) SERVICE MANUAL 5YU1-AE1 Email: info@motomatrix.co.uk...
Page 2 Manuals by Motomatrix / www.motomatrix.co.uk EAS20040 MT-01(T) 2005 SERVICE MANUAL ©2004 by Yamaha Motor Co., Ltd. First edition, December 2004 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
Page 3 EAS20070 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Page 4 Manuals by Motomatrix / www.motomatrix.co.uk EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
Page 5 Manuals by Motomatrix / www.motomatrix.co.uk EAS20100 1. Serviceable with engine mounted SYMBOLS 2. Filling fluid The following symbols are used in this manual 3. Lubricant for easier understanding. 4. Special tool NOTE: 5. Tightening torque The following symbols are not relevant to every 6.
Page 6: Table Of Contents
Manuals by Motomatrix / www.motomatrix.co.uk EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING Email: info@motomatrix.co.uk...
Page 7 Manuals by Motomatrix / www.motomatrix.co.uk INFO Email: info@motomatrix.co.uk...
Page 8: General Information
Manuals by Motomatrix / www.motomatrix.co.uk GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER ............. 1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 INSTRUMENT FUNCTIONS ..............1-4 IMPORTANT INFORMATION ................. 1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-7 REPLACEMENT PARTS................
Page 9 Manuals by Motomatrix / www.motomatrix.co.uk Email: info@motomatrix.co.uk...
Page 10: Identification
Manuals by Motomatrix / www.motomatrix.co.uk IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped on the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the lead holder under the seat.
Page 11: Features
Manuals by Motomatrix / www.motomatrix.co.uk FEATURES EAS20170 FEATURES ET5YU1009 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the 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 carburetor.
Page 12: Fi System
Manuals by Motomatrix / www.motomatrix.co.uk FEATURES ET5YU1010 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 392 kPa (3.92 kg/cm², 55.7 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
Page 13: Instrument Functions
Manuals by Motomatrix / www.motomatrix.co.uk FEATURES ET5YU1011 Tachometer INSTRUMENT FUNCTIONS Multifunction display EW5YU1005 WARNING Be sure to stop the vehicle before making any setting changes to the multifunction dis- play. 1. Tachometer 2. Tachometer red zone The electric tachometer allows the rider to mon- itor the engine speed and keep it within the ideal power range.
Page 14 Manuals by Motomatrix / www.motomatrix.co.uk FEATURES To set the clock: If the multifunction display indicates an error 1. Push the “SELECT” button and “RESET” but- code, note the code number, and then check the ton together for at least two seconds. vehicle.
Page 15 Manuals by Motomatrix / www.motomatrix.co.uk FEATURES 3. Tachometer needle The brightness can be adjusted for the following: • the tachometer panel (item number “1”) • the LCD (item number “2”) • the tachometer needle (item number “3”) Select the brightness control mode as follows. 1.
Page 16: Important Information
5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
Page 17: Bearings And Oil Seals
Manuals by Motomatrix / www.motomatrix.co.uk IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease.
Page 18: Checking The Connections
Manuals by Motomatrix / www.motomatrix.co.uk CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead NOTE: • Coupler • If there is no continuity, clean the terminals. •...
Page 19: Special Tools
Manuals by Motomatrix / www.motomatrix.co.uk SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques.
Page 20 Manuals by Motomatrix / www.motomatrix.co.uk SPECIAL TOOLS Tool name/Tool No. Illustration Reference pages Compression gauge 3-10 90890-03081 Engine compression tester YU-33223 Extension 3-10 90890-04082 Oil filter wrench 3-12 90890-01426 YU-38411 Steering nut wrench 3-26, 4-59 90890-01403 Spanner wrench YU-33975 Vacuum/pressure pump gauge set 4-5, 6-9 90890-06756 Fork spring compressor...
Page 21 Manuals by Motomatrix / www.motomatrix.co.uk SPECIAL TOOLS Tool name/Tool No. Illustration Reference pages Rod puller 4-53, 4-55 90890-01437 Universal damping rod bleeding tool YM-A8703 YM-A8703 Rod puller attachment (M10) 4-53, 4-55 90890-01436 Universal damping rod bleeding tool YM-A8703 YM-A8703 Ring nut wrench 4-59 90890-01268 Spanner wrench...
Page 22 Universal clutch holder 5-55, 5-58 90890-04086 YM-91042 Sheave holder 5-55, 5-57, 5-68, 90890-01701 5-69, 5-77, 5-79 Primary clutch holder YS-01880-A Yamaha bond No. 1215 5-57, 5-69, 5-78 90890-85505 Rotor puller 5-68 90890-01080 Stator rotor puller YM-01080-A Pressure gauge 90890-03153 1-13...
Page 23 Manuals by Motomatrix / www.motomatrix.co.uk SPECIAL TOOLS Tool name/Tool No. Illustration Reference pages Fuel pressure adapter 90890-03176 YM-03176 Digital circuit tester 6-10 90890-03174 Ignition checker 7-100 90890-06754 Opama pet-4000 spark checker YM-34487 1-14 Email: info@motomatrix.co.uk...
Page 24 Manuals by Motomatrix / www.motomatrix.co.uk SPEC Email: info@motomatrix.co.uk...
Page 25: Specifications
Manuals by Motomatrix / www.motomatrix.co.uk SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................ 2-10 ELECTRICAL SPECIFICATIONS ..............2-14 TIGHTENING TORQUES ................2-17 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-17 ENGINE TIGHTENING TORQUES............2-18 CHASSIS TIGHTENING TORQUES............2-23 LUBRICATION POINTS AND LUBRICANT TYPES ........2-28 ENGINE....................
Page 26 Manuals by Motomatrix / www.motomatrix.co.uk Email: info@motomatrix.co.uk...
Page 27: General Specifications
Manuals by Motomatrix / www.motomatrix.co.uk GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 5YU1 (Europe) 5YU2 (AUS) Dimensions Overall length 2185 mm (86.0 in) Overall width 790 mm (31.1 in) Overall height 1160 mm (45.7 in) Seat height 825 mm (32.5 in) Wheelbase 1525 mm (60.0 in) Ground clearance...
Page 28: Engine Specifications
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Air cooled 4-stroke, OHV Displacement 1670.0 cm³ (101.90 cu.in) Cylinder arrangement V-type 2 cylinders Bore × stroke 97.0 × 113.0 mm (3.82 × 4.45 in) Compression ratio 8.40 :1 Standard compression pressure (at sea level) 1200 kPa/200 r/min (170.7 psi/200 r/min) (12.0...
Page 29 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE SPECIFICATIONS Spark plug (s) Manufacturer/model NGK/DPR7EA-9 Manufacturer/model DENSO/X22EPR-U9 Spark plug gap 0.8–0.9 mm (0.031–0.035 in) Cylinder head Volume 98.60–103.60 cm³ (6.02–6.32 cu.in) Warpage limit* 0.03 mm (0.0012 in) Camshaft Drive system Gear drive Camshaft to crankcase clearance 0.050–0.084 mm (0.0020–0.0033 in) Camshaft lobe dimensions Intake A...
Page 30 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE SPECIFICATIONS Valve, valve seat, valve guide Valve clearance (cold) Intake 0.00–0.04 mm (0.0000–0.0016 in) Exhaust 0.00–0.04 mm (0.0000–0.0016 in) Valve dimensions Valve head diameter A (intake) 33.90–34.10 mm (1.3346–1.3425 in) Valve head diameter A (exhaust) 27.90–28.10 mm (1.0984–1.1063 in) Valve face width B (intake) 1.300–2.300 mm (0.0512–0.0906 in)
Page 31 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE SPECIFICATIONS Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in) Limit 0.100 mm (0.0039 in) Valve stem runout 0.010 mm (0.0004 in) Valve spring Inner spring Free length (intake) 38.26 mm (1.51 in)
Page 32 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE SPECIFICATIONS Installed compression spring force (exhaust) 139.00–161.00 N (31.25–36.19 lb) (14.17– 16.42 kgf) Spring tilt (intake) 2.5°/1.9 mm (2.5°/0.075 in) Spring tilt (exhaust) 2.5°/1.9 mm (2.5°/0.075 in) Winding direction (intake) Clockwise Winding direction (exhaust) Clockwise Valve lifter Valve lifter outside diameter (intake)
Page 33 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE SPECIFICATIONS Piston ring Top ring Ring type Barrel Dimensions (B × T) 1.20 × 3.80 mm (0.05 × 0.15 in) End gap (installed) 0.30–0.50 mm (0.01–0.02 in) Limit 0.70 mm (0.0276 in) Ring side clearance 0.030–0.080 mm (0.0012–0.0032 in) Limit 0.120 mm (0.0047 in)
Page 34 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE SPECIFICATIONS Crankshaft Width A 132.80–133.20 mm (5.23–5.24 in) Runout limit C 0.040 mm (0.0016 in) Big end side clearance D 0.320–0.474 mm (0.0126–0.0187 in) Big end radial clearance E 0.037–0.074 mm (0.0015–0.0029 in) Limit 0.09 mm (0.0035 in) ®...
Page 35 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE SPECIFICATIONS Shifting mechanism Shift mechanism type Guide bar Shift fork guide bar bending limit 0.025 mm (0.0010 in) Shift fork thickness 6.26–6.39 mm (0.2465–0.2516 in) Air filter Air filter element Oil-coated paper element Fuel pump Pump type Electrical Model/manufacturer...
Page 36: Chassis
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Double cradle Caster angle 25.00° Trail 103.0 mm (4.06 in) Front wheel Wheel type Cast wheel 17M/C × MT3.50 Rim size Rim material Aluminum Wheel travel 120.0 mm (4.72 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit...
Page 37 Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS SPECIFICATIONS Front brake Type Dual disc brake Operation Right hand operation Front brake lever free play 7.0–19.0 mm (0.28–0.75 in) Front disc brake Disc outside diameter × thickness 320.0 × 4.5 mm (12.60 × 0.18 in) Brake disc thickness limit 4.0 mm (0.16 in) Brake disc deflection limit...
Page 38 Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS SPECIFICATIONS Front suspension Type Telescopic fork Spring/shock absorber type Coil spring/oil damper Front fork travel 120.0 mm (4.72 in) Fork spring free length 251.0 mm (9.88 in) Limit 246.0 mm (9.69 in) Collar length 100.8 mm (3.97 in) Installed length 235.0 mm (9.25 in)
Page 39 Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS SPECIFICATIONS Rear suspension Type Swingarm (link suspension) Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel 50.0 mm (1.97 in) Spring free length 159.5 mm (6.28 in) Limit 156.0 mm (6.14 in) Installed length 150.0 mm (5.91 in) Spring rate K1...
Page 40: Electrical Specifications
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Transistorized coil ignition (digital) Advancer type Electric Ignition timing (B.T.D.C.) 10.0°/900 r/min Engine control unit Model/manufacturer F8T83071/MITSUBISHI Ignition coil Model/manufacturer 2JN/MORIC Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64 Ω...
Page 41 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL SPECIFICATIONS Bulb voltage, wattage × quantity 12 V, 51.0 W × 1 Low beam headlight 12 V, 55.0 W × 1 High beam headlight 12 V, 5.0 W × 3 Auxiliary light Tail/brake light 12 V, 10.0 W ×...
Page 42 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL SPECIFICATIONS Starting circuit cut-off relay Model/manufacturer G8R-30Y-U3/OMRON 162–198 Ω Coil resistance Headlight relay Model/manufacturer ACM33211M05/MATSUSHITA 86.40–105.60 Ω Coil resistance Fuel pump relay Model/manufacturer G8R-30Y-U3/OMRON 162–198 Ω Coil resistance Thermo unit Model/manufacturer 5PX/DENSO 898.38–1098.02 Ω Resistance at 100 °C Fuses Main fuse...
Page 43: Tightening Torques
Manuals by Motomatrix / www.motomatrix.co.uk TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual.
Page 44: Engine Tightening Torques
Manuals by Motomatrix / www.motomatrix.co.uk TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil tank: Oil pipe bolt 13 Nm (1.3 m·kg, 9.4 ft·lb) Oil tank and oil tank bracket nut 13 Nm (1.3 m·kg, 9.4 ft·lb) Oil tank bolt 13 Nm (1.3 m·kg, 9.4 ft·lb) Oil tank and down tube bolt...
Page 45 Manuals by Motomatrix / www.motomatrix.co.uk TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Cylinder head cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Rocker arm base bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Rocker arm base bolt 24 Nm (2.4 m·kg, 17 ft·lb) Locknut (rocker arm adjusting 20 Nm (2.0 m·kg, 14 ft·lb) screw)
Page 46 Manuals by Motomatrix / www.motomatrix.co.uk TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Stopper lever bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Generator and starter clutch: Oil pipe 2 bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Generator cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Stator coil assembly lead holder 10 Nm (1.0 m·kg, 7.2 ft·lb)
Page 47 Manuals by Motomatrix / www.motomatrix.co.uk TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Crankshaft: NOTE. Connecting rod bolt (1st) 15 Nm (1.5 m·kg, 11 ft·lb) NOTE. Connecting rod bolt (final) Specified angle 120°–150° Chain drive: Drive sprocket cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Drive chain guide bolt (drive 24 Nm (2.4 m·kg, 17 ft·lb)
Page 48 Manuals by Motomatrix / www.motomatrix.co.uk TIGHTENING TORQUES Oil tank tightening sequence: Cylinder head tightening sequence: A. Front cylinder B. Rear cylinder 2-22 Email: info@motomatrix.co.uk...
Page 49: Chassis Tightening Torques
Manuals by Motomatrix / www.motomatrix.co.uk TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting: Engine mounting bolt (left upper 53 Nm (5.3 m·kg, 38 ft·lb) side) Engine mounting bolt (right upper L=80 mm 53 Nm (5.3 m·kg, 38 ft·lb) side) (3.15 in) Engine mounting bolt (right upper...
Page 50 Manuals by Motomatrix / www.motomatrix.co.uk TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Cylinder-#2 right ignition coil 10 Nm (1.0 m·kg, 7.2 ft·lb) bracket bolt Cylinder-#2 left ignition coil 10 Nm (1.0 m·kg, 7.2 ft·lb) bracket bolt Engine bracket (right upper side) 7 Nm (0.7 m·kg, 5.1 ft·lb) and holder bolt Fuel tank bolt...
Page 51 Manuals by Motomatrix / www.motomatrix.co.uk TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Shift arm bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Left rider footrest assembly bolt 30 Nm (3.0 m·kg, 22 ft·lb) Right rider footrest assembly bolt 30 Nm (3.0 m·kg, 22 ft·lb) Footrest cover bracket 7 Nm (0.7 m·kg, 5.1 ft·lb) Passenger footrest nut...
Page 52 Manuals by Motomatrix / www.motomatrix.co.uk TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Grip end 29 Nm (2.9 m·kg, 21 ft·lb) Clutch master cylinder holder bolt 13 Nm (1.3 m·kg, 9.4 ft·lb) Rearview mirror 14 Nm (1.4 m·kg, 10 ft·lb) Front fork and steering head: Upper bracket pinch bolt 26 Nm (2.6 m·kg, 19 ft·lb)
Page 53 Manuals by Motomatrix / www.motomatrix.co.uk TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Drive chain guard bolt (swingarm 7 Nm (0.7 m·kg, 5.1 ft·lb) side) Drive chain guide bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Locknut (drive chain adjusting 16 Nm (1.6 m·kg, 11 ft·lb) bolt) NOTE:...
Page 54: Lubrication Points And Lubricant Types
Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Cylinder head nuts and washers Connecting rod small end and big end Crankshaft journals Piston surfaces Piston pins Connecting rod bolts...
Page 55 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Shift forks and shift fork guide bars Shift drum Shift shaft and shift shaft oil seal lip Yamaha bond Crankcase mating surface No.1215 Yamaha bond Stator coil lead grommet No.1215 Yamaha bond Crankshaft position sensor lead grommet No.1215...
Page 56: Chassis
Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Down tube bolt (front and rear) Steering bearings and upper bearing dust cover lip Lower bearing dust seal lip Steering ring nut thread (upper and lower) Main switch bracket spacer outer surfaces Front wheel oil seal lips (left and right) Rear wheel oil seal lips (left and right)
Page 57: Lubrication System Chart And Diagrams
Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-31 Email: info@motomatrix.co.uk...
Page 58 Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pan 2. Engine oil drain bolt (crankcase) 3. Oil strainer (crankcase) 4. Oil pump 5. Oil pump rotor 1 6. Oil pump rotor 2 7. Check ball 8. Relief valve 9.
Page 59: Lubrication Diagrams
Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-33 Email: info@motomatrix.co.uk...
Page 60 Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil delivery pipe 2. Push rod 3. Oil filter cartridge 4. Rocker arm shaft 5. Oil delivery pipe 2 2-34 Email: info@motomatrix.co.uk...
Page 61 Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35 Email: info@motomatrix.co.uk...
Page 62 Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Rocker arm shaft 2. Crankshaft 3. Valve lifter 4. Push rod 2-36 Email: info@motomatrix.co.uk...
Page 63 Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37 Email: info@motomatrix.co.uk...
Page 64 Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pump 2. Oil strainer (crankcase) 3. Oil pipe 1 2-38 Email: info@motomatrix.co.uk...
Page 65 Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION SYSTEM CHART AND DIAGRAMS 2-39 Email: info@motomatrix.co.uk...
Page 66 Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Drive axle 3. Oil pump 4. Oil strainer (crankcase) A. To oil filter cartridge 2-40 Email: info@motomatrix.co.uk...
Page 67: Cable Routing
Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING EAS20430 CABLE ROUTING 2-41 Email: info@motomatrix.co.uk...
Page 68 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 1. Air temperature sensor coupler 2. Sub-wire harness 3 coupler 3. Front turn signal light coupler 4. Headlight assembly coupler 5. Headlight coupler (low beam) 6. Wire harness 7. Clutch fluid reservoir hose 8.
Page 69 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 2-43 Email: info@motomatrix.co.uk...
Page 70: Engine
Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 1. Meter assembly lead Q. Route the cylinder-#1 left spark plug lead under the frame boss and to the outside of the wire 2. Clutch hose harness and clutch hose. 3. Left handlebar switch lead R.
Page 71 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 2-45 Email: info@motomatrix.co.uk...
Page 72 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 1. Fuel pump lead K. Fasten the wire harness and sub-wire harness 2 with the plastic band at the section just before the 2. Cylinder-#1 right spark plug lead split in the wire harness. Face the end of the plastic 3.
Page 73 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 2-47 Email: info@motomatrix.co.uk...
Page 74 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 1. Sub-wire harness 2 H. Route the tail/brake light lead and rear turn signal light leads along the side of the rear brake fluid 2. Intake solenoid lead reservoir, making sure that “UPPER” on the 3.
Page 75 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 2-49 Email: info@motomatrix.co.uk...
Page 76 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING AB.Route the starter motor lead and sub-wire harness 1 under the battery box, making sure that they are routed between the bolt holes in the battery box. AC.Route the seat lock cable under the wire harness to the left of the battery box.
Page 77 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING Manuals by Motomatrix / www.motomatrix.co.uk 2-51 Email: info@motomatrix.co.uk...
Page 78 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 1. Fuel tank 2. Pressure regulator 3. Fuel return hose 4. Fuel hose 5. Fuel return pipe 6. Fuel return hose (fuel return pipe to fuel pump) 7. Fuel pump 8. Fuel pipe 9.
Page 79 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 2-53 Email: info@motomatrix.co.uk...
Page 80 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 1. Fuel tank overflow hose 2. Fuel tank breather hose 3. Rollover valve hose 1 4. Rollover valve hose 2 5. Rollover valve 1 6. Rollover valve 2 7. Rollover valve hose 3 8.
Page 81 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING matrix.co.uk 2-55 Email: info@motomatrix.co.uk...
Page 82 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 1. Cylinder-#2 intake air pressure sensor 2. Cylinder-#2 ISC (idle speed control) unit outlet hose 3. ISC (idle speed control) unit 4. Intake solenoid vacuum hose (one-way valve to throttle body) 5. Cylinder-#1 ISC (idle speed control) unit outlet hose 6.
Page 83 Manuals by Motomatrix / www.motomatrix.co.uk Email: info@motomatrix.co.uk...
Page 84 Manuals by Motomatrix / www.motomatrix.co.uk PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE AND LUBRICATION CHART....... 3-1 ENGINE ......................3-3 ADJUSTING THE VALVE CLEARANCE ..........3-3 SYNCHRONIZING THE THROTTLE BODIES.......... 3-5 ADJUSTING THE THROTTLE CABLE FREE PLAY ........ 3-7 CHECKING THE SPARK PLUGS .............
Page 85 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL SYSTEM................. 3-33 CHECKING AND CHARGING THE BATTERY........3-33 CHECKING THE FUSES ................ 3-33 REPLACING THE HEADLIGHT BULBS ..........3-33 ADJUSTING THE HEADLIGHT BEAM ........... 3-34 Email: info@motomatrix.co.uk...
Page 86: Periodic Maintenance
• The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. • From 50000 km, repeat the maintenance intervals starting from 10000 km. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ×...
Page 87 Manuals by Motomatrix / www.motomatrix.co.uk PERIODIC MAINTENANCE × 1000 km) ANNU- ODOMETER READING ( ITEM CHECK OR MAINTENANCE JOB CHECK √ √ √ √ Shock absorber as- 19 * • Check operation and shock absorber for oil leakage. sembly Rear suspension re- √...
Page 88: Engine
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE EAS20470 • Air filter case ENGINE Refer to “GENERAL CHASSIS” on page 4-1. 2. Disconnect: EAS20530 • Spark plug caps ADJUSTING THE VALVE CLEARANCE 3. Remove: The following procedure applies to all of the •...
Page 89 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE d. Measure the valve clearance with a thickness Valve clearance (cold) gauge. Intake 0.00–0.04 mm (0.0000–0.0016 in) Thickness gauge Exhaust 90890-03079 0.00–0.04 mm (0.0000–0.0016 in) Narrow gauge set YM-34483 M MMM M MMM M MMM M MMM M MMM Piston #1 TDC (rear cylinder)
Page 90: Synchronizing The Throttle Bodies
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE d. Hold the adjusting screw to prevent it from M MMM M MMM M MMM M MMM M MMM a. Loosen the locknut “1” with the locknut moving and tighten the locknut to specifica- wrench “2”.
Page 91 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE 2. Remove: M MMM M MMM M MMM M MMM M MMM a. Start the engine, warm it up for several min- • Seat utes, and then let it run at the specified en- Refer to “GENERAL CHASSIS”...
Page 92: Adjusting The Throttle Cable Free Play
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE 9. Install: NOTE: • Air filter case ® Apply locking agent (LOCTITE ) to the threads Refer to “GENERAL CHASSIS” on page 4-1. of the adjusting nut “3”. • Fuel tank c. Loosen the locknut “4” on the accelerator ca- Refer to “FUEL TANK”...
Page 93: Checking The Spark Plugs
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE c. Tighten the locknut “1”. 5. Check: • Electrode “1” Damage/wear → Replace the spark plug. • Insulator “2” Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 6. Clean: • Spark plug (with a spark plug cleaner or wire brush) 7.
Page 94: Measuring The Compression Pressure
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE 1. Stand the vehicle on a level surface. 2. Remove: • Air duct “1” • Timing mark accessing screw “2” NOTE: The ignition timing is not adjustable. L LLL L LLL L LLL L LLL L LLL 3.
Page 95 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE M MMM M MMM M MMM M MMM M MMM a. Set the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. EWA12940 WARNING To prevent sparking, ground all spark plug...
Page 96: Checking The Engine Oil Level
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE EAS20730 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle on a level surface. NOTE: • Place the vehicle on a suitable stand. • Make sure the vehicle is upright. 2. Start the engine, warm it up for approximately 15 minutes until the oil temperature rises to 60 °C (140 °F), and then turn it off.
Page 97 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE 6. Remove: • Engine oil drain bolt (crankcase) “1” d. Tighten the new oil filter cartridge to specifi- cation with an oil filter wrench. 7. Drain: Oil filter cartridge • Engine oil 17 Nm (1.7 m·kg, 12 ft·lb) (completely from the oil tank and crankcase) 8.
Page 98: Adjusting The Clutch Lever
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE M MMM M MMM M MMM M MMM M MMM NOTE: a. Slightly loosen the oil gallery bolts “1”. Pour the engine oil in two stages. First, pour in 2.5 L of oil, then start the engine and rev it 3 to 5 times.
Page 99: Checking The Clutch Fluid Level
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE ECA13420 CAUTION: Clutch fluid may damage painted surfaces or plastic parts. Therefore, always clean up any spilt clutch fluid immediately. NOTE: In order to ensure a correct reading of the clutch fluid level, make sure the top of the reservoir is horizontal.
Page 100: Replacing The Air Filter Element
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE d. Place the other end of the hose into a con- tainer. e. Slowly squeeze the clutch lever several times. f. Fully squeeze the clutch lever without releas- ing it. g. Loosen the bleed screw. This will release the tension and cause the clutch lever to contact the handlebar grip.
Page 101: Checking The Throttle Body Joints
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE EAS21010 CHECKING THE THROTTLE BODY JOINTS 1. Remove: • Seat Refer to “GENERAL CHASSIS” on page 4-1. • Fuel tank Refer to “FUEL TANK” on page 6-1. • Air filter case Refer to “GENERAL CHASSIS” on page 4-1. 2.
Page 102: Checking The Oil Tank Breather Hose
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE • Fuel tank • Muffler bolts “13” Refer to “FUEL TANK” on page 6-1. Front exhaust pipe and front • Seat exhaust pipe joint bolt Refer to “GENERAL CHASSIS” on page 4-1. 20 Nm (2.0 m·kg, 14 ft·lb) Front exhaust pipe and rear EAS21060 CHECKING THE OIL TANK BREATHER...
Page 103: Adjusting The Exup Cables
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE EXUP cable free play (at the EXUP valve pulley) a: 3 mm (0.12 in) or less b: 0 mm 4. Install: • Seat Refer to “GENERAL CHASSIS” on page 4-1. EAS21100 ADJUSTING THE EXUP CABLES 1.
Page 104 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE d d c c e. Tighten both locknuts and then slide the rub- ber cover to its original position. f. Remove the pin. g. Turn the main switch to “ON”, check that the EXUP valve pulley contacts the stoppers (ful- ly-open and fully-closed positions), and then check that the notch in the EXUP valve pulley is aligned with the hole in the EXUP valve...
Page 105: Chassis
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS EAS21140 CHASSIS Installed rear brake master cylinder length 145.3–145.7 mm (5.72–5.74 in) EAS21160 ADJUSTING THE FRONT DISC BRAKE 1. Adjust: • Brake lever position (distance “a” from the throttle grip to the brake lever) NOTE: •...
Page 106: Checking The Brake Fluid Level
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS EW5YU1001 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.
Page 107: Checking The Rear Brake Pads
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS 3. Hold the vehicle upright and apply the brake several times. 4. Check: • Brake hoses Brake fluid leakage → Replace the damaged hoses. Refer to “FRONT BRAKE” on page 4-18. EAS21290 CHECKING THE REAR BRAKE HOSE 1.
Page 108: Bleeding The Hydraulic Brake System
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS M MMM M MMM M MMM M MMM M MMM M MMM M MMM M MMM M MMM M MMM a. Hold the main body “1” of the rear brake light a. Fill the brake fluid reservoir to the proper level switch so that it does not rotate and turn the with the recommended brake fluid.
Page 109: Adjusting The Shift Pedal
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS M MMM M MMM M MMM M MMM M MMM NOTE: a. Loosen both locknuts “1”. Loosening the bleed screw will release the pres- b. Turn the shift rod “2” in direction “a” or “b” until sure and cause the brake lever to contact the the specified installed shift rod length is ob- throttle grip or the brake pedal to fully extend.
Page 110: Lubricating The Drive Chain
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS NOTE: Rear wheel axle nut Measure the drive chain slack 85 mm (3.35 in) 150 Nm (15.0 m·kg, 110 ft·lb) “b” from the end of the drive chain guide. L LLL L LLL L LLL L LLL L LLL EAS21440...
Page 111: Checking The Front Fork
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS d. Check the steering head for looseness or M MMM M MMM M MMM M MMM M MMM a. Remove the lock washer “1”, the upper ring binding by turning the front fork all the way in nut “2”, and the rubber washer “3”.
Page 112: Adjusting The Front Fork Legs
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting bolt “1” in direction “a” or “b”. Direction “a” Spring preload is increased (suspension is harder). Direction “b” Spring preload is decreased (suspension is softer).
Page 113: Adjusting The Rear Shock Absorber Assembly
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting screw “1” in direction “a” or Compression damping adjusting positions “b”. Minimum 16 click(s) out* Direction “a” (turn in) Standard Rebound damping is increased 7 click(s) out* (suspension is harder).
Page 114: Specifications
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS M MMM M MMM M MMM M MMM M MMM Spring preload adjusting a. Turn the adjusting knob “1” in direction “a” or positions “b”. Installed spring length Minimum Direction “a” (turn in) 155.0 mm (6.10 in) Rebound damping is increased Standard (suspension is harder).
Page 115: Checking The Tires
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS Compression damping adjusting Tire air pressure (measured on positions cold tires) Minimum Loading condition 12 click(s) out* 0–90 kg (0–198 lb) Standard Front 10 click(s) out* 250 kPa (36 psi) (2.50 kgf/cm²) Maximum (2.50 bar) 1 click(s) out* Rear 290 kPa (42 psi) (2.90 kgf/cm²)
Page 116: Checking The Wheels
1. Check: en if a tire combination other than one • Wheel approved by Yamaha is used on this vehicle. Damage/out-of-round → Replace. EWA13260 WARNING Never attempt to make any repairs to the wheel.
Page 117: Checking And Lubricating The Cables
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS EAS21740 NOTE: LUBRICATING THE REAR SUSPENSION After a tire or wheel has been changed or re- Lubricate the pivoting point and metal-to-metal placed, always balance the wheel. moving parts of the rear suspension. Recommended lubricant EAS21690 CHECKING AND LUBRICATING THE Lithium-soap-based grease...
Page 118: Electrical System
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL SYSTEM EAS21750 ECA13690 ELECTRICAL SYSTEM CAUTION: Avoid touching the glass part of the head- EAS21760 light bulb to keep it free from oil, otherwise CHECKING AND CHARGING THE BATTERY the transparency of the glass, the life of the Refer to “ELECTRICAL COMPONENTS”...
Page 119 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL SYSTEM ECA13690 CAUTION: Direction “a” Headlight beam moves to the right. Avoid touching the glass part of the head- Direction “b” light bulb to keep it free from oil, otherwise Headlight beam moves to the left. the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected.
Page 120 Manuals by Motomatrix / www.motomatrix.co.uk CHAS Email: info@motomatrix.co.uk...
Page 121 Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS GENERAL CHASSIS..................4-1 CHECKING THE AIR FILTER CASE VALVE..........4-5 FRONT WHEEL....................4-6 REMOVING THE FRONT WHEEL............4-8 DISASSEMBLING THE FRONT WHEEL..........4-8 CHECKING THE FRONT WHEEL ............4-8 ASSEMBLING THE FRONT WHEEL............4-9 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......
Page 122 Manuals by Motomatrix / www.motomatrix.co.uk HANDLEBAR ....................4-42 REMOVING THE HANDLEBAR.............. 4-44 CHECKING THE HANDLEBAR .............. 4-44 INSTALLING THE HANDLEBAR ............4-44 FRONT FORK....................4-47 REMOVING THE FRONT FORK LEGS..........4-50 DISASSEMBLING THE FRONT FORK LEGS ........4-50 CHECKING THE FRONT FORK LEGS ..........4-51 ASSEMBLING THE FRONT FORK LEGS ..........
Page 123: General Chassis
Manuals by Motomatrix / www.motomatrix.co.uk GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat and battery 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 124 Manuals by Motomatrix / www.motomatrix.co.uk GENERAL CHASSIS Removing the side covers and headlight assembly 9 Nm (0.9 m kg, 6.5 ft • • 9 Nm (0.9 m kg, 6.5 ft • • 7 Nm (0.7 m kg, 5.1 ft • •...
Page 125 Manuals by Motomatrix / www.motomatrix.co.uk GENERAL CHASSIS Removing the tail/brake light assembly 7 Nm (0.7 m kg, 5.1 ft 7 Nm (0.7 m kg, 5.1 ft • • • • 3 4 5 Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Seat 4-1.
Page 126 Manuals by Motomatrix / www.motomatrix.co.uk GENERAL CHASSIS Removing the air filter case and oil catch tank 10 Nm (1.0 m kg, 7.2 ft • • 9 Nm (0.9 m kg, 6.5 ft • • Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK”...
Page 127: Checking The Air Filter Case Valve
Manuals by Motomatrix / www.motomatrix.co.uk GENERAL CHASSIS ET5YU1013 CHECKING THE AIR FILTER CASE VALVE 1. Check: • Air filter case valve operation M MMM M MMM M MMM M MMM M MMM a. Remove the air filter case (with the air filter case valve).
Page 128: Front Wheel
Manuals by Motomatrix / www.motomatrix.co.uk FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs 35 Nm (3.5 m kg, 25 ft • • 35 Nm (3.5 m kg, 25 ft • • 6 Nm (0.6 m kg, 4.3 ft •...
Page 129 Manuals by Motomatrix / www.motomatrix.co.uk FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer For assembly, reverse the disassembly procedure. Email: info@motomatrix.co.uk...
Page 130: Removing The Front Wheel
Manuals by Motomatrix / www.motomatrix.co.uk FRONT WHEEL EAS21900 EAS21920 REMOVING THE FRONT WHEEL CHECKING THE FRONT WHEEL 1. Stand the vehicle on a level surface. 1. Check: • Front wheel axle EWA13120 WARNING Roll the wheel axle on a flat surface. Bends →...
Page 131: Assembling The Front Wheel
Manuals by Motomatrix / www.motomatrix.co.uk FRONT WHEEL NOTE: Place the front wheel on a suitable balancing stand. M MMM M MMM M MMM M MMM M MMM a. Spin the front wheel. b. When the front wheel stops, put an “X ”...
Page 132: Checking The Front Brake Discs
Manuals by Motomatrix / www.motomatrix.co.uk FRONT WHEEL EAS22000 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) The following procedure applies to both of the front brake discs. 1. Install: • Front brake disc Front brake disc bolt 18 Nm (1.8 m·kg, 13 ft·lb) ®...
Page 133 Manuals by Motomatrix / www.motomatrix.co.uk FRONT WHEEL Front wheel axle 72 Nm (7.2 m·kg, 52 ft·lb) • Front wheel axle pinch bolt Front wheel axle pinch bolt 23 Nm (2.3 m·kg, 17 ft·lb) EC5YU1002 CAUTION: Before tightening the wheel axle, push down hard on the handlebar several times and check if the front fork rebounds smoothly.
Page 134: Rear Wheel
Manuals by Motomatrix / www.motomatrix.co.uk REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel 27 Nm (2.7 m kg, 19 ft • • 22 Nm (2.2 m kg, 16 ft • • 150 Nm (15.0 m kg, 110 ft • •...
Page 135 Manuals by Motomatrix / www.motomatrix.co.uk REAR WHEEL Removing the rear brake disc and rear wheel sprocket 100 Nm (10.0 m kg, 72 ft • • 18 Nm (1.8 m kg, 13 ft • • Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel sprocket Collar (brake disc side)
Page 136 Manuals by Motomatrix / www.motomatrix.co.uk REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Collar Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly procedure. 4-14 Email: info@motomatrix.co.uk...
Page 137: Removing The Rear Wheel
Manuals by Motomatrix / www.motomatrix.co.uk REAR WHEEL EAS22040 EAS22090 REMOVING THE REAR WHEEL CHECKING THE REAR WHEEL 1. Stand the vehicle on a level surface. 1. Check: • Rear wheel axle EWA13120 WARNING • Rear wheel Securely support the vehicle so that there is •...
Page 138: Assembling The Rear Wheel
Manuals by Motomatrix / www.motomatrix.co.uk REAR WHEEL EAS22150 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.
Page 139 Manuals by Motomatrix / www.motomatrix.co.uk REAR WHEEL • Collar (brake disc side) “2” NOTE: The collar (brake disc side) has marks “a” to dis- tinguish it from the collar (wheel sprocket side). 5. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK”...
Page 140: Front Brake
Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 6 Nm (0.6 m kg, 4.3 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 35 Nm (3.5 m kg, 25 ft •...
Page 141 Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE Removing the front brake master cylinder 10 Nm (1.0 m kg, 7.2 ft • • 14 Nm (1.4 m kg, 10 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty...
Page 142 Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE Removing the front brake master cylinder 10 Nm (1.0 m kg, 7.2 ft • • 14 Nm (1.4 m kg, 10 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty...
Page 143 Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Bleed screw Brake master cylinder body For assembly, reverse the disassembly procedure. 4-21 Email: info@motomatrix.co.uk...
Page 144 Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE Removing the front brake calipers 6 Nm (0.6 m kg, 4.3 ft • • 30 Nm (3.0 m kg, 22 ft • • 35 Nm (3.5 m kg, 25 ft • • Order Job/Parts to remove Q’ty Remarks...
Page 145 Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE Disassembling the front brake calipers Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Front brake pad Brake caliper piston Brake caliper piston seal Bleed screw...
Page 146: Introduction
Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE EAS22220 c. Remove the brake caliper. INTRODUCTION d. Hold the dial gauge at a right angle against EWA14100 the brake disc surface. WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: •...
Page 147: Replacing The Front Brake Pads
Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE d. Measure the brake disc deflection. 2. Install: e. If out of specification, repeat the adjustment • Brake pads steps until the brake disc deflection is within • Brake pad spring specification. NOTE: f.
Page 148: Removing The Front Brake Calipers
Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. L LLL L LLL L LLL L LLL L LLL 3. Install: • Brake pad pin •...
Page 149: Checking The Front Brake Calipers
Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE EAS22410 ASSEMBLING THE FRONT BRAKE CALIPERS EWA13620 WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.
Page 150: Removing The Front Brake Master Cylinder
Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE 3. Install: • Front brake pads • Brake pad spring • Brake pad pin • Brake pad clips • Front brake caliper Front brake caliper bolt 35 Nm (3.5 m·kg, 25 ft·lb) Refer to “REPLACING THE FRONT BRAKE 7.
Page 151: Assembling The Front Brake Master Cylinder
Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE 2. Check: • Front brake hose union bolt “2” • Brake master cylinder kit Damage/scratches/wear → Replace. Front brake hose union bolt 30 Nm (3.0 m·kg, 22 ft·lb) 3. Check: • Brake fluid reservoir EWA13530 Cracks/damage →...
Page 152 Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE ECA13540 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” on page 3-23. 5.
Page 153: Rear Brake
Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 17 Nm (1.7 m kg, 12 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft •...
Page 154 Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE Removing the rear brake master cylinder 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • 30 Nm (3.0 m kg, 22 ft •...
Page 155 Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake hose joint Bush Brake master cylinder body For assembly, reverse the disassembly procedure. 4-33 Email: info@motomatrix.co.uk...
Page 156 Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE Removing the rear brake caliper 30 Nm (3.0 m kg, 22 ft • • 22 Nm (2.2 m kg, 16 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Parts to remove Q’ty Remarks...
Page 157 Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kg, 4.3 ft • • 17 Nm (1.7 m kg, 12 ft • • 3 Nm (0.3 m kg, 2.2 ft • • Order Job/Parts to remove Q’ty Remarks...
Page 158: Introduction
Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14100 5.5 mm (0.22 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc deflection ventive measures: Refer to “CHECKING THE FRONT BRAKE •...
Page 159: Removing The Rear Brake Caliper
Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE 4. Check: NOTE: • Brake fluid level Always install new brake pads, brake pad shims, Below the minimum level mark “a” → Add the and a brake pad spring as a set. recommended brake fluid to the proper level. M MMM M MMM M MMM...
Page 160: Checking The Rear Brake Caliper
Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE • Brake caliper body “3” Cracks/damage → Replace the brake caliper assembly. • Brake fluid delivery passages (brake caliper body) Obstruction → Blow out with compressed air. EWA13610 WARNING Whenever a brake caliper is disassembled, replace the brake caliper piston seals.
Page 161: Installing The Rear Brake Caliper
Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE EAS22670 INSTALLING THE REAR BRAKE CALIPER Recommended fluid 1. Install: DOT 4 • Rear brake caliper “1” (temporarily) EWA13090 WARNING • Copper washers • Use only the designated brake fluid. Other • Rear brake hose “2” brake fluids may cause the rubber seals to •...
Page 162: Removing The Rear Brake Master Cylinder
Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE EAS22700 EAS22730 REMOVING THE REAR BRAKE MASTER ASSEMBLING THE REAR BRAKE MASTER CYLINDER CYLINDER EWA13520 NOTE: WARNING Before removing the rear brake master cylinder, • Before installation, all internal brake com- drain the brake fluid from the entire brake sys- ponents should be cleaned and lubricated tem.
Page 163 Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE EWA13090 7. Adjust: WARNING • Rear brake light operation timing • Use only the designated brake fluid. Other Refer to “ADJUSTING THE REAR BRAKE brake fluids may cause the rubber seals to LIGHT SWITCH” on page 3-22. deteriorate, causing leakage and poor brake performance.
Page 164: Handlebar
Manuals by Motomatrix / www.motomatrix.co.uk HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 20 Nm (2.0 m kg, 14 ft 14 Nm (1.4 m kg, 10 ft • • • • 29 Nm (2.9 m kg, 21 ft 14 Nm (1.4 m kg, 10 ft •...
Page 165 Manuals by Motomatrix / www.motomatrix.co.uk HANDLEBAR Removing the handlebar 20 Nm (2.0 m kg, 14 ft 14 Nm (1.4 m kg, 10 ft • • • • 29 Nm (2.9 m kg, 21 ft 14 Nm (1.4 m kg, 10 ft •...
Page 166: Removing The Handlebar
Manuals by Motomatrix / www.motomatrix.co.uk HANDLEBAR EAS22860 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Handlebar grip “1” NOTE: Blow compressed air between the handlebar 3.
Page 167 Manuals by Motomatrix / www.motomatrix.co.uk HANDLEBAR NOTE: Grip end • Align the mating surfaces of the clutch master 29 Nm (2.9 m·kg, 21 ft·lb) cylinder holder with the punch mark “a” on the handlebar. M MMM M MMM M MMM M MMM M MMM a.
Page 168 Manuals by Motomatrix / www.motomatrix.co.uk HANDLEBAR 9. Install: • Front brake master cylinder assembly • Front brake master cylinder holder “1” Front brake master cylinder holder bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) NOTE: • Align the end of the brake master cylinder hold- er with the punch mark “a”...
Page 169: Front Fork
Manuals by Motomatrix / www.motomatrix.co.uk FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 26 Nm (2.6 m kg, 19 ft • • 20 Nm (2.0 m kg, 14 ft • • 28 Nm (2.8 m kg, 20 ft •...
Page 170 Manuals by Motomatrix / www.motomatrix.co.uk FRONT FORK Disassembling the front fork legs 20 Nm (2.0 m kg, 14 ft • • 25 Nm (2.5 m kg, 18 ft • • 35 Nm (3.5 m kg, 25 ft • • Order Job/Parts to remove Q’ty Remarks...
Page 171 Manuals by Motomatrix / www.motomatrix.co.uk FRONT FORK Disassembling the front fork legs 20 Nm (2.0 m kg, 14 ft • • 25 Nm (2.5 m kg, 18 ft • • 35 Nm (3.5 m kg, 25 ft • • Order Job/Parts to remove Q’ty Remarks...
Page 172: Removing The Front Fork Legs
Manuals by Motomatrix / www.motomatrix.co.uk FRONT FORK EAS22960 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over.
Page 173: Checking The Front Fork Legs
Manuals by Motomatrix / www.motomatrix.co.uk FRONT FORK d. Remove the cap bolt. EAS23010 CHECKING THE FRONT FORK LEGS e. Remove the rod holder and fork spring com- The following procedure applies to both of the pressor. front fork legs. f. Remove the spacer and nut. 1.
Page 174: Assembling The Front Fork Legs
Manuals by Motomatrix / www.motomatrix.co.uk FRONT FORK ECA14200 CAUTION: • The front fork leg has a built-in damper ad- justing rod and a very sophisticated inter- nal construction, which are particularly sensitive to foreign material. • When disassembling and assembling the front fork leg, do not allow any foreign ma- terial to enter the front fork.
Page 175 Manuals by Motomatrix / www.motomatrix.co.uk FRONT FORK • Lubricate the outer surface of the inner tube NOTE: with fork oil. Adjust the oil seal clip so that it fits into the outer • Before installing the oil seal, cover the top of tube’s groove.
Page 176 Manuals by Motomatrix / www.motomatrix.co.uk FRONT FORK 14.Measure: • Front fork leg oil level “a” (from the top of the inner tube, with the outer tube fully compressed and without the fork spring) Out of specification → Correct. Level 65.0 mm (2.56 in) 10.Fully compress the front fork leg.
Page 177 Manuals by Motomatrix / www.motomatrix.co.uk FRONT FORK j. Install the nut “4” all the way onto the damper rod assembly. d. Install the upper spring seat and nut. e. Reinstall the rod puller attachment. f. Install the spacer. k. Install the damper adjusting rod. g.
Page 178: Installing The Front Fork Legs
Manuals by Motomatrix / www.motomatrix.co.uk FRONT FORK EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: • Front fork leg Temporarily tighten the upper and lower bracket pinch bolts. NOTE: Make sure the outer tube is flush with the top of the handlebar holder.
Page 179: Steering Head
Manuals by Motomatrix / www.motomatrix.co.uk STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 110 Nm (11.0 m kg, 80 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 180 Manuals by Motomatrix / www.motomatrix.co.uk STEERING HEAD Removing the lower bracket 110 Nm (11.0 m kg, 80 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 2nd 23 Nm (2.3 m kg, 17 ft •...
Page 181: Removing The Lower Bracket
Manuals by Motomatrix / www.motomatrix.co.uk STEERING HEAD EAS23110 3. Replace: REMOVING THE LOWER BRACKET • Bearings 1. Stand the vehicle on a level surface. • Bearing races EWA13120 M MMM M MMM M MMM M MMM M MMM WARNING a. Remove the bearing races from the steering Securely support the vehicle so that there is head pipe with a long rod “1”...
Page 182 Manuals by Motomatrix / www.motomatrix.co.uk STEERING HEAD 2. Install: • Lower ring nut “1” • Rubber washer “2” • Upper ring nut “3” • Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-25. 3. Install: •...
Page 183: Rear Shock Absorber Assembly
Manuals by Motomatrix / www.motomatrix.co.uk REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 40 Nm (4.0 m kg, 29 ft • • 40 Nm (4.0 m kg, 29 ft • • 49 Nm (4.9 m kg, 35 ft •...
Page 184: Handling The Rear Shock Absorber
Manuals by Motomatrix / www.motomatrix.co.uk REAR SHOCK ABSORBER ASSEMBLY EAS23180 NOTE: HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that the EWA13740 WARNING rear wheel is elevated. This rear shock absorber contains highly 2. Remove: compressed nitrogen gas.
Page 185: Installing The Connecting Arm And Relay Arm
Manuals by Motomatrix / www.motomatrix.co.uk REAR SHOCK ABSORBER ASSEMBLY • Oil seals Damage/pitting → Replace. 3. Check: • Collars • Spacers Damage/scratches → Replace. EAS23270 INSTALLING THE CONNECTING ARM AND RELAY ARM 1. Lubricate: • Spacers • Bearings Recommended lubricant Lithium-soap-based grease 2.
Page 186: Installing The Rear Shock Absorber Assembly
Manuals by Motomatrix / www.motomatrix.co.uk REAR SHOCK ABSORBER ASSEMBLY Relay arm nut (relay arm and connecting arm) 49 Nm (4.9 m·kg, 35 ft·lb) EAS23310 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: • Spacers • Bearings Recommended lubricant Lithium-soap-based grease 2.
Page 187: Swingarm
Manuals by Motomatrix / www.motomatrix.co.uk SWINGARM EAS23330 SWINGARM Removing the swingarm 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 25 Nm (2.5 m kg, 18 ft •...
Page 188 Manuals by Motomatrix / www.motomatrix.co.uk SWINGARM Removing the swingarm 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 25 Nm (2.5 m kg, 18 ft •...
Page 189: Removing The Swingarm
Manuals by Motomatrix / www.motomatrix.co.uk SWINGARM EAS23350 EAS23360 REMOVING THE SWINGARM CHECKING THE SWINGARM 1. Stand the vehicle on a level surface. 1. Check: • Swingarm EWA13120 WARNING Bends/cracks/damage → Replace. Securely support the vehicle so that there is 2. Check: no danger of it falling over.
Page 190 Manuals by Motomatrix / www.motomatrix.co.uk SWINGARM • Bearing “3” • Oil seal “4” Installed depth of bearing “a” 6.3 mm (0.25 in) Installed depth of bearing “b” 5.7 mm (0.22 in) Installed depth of oil seal “c” 0.5–1.0 mm (0.02–0.04 in) Installed depth of oil seal “d”...
Page 191: Chain Drive
Manuals by Motomatrix / www.motomatrix.co.uk CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive sprocket and drive chain 10 Nm (1.0 m kg, 7.2 ft 26 Nm (2.6 m kg, 19 ft • • • • 24 Nm (2.4 m kg, 17 ft •...
Page 192: Removing The Drive Chain
Manuals by Motomatrix / www.motomatrix.co.uk CHAIN DRIVE EAS23410 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.
Page 193: Checking The Drive Sprocket
Manuals by Motomatrix / www.motomatrix.co.uk CHAIN DRIVE b. Correct L LLL L LLL L LLL L LLL L LLL 1. Drive chain roller 4. Check: 2. Drive chain sprocket • O-rings “1” Damage → Replace the drive chain. EAS23470 • Drive chain rollers “2” CHECKING THE REAR WHEEL SPROCKET Damage/wear →...
Page 194 Manuals by Motomatrix / www.motomatrix.co.uk CHAIN DRIVE 3. Install: • Clutch release cylinder Refer to “INSTALLING THE CLUTCH RE- LEASE CYLINDER” on page 5-62. 4-72 Email: info@motomatrix.co.uk...
Page 195 Manuals by Motomatrix / www.motomatrix.co.uk Email: info@motomatrix.co.uk...
Page 196 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE ENGINE REMOVAL ..................5-1 CHECKING THE OIL PIPES ..............5-2 CHECKING THE OIL STRAINER ............. 5-2 INSTALLING THE OIL TANK ..............5-2 REMOVING THE MUFFLER END COVERS ..........5-4 INSTALLING THE MUFFLER END COVERS........... 5-4 REMOVING THE ENGINE ..............
Page 197 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH ......................5-46 REMOVING THE CLUTCH ..............5-55 REMOVING THE PRIMARY DRIVE GEAR ..........5-55 CHECKING THE FRICTION PLATES............. 5-55 CHECKING THE CLUTCH PLATES ............5-56 CHECKING THE CLUTCH SPRING PLATE........... 5-56 CHECKING THE CLUTCH HOUSING ............ 5-56 CHECKING THE CLUTCH BOSS............
Page 198 Manuals by Motomatrix / www.motomatrix.co.uk OIL PUMP...................... 5-81 CHECKING THE OIL PUMP ..............5-84 CHECKING THE RELIEF VALVE ............5-84 CHECKING THE OIL STRAINER ............5-84 ASSEMBLING THE OIL PUMP............... 5-84 INSTALLING THE OIL PUMP ..............5-85 CRANKSHAFT ....................5-86 REMOVING THE CONNECTING RODS ..........
Page 199 Manuals by Motomatrix / www.motomatrix.co.uk Email: info@motomatrix.co.uk...
Page 200: Engine Removal
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the oil tank 13 Nm (1.3 m kg, 9.4 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 13 Nm (1.3 m kg, 9.4 ft • •...
Page 201: Checking The Oil Pipes
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL ET5YU1027 CHECKING THE OIL PIPES 1. Check: • Oil pipes Damage → Replace. Obstruction → Wash and blow out with com- pressed air. ET5YU1028 CHECKING THE OIL STRAINER 1. Check: • Oil strainer (oil tank) Damage →...
Page 202 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL Removing the exhaust pipe 7 Nm (0.7 m kg, 5.1 ft • • 24 Nm (2.4 m kg, 17 ft • • 20 Nm (2.0 m kg, 14 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 203: Removing The Muffler End Covers
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL ET5YU1029 REMOVING THE MUFFLER END COVERS 1. Remove: • Muffler end covers “1” NOTE: Before removing a muffler end cover, turn it in the direction of the arrow shown in the illustra- tion. ET5YU1030 INSTALLING THE MUFFLER END COVERS 1.
Page 204 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL Removing the EXUP servo motor and rear exhaust pipe joint 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 205 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL Removing the EXUP servo motor and rear exhaust pipe joint 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 206 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL Removing the EXUP servo motor and rear exhaust pipe joint 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 207 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL Removing the leads 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Stator coil assembly lead Horn lead Wire harness Decompression solenoid coupler Disconnect. Speed sensor coupler Disconnect.
Page 208 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL Removing the down tube 53 Nm (5.3 m kg, 38 ft 53 Nm (5.3 m kg, 38 ft • • • • 53 Nm (5.3 m kg, 38 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 209 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL Removing the down tube 53 Nm (5.3 m kg, 38 ft 53 Nm (5.3 m kg, 38 ft • • • • 53 Nm (5.3 m kg, 38 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 210 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL Removing the engine 7 Nm (0.7 m kg, 5.1 ft • • 74 Nm (7.4 m kg, 53 ft • • 53 Nm (5.3 m kg, 38 ft • • 11 13 74 Nm (7.4 m kg, 53 ft •...
Page 211 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL Removing the engine 7 Nm (0.7 m kg, 5.1 ft • • 74 Nm (7.4 m kg, 53 ft • • 53 Nm (5.3 m kg, 38 ft • • 11 13 74 Nm (7.4 m kg, 53 ft •...
Page 212: Removing The Engine
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL ET5YU1031 3. Position the engine “6” under the vehicle for REMOVING THE ENGINE installation. NOTE: 4. Install: Pass a suitable rod through the hole in the swin- • Engine “6” garm pivot shaft and secure the rod to support •...
Page 213 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL NOTE: Engine mounting nut (front lower Do not fully tighten the bolts and nuts. side) 94 Nm (9.4 m·kg, 68 ft·lb) 7. Tighten: Engine bracket nut (front upper • Down tube nut (front side) “14” side) •...
Page 214 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL 5-15 Email: info@motomatrix.co.uk...
Page 215: Camshafts
Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS EAS23750 CAMSHAFTS Removing the camshaft sprocket cover 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 216 Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS Removing cylinder head covers 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Tappet cover bolt...
Page 217 Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS Removing the push rods and rocker arms 10 Nm (1.0 m kg, 7.2 ft • • 20 Nm (2.0 m kg, 14 ft • • 24 Nm (2.4 m kg, 17 ft • • Order Job/Parts to remove Q’ty...
Page 218 Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS Removing the valve lifters 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “CYLINDERS AND PISTONS” on Front cylinder page 5-41.
Page 219 Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS Removing the camshafts 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 220: Removing The Rocker Arms, Push Rods And Valve Lifters
Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS EAS23790 REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 1. Align: • TDC mark “a” on the crankshaft position sen- sor rotor (with the pointer “b” on the clutch cover) M MMM M MMM M MMM M MMM M MMM...
Page 221: Checking The Camshafts
Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS EAS23860 CHECKING THE CAMSHAFTS 1. Check: • Cam Blue discoloration/pitting/scratches → Re- place the camshaft. 2. Measure: • Cam dimensions “a” and “b” Out of specification → Replace the camshaft. Camshaft lobe dimensions 3. Remove: Intake A 38.241–38.341 mm (1.5055–...
Page 222 Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS Crankcase hole inside diameter 25.000–25.021 mm (0.9843– 0.9851 in) 3. Measure: • Camshaft journal diameter (crankcase side) “a” Out of specification → Replace the camshaft. 6. Measure: Camshaft journal diameter • Camshaft cover hole inside diameter “a” (crankcase side) Out of specification →...
Page 223: Checking The Rocker Arms And Rocker Arm Shafts
Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS NOTE: Rocker arm shaft outside Calculate the clearance by subtracting the cam- diameter shaft journal diameter (camshaft cover side) 17.976–17.991 mm (0.7077– from the camshaft cover hole inside diameter. 0.7083 in) Camshaft to camshaft cover clearance 0.020–0.054 mm (0.0008–0.0021 9.
Page 224: Checking The Valve Lifters And Valve Lifter Cases
Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS 4. Measure: EAS23920 • Valve lifter case inside diameter “a” CHECKING THE VALVE LIFTERS AND Out of specification → Replace. VALVE LIFTER CASES 1. Check: Valve lifter hole inside diameter • Valve lifter (intake) Blue discoloration/excessive wear/pitting/ 23.000–23.021 mm (0.9055–...
Page 225: Checking The Decompression System
Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS • O-ring Damage/wear → Replace the oil seal and O- ring as a set. EAS23980 CHECKING THE DECOMPRESSION SYSTEM 1. Check: • Decompression system NOTE: • Check the decompression system while the decompression push rod is installed in the 2.
Page 226: Bleeding A Valve Lifter
Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS • Align the punch mark “a” on the camshaft drive gear “1” with the punch mark “b” on the cam- shaft driven gear “2”. • Insert a cross-headed screwdriver into one of the holes in the outer camshaft driven gear and rotate the gear until the teeth of both driven gears are aligned.
Page 227 Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS ECA14630 CAUTION: • Do not pump the valve lifter excessively. • Kerosene is highly flammable. 1. Kerosene 2. Valve lifter b. Install the valve lifter into the engine. ECA14650 CAUTION: Be sure to install the valve lifter in its appro- priate position.
Page 228: Installing The Valve Lifters
Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS EAS24070 INSTALLING THE ROCKER ARMS AND PUSH RODS The following procedure applies to both cylin- ders. 1. Install: • Rocker arms “1” • Rocker arm shafts “2” (onto rocker arm base) NOTE: The thread hole “a” of the rocker arm shaft must face to the outside.
Page 229: Installing The Cylinder Head Covers
Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS NOTE: ® Apply locking agent (LOCTITE ) to the threads of the bolt “3”. Cylinder head cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Bolts “3”, “4”: l = 40 mm (1.57 in) Bolts “5”: l = 50 mm (1.97 in) Bolt with washer “6”: l = 50 mm (1.97 in) Bolts “7”: l = 60 mm (2.36 in) A.
Page 230: Cylinder Heads
Manuals by Motomatrix / www.motomatrix.co.uk CYLINDER HEADS EAS24110 CYLINDER HEADS Removing the cylinder heads 45 Nm (4.5 m kg, 32 ft • • 39 Nm (3.9 m kg, 28 ft • • 21 Nm (2.1 m kg, 15 ft • •...
Page 231: Removing The Cylinder Heads
Manuals by Motomatrix / www.motomatrix.co.uk CYLINDER HEADS EAS24140 REMOVING THE CYLINDER HEADS 1. Remove: • Cylinder head nuts NOTE: • Loosen the nuts in the proper sequence as shown. • Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.
Page 232: Installing The Cylinder Heads
Manuals by Motomatrix / www.motomatrix.co.uk CYLINDER HEADS EAS24250 INSTALLING THE CYLINDER HEADS 1. Tighten: • Cylinder head nuts (M12) “1”–“4” Cylinder head nut (M12) 45 Nm (4.5 m·kg, 32 ft·lb) • Cylinder head nuts (M10) “5”, “6” Cylinder head nut (M10) 39 Nm (3.9 m·kg, 28 ft·lb) NOTE: •...
Page 233 Manuals by Motomatrix / www.motomatrix.co.uk VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both cylinders. Cylinder heads Refer to “CYLINDER HEADS” on page 5-31. Valve cotter Upper spring seat Outer valve spring...
Page 234: Valves And Valve Springs
Manuals by Motomatrix / www.motomatrix.co.uk VALVES AND VALVE SPRINGS EAS24280 3. Remove: REMOVING THE VALVES • Upper spring seat “1” The following procedure applies to all of the • Outer valve spring “2” valves and related components. • Inner valve spring “3” NOTE: •...
Page 235 Manuals by Motomatrix / www.motomatrix.co.uk VALVES AND VALVE SPRINGS c. After installing the valve guide, bore the valve guide with the valve guide reamer “3” to ob- tain the proper valve-stem-to-valve-guide clearance. NOTE: After replacing the valve guide, reface the valve seat.
Page 236: Checking The Valve Seats
Manuals by Motomatrix / www.motomatrix.co.uk VALVES AND VALVE SPRINGS Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in) Limit 2.0 mm (0.08 in) Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Limit 2.0 mm (0.08 in) 6. Measure: • Valve stem runout Out of specification →...
Page 237: Checking The Valve Springs
Manuals by Motomatrix / www.motomatrix.co.uk VALVES AND VALVE SPRINGS M MMM M MMM M MMM M MMM M MMM a. Apply a coarse lapping compound “a” to the valve face. ECA13790 CAUTION: Do not let the lapping compound enter the gap between the valve stem and the valve guide.
Page 238: Installing The Valves
Manuals by Motomatrix / www.motomatrix.co.uk VALVES AND VALVE SPRINGS Inner spring Installed compression spring force (intake) 63.00–73.00 N (14.16–16.41 lb) (6.42–7.44 kgf) Installed compression spring force (exhaust) 63.00–73.00 N (14.16–16.41 lb) (6.42–7.44 kgf) Installed length (intake) 29.00 mm (1.14 in) Installed length (exhaust) EAS24340 INSTALLING THE VALVES...
Page 239 Manuals by Motomatrix / www.motomatrix.co.uk VALVES AND VALVE SPRINGS • Upper spring seat “7” 5. To secure the valve cotters onto the valve (into the cylinder head) stem, lightly tap the valve tip with a soft-face hammer. NOTE: ECA13800 Install the valve springs with the larger pitch “a” CAUTION: facing up.
Page 240: Cylinders And Pistons
Manuals by Motomatrix / www.motomatrix.co.uk CYLINDERS AND PISTONS EAS24360 CYLINDERS AND PISTONS Removing the cylinders and pistons Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEADS” on page 5-31. Front cylinder Rear cylinder Cylinder gasket Dowel pin Piston pin clip Piston pin Piston...
Page 241: Removing The Pistons
Manuals by Motomatrix / www.motomatrix.co.uk CYLINDERS AND PISTONS EAS24380 • Oil ring REMOVING THE PISTONS NOTE: The following procedure applies to all of the pis- When removing a piston ring, open the end gap tons. with your fingers and lift the other side of the ring 1.
Page 242: Checking The Piston Rings
Manuals by Motomatrix / www.motomatrix.co.uk CYLINDERS AND PISTONS EAS24430 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.
Page 243: Checking The Piston Pins
Manuals by Motomatrix / www.motomatrix.co.uk CYLINDERS AND PISTONS 3. Measure: 3. Measure: • Piston ring end gap • Piston pin bore diameter “b” Out of specification → Replace the piston Out of specification → Replace the piston. ring. Piston pin bore inside diameter NOTE: 22.004–22.015 mm (0.8663–...
Page 244 Manuals by Motomatrix / www.motomatrix.co.uk CYLINDERS AND PISTONS 90 ˚ 90 ˚ 45 ˚ 2. Install: a. Top ring • Piston “1” b. Upper oil ring rail • Piston pin “2” c. Oil ring expander • Piston pin clips “3” d.
Page 245: Clutch
Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH EAS25060 CLUTCH Removing the clutch cover 10 Nm (1.0 m kg, 7.2 ft • • (10) 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL”...
Page 246 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH Removing the crankshaft position sensor 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Oil seal Bearing Crankshaft position sensor lead holder Crankshaft position sensor For installation, reverse the removal procedure.
Page 247 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH Removing the clutch 23 22 125 Nm (12.5 m kg, 90 ft • • 12 11 10 9 100 Nm (10.0 m kg, 72 ft • • 8 Nm (0.8 m kg, 5.8 ft •...
Page 248 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH Removing the clutch 23 22 125 Nm (12.5 m kg, 90 ft • • 12 11 10 9 100 Nm (10.0 m kg, 72 ft • • 8 Nm (0.8 m kg, 5.8 ft •...
Page 249 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH Removing the clutch master cylinder 14 Nm (1.4 m kg, 10 ft • • 30 Nm (3.0 m kg, 22 ft • • 13 Nm (1.3 m kg, 9.4 ft • • Order Job/Parts to remove Q’ty Remarks Drain.
Page 250 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH Removing the clutch master cylinder 14 Nm (1.4 m kg, 10 ft • • 30 Nm (3.0 m kg, 22 ft • • 13 Nm (1.3 m kg, 9.4 ft • • Order Job/Parts to remove Q’ty Remarks Clutch master cylinder holder...
Page 251 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH Disassembling the clutch master cylinder Order Job/Parts to remove Q’ty Remarks Clutch master cylinder push rod Clutch master cylinder kit Dust seal Circlip Clutch fluid reservoir hose joint O-ring Clutch master cylinder body For assembly, reverse the disassembly procedure.
Page 252 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH Removing the clutch release cylinder 26 Nm (2.6 m kg, 19 ft 10 Nm (1.0 m kg, 7.2 ft • • • • Order Job/Parts to remove Q’ty Remarks Drain. Clutch fluid Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM”...
Page 253 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH Disassembling the clutch release cylinder 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Boots Clutch release cylinder piston Clutch release cylinder spring Clutch release cylinder piston seal Bleed screw For assembly, reverse the disassembly procedure.
Page 254: Removing The Clutch
Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH EAS25080 REMOVING THE CLUTCH Sheave holder 1. Loosen: 90890-01701 • Clutch boss nut “1” Primary clutch holder YS-01880-A NOTE: While holding the clutch boss “2” with the univer- sal clutch holder “3”, loosen the clutch boss nut. Universal clutch holder 90890-04086 YM-91042...
Page 255: Checking The Clutch Plates
Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH EAS25150 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 er- ratic clutch operation. EAS25110 CHECKING THE CLUTCH PLATES The following procedure applies to all of the...
Page 256: Checking The Clutch Push Rods
Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH EAS25190 CHECKING THE CLUTCH PUSH RODS Yamaha bond No. 1215 1. Check: 90890-85505 • O-ring • Short clutch push rod • Long clutch push rod • Ball Cracks/damage/wear → Replace the defec- tive part(s).
Page 257: Installing The Clutch
Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH 3. Install: • Clutch boss “1” • Conical spring washer “2” • Clutch boss nut “3” Clutch boss nut 125 Nm (12.5 m·kg, 90 ft·lb) NOTE: • Lubricate the clutch boss nut threads and con- ical spring washer mating surfaces with engine oil.
Page 258: Disassembling The Clutch Master Cylinder
Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH EAS25280 DISASSEMBLING THE CLUTCH MASTER CYLINDER ECA13840 CAUTION: • Clutch components rarely require disas- sembly. • Therefore, always follow these preventive measures: • Never disassemble clutch components un- less absolutely necessary. 6. Install: • If any connection on the hydraulic clutch •...
Page 259: Checking The Clutch Master Cylinder
Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH EAS25290 EAS25310 CHECKING THE CLUTCH MASTER INSTALLING THE CLUTCH MASTER CYLINDER CYLINDER 1. Install: Recommended clutch component replace- • Clutch master cylinder “1” ment schedule • Clutch master cylinder holder “2” Piston seals Every two years Clutch master cylinder holder Clutch hose Every four years...
Page 260: Removing The Clutch Release Cylinder
Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH 3. Fill: 6. Check: • Clutch fluid reservoir • Clutch lever operation Soft or spongy feeling → Bleed the clutch (with the specified amount of the recom- mended clutch fluid) system. Refer to “BLEEDING THE HYDRAULIC Recommended clutch fluid CLUTCH SYSTEM”...
Page 261: Assembling The Clutch Release Cylinder
Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH 1. Check: • Clutch release cylinder body Cracks/damage → Replace the clutch re- lease cylinder. 2. Check: • Clutch release cylinder • Clutch release cylinder piston Rust/scratches/wear → Replace the clutch release cylinder and clutch release cylinder piston as a set.
Page 262 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH 5. Check: • Clutch lever operation Soft or spongy feeling → Bleed the clutch system. Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 3-14. 5-63 Email: info@motomatrix.co.uk...
Page 263: Shift Shaft
Manuals by Motomatrix / www.motomatrix.co.uk SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kg, 16 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Clutch housing Refer to “CLUTCH”...
Page 264: Checking The Shift Shaft
Manuals by Motomatrix / www.motomatrix.co.uk SHIFT SHAFT EAS25420 • Hook the end of the shift shaft spring onto the CHECKING THE SHIFT SHAFT shift shaft spring stopper “3”. 1. Check: • Shift shaft Bends/damage/wear → Replace. • Shift shaft spring Damage/wear →...
Page 265: Generator And Starter Clutch
Manuals by Motomatrix / www.motomatrix.co.uk GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the stator coil assembly 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 266 Manuals by Motomatrix / www.motomatrix.co.uk GENERATOR AND STARTER CLUTCH Removing the generator rotor 80 Nm (8.0 m kg, 58 ft • • Order Job/Parts to remove Q’ty Remarks Starter clutch idle gear shaft #2 Starter clutch idle gear shaft #1 Starter clutch idle gear #2 Starter clutch idle gear #1 Generator rotor...
Page 267: Removing The Generator
Manuals by Motomatrix / www.motomatrix.co.uk GENERATOR AND STARTER CLUTCH EAS24490 2. Check: REMOVING THE GENERATOR • Starter clutch gear’s contacting surfaces 1. Remove: Damage/pitting/wear → Replace the starter • Generator rotor bolt “1” clutch gear. • Washer 3. Check: NOTE: •...
Page 268 Tighten the generator rotor bolt “1” while holding the generator rotor “2” with a sheave holder “3”. Sheave holder 90890-01701 Primary clutch holder YS-01880-A 3. Apply: • Sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505 5-69 Email: info@motomatrix.co.uk...
Page 269: Electric Starter
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Oil tank Refer to “ENGINE REMOVAL” on page 5-1. Starter motor lead Disconnect. Starter motor assembly For installation, reverse the removal procedure.
Page 270 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks Circlip Starter motor gear Starter motor rear cover Bearing Oil seal Circlip Starter motor front cover Brush Brush holder (along with the brushes) Brush seat (along with the brushes) Bearing Gasket...
Page 271: Checking The Starter Motor
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRIC STARTER EAS24790 M MMM M MMM M MMM M MMM M MMM CHECKING THE STARTER MOTOR a. Measure the armature assembly resistances 1. Check: with the pocket tester. • Commutator Dirt → Clean with 600 grit sandpaper. Pocket tester 2.
Page 272: Assembling The Starter Motor
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRIC STARTER 3. Install: • Starter motor yoke “1” • Starter motor front cover “2” • Starter motor rear cover “3” NOTE: Align the match mark “a” on the starter motor yoke with the match mark “b” on the starter mo- tor rear cover.
Page 273: Crankcase
Manuals by Motomatrix / www.motomatrix.co.uk CRANKCASE EAS25540 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Camshafts Refer to “CAMSHAFTS” on page 5-16. Refer to “CYLINDERS AND PISTONS” on Pistons page 5-41. Shift shaft Refer to “SHIFT SHAFT”...
Page 274 Manuals by Motomatrix / www.motomatrix.co.uk CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Right crankcase For installation, reverse the removal procedure. 5-75 Email: info@motomatrix.co.uk...
Page 275 Manuals by Motomatrix / www.motomatrix.co.uk CRANKCASE Removing the oil baffle plate and bearings Order Job/Parts to remove Q’ty Remarks Oil pump Refer to “OIL PUMP” on page 5-81. Crankshaft Refer to “CRANKSHAFT” on page 5-86. Transmission Refer to “TRANSMISSION” on page 5-92. Oil baffle plate Bearing retainer Bearing retainer...
Page 276: Disassembling The Crankcase
Manuals by Motomatrix / www.motomatrix.co.uk CRANKCASE • M6 × 75 mm bolts: “14”, “15” EAS25570 DISASSEMBLING THE CRANKCASE • M6 × 60 mm bolts: “4”–“7” NOTE: • M6 × 40 mm bolts: “8”, “10”–“12”, “16”–“20” Loosen the generator shaft bolt before removing the generator rotor.
Page 277: Checking The Crankcase
• Sealant 3. Check: (onto the crankcase mating surfaces) • Crankcase Cracks/damage → Replace. Yamaha bond No. 1215 • Oil delivery passages 90890-85505 Obstruction → Blow out with compressed air. NOTE: ET5YU1022 CHECKING THE BEARINGS AND OIL SEAL Do not allow any sealant to come into contact 1.
Page 278 Manuals by Motomatrix / www.motomatrix.co.uk CRANKCASE • Tap lightly on the left crankcase with a soft- face hammer. 4. Install: • Crankcase bolts (M8) • Crankcase bolts (M6) Crankcase bolt (M8) 24 Nm (2.4 m·kg, 17 ft·lb) Crankcase bolt (M6) 10 Nm (1.0 m·kg, 7.2 ft·lb) A.
Page 279 Manuals by Motomatrix / www.motomatrix.co.uk CRANKCASE 5-80 Email: info@motomatrix.co.uk...
Page 280: Oil Pump
Manuals by Motomatrix / www.motomatrix.co.uk OIL PUMP EAS24910 OIL PUMP Removing the oil pump Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-74. Oil strainer (crankcase) Oil pump assembly For installation, reverse the removal procedure. 5-81 Email: info@motomatrix.co.uk...
Page 281 Manuals by Motomatrix / www.motomatrix.co.uk OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Spring retainer Spring Relief valve Oil pump housing cover 1 Spring Collar Ball Oil pump outer rotor 1 Oil pump inner rotor 1 Oil pump housing cover 2 Oil pump shaft Oil pump inner rotor 2...
Page 282 Manuals by Motomatrix / www.motomatrix.co.uk OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil seal Oil pump housing For assembly, reverse the disassembly procedure. 5-83 Email: info@motomatrix.co.uk...
Page 283: Checking The Oil Pump
Manuals by Motomatrix / www.motomatrix.co.uk OIL PUMP EAS24960 3. Check: CHECKING THE OIL PUMP • Oil pump operation 1. Check: Rough movement → Repeat steps (1) and • Oil pump housing (2) or replace the defective part(s). • Oil pump housing cover Cracks/damage/wear →...
Page 284: Installing The Oil Pump
Manuals by Motomatrix / www.motomatrix.co.uk OIL PUMP • Oil pump shaft “6” 3. Check: • Pins “7” • Oil pump operation • Oil pump housing cover 2 “8” Refer to “CHECKING THE OIL PUMP” on page 5-84. Oil pump housing cover 2 screw 2 Nm (0.2 m·kg, 1.4 ft·lb) EAS25020 INSTALLING THE OIL PUMP...
Page 285: Crankshaft
Manuals by Motomatrix / www.motomatrix.co.uk CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-74. Crankshaft Generator shaft Connecting rod cap Big end lower bearing Connecting rod Big end upper bearing For installation, reverse the removal procedure.
Page 286: Removing The Connecting Rods
Manuals by Motomatrix / www.motomatrix.co.uk CRANKSHAFT EAS26010 REMOVING THE CONNECTING RODS The following procedure applies to all of the con- necting rods. 1. Remove: • Connecting rod caps “1” • Connecting rod • Big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.
Page 287 Manuals by Motomatrix / www.motomatrix.co.uk CRANKSHAFT ® c. Put a piece of Plastigauge “1” on the crank- g. Put a mark “1” on the connecting rod bolts “2” shaft pin. and the connecting rod cap “3”. d. Assemble the connecting rod halves. h.
Page 288 Manuals by Motomatrix / www.motomatrix.co.uk CRANKSHAFT For example, if the connecting rod “P ” and the crankshaft web “P” numbers are “5” and “2” respectively, then the bearing size for “P ” “P ” (connecting rod) - “P” (crankshaft) 5 - 2 = 3 (brown) Bearing color code 1.Blue 2.Black 3.Brown 4.Green L LLL...
Page 289: Installing The Connecting Rods
Manuals by Motomatrix / www.motomatrix.co.uk CRANKSHAFT • Be sure to reinstall each big end bearing in its original place. • Make sure the projections “c” on the connect- ing rods face towards the left side of the crank- shaft. • Make sure the characters “d” on both the con- necting rod and connecting rod cap are aligned.
Page 290: Installing The Crankshaft Assembly
Manuals by Motomatrix / www.motomatrix.co.uk CRANKSHAFT a. Tighten the connecting rod bolts to the spec- ECA13970 CAUTION: ified torque. To avoid scratching the crankshaft and to Connecting rod bolt (1st) ease the installation procedure, lubricate the 15 Nm (1.5 m·kg, 11 ft·lb) oil seal lips with lithium-soap-based grease and each bearing with engine oil.
Page 291: Transmission
Manuals by Motomatrix / www.motomatrix.co.uk TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-74. Shift fork guide bar Shift drum assembly Shift fork-L Shift fork-R Shift fork-C Drive axle assembly...
Page 292 Manuals by Motomatrix / www.motomatrix.co.uk TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks Circlip Washer 5th pinion gear Collar Washer 2nd/3rd pinion gear Circlip Washer 4th pinion gear Collar Main axle/1st pinion gear For assembly, reverse the disassembly procedure.
Page 293 Manuals by Motomatrix / www.motomatrix.co.uk TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks 5th wheel gear Circlip Washer 2nd wheel gear Collar Circlip Washer 1st wheel gear Collar Washer 4th wheel gear Circlip Washer 3rd wheel gear Collar Drive axle For assembly, reverse the disassembly...
Page 294: Checking The Shift Forks
Manuals by Motomatrix / www.motomatrix.co.uk TRANSMISSION EAS26260 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. EAS26300 CHECKING THE TRANSMISSION 1.
Page 295: Assembling The Main Axle And Drive Axle
Manuals by Motomatrix / www.motomatrix.co.uk TRANSMISSION • Transmission gear dogs EAS26320 INSTALLING THE SHIFT FORKS AND SHIFT Cracks/damage/rounded edges → Replace DRUM ASSEMBLY the defective gear(s). 1. Install: 4. Check: • Shift fork-R “1” • Transmission gear engagement • Shift fork-C “2” (each pinion gear to its respective wheel •...
Page 296 Manuals by Motomatrix / www.motomatrix.co.uk FUEL Email: info@motomatrix.co.uk...
Page 297 Manuals by Motomatrix / www.motomatrix.co.uk FUEL SYSTEM FUEL TANK..................... 6-1 REMOVING THE FUEL TANK ..............6-2 REMOVING THE FUEL PUMP ..............6-2 CHECKING THE FUEL PUMP BODY............6-2 CHECKING THE FUEL PUMP OPERATION..........6-2 INSTALLING THE FUEL PUMP..............6-2 INSTALLING THE FUEL TANK..............6-2 THROTTLE BODIES ..................
Page 298 Manuals by Motomatrix / www.motomatrix.co.uk Email: info@motomatrix.co.uk...
Page 299: Fuel Tank
Manuals by Motomatrix / www.motomatrix.co.uk FUEL TANK EAS26620 FUEL TANK Removing the fuel tank and fuel pump 7 Nm (0.7 m kg, 5.1 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
Page 300: Removing The Fuel Tank
Manuals by Motomatrix / www.motomatrix.co.uk FUEL TANK EAS26630 EAS26670 REMOVING THE FUEL TANK CHECKING THE FUEL PUMP BODY 1. Extract the fuel in the fuel tank through the 1. Check: fuel tank cap with a pump. • Fuel pump body Obstruction →...
Page 301 Manuals by Motomatrix / www.motomatrix.co.uk FUEL TANK EC5YU1017 CAUTION: When installing the fuel hose and the fuel re- turn hose, make sure that they are securely connected, and that the fuel hose connector cover on the fuel hose is in the correct posi- tion, otherwise the fuel hose will not be prop- erly installed.
Page 302: Throttle Bodies
Manuals by Motomatrix / www.motomatrix.co.uk THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the pressure regulator and rollover valves 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 9 Nm (0.9 m kg, 6.5 ft •...
Page 303 Manuals by Motomatrix / www.motomatrix.co.uk THROTTLE BODIES Removing the pressure regulator and rollover valves 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 9 Nm (0.9 m kg, 6.5 ft • •...
Page 304 Manuals by Motomatrix / www.motomatrix.co.uk THROTTLE BODIES Removing the throttle bodies 4 Nm (0.4 m kg, 2.9 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
Page 305 Manuals by Motomatrix / www.motomatrix.co.uk THROTTLE BODIES Removing the intake manifolds 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Fuel hose Fuel hose (intake manifold assembly to pressure regulator) Cylinder-#2 ISC (idle speed control) unit outlet hose Cylinder-#1 ISC (idle speed control) unit outlet hose...
Page 306 Manuals by Motomatrix / www.motomatrix.co.uk THROTTLE BODIES Removing the injectors 30 Nm (3.0 m kg, 22 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Parts to remove Q’ty Remarks Fuel pipe...
Page 307: Checking The Injectors
Manuals by Motomatrix / www.motomatrix.co.uk THROTTLE BODIES EAS26980 EAS27010 CHECKING THE INJECTORS CHECKING THE PRESSURE REGULATOR 1. Check: OPERATION • Injectors 1. Check: Damage → Replace. • Pressure regulator operation M MMM M MMM M MMM M MMM M MMM a.
Page 308: Adjusting The Throttle Position Sensor
Manuals by Motomatrix / www.motomatrix.co.uk THROTTLE BODIES h. Use the vacuum/pressure pump gauge set to adjust the fuel pressure in relation to the vac- uum pressure as described below. NOTE: The vacuum pressure should not exceed 100 kPa (760 mm Hg). •...
Page 309: Isc (Idle Speed Control) Unit
Manuals by Motomatrix / www.motomatrix.co.uk ISC (IDLE SPEED CONTROL) UNIT ET5YU1012 ISC (IDLE SPEED CONTROL) UNIT Removing the ISC (idle speed control) unit and intake solenoid 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft 9 Nm (0.9 m kg, 6.5 ft •...
Page 310 Manuals by Motomatrix / www.motomatrix.co.uk ISC (IDLE SPEED CONTROL) UNIT Removing the ISC (idle speed control) unit and intake solenoid 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft 9 Nm (0.9 m kg, 6.5 ft •...
Page 311: Checking The Isc (Idle Speed Control) System
Manuals by Motomatrix / www.motomatrix.co.uk ISC (IDLE SPEED CONTROL) UNIT ET5YU1015 CHECKING THE ISC (IDLE SPEED CONTROL) SYSTEM 1. Check: • Hoses Loose connections → Connect properly. Cracks/damage → Replace. 2. Check: • Surge tank Cracks/damage → Replace. 3. Check: •...
Page 312 Manuals by Motomatrix / www.motomatrix.co.uk Email: info@motomatrix.co.uk...
Page 313 Manuals by Motomatrix / www.motomatrix.co.uk – ELEC Email: info@motomatrix.co.uk...
Page 314 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL SYSTEM IGNITION SYSTEM ..................7-1 CIRCUIT DIAGRAM .................. 7-1 TROUBLESHOOTING ................7-3 ELECTRIC STARTING SYSTEM ..............7-5 CIRCUIT DIAGRAM .................. 7-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......7-7 TROUBLESHOOTING ................7-9 CHARGING SYSTEM..................7-11 CIRCUIT DIAGRAM ................
Page 315 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS..............7-85 CHECKING THE SWITCHES ..............7-89 CHECKING THE BULBS AND BULB SOCKETS ........7-92 CHECKING THE FUSES ................ 7-93 CHECKING AND CHARGING THE BATTERY........7-94 CHECKING THE RELAYS ..............7-96 CHECKING THE TURN SIGNAL/HAZARD RELAY........ 7-97 CHECKING THE RELAY UNIT (DIODE) ..........
Page 316: Ignition System
Manuals by Motomatrix / www.motomatrix.co.uk IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM Email: info@motomatrix.co.uk...
Page 317 Manuals by Motomatrix / www.motomatrix.co.uk IGNITION SYSTEM 3. Main switch 4. Battery 8. Main fuse 10.ECU fuse 13.Relay unit 14.Starting circuit cut-off relay 16.Neutral switch 19.Sidestand switch 20.Crankshaft position sensor 24.Lean angle cut-off switch 29.ECU (electronic control unit) 32.Spark plug 33.Cylinder-#2 right ignition coil 34.Cylinder-#2 left ignition coil 35.Cylinder-#1 left ignition coil...
Page 318: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk IGNITION SYSTEM EAS27150 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Air filter case 4. Battery box 5.
Page 319 Manuals by Motomatrix / www.motomatrix.co.uk IGNITION SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch/immobilizer unit. SWITCHES” on page 7-89. OK ↓ NG → 9. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch.
Page 320: Electric Starting System
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM Email: info@motomatrix.co.uk...
Page 321 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRIC STARTING SYSTEM 3. Main switch 4. Battery 6. Starter relay 7. Starter motor 8. Main fuse 10.ECU fuse 13.Relay unit 14.Starting circuit cut-off relay 16.Neutral switch 19.Sidestand switch 29.ECU (electronic control unit) 38.Decompression solenoid 56.Clutch switch 70.Auto decompression fuse 73.Engine stop switch...
Page 322: Starting Circuit Cut-Off System Operation
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is turned “ON” (both switch circuits are closed), the starter motor can only operate if at least one of the following conditions is met: •...
Page 323 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEUTRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5.
Page 324: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Air filter case 4. Oil tank NG → 1. Check the fuses. (Main, ignition, auto decompression, and ECU) Replace the fuse(s).
Page 325 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRIC STARTING SYSTEM NG → 8. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 7-89. OK ↓ NG → 9. Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch.
Page 326: Charging System
Manuals by Motomatrix / www.motomatrix.co.uk CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 7-11 Email: info@motomatrix.co.uk...
Page 327 Manuals by Motomatrix / www.motomatrix.co.uk CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 4. Battery 8. Main fuse 7-12 Email: info@motomatrix.co.uk...
Page 328: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk CHARGING SYSTEM EAS27220 TROUBLESHOOTING The battery is not being charged. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUSES” on page 7-93.
Page 329 Manuals by Motomatrix / www.motomatrix.co.uk CHARGING SYSTEM 7-14 Email: info@motomatrix.co.uk...
Page 330: Lighting System
Manuals by Motomatrix / www.motomatrix.co.uk LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 7-15 Email: info@motomatrix.co.uk...
Page 331 Manuals by Motomatrix / www.motomatrix.co.uk LIGHTING SYSTEM 3. Main switch 4. Battery 8. Main fuse 10.ECU fuse 29.ECU (electronic control unit) 47.High beam indicator light 50.Meter light 54.Headlight relay 57.Pass switch 58.Dimmer switch 67.Auxiliary light 68.Headlight (high beam) 69.Headlight (low beam) 75.Tail/brake light 76.License plate light 80.Headlight fuse...
Page 332: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight (high beam), headlight (low beam), high beam indicator light, taillight, license plate light, auxiliary light or meter light. NOTE: • Before troubleshooting, remove the following part(s): 1.
Page 333 Manuals by Motomatrix / www.motomatrix.co.uk LIGHTING SYSTEM NG → 8. Check the entire lighting system wiring. Properly connect or repair the lighting Refer to “CIRCUIT DIAGRAM” on system wiring. page 7-15. OK ↓ This circuit is OK. 7-18 Email: info@motomatrix.co.uk...
Page 334: Signaling System
Manuals by Motomatrix / www.motomatrix.co.uk SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 7-19 Email: info@motomatrix.co.uk...
Page 335 Manuals by Motomatrix / www.motomatrix.co.uk SIGNALING SYSTEM 3. Main switch 4. Battery 8. Main fuse 10.ECU fuse 12.Backup fuse (odometer, clock and immobilizer system) 13.Relay unit 16.Neutral switch 18.Fuel sender 25.Speed sensor 29.ECU (electronic control unit) 42.Fuel level warning light 43.Neutral indicator light 44.Multi-function meter 45.Engine trouble warning light...
Page 336: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or indicator light. • The horn fails to sound. • The speedometer fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1.
Page 337 Manuals by Motomatrix / www.motomatrix.co.uk SIGNALING SYSTEM NG → 3. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 7-19. OK ↓ This circuit is OK. The tail/brake light fails to come on. NG →...
Page 338 Manuals by Motomatrix / www.motomatrix.co.uk SIGNALING SYSTEM NG → 5. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 7-19. OK ↓ This circuit is OK. The neutral indicator light fails to come on. NG →...
Page 339 Manuals by Motomatrix / www.motomatrix.co.uk SIGNALING SYSTEM 7-24 Email: info@motomatrix.co.uk...
Page 340: Fuel Injection System
Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 7-25 Email: info@motomatrix.co.uk...
Page 341 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM 3. Main switch 4. Battery 5. Fuel injection system fuse 8. Main fuse 10.ECU fuse 15.Fuel pump relay 16.Neutral switch 17.Fuel pump 19.Sidestand switch 20.Crankshaft position sensor 21.Throttle position sensor 22.Cylinder-#1 intake air pressure sensor 23.Cylinder-#2 intake air pressure sensor 24.Lean angle cut-off switch 25.Speed sensor...
Page 342: Ecu Self-Diagnostic Function
Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Page 343: Self-Diagnostic Function Table
Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM a. Main switch “OFF” d. Engine trouble warning light on for 1.4 seconds b. Main switch “ON” c. Engine trouble warning light off EAS27380 SELF-DIAGNOSTIC FUNCTION TABLE If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.
Page 344 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive No normal signal is received from sensor Able Able the O sensor. Cylinder-#2 intake air Cylinder-#2 intake air pressure pressure sensor sensor: open or short circuit...
Page 345 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive No normal signals are received Speed sensor from the speed sensor. Able Able Open or short circuit is detected in Neutral switch the neutral switch.
Page 346: Troubleshooting Method
Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM EAS27400 4. Turn the main switch to “OFF” and back to TROUBLESHOOTING METHOD “ON”, then check that no fault code number is displayed. The engine operation is not normal and the NOTE: engine trouble warning light comes on.
Page 347 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM NOTE: • All displays on the meter disappear except the clock and odometer/trip meter/fuel reserve trip meter displays. • “dIAG” appears on the odometer/trip meter/fuel reserve trip meter LCD. 4. Press the “SELECT” button to select the diagnostic mode “dIAG”. 5.
Page 348 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. Cylinder-#1 intake air pressure sensor: hose • Cylinder-#1 intake air pressure sensor hose system malfunction is detached, clogged, kinked, or pinched. (clogged or detached •...
Page 349 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in wire sub lead. • Open or short circuit in wire harness. Malfunction detected in the • Malfunction in cylinder-#1 left or right primary wire of the ignition coil.
Page 350 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open circuit in wire harness. • Defective speed sensor. No normal signals are • Malfunction in vehicle speed sensor received from the speed detected.
Page 351 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. Non-registered data has • Improper connection in wire harness. Er-4 been received from the • Malfunction in meter. — meter. • Malfunction in ECU. Sensor operation table Diag- nostic...
Page 352 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Engine temperature Displays the engine Compare the actually temperature. measured engine temperature with the meter display value. Muffler cooling fan Displays the muffler cooling Compare the actually temperature fan temperature.
Page 353 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Stopping the flashing of the To stop the flashing of the engine trouble warning light engine trouble warning (erasing the muffler cooling light, set the engine stop fan temperature sensor switch to “...
Page 354: Troubleshooting Details
Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the fuel pump relay for five times every second. Illuminates the engine trouble warning light. Check the operating sound Fuel pump relay (The engine trouble warning of the fuel pump relay five light is OFF when the relay is times.
Page 355 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Code number displayed on the meter when the engine failed to work normally. Refer to “Self-Diagnos- tic Function table”. Diagnostic code No.: Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOSTIC MODE”...
Page 356 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Cylinder-#1 intake air pressure sensor: open or short cir- cuit detected. Diagnostic code No. Cylinder-#1 intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections...
Page 357 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Cylinder-#1 intake air pressure sensor: hose system mal- function (clogged or detached hose). Diagnostic code No. Cylinder-#1 intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method...
Page 358 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor: open or short circuit detected. Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position •...
Page 359 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom EXUP servo motor circuit: open or short circuit detected. Diagnostic code No. EXUP servo motor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
Page 360 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom A break or disconnection of the blue/yellow lead of the ECU is detected. Diagnostic code No. Sidestand switch Order Item/components and probable Check or maintenance job Reinstatement cause method Connections •...
Page 361 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom No normal signal is received from the O sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed state of O sensor.
Page 362 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Cylinder-#2 intake air pressure sensor: open or short cir- cuit detected. Diagnostic code No. Cylinder-#2 intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections...
Page 363 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Cylinder-#2 intake air pressure sensor: hose system mal- function (clogged or detached hose). Diagnostic code No. Cylinder-#2 intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method...
Page 364 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Engine temperature sensor: open or short circuit detect- Diagnostic code No. Engine temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed state of engine temperature Check for looseness or pinching.
Page 365 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Decompression solenoid (thermistor): open or short cir- cuit detected. Diagnostic code No. Decompression solenoid Order Item/components and probable Check or maintenance job Reinstatement cause method Installed state of decompression Check for looseness or pinching.
Page 366 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinder-#1 left or right ignition coil. Diagnostic code No. 30, 32 Cylinder-#1 left or right ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause...
Page 367 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinder-#2 left ignition coil. Diagnostic code No. Cylinder-#2 left ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections...
Page 368 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinder-#1 left or right ignition coil. Diagnostic code No. 30, 32 Cylinder-#1 left or right ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause...
Page 369 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinder-#2 right ignition coil. Diagnostic code No. Cylinder-#2 right ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections...
Page 370 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Engine speed is high when the engine is idling. Diagnostic code No. ISC valve Order Item/components and probable Check or maintenance job Reinstatement cause method ECU fuse is blown. •...
Page 371 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Decompression solenoid: open or short circuit detected. Diagnostic code No. Decompression solenoid Order Item/components and probable Check or maintenance job Reinstatement cause method Installed state of decompression Check for looseness or pinching. Turning the solenoid.
Page 372 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Lean angle cut-off switch: open or short circuit detected. Diagnostic code No. Lean angle cut-off switch Order Item/components and probable Check or maintenance job Reinstatement cause method Connections •...
Page 373 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. Diagnostic code No. Speed sensor Neutral switch Order Item/components and probable Check or maintenance job Reinstatement cause...
Page 374 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. Diagnostic code No. Speed sensor Neutral switch Order Item/components and probable Check or maintenance job Reinstatement cause...
Page 375 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom The ECU is unable to monitor the battery voltage (an open or short circuit in the line to the ECU). Diagnostic code No. Fuel system voltage Order Item/components and probable Check or maintenance job Reinstatement cause...
Page 376 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the fuel injection system is not normal. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the •...
Page 377 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Muffler cooling fan temperature sensor: open or short cir- cuit detected. Diagnostic code No. Muffler cooling fan temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of muffler cooling...
Page 378 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Engine trouble warning light is flashing. (Abnormally high temperature is detected by muffler cooling fan tempera- ture sensor.) Diagnostic code No. Muffler cooling fan temperature sensor Muffler cooling fan motor relay Stopping the flashing of the engine trouble warning light (erasing the muffler cooling fan temperature sensor fault code)
Page 379 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Er-2 Symptom No signals are received from the ECU within the specified duration. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections •...
Page 380 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom Non-registered data has been received from the meter. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
Page 381 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM 7-66 Email: info@motomatrix.co.uk...
Page 382: Fuel Pump System
Manuals by Motomatrix / www.motomatrix.co.uk FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 7-67 Email: info@motomatrix.co.uk...
Page 383 Manuals by Motomatrix / www.motomatrix.co.uk FUEL PUMP SYSTEM 3. Main switch 4. Battery 5. Fuel injection system fuse 8. Main fuse 10.ECU fuse 15.Fuel pump relay 17.Fuel pump 29.ECU (electronic control unit) 73.Engine stop switch 81.Ignition fuse 7-68 Email: info@motomatrix.co.uk...
Page 384: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Air filter case NG → 1. Check the fuses. (Main, ignition, fuel injection system, and ECU) Replace the fuse(s).
Page 385 Manuals by Motomatrix / www.motomatrix.co.uk FUEL PUMP SYSTEM 7-70 Email: info@motomatrix.co.uk...
Page 386: Muffler Cooling System
Manuals by Motomatrix / www.motomatrix.co.uk MUFFLER COOLING SYSTEM ET5YU1002 MUFFLER COOLING SYSTEM ET5YU1003 CIRCUIT DIAGRAM 7-71 Email: info@motomatrix.co.uk...
Page 387 Manuals by Motomatrix / www.motomatrix.co.uk MUFFLER COOLING SYSTEM 4. Battery 8. Main fuse 9. Muffler cover fan fuse 10.ECU fuse 26.Muffler cooling fan temperature sensor 29.ECU (electronic control unit) 78.Muffler cooling fan motor 79.Muffler cooling fan motor relay 7-72 Email: info@motomatrix.co.uk...
Page 388: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk MUFFLER COOLING SYSTEM ET5YU1004 TROUBLESHOOTING The muffler cooling fan motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat NG → 1. Check the fuses. (Main, muffler cover fan, and ECU) Replace the fuse(s).
Page 389 Manuals by Motomatrix / www.motomatrix.co.uk MUFFLER COOLING SYSTEM 7-74 Email: info@motomatrix.co.uk...
Page 390: Immobilizer System
Manuals by Motomatrix / www.motomatrix.co.uk IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 7-75 Email: info@motomatrix.co.uk...
Page 391 Manuals by Motomatrix / www.motomatrix.co.uk IMMOBILIZER SYSTEM 3. Main switch 4. Battery 8. Main fuse 10.ECU fuse 11.Immobilizer unit 12.Backup fuse (odometer, clock and immobilizer system) 29.ECU (electronic control unit) 44.Multi-function meter 46.Immobilizer system indicator light 81.Ignition fuse 7-76 Email: info@motomatrix.co.uk...
Page 392: General Information
Manuals by Motomatrix / www.motomatrix.co.uk IMMOBILIZER SYSTEM EAS27670 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) •...
Page 393 Manuals by Motomatrix / www.motomatrix.co.uk IMMOBILIZER SYSTEM Parts to be replaced Main switch/immo- Key registration re- Accesso- bilizer unit Standard quirement ry lock* Main Immobiliz- and key switch er unit √ Standard key is lost New standard key All keys have been Code re-registering √...
Page 394 Manuals by Motomatrix / www.motomatrix.co.uk IMMOBILIZER SYSTEM Standby mode a. Main switch “ON” d. LED off b. Main switch “OFF” e. Standby mode on c. LED on f. Standby mode off Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced.
Page 395 Manuals by Motomatrix / www.motomatrix.co.uk IMMOBILIZER SYSTEM Standard key registration a. Main switch “ON” g. First standard key b. Main switch “OFF” h. Second standard key c. LED on i. Registration mode d. LED off A. Registration of the second standard key is e.
Page 396: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk IMMOBILIZER SYSTEM EAS27700 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. NG → 1. Check the fuses. (Main, ignition, backup, and ECU) Replace the fuse(s). Refer to “CHECKING THE FUSES”...
Page 397 Manuals by Motomatrix / www.motomatrix.co.uk IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code IMMOBILIZER Codes between the 1. Signal received from 1. Place the UNIT key and immobilizer other transponder immobilizer unit unit do not match. (failed to recognize at least 50 mm code after ten away from the consecutive...
Page 398 Manuals by Motomatrix / www.motomatrix.co.uk IMMOBILIZER SYSTEM Example: fault code 52 a. Light on b. Light off 7-83 Email: info@motomatrix.co.uk...
Page 399 Manuals by Motomatrix / www.motomatrix.co.uk IMMOBILIZER SYSTEM 7-84 Email: info@motomatrix.co.uk...
Page 400: Electrical Components
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 7-85 Email: info@motomatrix.co.uk...
Page 401 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS 1. Air temperature sensor 2. Cylinder-#2 left ignition coil 3. Cylinder-#2 right ignition coil 4. ISC (idle speed control) unit 5. Intake solenoid 6. Cylinder-#1 right ignition coil 7. Cylinder-#1 left ignition coil 8.
Page 402 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS 7-87 Email: info@motomatrix.co.uk...
Page 403 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS 1. Cylinder-#1 intake air pressure sensor 2. Cylinder-#2 intake air pressure sensor 3. Immobilizer unit 4. Throttle position sensor 5. Main fuse 6. Fuse box 7. Muffler cooling fan motor relay 8. ECU (electronic control unit) 9.
Page 404: Checking The Switches
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES R/W L/W (BLUE) R/W R/B Br/R R Br/L Br/R L/W B/Y L/W B/Y Br/L Br/W (BROWN) (BLUE) Dg Br/W Ch (BLACK) Dg Br/W Ch R/Y Y Y L/B G P B/Y 7-89 Email: info@motomatrix.co.uk...
Page 405 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS 1. Front brake light switch 2. Engine stop switch 3. Start switch 4. Main switch 5. Neutral switch 6. Sidestand switch 7. Rear brake light switch 8. Hazard switch 9. Turn signal switch 10.Horn switch 11.Clutch switch 12.Pass switch...
Page 406 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
Page 407: Checking The Bulbs And Bulb Sockets
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS EAS27990 1. Remove: CHECKING THE BULBS AND BULB • Bulb SOCKETS EW5YU1009 NOTE: WARNING Do not check any of the lights that use LEDs. Since headlight bulbs get extremely hot, keep flammable products and your hands Check each bulb and bulb socket for damage or away from them until they have cooled wear, proper connections, and also for continuity...
Page 408: Checking The Fuses
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester YU-03112-C...
Page 409: Checking And Charging The Battery
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS cal system, cause the lighting and ignition electrolyte level will drop considerably. systems to malfunction and could possibly Therefore, take special care when charging cause a fire. the battery. L LLL L LLL L LLL L LLL L LLL...
Page 410 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS b. Check the charge of the battery, as shown in M MMM M MMM M MMM M MMM M MMM Charging method using a variable-current the charts and the following example. (voltage) charger Example a.
Page 411: Checking The Relays
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS 8. Check: M MMM M MMM M MMM M MMM M MMM Charging method using a constant volt- • Battery terminals age charger Dirt → Clean with a wire brush. a. Measure the open-circuit voltage prior to Loose connection →...
Page 412 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS Relay unit (starting circuit cut-off relay) 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Result Continuity (between “3” and “4”) Sb/W R/L L/R Muffler cooling fan motor relay L/G L/Y Sb B/Y L/W 1.
Page 413: Checking The Relay Unit (Diode)
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS EAS28050 CHECKING THE RELAY UNIT (DIODE) 1. Check: • Relay unit (diode) Out of specification → Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. Turn the main switch to “ON”. NOTE: c. Measure the turn signal/hazard relay input The pocket tester and the analog pocket tester voltage.
Page 414: Checking The Spark Plug Caps
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS EAS28100 CHECKING THE IGNITION COILS The following procedure applies to all of the igni- tion coils. 1. Check: • Primary coil resistance Out of specification → Replace. Sb/W R/L L/R Primary coil resistance L/G L/Y Sb B/Y 2.16–2.64 Ω...
Page 415: Checking The Ignition Spark Gap
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS • Positive tester probe → c. Turn the main switch to “ON” and engine stop switch to “ ”. black/red “1” • Negative tester probe → d. Measure the ignition spark gap “a”. spark plug lead “2”...
Page 416: Checking The Stator Coil
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS 2. Check: M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (Ω × 1) to the stator • Lean angle cut-off switch output voltage Out of specification → Replace. coil coupler as shown.
Page 417: Checking The Horn
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM a. Set the engine tachometer to the cylinder-#1 left spark plug lead or right spark plug lead. b. Connect the pocket tester (DC 20 V) to the rectifier/regulator coupler as shown.
Page 418: Checking The Fuel Sender
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (Ω × 1k) to the en- Fuel sender resistance 1.35–1.65 kΩ at 25 °C (77 °F) gine temperature sensor terminal as shown. Pocket tester M MMM M MMM...
Page 419: Checking The Throttle Position Sensor
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS b. Turn the main switch to “ON”. b. Measure the throttle position sensor maxi- c. Elevate the rear wheel and slowly rotate it. mum resistance. d. Measure the voltage of white/yellow and L LLL L LLL L LLL L LLL...
Page 420: Checking The Exup Servo Motor
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM For counterclockwise rotation “a” a. Insert a plug “1” into the fuel return hose end. • Positive battery lead → b. Fill the fuel tank. black/green “1”...
Page 421: Checking The Intake Air Pressure Sensors
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM a. Disconnect the decompression solenoid cou- plers from the wire harness. b. Connect the pocket tester (Ω × 10) to the de- compression solenoid coupler as shown. Pocket tester 90890-03112 Analog pocket tester...
Page 422: Checking The Air Temperature Sensor
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS ET5YU1007 ET5YU1008 CHECKING THE AIR TEMPERATURE CHECKING THE INTAKE SOLENOID SENSOR 1. Check: 1. Remove: • Intake solenoid resistance Out of specification → Replace. • Air temperature sensor EW5YU1002 WARNING Intake solenoid resistance 42–48 Ω...
Page 423: Checking The Muffler Cooling Fan Temperature Sensor
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS c. Check the muffler cooling fan motor move- b. Immerse the muffler cooling fan temperature ment. sensor “3” in a container filled with water “4”. L LLL L LLL L LLL L LLL L LLL NOTE: Make sure that the muffler cooling fan tempera-...
Page 424 Manuals by Motomatrix / www.motomatrix.co.uk TRBL SHTG Email: info@motomatrix.co.uk...
Page 425 Manuals by Motomatrix / www.motomatrix.co.uk TROUBLESHOOTING TROUBLESHOOTING..................8-1 GENERAL INFORMATION ............... 8-1 STARTING FAILURES................8-1 INCORRECT ENGINE IDLING SPEED ............ 8-1 POOR MEDIUM AND HIGH-SPEED PERFORMANCE ......8-2 FAULTY GEAR SHIFTING................ 8-2 SHIFT PEDAL DOES NOT MOVE ............8-2 JUMPS OUT OF GEAR................8-2 FAULTY CLUTCH ..................
Page 426 Manuals by Motomatrix / www.motomatrix.co.uk Email: info@motomatrix.co.uk...
Page 427: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk TROUBLESHOOTING EAS28450 Electrical system TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) NOTE: • Blown, damaged or incorrect fuse The following guide for troubleshooting does not • Improperly installed fuse cover all the possible causes of trouble.
Page 428: Poor Medium And High-Speed Performance
Manuals by Motomatrix / www.motomatrix.co.uk TROUBLESHOOTING Electrical system EAS28550 JUMPS OUT OF GEAR 1. Battery • Discharged battery Shift shaft • Faulty battery • Incorrect shift pedal position 2. Spark plug(s) • Improperly returned stopper lever • Incorrect spark plug gap •...
Page 429: Overheating
Manuals by Motomatrix / www.motomatrix.co.uk TROUBLESHOOTING EAS28590 Malfunction OVERHEATING • Bent or damaged inner tube • Bent or damaged outer tube Engine • Damaged fork spring 1. Cylinder head(s) and piston(s) • Worn or damaged outer tube bushing • Heavy carbon buildup •...
Page 430 Manuals by Motomatrix / www.motomatrix.co.uk TROUBLESHOOTING • Incorrect connection • Faulty main switch • Improperly grounded circuit • Faulty horn switch • Poor contacts (main or light switch) • Faulty battery • Burnt-out headlight bulb • Blown, damaged or incorrect fuse •...
Page 431 Manuals by Motomatrix / www.motomatrix.co.uk EAS28740 57. Pass switch WIRING DIAGRAM 58. Dimmer switch MT-01(T) 2005 59. Hazard switch 1. AC magneto 60. Turn signal switch 2. Rectifier/regulator 61. Horn switch 3. Main switch 62. Front left turn signal light 4.
Page 432 Manuals by Motomatrix / www.motomatrix.co.uk Blue/Black Blue/Green Blue/Red Blue/White Blue/Yellow Pink/Blue Pink/White Pink/Yellow Red/Black Red/Green Red/Blue Red/White Red/Yellow Sb/W Sky blue/White White/Black White/Green White/Red White/Yellow Yellow/Black Yellow/Green Yellow/Blue Email: info@motomatrix.co.uk...
Page 433 Manuals by Motomatrix / www.motomatrix.co.uk Email: info@motomatrix.co.uk...
Page 434 Manuals by Motomatrix / www.motomatrix.co.uk YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN Email: info@motomatrix.co.uk...
Page 435 Manuals by Motomatrix / www.motomatrix.co.uk MT-01(T) 2005 WIRING DIAGRAM Sb/W Sb/W L/W1 L/W1 WIRE HARNESS SUB-WIRE-HARNESS1 Br/W Br/Y Gy/G R/L R/W B/Br B/Br Br/L R/G B2 Br/B R/W Lg R/W Lg Y/L Gy/W Br/B Gy/R Gy/B (BLUE) Br/B Br/B (BLACK)
Page 436 Manuals by Motomatrix / www.motomatrix.co.uk 2007 MT01(W) SERVICE MANUAL 5YU-28197-E2 Email: info@motomatrix.co.uk...
Page 437 Manuals by Motomatrix / www.motomatrix.co.uk EAS20040 MT01(W) 2007 SERVICE MANUAL ©2006 by Yamaha Motor Co., Ltd. First edition, September 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
Page 438 EAS20070 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Page 439 Manuals by Motomatrix / www.motomatrix.co.uk EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
Page 440 Manuals by Motomatrix / www.motomatrix.co.uk EAS20100 1. Serviceable with engine mounted SYMBOLS 2. Filling fluid The following symbols are used in this manual 3. Lubricant for easier understanding. 4. Special tool NOTE: 5. Tightening torque The following symbols are not relevant to every 6.
Page 441 Manuals by Motomatrix / www.motomatrix.co.uk Email: info@motomatrix.co.uk...
Page 442 Manuals by Motomatrix / www.motomatrix.co.uk EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING Email: info@motomatrix.co.uk...
Page 443 Manuals by Motomatrix / www.motomatrix.co.uk Email: info@motomatrix.co.uk...
Page 444: General Information
Manuals by Motomatrix / www.motomatrix.co.uk GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER ............. 1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 INSTRUMENT FUNCTIONS ..............1-4 IMPORTANT INFORMATION ................. 1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-7 REPLACEMENT PARTS................
Page 445: Identification
Manuals by Motomatrix / www.motomatrix.co.uk IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped on the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the lead holder under the seat.
Page 446: Features
Manuals by Motomatrix / www.motomatrix.co.uk FEATURES EAS20170 FEATURES ET5YU1009 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the 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 carburetor.
Page 447: Fi System
Manuals by Motomatrix / www.motomatrix.co.uk FEATURES ET5YU1010 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 392 kPa (3.92 kg/cm², 55.7 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
Page 448: Instrument Functions
Manuals by Motomatrix / www.motomatrix.co.uk FEATURES ET5YU1011 Tachometer INSTRUMENT FUNCTIONS Multi-function display EW5YU1005 WARNING Be sure to stop the vehicle before making any setting changes to the multi-function display. 1. Tachometer 2. Tachometer red zone The electric tachometer allows the rider to mon- itor the engine speed and keep it within the ideal power range.
Page 449 Manuals by Motomatrix / www.motomatrix.co.uk FEATURES To set the clock: If the multi-function display indicates an error 1. Push the “SELECT” button and “RESET” but- code, note the code number, and then check the ton together for at least two seconds. vehicle.
Page 450 Manuals by Motomatrix / www.motomatrix.co.uk FEATURES Brightness control mode 1. LCD 1. Tachometer panel 2. Item number 2. LCD 3. Brightness level 3. Tachometer needle 6. Push the “SELECT” button to select the ta- The brightness can be adjusted for the following: chometer needle.
Page 451: Important Information
5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
Page 452: Bearings And Oil Seals
Manuals by Motomatrix / www.motomatrix.co.uk IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease.
Page 453: Checking The Connections
Manuals by Motomatrix / www.motomatrix.co.uk CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead NOTE: • Coupler • If there is no continuity, clean the terminals. •...
Page 454: Special Tools
Manuals by Motomatrix / www.motomatrix.co.uk SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques.
Page 455 Manuals by Motomatrix / www.motomatrix.co.uk SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Timing light 90890-03141 Inductive clamp timing light YU-03141 Compression gauge 3-10 90890-03081 Engine compression tester YU-33223 Extension 3-10 90890-04082 Oil filter wrench 3-12 90890-01426 YU-38411 Steering nut wrench 3-26, 4-58 90890-01403 Spanner wrench...
Page 456 Manuals by Motomatrix / www.motomatrix.co.uk SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Fork seal driver 4-52 90890-01442 Adjustable fork seal driver (36–46 mm) YM-01442 Rod puller 4-53, 4-54 90890-01437 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Rod puller attachment (M10) 4-53, 4-54 90890-01436 Universal damping rod bleeding tool set...
Page 457 Manuals by Motomatrix / www.motomatrix.co.uk SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide remover (ø6) 5-37 90890-04064 Valve guide remover (6.0 mm) YM-04064-A Valve guide installer (ø6) 5-37 90890-04065 Valve guide installer (6.0 mm) YM-04065-A Valve guide reamer (ø6) 5-37 90890-04066 Valve guide reamer (6.0 mm)
Page 458 Manuals by Motomatrix / www.motomatrix.co.uk SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Yamaha bond No. 1215 5-58, 5-70, 90890-85505 5-79 ® (Three Bond No.1215 Rotor puller 5-69 90890-01080 Stator rotor puller YM-01080-A Pressure gauge 90890-03153 YU-03153 Fuel pressure adapter...
Page 459 Manuals by Motomatrix / www.motomatrix.co.uk SPECIAL TOOLS 1-15 Email: info@motomatrix.co.uk...
Page 460: Specifications
Manuals by Motomatrix / www.motomatrix.co.uk SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................ 2-10 ELECTRICAL SPECIFICATIONS ..............2-13 TIGHTENING TORQUES ................2-16 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-16 ENGINE TIGHTENING TORQUES............2-17 CHASSIS TIGHTENING TORQUES............2-22 LUBRICATION POINTS AND LUBRICANT TYPES ........2-27 ENGINE....................
Page 461: General Specifications
Manuals by Motomatrix / www.motomatrix.co.uk GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 5YU8 (Europe) (ZA) 5YUA (AUS) 5YUB (Europe) (ZA) 5YUC (AUS) Dimensions Overall length 2185 mm (86.0 in) Overall width 800 mm (31.5 in) Overall height 1105 mm (43.5 in) Seat height 825 mm (32.5 in) Wheelbase...
Page 462: Engine Specifications
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Air cooled 4-stroke, OHV Displacement 1670.0 cm³ Cylinder arrangement V-type 2-cylinder Bore × stroke 97.0 × 113.0 mm (3.82 × 4.45 in) Compression ratio 8.40 :1 Standard compression pressure (at sea level) 1200 kPa/200 r/min (170.7 psi/200 r/min) (12.0 kgf/cm²/200 r/min) Minimum–maximum...
Page 463 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE SPECIFICATIONS Cylinder head Volume 98.60–103.60 cm³ (6.02–6.32 cu.in) Warpage limit 0.03 mm (0.0012 in) Camshaft Drive system Gear drive Crankcase hole inside diameter 25.000–25.021 mm (0.9843–0.9851 in) Camshaft journal diameter (crankcase side) 24.942–24.965 mm (0.9820–0.9829 in) Camshaft to crankcase clearance 0.035–0.079 mm (0.0014–0.0031 in) Camshaft cover hole inside diameter...
Page 464 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE SPECIFICATIONS Valve dimensions Valve head diameter A (intake) 33.90–34.10 mm (1.3346–1.3425 in) Valve head diameter A (exhaust) 27.90–28.10 mm (1.0984–1.1063 in) Valve face width B (intake) 1.300–2.300 mm (0.0512–0.0906 in) Valve face width B (exhaust) 1.200–2.400 mm (0.0472–0.0945 in) Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in)
Page 465 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE SPECIFICATIONS Valve stem runout 0.010 mm (0.0004 in) Valve spring Inner spring Free length (intake) 38.26 mm (1.51 in) Limit 36.26 mm (1.43 in) Free length (exhaust) 38.26 mm (1.51 in) Limit 36.26 mm (1.43 in) Installed length (intake) 29.00 mm (1.14 in) Installed length (exhaust)
Page 466 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE SPECIFICATIONS Valve lifter Valve lifter outside diameter (intake) 22.962–22.974 mm (0.9040–0.9045 in) Valve lifter outside diameter (exhaust) 22.962–22.974 mm (0.9040–0.9045 in) Valve lifter hole inside diameter (intake) 23.000–23.021 mm (0.9055–0.9063 in) Valve lifter hole inside diameter (exhaust) 23.000–23.021 mm (0.9055–0.9063 in) Valve-lifter-to-valve-lifter-hole clearance 0.0260–0.0590 mm (0.0010–0.0023 in)
Page 467 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE SPECIFICATIONS Dimensions (B × T) 1.20 × 3.80 mm (0.05 × 0.15 in) End gap (installed) 0.30–0.45 mm (0.0118–0.0177 in) Limit 0.80 mm (0.0315 in) Ring side clearance 0.030–0.070 mm (0.0012–0.0028 in) Limit 0.120 mm (0.0047 in) Oil ring Dimensions (B ×...
Page 468 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE SPECIFICATIONS Clutch spring free length 6.88 mm (0.27 in) Minimum length 6.38 mm (0.25 in) Spring quantity 1 pc Clutch housing thrust clearance 0.100–0.110 mm (0.0039–0.0043 in) Clutch housing radial clearance 0.020–0.066 mm (0.0008–0.0026 in) Transmission Transmission type Constant mesh 5-speed...
Page 469 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE SPECIFICATIONS Engine temperature sensor resistance 0.90–1.10 kΩ at 100 °C (212 °F) Idling condition Engine idling speed 850–950 r/min Intake vacuum 26.6 kPa (7.9 inHg) (200 mmHg) Oil temperature 80.0–90.0 °C (176.00–194.00 °F) Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) Email: info@motomatrix.co.uk...
Page 470: Chassis Specifications
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Double cradle Caster angle 25.00° Trail 103.0 mm (4.06 in) Front wheel Wheel type Cast wheel 17M/C × MT3.50 Rim size Rim material Aluminum Wheel travel 120.0 mm (4.72 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit...
Page 471 Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS SPECIFICATIONS Front disc brake Disc outside diameter × thickness 310.0 × 5.5 mm (12.20 × 0.22 in) Brake disc thickness limit 5.0 mm (0.20 in) Brake disc deflection limit 0.10 mm (0.0039 in) Brake pad lining thickness (inner) 4.5 mm (0.18 in) Limit 0.8 mm (0.03 in)
Page 472 Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS SPECIFICATIONS Rebound damping adjusting positions *With the adjusting screw fully turned in Minimum 17 click(s) out* Standard 15 click(s) out* Maximum 1 click(s) out* Compression damping adjusting positions *With the adjusting screw fully turned in Minimum 16 click(s) out* Standard...
Page 473: Electrical Specifications
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Transistorized coil ignition (digital) Advancer type Electrical Ignition timing (B.T.D.C.) 10.0°/900 r/min Engine control unit Model/manufacturer F8T830/MITSUBISHI Ignition coil Model/manufacturer 2JN/MORIC Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64 Ω...
Page 474 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL SPECIFICATIONS Meter lighting Indicator light Neutral indicator light Turn signal indicator light High beam indicator light Fuel level warning light Engine trouble warning light Immobilizer system indicator light Electric starting system System type Constant mesh Starter motor Model/manufacturer 5YU/MORIC...
Page 475 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL SPECIFICATIONS Fuel pump relay Model/manufacturer G8R-30Y-U3/OMRON 162.0–198.0 Ω Coil resistance Fuses Main fuse 50.0 A Headlight fuse 15.0 A Signaling system fuse 10.0 A Ignition fuse 25.0 A Parking lighting fuse 10.0 A ECU fuse 10.0 A Fuel injection system fuse 15.0 A...
Page 476: Tightening Torques
Manuals by Motomatrix / www.motomatrix.co.uk TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual.
Page 477: Engine Tightening Torques
Manuals by Motomatrix / www.motomatrix.co.uk TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil tank: Oil pipe bolt 13 Nm (1.3 m·kg, 9.4 ft·lb) Oil tank and oil tank bracket nut 13 Nm (1.3 m·kg, 9.4 ft·lb) Oil tank bolt 13 Nm (1.3 m·kg, 9.4 ft·lb) Oil tank and down tube bolt...
Page 478 Manuals by Motomatrix / www.motomatrix.co.uk TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rocker arm base bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Rocker arm base bolt 24 Nm (2.4 m·kg, 17 ft·lb) Locknut (rocker arm adjusting 20 Nm (2.0 m·kg, 14 ft·lb) screw) Valve lifter case bolt 10 Nm (1.0 m·kg, 7.2 ft·lb)
Page 479 Manuals by Motomatrix / www.motomatrix.co.uk TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Generator and starter clutch: Oil pipe 2 bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Generator cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Stator coil assembly lead holder 10 Nm (1.0 m·kg, 7.2 ft·lb) screw Stator coil assembly screw...
Page 480 Manuals by Motomatrix / www.motomatrix.co.uk TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size NOTE. Connecting rod bolt (final) Specified angle 120°–150° Chain drive: Drive sprocket cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Drive chain guide bolt (drive 24 Nm (2.4 m·kg, 17 ft·lb) sprocket side) Stake Drive sprocket nut...
Page 481 Manuals by Motomatrix / www.motomatrix.co.uk TIGHTENING TORQUES Oil tank tightening sequence: Cylinder head tightening sequence: A. Front cylinder B. Rear cylinder 2-21 Email: info@motomatrix.co.uk...
Page 482: Chassis Tightening Torques
Manuals by Motomatrix / www.motomatrix.co.uk TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting: Engine mounting bolt (left upper 53 Nm (5.3 m·kg, 38 ft·lb) side) Engine mounting bolt (right upper L=80 mm 53 Nm (5.3 m·kg, 38 ft·lb) side) (3.15 in) Engine mounting bolt (right upper...
Page 483 Manuals by Motomatrix / www.motomatrix.co.uk TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Cylinder-#2 right ignition coil 10 Nm (1.0 m·kg, 7.2 ft·lb) bracket bolt Cylinder-#2 left ignition coil 10 Nm (1.0 m·kg, 7.2 ft·lb) bracket bolt Engine bracket (right upper side) 7 Nm (0.7 m·kg, 5.1 ft·lb) and holder bolt Fuel tank bolt...
Page 484 Manuals by Motomatrix / www.motomatrix.co.uk TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Left rider footrest assembly bolt 30 Nm (3.0 m·kg, 22 ft·lb) Right rider footrest assembly bolt 30 Nm (3.0 m·kg, 22 ft·lb) Footrest cover bracket 7 Nm (0.7 m·kg, 5.1 ft·lb) Passenger footrest nut 28 Nm (2.8 m·kg, 20 ft·lb) Front wheel:...
Page 485 Manuals by Motomatrix / www.motomatrix.co.uk TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front fork and steering head: Upper bracket pinch bolt 26 Nm (2.6 m·kg, 19 ft·lb) Steering stem nut 110 Nm (11.0 m·kg, 80 ft·lb) Lower ring nut (initial tightening 52 Nm (5.2m·kg, 37 ft·lb) torque) NOTE.
Page 486 Manuals by Motomatrix / www.motomatrix.co.uk TIGHTENING TORQUES NOTE: 1. First, tighten the lower ring nut to approximately 52 Nm (5.2 m·kg, 37 ft·lb) with a torque wrench, then loosen the lower ring nut completely. 2. Retighten the lower ring nut to 23 Nm (2.3 m·kg, 17 ft·lb) with a torque wrench. 2-26 Email: info@motomatrix.co.uk...
Page 487: Lubrication Points And Lubricant Types
Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Cylinder head nuts and washers Connecting rod small end and big end Crankshaft journals Piston surfaces Piston pins Connecting rod bolts...
Page 488 Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Yamaha bond No.1215 (Three Bond Crankcase mating surface ® No.1215 Yamaha bond No.1215 (Three Bond Stator coil lead grommet ® No.1215 Yamaha bond No.1215 (Three Bond Crankshaft position sensor lead grommet ®...
Page 489: Chassis
Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Down tube bolt (front and rear) Steering bearings and upper bearing dust cover lip Lower bearing dust seal lip Steering ring nut thread (upper and lower) Main switch bracket spacer outer surfaces Front wheel oil seal lips (left and right) Rear wheel oil seal lips (left and right)
Page 490 Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION POINTS AND LUBRICANT TYPES 2-30 Email: info@motomatrix.co.uk...
Page 491: Lubrication System Chart And Diagrams
Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-31 Email: info@motomatrix.co.uk...
Page 492 Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pan 2. Engine oil drain bolt (crankcase) 3. Oil strainer (crankcase) 4. Oil pump 5. Oil pump rotor 1 6. Oil pump rotor 2 7. Check ball 8. Relief valve 9.
Page 493: Lubrication Diagrams
Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-33 Email: info@motomatrix.co.uk...
Page 494 Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil delivery pipe 2. Push rod 3. Oil filter cartridge 4. Rocker arm shaft 5. Oil delivery pipe 2 2-34 Email: info@motomatrix.co.uk...
Page 495 Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35 Email: info@motomatrix.co.uk...
Page 496 Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Rocker arm shaft 2. Crankshaft 3. Valve lifter 4. Push rod 2-36 Email: info@motomatrix.co.uk...
Page 497 Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37 Email: info@motomatrix.co.uk...
Page 498 Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pump 2. Oil strainer (crankcase) 3. Oil pipe 1 2-38 Email: info@motomatrix.co.uk...
Page 499 Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION SYSTEM CHART AND DIAGRAMS 2-39 Email: info@motomatrix.co.uk...
Page 500 Manuals by Motomatrix / www.motomatrix.co.uk LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Drive axle 3. Oil pump 4. Oil strainer (crankcase) A. To oil filter cartridge 2-40 Email: info@motomatrix.co.uk...
Page 501: Cable Routing
Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING EAS20430 CABLE ROUTING 2-41 Email: info@motomatrix.co.uk...
Page 502 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 1. Air temperature sensor coupler 2. Sub-wire harness 3 coupler 3. Front turn signal light coupler 4. Headlight assembly coupler 5. Headlight coupler (low beam) 6. Wire harness 7. Clutch fluid reservoir hose 8.
Page 503 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 2-43 Email: info@motomatrix.co.uk...
Page 504 Manuls byt Motomatrix / www.motomatrix.co.uk CABLE ROUTING 1. Meter assembly lead O. The wire harness should not protrude to the inside of the frame. 2. Clutch hose P. The rubber sheet should hang down over the wire 3. Left handlebar switch lead harness, clutch hose, cylinder-#1 left spark plug 4.
Page 505 Manuls byt Motomatrix / www.motomatrix.co.uk CABLE ROUTING 9 10 2-45 Email: info@motomatrix.co.uk...
Page 506 Manuls by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 1. Fuel pump lead L. Wrap the protective covering around the right handlebar switch coupler, headlight coupler, 2. Cylinder-#1 right spark plug lead immobilizer unit coupler, and main switch coupler, 3. Sub-wire harness 2 making sure to cover the sections of the leads that 4.
Page 507 Manuls by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 2-47 Email: info@motomatrix.co.uk...
Page 508 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 1. Sub-wire harness 2 H. Route the tail/brake light lead and rear turn signal light leads along the side of the rear brake fluid 2. Intake solenoid lead reservoir, making sure that “UPPER” on the 3.
Page 509 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 2-49 Email: info@motomatrix.co.uk...
Page 510 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING Y. Route the sub-wire harness 1 under the wire- harness-to-main-fuse lead. Z. To cylinder-#1 right spark plug AA.Route the rear brake fluid reservoir hose under the wire harness to the right of the battery box. Be sure not to pinch the rear brake fluid reservoir hose when installing the battery box.
Page 511 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 2-51 Email: info@motomatrix.co.uk...
Page 512 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 1. Fuel tank 2. Pressure regulator 3. Fuel return hose 4. Fuel hose 5. Fuel return pipe 6. Fuel return hose (fuel return pipe to fuel pump) 7. Fuel pump 8. Fuel pipe 9.
Page 513 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 2-53 Email: info@motomatrix.co.uk...
Page 514 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 1. Fuel tank overflow hose 2. Fuel tank breather hose 3. Rollover valve hose 1 4. Rollover valve hose 2 5. Rollover valve 1 6. Rollover valve 2 7. Rollover valve hose 3 8.
Page 515 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 2-55 Email: info@motomatrix.co.uk...
Page 516 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 1. Cylinder-#2 intake air pressure sensor 2. Cylinder-#2 ISC (idle speed control) unit outlet hose 3. ISC (idle speed control) unit 4. Intake solenoid vacuum hose (one-way valve to throttle body) 5. Cylinder-#1 ISC (idle speed control) unit outlet hose 6.
Page 517 Manuals by Motomatrix / www.motomatrix.co.uk CABLE ROUTING 2-57 Email: info@motomatrix.co.uk...
Page 518: Periodic Checks And Adjustments
Manuals by Motomatrix / www.motomatrix.co.uk PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE AND LUBRICATION CHART....... 3-1 ENGINE ......................3-3 ADJUSTING THE VALVE CLEARANCE ..........3-3 SYNCHRONIZING THE THROTTLE BODIES.......... 3-5 ADJUSTING THE THROTTLE CABLE FREE PLAY ........ 3-7 CHECKING THE SPARK PLUGS .............
Page 519 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL SYSTEM................. 3-33 CHECKING AND CHARGING THE BATTERY........3-33 CHECKING THE FUSES ................ 3-33 REPLACING THE HEADLIGHT BULBS ..........3-33 ADJUSTING THE HEADLIGHT BEAM ........... 3-34 Email: info@motomatrix.co.uk...
Page 520 Manuals by Motomatrix / www.motomatrix.co.uk Email: info@motomatrix.co.uk...
Page 521: Periodic Maintenance
• From 50000 km, repeat the maintenance intervals starting from 10000 km. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1000 km)
Page 522 Manuals by Motomatrix / www.motomatrix.co.uk PERIODIC MAINTENANCE ODOMETER READING (× 1000 km) ANNU- ITEM CHECK OR MAINTENANCE JOB CHECK Shock absorber as- √ √ √ √ 19 * • Check operation and shock absorber for oil leakage. sembly Rear suspension re- lay arm and connect- √...
Page 523: Engine
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE EAS20470 • Fuel tank ENGINE Refer to “FUEL TANK” on page 6-1. • Air filter case EAS20530 Refer to “GENERAL CHASSIS” on page 4-1. ADJUSTING THE VALVE CLEARANCE 2. Disconnect: The following procedure applies to all of the •...
Page 524 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE Valve clearance (cold) Thickness gauge Intake 90890-03079 0.00–0.04 mm (0.0000–0.0016 in) Narrow gauge set Exhaust YM-34483 0.00–0.04 mm (0.0000–0.0016 in) L LLL L LLL L LLL L LLL L LLL M MMM M MMM M MMM M MMM M MMM...
Page 525: Synchronizing The Throttle Bodies
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE NOTE: Locknut wrench Set the torque wrench at a right angle to the 90890-04150 locknut wrench. YM-04150 Locknut (rocker arm adjusting screw) 20 Nm (2.0 m·kg, 14 ft·lb) Locknut wrench 90890-04150 YM-04150 b. Insert a thickness gauge “3” between the end of the adjusting screw and the valve tip.
Page 526 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE • Fuel tank M MMM M MMM M MMM M MMM M MMM a. Start the engine, warm it up for several min- Refer to “FUEL TANK” on page 6-1. utes, and then let it run at the specified en- •...
Page 527: Adjusting The Throttle Cable Free Play
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE 9. Install: NOTE: • Air filter case ® Apply locking agent (LOCTITE ) to the threads Refer to “GENERAL CHASSIS” on page 4-1. of the adjusting nut “3”. • Fuel tank Refer to “FUEL TANK” on page 6-1. c.
Page 528: Checking The Spark Plugs
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE 5. Check: • Electrode “1” Damage/wear → Replace the spark plug. • Insulator “2” Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 6. Clean: • Spark plug (with a spark plug cleaner or wire brush) 7.
Page 529: Measuring The Compression Pressure
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE 1. Stand the vehicle on a level surface. 2. Remove: • Air duct “1” • Timing mark accessing screw “2” NOTE: The ignition timing is not adjustable. L LLL L LLL L LLL L LLL L LLL 3.
Page 530 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE Standard compression pressure (at sea level) 1200 kPa/200 r/min (170.7 psi/200 r/min) (12.0 kgf/cm²/200 r/min) Minimum–maximum 1000–1400 kPa (142.2–199.1 psi) (10.0–14.0 kgf/cm²) M MMM M MMM M MMM M MMM M MMM a. Set the main switch to “ON”. 5.
Page 531: Checking The Engine Oil Level
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE 11.Connect: add any chemical additives, or use engine • Decompression solenoid couplers oils with a grade of CD “a” or higher, and do 12.Install: not use oils labeled “ENERGY CONSERV- • Fuel tank ING II” “b”. Refer to “FUEL TANK”...
Page 532 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE 6. Remove: c. Lubricate the O-ring “1” of the new oil filter • Engine oil drain bolt (crankcase) “1” cartridge with a thin coat of engine oil. EC5YU1019 CAUTION: Make sure the O-ring “1” is positioned cor- rectly in the groove of the oil filter cartridge.
Page 533: Adjusting The Clutch Lever
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE 11.Fill: 13.Install: • Oil tank • Engine oil filler cap (with the specified amount of the recom- 14.Start the engine, warm it up for several min- mended engine oil) utes, and then turn it off. 15.Check: Engine oil quantity •...
Page 534: Checking The Clutch Fluid Level
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE EWA13370 NOTE: WARNING Be sure to align the setting on the adjusting dial • Use only the designated clutch fluid. Other with the arrow mark “2” on the clutch lever hold- clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance.
Page 535: Replacing The Air Filter Element
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE • If bleeding is difficult, it may be necessary to let EAS20960 REPLACING THE AIR FILTER ELEMENT the clutch fluid settle for a few hours. Repeat 1. Remove: the bleeding procedure when the tiny bubbles •...
Page 536: Checking The Throttle Body Joints
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE 6. Install: EAS21030 CHECKING THE FUEL LINE • Air filter case cover 1. Remove: EC5YU1005 • Seat CAUTION: Refer to “GENERAL CHASSIS” on page 4-1. Never operate the engine without the air filter • Fuel tank element installed.
Page 537: Checking The Oil Tank Breather Hose
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE Loose connection → Connect properly. 2. Check: • Front exhaust pipe “1” EC5YU1028 CAUTION: • Rear exhaust pipe “2” Make sure the cylinder head breather hoses • Catalyst pipe “3” are routed correctly. • Mufflers “4” Cracks/damage →...
Page 538: Adjusting The Exup Cables
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE 2. Check: • EXUP system operation M MMM M MMM M MMM M MMM M MMM a. Turn the main switch to “ON”. b. Check that the EXUP valve operates proper- NOTE: Check that the projections “a” on the EXUP valve pulley contact the stopper “b”...
Page 539 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE 4. Adjust: check that the notch in the EXUP valve pulley • EXUP cable free play is aligned with the hole in the EXUP valve cover. M MMM M MMM M MMM M MMM M MMM a.
Page 540: Chassis
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS EAS21140 1. Measure: CHASSIS • Installed rear brake master cylinder length “a” Incorrect → Adjust. EAS21160 ADJUSTING THE FRONT DISC BRAKE Installed rear brake master cylin- 1. Adjust: der length • Brake lever position 145.3–145.7 mm (5.72–5.74 in) (distance “a”...
Page 541: Checking The Brake Fluid Level
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS È Locknut (rear brake master cylin- der) 16 Nm (1.6 m·kg, 11 ft·lb) EW5YU1001 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.
Page 542: Checking The Front Brake Pads
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS EAS21250 EAS21280 CHECKING THE FRONT BRAKE PADS CHECKING THE FRONT BRAKE HOSES The following procedure applies to all of the The following procedure applies to all of the brake pads. brake hoses and brake hose holders. 1.
Page 543: Bleeding The Hydraulic Brake System
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS 4. Hold the vehicle upright and apply the brake • a brake hose is loosened, disconnected or several times. replaced. 5. Check: • the brake fluid level is very low. • Brake hoses • brake operation is faulty. Brake fluid leakage →...
Page 544: Adjusting The Shift Pedal
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS EWA13110 WARNING After bleeding the hydraulic brake system, check the brake operation. L LLL L LLL L LLL L LLL L LLL 3. Install: • Seat Refer to “GENERAL CHASSIS” on page 4-1. EAS21380 ADJUSTING THE SHIFT PEDAL NOTE: The shift pedal position is determined by the in-...
Page 545: Adjusting The Drive Chain Slack
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS c. Tighten both locknuts to specification. 3. Adjust: • Drive chain slack Locknut (shift rod) M MMM M MMM M MMM M MMM M MMM 7 Nm (0.7 m·kg, 5.1 ft·lb) a. Loosen the wheel axle nut “1”. b.
Page 546: Lubricating The Drive Chain
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS EAS21440 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained proper- ly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas.
Page 547: Checking The Front Fork
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS Refer to “STEERING HEAD” on page 4-56. 3. Hold the vehicle upright and apply the front e. Install the rubber washer “3”. brake. f. Install the upper ring nut “2”. 4. Check: g. Finger tighten the upper ring nut “2”, then •...
Page 548 Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS Spring preload adjusting positions Rebound damping adjusting posi- Minimum tions Minimum Standard 17 click(s) out* Standard Maximum 15 click(s) out* Maximum 1 click(s) out* * With the adjusting screw fully turned in L LLL L LLL L LLL L LLL...
Page 549: Adjusting The Rear Shock Absorber Assembly
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS L LLL L LLL L LLL L LLL L LLL EAS21620 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Spring preload ECA13590 c.
Page 550: Checking The Tires
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS Rebound damping adjusting posi- tions Minimum 20 click(s) out* Standard 12 click(s) out* Maximum 3 click(s) out* * With the adjusting knob fully turned in L LLL L LLL L LLL L LLL L LLL EAS21650 CHECKING THE TIRES The following procedure applies to both of the...
Page 551 No guarantee con- cerning handling characteristics can be giv- en if a tire combination other than one approved by Yamaha is used on this vehicle. Front tire Size 1. Tire tread depth...
Page 552: Checking The Wheels
Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS EWA13270 WARNING Rear tire Size Damaged outer cable may cause the cable to 190/50 ZR17 M/C (73W) corrode and interfere with its movement. Re- Manufacturer/model place damaged outer cable and inner cables METZELER/ROADTEC Z6 E as soon as possible.
Page 553 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL SYSTEM EAS21750 ECA13690 ELECTRICAL SYSTEM CAUTION: Avoid touching the glass part of the head- EAS21760 light bulb to keep it free from oil, otherwise CHECKING AND CHARGING THE BATTERY the transparency of the glass, the life of the Refer to “ELECTRICAL COMPONENTS”...
Page 554 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL SYSTEM M MMM M MMM M MMM M MMM M MMM • Headlight bulb a. Turn the adjusting screw “1” in direction “a” or Secure the new headlight bulb with the head- “b”. light bulb holder. ECA13690 Direction “a”...
Page 555 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL SYSTEM 3-35 Email: info@motomatrix.co.uk...
Page 556 Manuals by Motomatrix / www.motomatrix.co.uk CHASSIS GENERAL CHASSIS..................4-1 CHECKING THE AIR FILTER CASE VALVE..........4-5 FRONT WHEEL....................4-6 REMOVING THE FRONT WHEEL............4-8 DISASSEMBLING THE FRONT WHEEL..........4-8 CHECKING THE FRONT WHEEL ............4-8 ASSEMBLING THE FRONT WHEEL............4-9 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......
Page 557 Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE ....................4-30 INTRODUCTION ..................4-35 CHECKING THE REAR BRAKE DISC............ 4-35 REPLACING THE REAR BRAKE PADS..........4-35 REMOVING THE REAR BRAKE CALIPER ..........4-36 DISASSEMBLING THE REAR BRAKE CALIPER ........4-36 CHECKING THE REAR BRAKE CALIPER..........4-37 ASSEMBLING THE REAR BRAKE CALIPER ........
Page 558 Manuals by Motomatrix / www.motomatrix.co.uk CHAIN DRIVE....................4-68 REMOVING THE DRIVE CHAIN............. 4-69 CHECKING THE DRIVE CHAIN ............. 4-69 CHECKING THE DRIVE SPROCKET............. 4-70 CHECKING THE REAR WHEEL SPROCKET........4-70 CHECKING THE REAR WHEEL DRIVE HUB ........4-70 INSTALLING THE DRIVE CHAIN ............4-70 Email: info@motomatrix.co.uk...
Page 559: General Chassis
Manuals by Motomatrix / www.motomatrix.co.uk GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat and battery 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 560 Manuals by Motomatrix / www.motomatrix.co.uk GENERAL CHASSIS Removing the side covers and headlight assembly 9 Nm (0.9 m kg, 6.5 ft • • 9 Nm (0.9 m kg, 6.5 ft • • 7 Nm (0.7 m kg, 5.1 ft • •...
Page 561 Manuals by Motomatrix / www.motomatrix.co.uk GENERAL CHASSIS Removing the tail/brake light assembly 7 Nm (0.7 m kg, 5.1 ft 7 Nm (0.7 m kg, 5.1 ft • • • • 3 4 5 Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Seat 4-1.
Page 562 Manuals by Motomatrix / www.motomatrix.co.uk GENERAL CHASSIS Removing the air filter case and oil catch tank 10 Nm (1.0 m kg, 7.2 ft • • 9 Nm (0.9 m kg, 6.5 ft • • Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK”...
Page 563: Checking The Air Filter Case Valve
Manuals by Motomatrix / www.motomatrix.co.uk GENERAL CHASSIS ET5YU1013 CHECKING THE AIR FILTER CASE VALVE 1. Check: • Air filter case valve operation M MMM M MMM M MMM M MMM M MMM a. Remove the air filter case (with the air filter case valve).
Page 564: Front Wheel
Manuals by Motomatrix / www.motomatrix.co.uk FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs 35 Nm (3.5 m kg, 25 ft • • 35 Nm (3.5 m kg, 25 ft • • 6 Nm (0.6 m kg, 4.3 ft •...
Page 565 Manuals by Motomatrix / www.motomatrix.co.uk FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure. Email: info@motomatrix.co.uk...
Page 566: Removing The Front Wheel
Manuals by Motomatrix / www.motomatrix.co.uk FRONT WHEEL EAS21900 EAS21920 REMOVING THE FRONT WHEEL CHECKING THE FRONT WHEEL 1. Stand the vehicle on a level surface. 1. Check: • Front wheel axle EWA13120 WARNING Roll the wheel axle on a flat surface. Bends →...
Page 567: Assembling The Front Wheel
Manuals by Motomatrix / www.motomatrix.co.uk FRONT WHEEL 2. Find: • Front wheel’s heavy spot NOTE: Place the front wheel on a suitable balancing stand. M MMM M MMM M MMM M MMM M MMM a. Spin the front wheel. b. When the front wheel stops, put an “X ”...
Page 568: Checking The Front Brake Discs
Manuals by Motomatrix / www.motomatrix.co.uk FRONT WHEEL EAS22000 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) The following procedure applies to both of the front brake discs. 1. Install: • Front brake disc Front brake disc bolt 18 Nm (1.8 m·kg, 13 ft·lb) ®...
Page 569 Manuals by Motomatrix / www.motomatrix.co.uk FRONT WHEEL 5. Tighten: • Front wheel axle Front wheel axle 72 Nm (7.2 m·kg, 52 ft·lb) • Front wheel axle pinch bolt Front wheel axle pinch bolt 23 Nm (2.3 m·kg, 17 ft·lb) EC5YU1002 CAUTION: Before tightening the wheel axle, push down hard on the handlebar several times and...
Page 570: Rear Wheel
Manuals by Motomatrix / www.motomatrix.co.uk REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel 27 Nm (2.7 m kg, 19 ft • • 22 Nm (2.2 m kg, 16 ft • • 150 Nm (15.0 m kg, 110 ft • •...
Page 571 Manuals by Motomatrix / www.motomatrix.co.uk REAR WHEEL Removing the rear brake disc and rear wheel sprocket 100 Nm (10.0 m kg, 72 ft • • 18 Nm (1.8 m kg, 13 ft • • Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel sprocket Collar (brake disc side)
Page 572 Manuals by Motomatrix / www.motomatrix.co.uk REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Collar Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly pro- cedure. 4-14 Email: info@motomatrix.co.uk...
Page 573: Removing The Rear Wheel
Manuals by Motomatrix / www.motomatrix.co.uk REAR WHEEL EAS22040 EAS22090 REMOVING THE REAR WHEEL CHECKING THE REAR WHEEL 1. Stand the vehicle on a level surface. 1. Check: • Rear wheel axle EWA13120 WARNING • Rear wheel Securely support the vehicle so that there is •...
Page 574: Assembling The Rear Wheel
Manuals by Motomatrix / www.motomatrix.co.uk REAR WHEEL EAS22150 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.
Page 575 Manuals by Motomatrix / www.motomatrix.co.uk REAR WHEEL • Collar (brake disc side) “2” NOTE: The collar (brake disc side) has marks “a” to dis- tinguish it from the collar (wheel sprocket side). 5. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK”...
Page 576: Front Brake
Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 6 Nm (0.6 m kg, 4.3 ft • • 35 Nm (3.5 m kg, 25 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
Page 577 Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE Removing the front brake master cylinder 10 Nm (1.0 m kg, 7.2 ft • • ∗ 13 Nm (1.3 m kg, 9.4 ft • • 30 Nm (3.0 m kg, 22 ft • •...
Page 578 Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-20 Email: info@motomatrix.co.uk...
Page 579 Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE Removing the front brake calipers 35 Nm (3.5 m kg, 25 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
Page 580 Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE Disassembling the front brake calipers 6 Nm (0.6 m kg, 4.3 ft • • ∗ ∗ ∗ ∗ ∗ ∗ Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
Page 581: Introduction
Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE EAS22220 INTRODUCTION EWA14100 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, e.
Page 582: Replacing The Front Brake Pads
Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE d. Measure the brake disc deflection. 2. Install: e. If out of specification, repeat the adjustment • Brake pads steps until the brake disc deflection is within • Brake pad springs specification. NOTE: f.
Page 583: Removing The Front Brake Calipers
Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE • Copper washers “3” • Front brake hose “4” NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. L LLL L LLL L LLL L LLL L LLL 3.
Page 584: Checking The Front Brake Calipers
Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE EAS22410 ASSEMBLING THE FRONT BRAKE CALIPERS EWA13620 WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.
Page 585: Checking The Front Brake Master Cylinder
Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE 2. Remove: • Front brake caliper 3. Install: • Front brake pads • Brake pad springs • Brake pad pins • Brake pad clips • Front brake caliper Front brake caliper bolt 35 Nm (3.5 m·kg, 25 ft·lb) 7.
Page 586: Assembling The Front Brake Master Cylinder
Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE 2. Check: 2. Install: • Brake master cylinder kit • Copper washers Damage/scratches/wear → Replace. • Front brake hose “1” 3. Check: • Front brake hose union bolt “2” • Brake master cylinder reservoir Cracks/damage →...
Page 587 Manuals by Motomatrix / www.motomatrix.co.uk FRONT BRAKE • 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. ECA13540 CAUTION: Brake fluid may damage painted surfaces and plastic parts.
Page 588 Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 17 Nm (1.7 m kg, 12 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft •...
Page 589 Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE Removing the rear brake master cylinder 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • 30 Nm (3.0 m kg, 22 ft •...
Page 590 Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake hose joint Bush Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-32 Email: info@motomatrix.co.uk...
Page 591 Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE Removing the rear brake caliper 30 Nm (3.0 m kg, 22 ft • • 22 Nm (2.2 m kg, 16 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Parts to remove Q’ty Remarks...
Page 592 Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kg, 4.3 ft • • 17 Nm (1.7 m kg, 12 ft • • 3 Nm (0.3 m kg, 2.2 ft • • Order Job/Parts to remove Q’ty Remarks...
Page 593 Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14100 5.5 mm (0.22 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc deflection ventive measures: Refer to “CHECKING THE FRONT BRAKE •...
Page 594 Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE 4. Check: NOTE: • Brake fluid level Always install new brake pads, brake pad shims, Below the minimum level mark “a” → Add the and a brake pad spring as a set. recommended brake fluid to the proper level. M MMM M MMM M MMM...
Page 595 Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE • Brake caliper body “3” Cracks/damage → Replace the brake caliper assembly. • Brake fluid delivery passages (brake caliper body) Obstruction → Blow out with compressed air. EWA13610 WARNING Whenever a brake caliper is disassembled, replace the brake caliper piston seals.
Page 596 Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE EAS22670 INSTALLING THE REAR BRAKE CALIPER Recommended fluid 1. Install: DOT 4 • Rear brake caliper “1” (temporarily) EWA13090 WARNING • Copper washers • Use only the designated brake fluid. Other • Rear brake hose “2” brake fluids may cause the rubber seals to •...
Page 597 Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE EAS22700 EAS22730 REMOVING THE REAR BRAKE MASTER ASSEMBLING THE REAR BRAKE MASTER CYLINDER CYLINDER EWA13520 NOTE: WARNING Before removing the rear brake master cylinder, • Before installation, all internal brake com- drain the brake fluid from the entire brake sys- ponents should be cleaned and lubricated tem.
Page 598 Manuals by Motomatrix / www.motomatrix.co.uk REAR BRAKE EWA13090 7. Adjust: WARNING • Rear brake light operation timing • Use only the designated brake fluid. Other Refer to “ADJUSTING THE REAR BRAKE brake fluids may cause the rubber seals to LIGHT SWITCH” on page 3-23. deteriorate, causing leakage and poor brake performance.
Page 599 Manuals by Motomatrix / www.motomatrix.co.uk HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 13 Nm (1.3 m kg, 9.4 ft •...
Page 600 Manuals by Motomatrix / www.motomatrix.co.uk HANDLEBAR Removing the handlebar 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 13 Nm (1.3 m kg, 9.4 ft •...
Page 601 Manuals by Motomatrix / www.motomatrix.co.uk HANDLEBAR EAS22860 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Handlebar grip “1” NOTE: Blow compressed air between the handlebar 3.
Page 602 Manuals by Motomatrix / www.motomatrix.co.uk HANDLEBAR Grip end Clutch master cylinder holder 29 Nm (2.9 m·kg, 21 ft·lb) bolt 14 Nm (1.4 m·kg, 10 ft·lb) M MMM M MMM M MMM M MMM M MMM a. Apply a thin coat of rubber adhesive onto the NOTE: left end of the handlebar.
Page 603 Manuals by Motomatrix / www.motomatrix.co.uk HANDLEBAR 9. Install: • Front brake master cylinder assembly • Front brake master cylinder holder “1” Front brake master cylinder hold- er bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) NOTE: • The front brake master cylinder holder should be installed with the punch mark “a”...
Page 604 Manuals by Motomatrix / www.motomatrix.co.uk FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 26 Nm (2.6 m kg, 19 ft • • 20 Nm (2.0 m kg, 14 ft • • 28 Nm (2.8 m kg, 20 ft •...
Page 605 Manuals by Motomatrix / www.motomatrix.co.uk FRONT FORK Disassembling the front fork legs 20 Nm (2.0 m kg, 14 ft • • 25 Nm (2.5 m kg, 18 ft • • 35 Nm (3.5 m kg, 25 ft • • Order Job/Parts to remove Q’ty Remarks...
Page 606 Manuals by Motomatrix / www.motomatrix.co.uk FRONT FORK Disassembling the front fork legs 20 Nm (2.0 m kg, 14 ft • • 25 Nm (2.5 m kg, 18 ft • • 35 Nm (3.5 m kg, 25 ft • • Order Job/Parts to remove Q’ty Remarks...
Page 607 Manuals by Motomatrix / www.motomatrix.co.uk FRONT FORK EAS22960 1. Position the collar “1” as shown in the illustra- REMOVING THE FRONT FORK LEGS tion by turning the spring preload adjusting The following procedure applies to both of the bolt “2” counterclockwise until it stops. front fork legs.
Page 608 Manuals by Motomatrix / www.motomatrix.co.uk FRONT FORK NOTE: Loosen the nut using a proper tool that has a thickness of 3 mm (0.12 in) or less. 5. Remove: • Oil seal clip “1” (with a flat-head screwdriver) d. Remove the cap bolt. e.
Page 609 Manuals by Motomatrix / www.motomatrix.co.uk FRONT FORK NOTE: • When assembling the front fork leg, be sure to replace the following parts: – Oil seal – Dust seal – O-ring • Before assembling the front fork leg, make sure all of the components are clean. 1.
Page 610 Manuals by Motomatrix / www.motomatrix.co.uk FRONT FORK 5. Install: • Outer tube (to the inner tube) 6. Install: • Washer • Oil seal “1” (with the fork seal driver “2”) Fork seal driver 90890-01442 Adjustable fork seal driver (36–46 4. Install: YM-01442 •...
Page 611 Manuals by Motomatrix / www.motomatrix.co.uk FRONT FORK • When disassembling and assembling the front fork leg, do not allow any foreign ma- terial to enter the front fork. 12.After filling the front fork leg, slowly stroke the damper rod “1” up and down (at least ten times) to distribute the fork oil.
Page 612 Manuals by Motomatrix / www.motomatrix.co.uk FRONT FORK • Damper adjusting rod “6” Rod puller • Washer “7” 90890-01437 • Cap bolt “8” Universal damping rod bleeding (with O-ring) tool set YM-A8703 Rod puller attachment (M10) 90890-01436 Universal damping rod bleeding tool set YM-A8703 Fork spring compressor...
Page 613 Manuals by Motomatrix / www.motomatrix.co.uk FRONT FORK EWA13670 • Cap bolt “2” WARNING Cap bolt Always use a new cap bolt O-ring. 20 Nm (2.0 m·kg, 14 ft·lb) EC5YU1012 CAUTION: • Upper bracket pinch bolt “3” When tightening the spring preload adjust- ing bolt “11”...
Page 614 Manuals by Motomatrix / www.motomatrix.co.uk STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 110 Nm (11.0 m kg, 80 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 615 Manuals by Motomatrix / www.motomatrix.co.uk STEERING HEAD Removing the lower bracket 110 Nm (11.0 m kg, 80 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 2nd 23 Nm (2.3 m kg, 17 ft •...
Page 616 Manuals by Motomatrix / www.motomatrix.co.uk STEERING HEAD EAS23110 3. Replace: REMOVING THE LOWER BRACKET • Bearings 1. Stand the vehicle on a level surface. • Bearing races EWA13120 M MMM M MMM M MMM M MMM M MMM WARNING a. Remove the bearing races from the steering Securely support the vehicle so that there is head pipe with a long rod “1”...
Page 617 Manuals by Motomatrix / www.motomatrix.co.uk STEERING HEAD 6. Tighten: Recommended lubricant • Steering stem nut Lithium-soap-based grease Steering stem nut 2. Install: 110 Nm (11.0 m·kg, 80 ft·lb) • Lower ring nut “1” • Rubber washer “2” • Upper ring nut “3” •...
Page 618 Manuals by Motomatrix / www.motomatrix.co.uk REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 40 Nm (4.0 m kg, 29 ft • • 40 Nm (4.0 m kg, 29 ft • • 49 Nm (4.9 m kg, 35 ft •...
Page 619 Manuals by Motomatrix / www.motomatrix.co.uk REAR SHOCK ABSORBER ASSEMBLY EAS23180 NOTE: HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that the EWA13740 WARNING rear wheel is elevated. This rear shock absorber contains highly 2. Remove: compressed nitrogen gas.
Page 620 Manuals by Motomatrix / www.motomatrix.co.uk REAR SHOCK ABSORBER ASSEMBLY • Oil seals Damage/pitting → Replace. 3. Check: • Collars • Spacers Damage/scratches → Replace. EAS23270 INSTALLING THE CONNECTING ARM AND RELAY ARM 1. Lubricate: • Spacers • Bearings Recommended lubricant Lithium-soap-based grease 2.
Page 621 Manuals by Motomatrix / www.motomatrix.co.uk REAR SHOCK ABSORBER ASSEMBLY • Relay arm nut (relay arm and connecting arm) Relay arm nut (relay arm and con- necting arm) 49 Nm (4.9 m·kg, 35 ft·lb) EAS23310 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1.
Page 622 Manuals by Motomatrix / www.motomatrix.co.uk SWINGARM EAS23330 SWINGARM Removing the swingarm 7 Nm (0.7 m kg, 5.1 ft • • 9 Nm (0.9 m kg, 6.5 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 9 Nm (0.9 m kg, 6.5 ft •...
Page 623 Manuals by Motomatrix / www.motomatrix.co.uk SWINGARM Removing the swingarm 7 Nm (0.7 m kg, 5.1 ft • • 9 Nm (0.9 m kg, 6.5 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 9 Nm (0.9 m kg, 6.5 ft •...
Page 624 Manuals by Motomatrix / www.motomatrix.co.uk SWINGARM EAS23350 EAS23360 REMOVING THE SWINGARM CHECKING THE SWINGARM 1. Stand the vehicle on a level surface. 1. Check: • Swingarm EWA13120 WARNING Bends/cracks/damage → Replace. Securely support the vehicle so that there is 2. Check: no danger of it falling over.
Page 625 Manuals by Motomatrix / www.motomatrix.co.uk SWINGARM • Oil seals “2” • Bearing “3” • Oil seal “4” Installed depth of bearing “a” 6.3 mm (0.25 in) Installed depth of bearing “b” 5.7 mm (0.22 in) Installed depth of oil seal “c” 0.5–1.0 mm (0.02–0.04 in) Installed depth of oil seal “d”...
Page 626 Manuals by Motomatrix / www.motomatrix.co.uk CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive sprocket and drive chain 10 Nm (1.0 m kg, 7.2 ft 26 Nm (2.6 m kg, 19 ft • • • • 24 Nm (2.4 m kg, 17 ft •...
Page 627 Manuals by Motomatrix / www.motomatrix.co.uk CHAIN DRIVE EAS23410 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.
Page 628 Manuals by Motomatrix / www.motomatrix.co.uk CHAIN DRIVE b. Correct L LLL L LLL L LLL L LLL L LLL 1. Drive chain roller 4. Check: 2. Drive chain sprocket • O-rings “1” Damage → Replace the drive chain. EAS23470 • Drive chain rollers “2” CHECKING THE REAR WHEEL SPROCKET Damage/wear →...
Page 629 Manuals by Motomatrix / www.motomatrix.co.uk CHAIN DRIVE 3. Install: • Clutch release cylinder Refer to “INSTALLING THE CLUTCH RE- LEASE CYLINDER” on page 5-63. 4-71 Email: info@motomatrix.co.uk...
Page 630: Engine
Manuals by Motomatrix / www.motomatrix.co.uk ENGINE ENGINE REMOVAL ..................5-1 CHECKING THE OIL PIPES ..............5-2 CHECKING THE OIL STRAINER ............. 5-2 INSTALLING THE OIL TANK ..............5-2 REMOVING THE MUFFLER END COVERS ..........5-4 INSTALLING THE MUFFLER END COVERS........... 5-4 REMOVING THE ENGINE ..............
Page 631 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH ......................5-47 REMOVING THE CLUTCH ..............5-56 REMOVING THE PRIMARY DRIVE GEAR ..........5-56 CHECKING THE FRICTION PLATES............. 5-56 CHECKING THE CLUTCH PLATES ............5-57 CHECKING THE CLUTCH SPRING PLATE........... 5-57 CHECKING THE CLUTCH HOUSING ............ 5-57 CHECKING THE CLUTCH BOSS............
Page 632 Manuals by Motomatrix / www.motomatrix.co.uk OIL PUMP...................... 5-82 CHECKING THE OIL PUMP ..............5-85 CHECKING THE RELIEF VALVE ............5-85 CHECKING THE OIL STRAINER ............5-85 ASSEMBLING THE OIL PUMP............... 5-85 INSTALLING THE OIL PUMP ..............5-86 CRANKSHAFT ....................5-87 REMOVING THE CONNECTING RODS ..........
Page 633 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the oil tank 13 Nm (1.3 m kg, 9.4 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 13 Nm (1.3 m kg, 9.4 ft • •...
Page 634 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL ET5YU1027 CHECKING THE OIL PIPES 1. Check: • Oil pipes Damage → Replace. Obstruction → Wash and blow out with com- pressed air. ET5YU1028 CHECKING THE OIL STRAINER 1. Check: • Oil strainer (oil tank) Damage →...
Page 635 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL Removing the exhaust pipe 7 Nm (0.7 m kg, 5.1 ft • • 24 Nm (2.4 m kg, 17 ft • • 20 Nm (2.0 m kg, 14 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 636 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL ET5YU1029 REMOVING THE MUFFLER END COVERS 1. Remove: • Muffler end covers “1” NOTE: Before removing a muffler end cover, turn it in the direction of the arrow shown in the illustra- tion. ET5YU1030 INSTALLING THE MUFFLER END COVERS 1.
Page 637 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL Removing the EXUP servo motor and rear exhaust pipe joint 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 638 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL Removing the EXUP servo motor and rear exhaust pipe joint 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 639 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL Removing the EXUP servo motor and rear exhaust pipe joint 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 640 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL Removing the leads 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Stator coil assembly lead Horn lead Wire harness Decompression solenoid coupler Disconnect. Speed sensor coupler Disconnect.
Page 641 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL Removing the down tube 53 Nm (5.3 m kg, 38 ft 53 Nm (5.3 m kg, 38 ft • • • • 53 Nm (5.3 m kg, 38 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 642 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL Removing the down tube 53 Nm (5.3 m kg, 38 ft 53 Nm (5.3 m kg, 38 ft • • • • 53 Nm (5.3 m kg, 38 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 643 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL Removing the engine 7 Nm (0.7 m kg, 5.1 ft • • 74 Nm (7.4 m kg, 53 ft • • 53 Nm (5.3 m kg, 38 ft • • 11 13 74 Nm (7.4 m kg, 53 ft •...
Page 644 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL Removing the engine 7 Nm (0.7 m kg, 5.1 ft • • 74 Nm (7.4 m kg, 53 ft • • 53 Nm (5.3 m kg, 38 ft • • 11 13 74 Nm (7.4 m kg, 53 ft •...
Page 645 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL ET5YU1031 3. Position the engine “6” under the vehicle for REMOVING THE ENGINE installation. NOTE: 4. Install: Pass a suitable rod through the hole in the swin- • Engine “6” garm pivot shaft and secure the rod to support •...
Page 646 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL NOTE: Engine mounting nut (front lower Do not fully tighten the bolts and nuts. side) 94 Nm (9.4 m·kg, 68 ft·lb) 7. Tighten: Engine bracket nut (front upper • Down tube nut (front side) “14” side) •...
Page 647 Manuals by Motomatrix / www.motomatrix.co.uk ENGINE REMOVAL 5-15 Email: info@motomatrix.co.uk...
Page 648 Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS EAS23750 CAMSHAFTS Removing the camshaft sprocket cover 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 649 Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS Removing cylinder head covers 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Tappet cover bolt...
Page 650 Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS Removing the push rods and rocker arms 10 Nm (1.0 m kg, 7.2 ft • • 20 Nm (2.0 m kg, 14 ft • • 24 Nm (2.4 m kg, 17 ft • • Order Job/Parts to remove Q’ty...
Page 651 Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS Removing the valve lifters 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “CYLINDERS AND PISTONS” on Front cylinder page 5-42.
Page 652 Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS Removing the camshafts 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 653 Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS EAS23790 REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 1. Align: • TDC mark “a” on the crankshaft position sen- sor rotor (with the pointer “b” on the clutch cover) M MMM M MMM M MMM M MMM M MMM...
Page 654 Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS EAS23860 CHECKING THE CAMSHAFTS 1. Check: • Cam Blue discoloration/pitting/scratches → Re- place the camshaft. 2. Measure: • Cam dimensions “a” and “b” Out of specification → Replace the camshaft. Camshaft lobe dimensions Intake A 3.
Page 655 Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS 5. Measure: • Crankcase hole inside diameter “a” Out of specification → Replace the crank- case. Crankcase hole inside diameter 25.000–25.021 mm (0.9843– 0.9851 in) 3. Measure: • Camshaft journal diameter (crankcase side) “a” Out of specification →...
Page 656 Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS 8. Calculate: 4. Measure: • Camshaft to camshaft cover clearance • Rocker arm shaft outside diameter “a” Out of specification → Replace the defective Out of specification → Replace. part(s). Rocker arm shaft outside diame- NOTE: Calculate the clearance by subtracting the cam- 17.976–17.991 mm (0.7077–...
Page 657 Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS 4. Measure: EAS23920 CHECKING THE VALVE LIFTERS AND • Valve lifter case inside diameter “a” Out of specification → Replace. VALVE LIFTER CASES 1. Check: Valve lifter hole inside diameter • Valve lifter (intake) Blue discoloration/excessive wear/pitting/ 23.000–23.021 mm (0.9055–...
Page 658 Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS • O-ring Damage/wear → Replace the oil seal and O- ring as a set. EAS23980 CHECKING THE DECOMPRESSION SYSTEM 1. Check: • Decompression system NOTE: • Check the decompression system while the decompression push rod is installed in the 2.
Page 659 Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS NOTE: • Cover the crankcase hole with a clean rag “3” to prevent the straight keys from falling into the crankcase. • Align the punch mark “a” on the camshaft drive gear “1” with the punch mark “b” on the cam- shaft driven gear “2”.
Page 660 Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS Pump the plunger side of the valve lifter with a press a number of times to let in kerosene. ECA14630 CAUTION: • Do not pump the valve lifter excessively. • Kerosene is highly flammable. 1.
Page 661 Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS EAS24070 INSTALLING THE ROCKER ARMS AND PUSH RODS The following procedure applies to both cylin- ders. 1. Install: • Rocker arms “1” • Rocker arm shafts “2” (onto rocker arm base) NOTE: The thread hole “a” of the rocker arm shaft must face to the outside.
Page 662 Manuals by Motomatrix / www.motomatrix.co.uk CAMSHAFTS NOTE: ® Apply locking agent (LOCTITE ) to the threads of the bolt “3”. Cylinder head cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Bolts “3”, “4”: l = 40 mm (1.57 in) Bolts “5”: l = 50 mm (1.97 in) Bolt with washer “6”: l = 50 mm (1.97 in) Bolts “7”: l = 60 mm (2.36 in) A.
Page 663 Manuals by Motomatrix / www.motomatrix.co.uk CYLINDER HEADS EAS24110 CYLINDER HEADS Removing the cylinder heads 45 Nm (4.5 m kg, 32 ft • • 39 Nm (3.9 m kg, 28 ft • • 21 Nm (2.1 m kg, 15 ft • •...
Page 664 Manuals by Motomatrix / www.motomatrix.co.uk CYLINDER HEADS EAS24140 REMOVING THE CYLINDER HEADS 1. Remove: • Cylinder head nuts NOTE: • Loosen the nuts in the proper sequence as shown. • Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.
Page 665 Manuals by Motomatrix / www.motomatrix.co.uk CYLINDER HEADS EAS24250 INSTALLING THE CYLINDER HEADS 1. Tighten: • Cylinder head nuts (M12) “1”–“4” Cylinder head nut (M12) 45 Nm (4.5 m·kg, 32 ft·lb) • Cylinder head nuts (M10) “5”, “6” Cylinder head nut (M10) 39 Nm (3.9 m·kg, 28 ft·lb) NOTE: •...
Page 666 Manuals by Motomatrix / www.motomatrix.co.uk VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both cyl- inders. Cylinder heads Refer to “CYLINDER HEADS” on page 5-31. Valve cotter Upper spring seat Outer valve spring...
Page 667 Manuals by Motomatrix / www.motomatrix.co.uk VALVES AND VALVE SPRINGS EAS24280 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.
Page 668 Manuals by Motomatrix / www.motomatrix.co.uk VALVES AND VALVE SPRINGS Valve-stem-to-valve-guide clear- ance (intake) 0.010–0.037 mm (0.0004–0.0015 Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clear- ance (exhaust) 0.025–0.052 mm (0.0010–0.0020 Limit b. Install the new valve guide with the valve 0.100 mm (0.0039 in) guide installer “2”...
Page 669 Manuals by Motomatrix / www.motomatrix.co.uk VALVES AND VALVE SPRINGS • If the valve is removed or replaced, always re- Valve guide remover (ø6) place the oil seal. 90890-04064 Valve guide remover (6.0 mm) Valve stem runout YM-04064-A 0.010 mm (0.0004 in) Valve guide installer (ø6) 90890-04065 Valve guide installer (6.0 mm)
Page 670 Manuals by Motomatrix / www.motomatrix.co.uk VALVES AND VALVE SPRINGS 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 be- tween your hands.
Page 671 Manuals by Motomatrix / www.motomatrix.co.uk VALVES AND VALVE SPRINGS Inner spring Inner spring Free length (intake) Installed compression spring 38.26 mm (1.51 in) force (intake) Limit 63.00–73.00 N (14.16–16.41 lb) 36.26 mm (1.43 in) (6.42–7.44 kgf) Free length (exhaust) Installed compression spring 38.26 mm (1.51 in) force (exhaust) Limit...
Page 672 Manuals by Motomatrix / www.motomatrix.co.uk VALVES AND VALVE SPRINGS • Upper spring seat “7” (into the cylinder head) NOTE: Install the valve springs with the larger pitch “a” facing up. EAS24340 INSTALLING THE VALVES The following procedure applies to all of the valves and related components.
Page 673 Manuals by Motomatrix / www.motomatrix.co.uk VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. ECA13800 CAUTION: Hitting the valve tip with excessive force could damage the valve. 5-41 Email: info@motomatrix.co.uk...
Page 674 Manuals by Motomatrix / www.motomatrix.co.uk CYLINDERS AND PISTONS EAS24360 CYLINDERS AND PISTONS Removing the cylinders and pistons Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEADS” on page 5-31. Front cylinder Rear cylinder Cylinder gasket Dowel pin Piston pin clip Piston pin Piston...
Page 675 Manuals by Motomatrix / www.motomatrix.co.uk CYLINDERS AND PISTONS EAS24380 • 2nd ring REMOVING THE PISTONS • Oil ring The following procedure applies to all of the pis- NOTE: tons. When removing a piston ring, open the end gap 1. Remove: with your fingers and lift the other side of the ring •...
Page 676 Manuals by Motomatrix / www.motomatrix.co.uk CYLINDERS AND PISTONS EAS24430 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.
Page 677 Manuals by Motomatrix / www.motomatrix.co.uk CYLINDERS AND PISTONS 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 exces- sive, replace all three piston rings.
Page 678 Manuals by Motomatrix / www.motomatrix.co.uk CYLINDERS AND PISTONS • Lower oil ring rail “3” • Upper oil ring rail “4” 90 ˚ • Oil ring expander “5” NOTE: Be sure to install the piston rings so that the 90 ˚ manufacturer’s marks or numbers face up.
Page 679 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH EAS25060 CLUTCH Removing the clutch cover 10 Nm (1.0 m kg, 7.2 ft • • (10) 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL”...
Page 680 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH Removing the crankshaft position sensor 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Oil seal Bearing Crankshaft position sensor lead holder Crankshaft position sensor For installation, reverse the removal proce- dure.
Page 681 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH Removing the clutch 23 22 125 Nm (12.5 m kg, 90 ft • • 12 11 10 9 100 Nm (10.0 m kg, 72 ft • • 8 Nm (0.8 m kg, 5.8 ft •...
Page 682 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH Removing the clutch 23 22 125 Nm (12.5 m kg, 90 ft • • 12 11 10 9 100 Nm (10.0 m kg, 72 ft • • 8 Nm (0.8 m kg, 5.8 ft •...
Page 683 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH Removing the clutch master cylinder 14 Nm (1.4 m kg, 10 ft • • 13 Nm (1.3 m kg, 9.4 ft 30 Nm (3.0 m kg, 22 ft • • • • ∗ ∗ Order Job/Parts to remove Q’ty...
Page 684 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH Removing the clutch master cylinder 14 Nm (1.4 m kg, 10 ft • • 13 Nm (1.3 m kg, 9.4 ft 30 Nm (3.0 m kg, 22 ft • • • • ∗ ∗ Order Job/Parts to remove Q’ty...
Page 685 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH Disassembling the clutch master cylinder ∗ Order Job/Parts to remove Q’ty Remarks Clutch master cylinder push rod Clutch master cylinder kit Clutch master cylinder body For assembly, reverse the disassembly pro- cedure. * Apply silicone grease. 5-53 Email: info@motomatrix.co.uk...
Page 686 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH Removing the clutch release cylinder 26 Nm (2.6 m kg, 19 ft 10 Nm (1.0 m kg, 7.2 ft • • • • Order Job/Parts to remove Q’ty Remarks Drain. Clutch fluid Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM”...
Page 687 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH Disassembling the clutch release cylinder 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Boots Clutch release cylinder piston Clutch release cylinder spring Clutch release cylinder piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.
Page 688 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH EAS25080 REMOVING THE CLUTCH Sheave holder 1. Loosen: 90890-01701 • Clutch boss nut “1” Primary clutch holder YS-01880-A NOTE: While holding the clutch boss “2” with the univer- sal clutch holder “3”, loosen the clutch boss nut. Universal clutch holder 90890-04086 YM-91042...
Page 689 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH EAS25150 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 er- ratic clutch operation. EAS25110 CHECKING THE CLUTCH PLATES The following procedure applies to all of the...
Page 690 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH EAS25190 CHECKING THE CLUTCH PUSH RODS Yamaha bond No. 1215 1. Check: 90890-85505 • O-ring ® (Three Bond No.1215 • Short clutch push rod • Long clutch push rod • Ball Cracks/damage/wear → Replace the defec- tive part(s).
Page 691 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH 3. Install: • Clutch boss “1” • Conical spring washer “2” • Clutch boss nut “3” Clutch boss nut 125 Nm (12.5 m·kg, 90 ft·lb) NOTE: • Lubricate the clutch boss nut threads and con- ical spring washer mating surfaces with engine oil.
Page 692 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH EAS25280 DISASSEMBLING THE CLUTCH MASTER CYLINDER ECA13840 CAUTION: • Clutch components rarely require disas- sembly. • Therefore, always follow these preventive measures: • Never disassemble clutch components un- less absolutely necessary. • If any connection on the hydraulic clutch 6.
Page 693 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH EAS25290 EAS25310 CHECKING THE CLUTCH MASTER INSTALLING THE CLUTCH MASTER CYLINDER CYLINDER 1. Install: Recommended clutch component replace- • Clutch master cylinder “1” ment schedule • Clutch master cylinder holder “2” Piston seals Every two years Clutch master cylinder holder Clutch hose Every four years...
Page 694 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH UPPER LOWER 3. Fill: 6. Check: • Clutch master cylinder reservoir • Clutch lever operation Soft or spongy feeling → Bleed the clutch (with the specified amount of the recom- mended clutch fluid) system. Refer to “BLEEDING THE HYDRAULIC Recommended clutch fluid CLUTCH SYSTEM”...
Page 695 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH 1. Check: • Clutch release cylinder body Cracks/damage → Replace the clutch re- lease cylinder. 2. Check: • Clutch release cylinder • Clutch release cylinder piston Rust/scratches/wear → Replace the clutch release cylinder and clutch release cylinder piston as a set.
Page 696 Manuals by Motomatrix / www.motomatrix.co.uk CLUTCH UPPER LOWER 5. Check: • Clutch lever operation Soft or spongy feeling → Bleed the clutch system. Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 3-14. 5-64 Email: info@motomatrix.co.uk...
Page 697 Manuals by Motomatrix / www.motomatrix.co.uk SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kg, 16 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Clutch housing Refer to “CLUTCH”...
Page 698 Manuals by Motomatrix / www.motomatrix.co.uk SHIFT SHAFT EAS25420 • Hook the end of the shift shaft spring onto the CHECKING THE SHIFT SHAFT shift shaft spring stopper “3”. 1. Check: • Shift shaft Bends/damage/wear → Replace. • Shift shaft spring Damage/wear →...
Page 699 Manuals by Motomatrix / www.motomatrix.co.uk GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the stator coil assembly 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 700 Manuals by Motomatrix / www.motomatrix.co.uk GENERATOR AND STARTER CLUTCH Removing the generator rotor 80 Nm (8.0 m kg, 58 ft • • Order Job/Parts to remove Q’ty Remarks Starter clutch idle gear shaft #2 Starter clutch idle gear shaft #1 Starter clutch idle gear #2 Starter clutch idle gear #1 Generator rotor...
Page 701 Manuals by Motomatrix / www.motomatrix.co.uk GENERATOR AND STARTER CLUTCH EAS24490 2. Check: REMOVING THE GENERATOR • Starter clutch gear’s contacting surfaces 1. Remove: Damage/pitting/wear → Replace the starter • Generator rotor bolt “1” clutch gear. • Washer 3. Check: NOTE: •...
Page 702 Tighten the generator rotor bolt “1” while holding the generator rotor “2” with a sheave holder “3”. Sheave holder 90890-01701 Primary clutch holder YS-01880-A 3. Apply: • Sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505 ® (Three Bond No.1215 5-70 Email: info@motomatrix.co.uk...
Page 703 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Oil tank Refer to “ENGINE REMOVAL” on page 5-1. Starter motor lead Disconnect. Starter motor assembly For installation, reverse the removal proce- dure.
Page 704 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks Circlip Starter motor gear Starter motor rear cover Bearing Oil seal Circlip Starter motor front cover Brush Brush holder (along with the brushes) Brush seat (along with the brushes) Bearing Gasket...
Page 705 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR Pocket tester 1. Check: 90890-03112 • Commutator Analog pocket tester Dirt → Clean with 600 grit sandpaper. YU-03112-C 2. Measure: • Commutator diameter “a” Armature coil Out of specification → Replace the starter Commutator resistance “1”...
Page 706 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRIC STARTER 3. Install: • Starter motor yoke “1” • Starter motor front cover “2” • Starter motor rear cover “3” NOTE: Align the match mark “a” on the starter motor yoke with the match mark “b” on the starter mo- tor rear cover.
Page 707 Manuals by Motomatrix / www.motomatrix.co.uk CRANKCASE EAS25540 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Camshafts Refer to “CAMSHAFTS” on page 5-16. Refer to “CYLINDERS AND PISTONS” on Pistons page 5-42. Shift shaft Refer to “SHIFT SHAFT”...
Page 708 Manuals by Motomatrix / www.motomatrix.co.uk CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Right crankcase For installation, reverse the removal proce- dure. 5-76 Email: info@motomatrix.co.uk...
Page 709 Manuals by Motomatrix / www.motomatrix.co.uk CRANKCASE Removing the oil baffle plate and bearings Order Job/Parts to remove Q’ty Remarks Oil pump Refer to “OIL PUMP” on page 5-82. Crankshaft Refer to “CRANKSHAFT” on page 5-87. Transmission Refer to “TRANSMISSION” on page 5-93. Oil baffle plate Bearing retainer Bearing retainer...
Page 710 Manuals by Motomatrix / www.motomatrix.co.uk CRANKCASE • M6 × 75 mm bolts: “14”, “15” EAS25570 DISASSEMBLING THE CRANKCASE • M6 × 60 mm bolts: “4”–“7” NOTE: • M6 × 40 mm bolts: “8”, “10”–“12”, “16”–“20” Loosen the generator shaft bolt before removing the generator rotor.
Page 711 1. Apply: crankcase mating surfaces. • Sealant 3. Check: (onto the crankcase mating surfaces) • Crankcase Cracks/damage → Replace. Yamaha bond No. 1215 • Oil delivery passages 90890-85505 Obstruction → Blow out with compressed air. ® (Three Bond No.1215 ET5YU1022...
Page 712 Manuals by Motomatrix / www.motomatrix.co.uk CRANKCASE • Tap lightly on the left crankcase with a soft- face hammer. 4. Install: • Crankcase bolts (M8) • Crankcase bolts (M6) Crankcase bolt (M8) 24 Nm (2.4 m·kg, 17 ft·lb) Crankcase bolt (M6) 10 Nm (1.0 m·kg, 7.2 ft·lb) A.
Page 713 Manuals by Motomatrix / www.motomatrix.co.uk CRANKCASE 5-81 Email: info@motomatrix.co.uk...
Page 714 Manuals by Motomatrix / www.motomatrix.co.uk OIL PUMP EAS24910 OIL PUMP Removing the oil pump Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-75. Oil strainer (crankcase) Oil pump assembly For installation, reverse the removal proce- dure.
Page 715 Manuals by Motomatrix / www.motomatrix.co.uk OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Spring retainer Spring Relief valve Oil pump housing cover 1 Spring Collar Ball Oil pump outer rotor 1 Oil pump inner rotor 1 Oil pump housing cover 2 Oil pump shaft Oil pump inner rotor 2...
Page 716 Manuals by Motomatrix / www.motomatrix.co.uk OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil seal Oil pump housing For assembly, reverse the disassembly pro- cedure. 5-84 Email: info@motomatrix.co.uk...
Page 717 Manuals by Motomatrix / www.motomatrix.co.uk OIL PUMP EAS24960 3. Check: CHECKING THE OIL PUMP • Oil pump operation 1. Check: Rough movement → Repeat steps (1) and • Oil pump housing (2) or replace the defective part(s). • Oil pump housing cover Cracks/damage/wear →...
Page 718 Manuals by Motomatrix / www.motomatrix.co.uk OIL PUMP • Oil pump shaft “6” 3. Check: • Pins “7” • Oil pump operation • Oil pump housing cover 2 “8” Refer to “CHECKING THE OIL PUMP” on page 5-85. Oil pump housing cover 2 screw 2 Nm (0.2 m·kg, 1.4 ft·lb) EAS25020 INSTALLING THE OIL PUMP...
Page 719 Manuals by Motomatrix / www.motomatrix.co.uk CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-75. Crankshaft Generator shaft Connecting rod cap Big end lower bearing Connecting rod Big end upper bearing For installation, reverse the removal proce- dure.
Page 720 Manuals by Motomatrix / www.motomatrix.co.uk CRANKSHAFT EAS26010 REMOVING THE CONNECTING RODS The following procedure applies to all of the con- necting rods. 1. Remove: • Connecting rod caps “1” • Connecting rod • Big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.
Page 721 Manuals by Motomatrix / www.motomatrix.co.uk CRANKSHAFT ® g. Put a mark “1” on the connecting rod bolts “2” c. Put a piece of Plastigauge “1” on the crank- and the connecting rod cap “3”. shaft pin. h. Tighten the connecting rod bolts further to d.
Page 722 Manuals by Motomatrix / www.motomatrix.co.uk CRANKSHAFT For example, if the connecting rod “P ” and the crankshaft web “P” numbers are “5” and “2” respectively, then the bearing size for “P ” “P ” (connecting rod) - “P” (crankshaft) 5 - 2 = 3 (brown) Bearing color code 1.Blue 2.Black 3.Brown 4.Green L LLL...
Page 723 Manuals by Motomatrix / www.motomatrix.co.uk CRANKSHAFT NOTE: • Align the projections “a” on the big end bear- ings with the notches “b” in the connecting rods and connecting rod caps. • Be sure to reinstall each big end bearing in its original place.
Page 724 Manuals by Motomatrix / www.motomatrix.co.uk CRANKSHAFT EAS26210 NOTE: INSTALLING THE CRANKSHAFT The tightening procedure of the connecting rod ASSEMBLY bolts is angle controlled, therefore tighten the 1. Install: bolts using the following procedure. • Crankshaft assembly ECA13970 a. Tighten the connecting rod bolts to the spec- CAUTION: ified torque.
Page 725 Manuals by Motomatrix / www.motomatrix.co.uk TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-75. Shift fork guide bar Shift drum assembly Shift fork-L Shift fork-R Shift fork-C Drive axle assembly...
Page 726 Manuals by Motomatrix / www.motomatrix.co.uk TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks Circlip Washer 5th pinion gear Collar Washer 2nd/3rd pinion gear Circlip Washer 4th pinion gear Collar Main axle/1st pinion gear For assembly, reverse the disassembly pro- cedure.
Page 727 Manuals by Motomatrix / www.motomatrix.co.uk TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks 5th wheel gear Circlip Washer 2nd wheel gear Collar Circlip Washer 1st wheel gear Collar Washer 4th wheel gear Circlip Washer 3rd wheel gear Collar Drive axle For assembly, reverse the disassembly pro-...
Page 728 Manuals by Motomatrix / www.motomatrix.co.uk TRANSMISSION EAS26260 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. EAS26300 CHECKING THE TRANSMISSION 1.
Page 729 Manuals by Motomatrix / www.motomatrix.co.uk TRANSMISSION • Transmission gear dogs EAS26320 INSTALLING THE SHIFT FORKS AND SHIFT Cracks/damage/rounded edges → Replace DRUM ASSEMBLY the defective gear(s). 1. Install: 4. Check: • Shift fork-R “1” • Transmission gear engagement • Shift fork-C “2” (each pinion gear to its respective wheel •...
Page 730: Fuel System
Manuals by Motomatrix / www.motomatrix.co.uk FUEL SYSTEM FUEL TANK..................... 6-1 REMOVING THE FUEL TANK ..............6-2 REMOVING THE FUEL PUMP ..............6-2 CHECKING THE FUEL PUMP BODY............6-2 CHECKING THE FUEL PUMP OPERATION..........6-2 INSTALLING THE FUEL PUMP..............6-2 INSTALLING THE FUEL TANK..............6-2 THROTTLE BODIES ..................
Page 731 Manuals by Motomatrix / www.motomatrix.co.uk FUEL TANK EAS26620 FUEL TANK Removing the fuel tank and fuel pump 7 Nm (0.7 m kg, 5.1 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
Page 732 Manuals by Motomatrix / www.motomatrix.co.uk FUEL TANK EAS26630 EAS26670 REMOVING THE FUEL TANK CHECKING THE FUEL PUMP BODY 1. Extract the fuel in the fuel tank through the 1. Check: fuel tank cap with a pump. • Fuel pump body Obstruction →...
Page 733 Manuals by Motomatrix / www.motomatrix.co.uk FUEL TANK EC5YU1017 CAUTION: When installing the fuel hose and the fuel re- turn hose, make sure that they are securely connected, and that the fuel hose connector cover on the fuel hose is in the correct posi- tion, otherwise the fuel hose will not be prop- erly installed.
Page 734 Manuals by Motomatrix / www.motomatrix.co.uk THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the pressure regulator and rollover valves 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 9 Nm (0.9 m kg, 6.5 ft •...
Page 735 Manuals by Motomatrix / www.motomatrix.co.uk THROTTLE BODIES Removing the pressure regulator and rollover valves 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 9 Nm (0.9 m kg, 6.5 ft • •...
Page 736 Manuals by Motomatrix / www.motomatrix.co.uk THROTTLE BODIES Removing the throttle bodies 4 Nm (0.4 m kg, 2.9 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
Page 737 Manuals by Motomatrix / www.motomatrix.co.uk THROTTLE BODIES Removing the intake manifolds 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Fuel hose Fuel hose (intake manifold assembly to pres- sure regulator) Cylinder-#2 ISC (idle speed control) unit outlet hose Cylinder-#1 ISC (idle speed control) unit outlet hose...
Page 738 Manuals by Motomatrix / www.motomatrix.co.uk THROTTLE BODIES Removing the injectors 30 Nm (3.0 m kg, 22 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Parts to remove Q’ty Remarks Fuel pipe...
Page 739 Manuals by Motomatrix / www.motomatrix.co.uk THROTTLE BODIES EAS26980 EAS27010 CHECKING THE INJECTORS CHECKING THE PRESSURE REGULATOR 1. Check: OPERATION • Injectors 1. Check: Damage → Replace. • Pressure regulator operation M MMM M MMM M MMM M MMM M MMM a.
Page 740 Manuals by Motomatrix / www.motomatrix.co.uk THROTTLE BODIES Fuel pressure 392 kPa (3.92 kg/cm², 55.7 psi) h. Use the vacuum/pressure pump gauge set to adjust the fuel pressure in relation to the vac- uum pressure as described below. NOTE: The vacuum pressure should not exceed 100 kPa (760 mm Hg).
Page 741 Manuals by Motomatrix / www.motomatrix.co.uk ISC (IDLE SPEED CONTROL) UNIT ET5YU1012 ISC (IDLE SPEED CONTROL) UNIT Removing the ISC (idle speed control) unit and intake solenoid 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft 9 Nm (0.9 m kg, 6.5 ft •...
Page 742 Manuals by Motomatrix / www.motomatrix.co.uk ISC (IDLE SPEED CONTROL) UNIT Removing the ISC (idle speed control) unit and intake solenoid 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft 9 Nm (0.9 m kg, 6.5 ft •...
Page 743 Manuals by Motomatrix / www.motomatrix.co.uk ISC (IDLE SPEED CONTROL) UNIT ET5YU1015 CHECKING THE ISC (IDLE SPEED CONTROL) SYSTEM 1. Check: • Hoses Loose connections → Connect properly. Cracks/damage → Replace. 2. Check: • Surge tank Cracks/damage → Replace. 3. Check: •...
Page 744: Electrical System
Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL SYSTEM IGNITION SYSTEM ..................7-1 CIRCUIT DIAGRAM .................. 7-1 TROUBLESHOOTING ................7-3 ELECTRIC STARTING SYSTEM ..............7-5 CIRCUIT DIAGRAM .................. 7-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......7-7 TROUBLESHOOTING ................7-9 CHARGING SYSTEM..................7-11 CIRCUIT DIAGRAM ................
Page 745 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS..............7-85 CHECKING THE SWITCHES ..............7-89 CHECKING THE BULBS AND BULB SOCKETS ........7-92 CHECKING THE FUSES ................ 7-93 CHECKING AND CHARGING THE BATTERY........7-94 CHECKING THE RELAYS ..............7-96 CHECKING THE TURN SIGNAL/HAZARD RELAY........ 7-97 CHECKING THE RELAY UNIT (DIODE) ..........
Page 746 Manuals by Motomatrix / www.motomatrix.co.uk Email: info@motomatrix.co.uk...
Page 747 Manuals by Motomatrix / www.motomatrix.co.uk IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM Email: info@motomatrix.co.uk...
Page 748 Manuals by Motomatrix / www.motomatrix.co.uk IGNITION SYSTEM 3. Main switch 4. Battery 8. Main fuse 10.ECU fuse 13.Relay unit 14.Starting circuit cut-off relay 16.Neutral switch 19.Sidestand switch 20.Crankshaft position sensor 24.Lean angle cut-off switch 29.ECU (electronic control unit) 32.Spark plug 33.Cylinder-#2 right ignition coil 34.Cylinder-#2 left ignition coil 35.Cylinder-#1 left ignition coil...
Page 749 Manuals by Motomatrix / www.motomatrix.co.uk IGNITION SYSTEM EAS27150 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Air filter case 4. Battery box 5.
Page 750 Manuals by Motomatrix / www.motomatrix.co.uk IGNITION SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch/immobilizer unit. SWITCHES” on page 7-89. OK ↓ NG → 9. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch.
Page 751 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM Email: info@motomatrix.co.uk...
Page 752 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRIC STARTING SYSTEM 3. Main switch 4. Battery 6. Starter relay 7. Starter motor 8. Main fuse 10.ECU fuse 13.Relay unit 14.Starting circuit cut-off relay 16.Neutral switch 19.Sidestand switch 29.ECU (electronic control unit) 38.Decompression solenoid 56.Clutch switch 70.Auto decompression fuse 73.Engine stop switch...
Page 753 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is turned “ON” (both switch circuits are closed), the starter motor can only operate if at least one of the following conditions is met: •...
Page 754 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEUTRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5.
Page 755 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Air filter case 4. Oil tank NG → 1. Check the fuses. (Main, ignition, auto decompres- sion, and ECU) Replace the fuse(s).
Page 756 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRIC STARTING SYSTEM NG → 8. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 7-89. OK ↓ NG → 9. Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch.
Page 757 Manuals by Motomatrix / www.motomatrix.co.uk CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 7-11 Email: info@motomatrix.co.uk...
Page 758 Manuals by Motomatrix / www.motomatrix.co.uk CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 4. Battery 8. Main fuse 7-12 Email: info@motomatrix.co.uk...
Page 759 Manuals by Motomatrix / www.motomatrix.co.uk CHARGING SYSTEM EAS27220 TROUBLESHOOTING The battery is not being charged. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”...
Page 760 Manuals by Motomatrix / www.motomatrix.co.uk CHARGING SYSTEM 7-14 Email: info@motomatrix.co.uk...
Page 761 Manuals by Motomatrix / www.motomatrix.co.uk LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 7-15 Email: info@motomatrix.co.uk...
Page 762 Manuals by Motomatrix / www.motomatrix.co.uk LIGHTING SYSTEM 3. Main switch 4. Battery 8. Main fuse 10.ECU fuse 29.ECU (electronic control unit) 47.High beam indicator light 50.Meter light 54.Headlight relay 57.Pass switch 58.Dimmer switch 67.Auxiliary light 68.Headlight (high beam) 69.Headlight (low beam) 75.Tail/brake light 76.License plate light 80.Headlight fuse...
Page 763 Manuals by Motomatrix / www.motomatrix.co.uk LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight (high beam), headlight (low beam), high beam indicator light, taillight, license plate light, auxiliary light or meter light. NOTE: • Before troubleshooting, remove the following part(s): 1.
Page 764 Manuals by Motomatrix / www.motomatrix.co.uk LIGHTING SYSTEM NG → 8. Check the entire lighting system wiring. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM” on tem wiring. page 7-15. OK ↓ This circuit is OK. 7-18 Email: info@motomatrix.co.uk...
Page 765 Manuals by Motomatrix / www.motomatrix.co.uk SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 7-19 Email: info@motomatrix.co.uk...
Page 766 Manuals by Motomatrix / www.motomatrix.co.uk SIGNALING SYSTEM 3. Main switch 4. Battery 8. Main fuse 10.ECU fuse 12.Backup fuse (odometer, clock and immobilizer system) 13.Relay unit 16.Neutral switch 18.Fuel sender 25.Speed sensor 29.ECU (electronic control unit) 42.Fuel level warning light 43.Neutral indicator light 44.Multi-function meter 45.Engine trouble warning light...
Page 767 Manuals by Motomatrix / www.motomatrix.co.uk SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or indicator light. • The horn fails to sound. • The speedometer fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1.
Page 768 Manuals by Motomatrix / www.motomatrix.co.uk SIGNALING SYSTEM NG → 3. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 7-19. OK ↓ This circuit is OK. The tail/brake light fails to come on. NG →...
Page 769 Manuals by Motomatrix / www.motomatrix.co.uk SIGNALING SYSTEM NG → 5. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 7-19. OK ↓ This circuit is OK. The neutral indicator light fails to come on. NG →...
Page 770 Manuals by Motomatrix / www.motomatrix.co.uk SIGNALING SYSTEM 7-24 Email: info@motomatrix.co.uk...
Page 771 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 7-25 Email: info@motomatrix.co.uk...
Page 772 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM 3. Main switch 4. Battery 5. Fuel injection system fuse 8. Main fuse 10.ECU fuse 15.Fuel pump relay 16.Neutral switch 17.Fuel pump 19.Sidestand switch 20.Crankshaft position sensor 21.Throttle position sensor 22.Cylinder-#1 intake air pressure sensor 23.Cylinder-#2 intake air pressure sensor 24.Lean angle cut-off switch 25.Speed sensor...
Page 773 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Page 774 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM a. Main switch “OFF” d. Engine trouble warning light on for 1.4 seconds b. Main switch “ON” c. Engine trouble warning light off EAS27380 SELF-DIAGNOSTIC FUNCTION TABLE If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.
Page 775 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive No normal signal is received from sensor Able Able the O sensor. Cylinder-#2 intake air Cylinder-#2 intake air pressure pressure sensor sensor: open or short circuit de-...
Page 776 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive No normal signals are received Speed sensor from the speed sensor. Able Able Open or short circuit is detected in Neutral switch the neutral switch.
Page 777 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM EAS27400 4. Turn the main switch to “OFF” and back to TROUBLESHOOTING METHOD “ON”, then check that no fault code number is displayed. The engine operation is not normal and the NOTE: engine trouble warning light comes on.
Page 778 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM NOTE: • All displays on the meter disappear except the clock and odometer/trip meter/fuel reserve trip meter displays. • “dIAG” appears on the odometer/trip meter/fuel reserve trip meter LCD. 4. Press the “SELECT” button to select the diagnostic mode “dIAG”. 5.
Page 779 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. Cylinder-#1 intake air pres- • Cylinder-#1 intake air pressure sensor hose sure sensor: hose system is detached, clogged, kinked, or pinched. malfunction (clogged or de- •...
Page 780 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in wire sub lead. • Open or short circuit in wire harness. Malfunction detected in the • Malfunction in cylinder-#1 left or right igni- primary wire of the cylin- tion coil.
Page 781 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. The ECU is unable to moni- tor the battery voltage (an • Open or short circuit in wire harness. open or short circuit in the •...
Page 782 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Sensor operation table Diag- nostic Item Meter display Checking method code Throttle angle • Fully closed position 15–20 Check with throttle fully closed. • Fully opened position 95–100 Check with throttle fully open.
Page 783 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Sidestand switch Set ON/OFF the Sidestand switch. (with the transmis- • Stand retracted sion in gear.) • Stand extended Neutral switch Shift the transmission. •...
Page 784 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Actuator operation table Diag- nostic Item Actuation Checking method code Actuates the cylinder-#1 left or right ignition coil five times Check the spark five times. Cylinder-#1 left or right ig- at one-second intervals. •...
Page 785 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the muffler cooling fan motor relay for five cycles Check the operating sound Muffler cooling fan motor of five seconds. (ON 2 sec- of the muffler cooling fan relay onds, OFF 3 seconds) motor relay five times.
Page 786 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the crankshaft posi- tion sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of crankshaft posi- Check for looseness or pinching.
Page 787 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Cylinder-#1 intake air pressure sensor: open or short cir- cuit detected. Diagnostic code No. Cylinder-#1 intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections...
Page 788 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Cylinder-#1 intake air pressure sensor: hose system mal- function (clogged or detached hose). Diagnostic code No. Cylinder-#1 intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method...
Page 789 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor: open or short circuit detected. Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position •...
Page 790 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom EXUP servo motor circuit: open or short circuit detected. Diagnostic code No. EXUP servo motor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
Page 791 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom A break or disconnection of the blue/yellow lead of the ECU is detected. Diagnostic code No. Sidestand switch Order Item/components and probable Check or maintenance job Reinstatement cause method Connections •...
Page 792 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom No normal signal is received from the O sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed state of O sensor.
Page 793 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Cylinder-#2 intake air pressure sensor: open or short cir- cuit detected. Diagnostic code No. Cylinder-#2 intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections...
Page 794 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Cylinder-#2 intake air pressure sensor: hose system mal- function (clogged or detached hose). Diagnostic code No. Cylinder-#2 intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method...
Page 795 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Engine temperature sensor: open or short circuit detect- Diagnostic code No. Engine temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed state of engine temperature Check for looseness or pinching.
Page 796 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Decompression solenoid (thermistor): open or short cir- cuit detected. Diagnostic code No. Decompression solenoid Order Item/components and probable Check or maintenance job Reinstatement cause method Installed state of decompression sole- Check for looseness or pinching.
Page 797 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinder-#1 left or right ignition coil. Diagnostic code No. 30, 32 Cylinder-#1 left or right ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause...
Page 798 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinder-#2 left ignition coil. Diagnostic code No. Cylinder-#2 left ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections...
Page 799 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinder-#1 left or right ignition coil. Diagnostic code No. 30, 32 Cylinder-#1 left or right ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause...
Page 800 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinder-#2 right ignition coil. Diagnostic code No. Cylinder-#2 right ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections...
Page 801 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Engine speed is high when the engine is idling. Diagnostic code No. ISC valve Order Item/components and probable Check or maintenance job Reinstatement cause method ECU fuse is blown. •...
Page 802 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Decompression solenoid: open or short circuit detected. Diagnostic code No. Decompression solenoid Order Item/components and probable Check or maintenance job Reinstatement cause method Installed state of decompression sole- Check for looseness or pinching.
Page 803 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Lean angle cut-off switch: open or short circuit detected. Diagnostic code No. Lean angle cut-off switch Order Item/components and probable Check or maintenance job Reinstatement cause method Connections •...
Page 804 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. Diagnostic code No. Speed sensor Neutral switch Order Item/components and probable Check or maintenance job Reinstatement cause...
Page 805 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. Diagnostic code No. Speed sensor Neutral switch Order Item/components and probable Check or maintenance job Reinstatement cause...
Page 806 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom The ECU is unable to monitor the battery voltage (an open or short circuit in the line to the ECU). Diagnostic code No. Fuel system voltage Order Item/components and probable Check or maintenance job Reinstatement cause...
Page 807 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the fuel injection system is not normal. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the en- •...
Page 808 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Muffler cooling fan temperature sensor: open or short cir- cuit detected. Diagnostic code No. Muffler cooling fan temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of muffler cooling...
Page 809 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Symptom Engine trouble warning light is flashing. (Abnormally high temperature is detected by muffler cooling fan tempera- ture sensor.) Diagnostic code No. Muffler cooling fan temperature sensor Muffler cooling fan motor relay Stopping the flashing of the engine trouble warning light (erasing the muffler cooling fan temperature sensor fault code)
Page 810 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Er-2 Symptom No signals are received from the ECU within the specified duration. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections •...
Page 811 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom Non-registered data has been received from the meter. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
Page 812 Manuals by Motomatrix / www.motomatrix.co.uk FUEL INJECTION SYSTEM 7-66 Email: info@motomatrix.co.uk...
Page 813 Manuals by Motomatrix / www.motomatrix.co.uk FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 7-67 Email: info@motomatrix.co.uk...
Page 814 Manuals by Motomatrix / www.motomatrix.co.uk FUEL PUMP SYSTEM 3. Main switch 4. Battery 5. Fuel injection system fuse 8. Main fuse 10.ECU fuse 15.Fuel pump relay 17.Fuel pump 29.ECU (electronic control unit) 73.Engine stop switch 81.Ignition fuse 7-68 Email: info@motomatrix.co.uk...
Page 815 Manuals by Motomatrix / www.motomatrix.co.uk FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Air filter case NG → 1. Check the fuses. (Main, ignition, fuel injection sys- tem, and ECU) Replace the fuse(s).
Page 816 Manuals by Motomatrix / www.motomatrix.co.uk FUEL PUMP SYSTEM 7-70 Email: info@motomatrix.co.uk...
Page 817 Manuals by Motomatrix / www.motomatrix.co.uk MUFFLER COOLING SYSTEM ET5YU1002 MUFFLER COOLING SYSTEM ET5YU1003 CIRCUIT DIAGRAM 7-71 Email: info@motomatrix.co.uk...
Page 818 Manuals by Motomatrix / www.motomatrix.co.uk MUFFLER COOLING SYSTEM 4. Battery 8. Main fuse 9. Muffler cover fan fuse 10.ECU fuse 26.Muffler cooling fan temperature sensor 29.ECU (electronic control unit) 78.Muffler cooling fan motor 79.Muffler cooling fan motor relay 7-72 Email: info@motomatrix.co.uk...
Page 819 Manuals by Motomatrix / www.motomatrix.co.uk MUFFLER COOLING SYSTEM ET5YU1004 TROUBLESHOOTING The muffler cooling fan motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat NG → 1. Check the fuses. (Main, muffler cover fan, and ECU) Replace the fuse(s).
Page 820 Manuals by Motomatrix / www.motomatrix.co.uk MUFFLER COOLING SYSTEM 7-74 Email: info@motomatrix.co.uk...
Page 821 Manuals by Motomatrix / www.motomatrix.co.uk IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 7-75 Email: info@motomatrix.co.uk...
Page 822 Manuals by Motomatrix / www.motomatrix.co.uk IMMOBILIZER SYSTEM 3. Main switch 4. Battery 8. Main fuse 10.ECU fuse 11.Immobilizer unit 12.Backup fuse (odometer, clock and immobilizer system) 29.ECU (electronic control unit) 44.Multi-function meter 46.Immobilizer system indicator light 81.Ignition fuse 7-76 Email: info@motomatrix.co.uk...
Page 823 Manuals by Motomatrix / www.motomatrix.co.uk IMMOBILIZER SYSTEM EAS27670 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) •...
Page 824 Manuals by Motomatrix / www.motomatrix.co.uk IMMOBILIZER SYSTEM Parts to be replaced Main switch/immo- Key registration re- Accesso- bilizer unit Standard quirement ry lock* Main Immobiliz- and key switch er unit √ Standard key is lost New standard key All keys have been Code re-registering √...
Page 825 Manuals by Motomatrix / www.motomatrix.co.uk IMMOBILIZER SYSTEM Standby mode a. Main switch “ON” e. Standby mode on b. Main switch “OFF” f. Standby mode off c. LED on d. LED off Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced.
Page 826 Manuals by Motomatrix / www.motomatrix.co.uk IMMOBILIZER SYSTEM Standard key registration a. Main switch “ON” B. Immobilizer system indicator light stops flashing when the registration of the second b. Main switch “OFF” standard key is complete. c. LED on d. LED off e.
Page 827 Manuals by Motomatrix / www.motomatrix.co.uk IMMOBILIZER SYSTEM EAS27700 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. NG → 1. Check the fuses. (Main, ignition, backup, and ECU) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
Page 828 Manuals by Motomatrix / www.motomatrix.co.uk IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code IMMOBILIZER Codes between the 1. Signal received from 1. Place the immo- UNIT key and immobilizer other transponder bilizer unit at unit do not match. (failed to recognize least 50 mm code after ten con- away from the...
Page 829 Manuals by Motomatrix / www.motomatrix.co.uk IMMOBILIZER SYSTEM a. Light on b. Light off 7-83 Email: info@motomatrix.co.uk...
Page 830 Manuals by Motomatrix / www.motomatrix.co.uk IMMOBILIZER SYSTEM 7-84 Email: info@motomatrix.co.uk...
Page 831 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 7-85 Email: info@motomatrix.co.uk...
Page 832 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS 1. Air temperature sensor 2. Cylinder-#2 left ignition coil 3. Cylinder-#2 right ignition coil 4. ISC (idle speed control) unit 5. Intake solenoid 6. Cylinder-#1 right ignition coil 7. Cylinder-#1 left ignition coil 8.
Page 833 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS 7-87 Email: info@motomatrix.co.uk...
Page 834 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS 1. Cylinder-#1 intake air pressure sensor 2. Cylinder-#2 intake air pressure sensor 3. Immobilizer unit 4. Throttle position sensor 5. Main fuse 6. Fuse box 7. Muffler cooling fan motor relay 8. ECU (electronic control unit) 9.
Page 835 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES R/W L/W (BLUE) R/W R/B Br/R R Br/L Br/R L/W B/Y L/W B/Y Br/L Br/W (BROWN) (BLUE) Dg Br/W Ch (BLACK) Dg Br/W Ch R/Y Y Y L/B G P B/Y 7-89 Email: info@motomatrix.co.uk...
Page 836 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS 1. Front brake light switch 2. Engine stop switch 3. Start switch 4. Main switch 5. Neutral switch 6. Sidestand switch 7. Rear brake light switch 8. Hazard switch 9. Turn signal switch 10.
Page 837 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
Page 838 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS EAS27990 Checking the condition of the bulbs CHECKING THE BULBS AND BULB The following procedure applies to all of the SOCKETS bulbs. NOTE: 1. Remove: Do not check any of the lights that use LEDs. •...
Page 839 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. If the pocket tester indicates “∞”, replace the fuse. L LLL L LLL L LLL L LLL L LLL Checking the condition of the bulb sockets...
Page 840 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS 4. Install: NOTE: • Lead holder Since MF batteries are sealed, it is not possible • Seat to check the charge state of the battery by mea- Refer to “GENERAL CHASSIS” on page 4-1. suring the specific gravity of the electrolyte.
Page 841 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM Example Charging method using a variable-current Open-circuit voltage = 12.0 V (voltage) charger Charging time = 6.5 hours a. Measure the open-circuit voltage prior to Charge of the battery = 20–30% charging.
Page 842 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS 9. Lubricate: NOTE: • Battery terminals Voltage should be measured 30 minutes after the engine is stopped. Recommended lubricant Dielectric grease b. Connect a charger and ammeter to the bat- tery and start charging. 10.Install: c.
Page 843 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS Relay unit (starting circuit cut-off relay) Headlight relay Sb/W R/L L/R L/G L/Y Sb B/Y L/W 1. Positive battery terminal 1. Positive battery terminal 2. Negative battery terminal 2. Negative battery terminal 3. Positive tester probe 3.
Page 844 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (DC 20 V) to the turn signal/hazard relay terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C •...
Page 845 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS b. Connect the pocket tester (Ω × 1) to the relay Continuity unit terminal as shown. Positive tester probe → sky blue c. Check the relay unit (diode) for continuity. “1” d. Check the relay unit (diode) for no continuity. Negative tester probe →...
Page 846 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS b. Connect the pocket tester (Ω × 1) to the igni- tion coil as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe → black/red “1” • Negative tester probe → orange or gray/red or gray/black “2”...
Page 847 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS e. Crank the engine by pushing the start switch Lean angle cut-off switch output “ ” and gradually increase the spark gap un- voltage til a misfire occurs. Less than 65°: 0.4–1.4 V L LLL L LLL L LLL...
Page 848 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS • Positive tester probe → Pocket tester red “1” 90890-03112 • Negative tester probe → Analog pocket tester black “2” YU-03112-C • Positive tester probe → black “1” • Negative tester probe → black “2”...
Page 849 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS c. Measure the horn resistance. L LLL L LLL L LLL L LLL L LLL 2. Check: • Horn sound Faulty sound → Adjust or replace. M MMM M MMM M MMM M MMM M MMM a.
Page 850 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe → green “1” • Negative tester probe → black “2” b. Turn the main switch to “ON”. c. Elevate the rear wheel and slowly rotate it. d.
Page 851 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS d. Connect the battery (DC 12 V) to the fuel pump terminal as shown. • Positive battery lead → red/blue “3” • Negative battery lead → black “4” b. Measure the throttle position sensor maxi- mum resistance.
Page 852 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS d. Check that the EXUP servo motor pulley ro- c. Measure the decompression solenoid (ther- tates several times in directions “a” and “b”. mistor) resistance. EC5YU1023 L LLL L LLL L LLL L LLL L LLL CAUTION: 2.
Page 853 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS 1. Check: Air temperature sensor resis- • Intake air pressure sensor output voltage tance Out of specification → Replace. 290–390 Ω at 80 °C (176 °F) Intake air pressure sensor output M MMM M MMM M MMM M MMM...
Page 854 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS EW5YU1003 • Positive tester probe WARNING brown/black “1” • Handle the muffler cooling fan temperature • Negative tester probe sensor with special care. red/white “2” • Never subject the intake muffler cooling fan temperature sensor to strong shocks.
Page 855 Manuals by Motomatrix / www.motomatrix.co.uk ELECTRICAL COMPONENTS 3. Install: • Muffler cooling fan temperature sensor 7-109 Email: info@motomatrix.co.uk...
Page 856: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk TROUBLESHOOTING TROUBLESHOOTING..................8-1 GENERAL INFORMATION ............... 8-1 STARTING FAILURES................8-1 INCORRECT ENGINE IDLING SPEED ............ 8-1 POOR MEDIUM AND HIGH-SPEED PERFORMANCE ......8-2 FAULTY GEAR SHIFTING................ 8-2 SHIFT PEDAL DOES NOT MOVE ............8-2 JUMPS OUT OF GEAR................8-2 FAULTY CLUTCH ..................
Page 857 Manuals by Motomatrix / www.motomatrix.co.uk TROUBLESHOOTING EAS28450 Electrical system TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) NOTE: • Blown, damaged or incorrect fuse The following guide for troubleshooting does not • Improperly installed fuse cover all the possible causes of trouble.
Page 858 Manuals by Motomatrix / www.motomatrix.co.uk TROUBLESHOOTING Electrical system EAS28550 JUMPS OUT OF GEAR 1. Battery • Discharged battery Shift shaft • Faulty battery • Incorrect shift pedal position 2. Spark plug(s) • Improperly returned stopper lever • Incorrect spark plug gap •...
Page 859 Manuals by Motomatrix / www.motomatrix.co.uk TROUBLESHOOTING EAS28590 Malfunction OVERHEATING • Bent or damaged inner tube • Bent or damaged outer tube Engine • Damaged fork spring 1. Cylinder head(s) and piston(s) • Worn or damaged outer tube bushing • Heavy carbon buildup •...
Page 860 Manuals by Motomatrix / www.motomatrix.co.uk TROUBLESHOOTING • Improperly grounded circuit • Faulty horn switch • Poor contacts (main or light switch) • Faulty battery • Burnt-out headlight bulb • Blown, damaged or incorrect fuse • Faulty wire harness Headlight bulb burnt out •...
Page 861 Manuals by Motomatrix / www.motomatrix.co.uk EAS28740 53. Turn signal/hazard relay Gy/B Gray/Black WIRING DIAGRAM 54. Headlight relay Gy/G Gray/Green 55. Left handlebar switch MT01(T–W) 2005–2007 Gy/R Gray/Red 56. Clutch switch Gy/W Gray/White 1. AC magneto Blue/Black 57. Pass switch 2. Rectifier/regulator Blue/Green 58.
Page 862 Manuals by Motomatrix / www.motomatrix.co.uk Email: info@motomatrix.co.uk...
Page 863 Manuals by Motomatrix / www.motomatrix.co.uk YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN Email: info@motomatrix.co.uk...
Page 864 Manuals by Motomatrix / www.motomatrix.co.uk MT01(T–W) 2005–2007 MT01(T–W) 2005–2007 MT01(T–W) 2005–2007 MT01(T–W) 2005–2007 MT01(T–W) 2005–2007 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO Sb/W Sb/W L/W1 L/W1 WIRE HARNESS SUB-WIRE-HARNESS1 Br/W Br/Y Gy/G R/L R/W B/Br B/Br Br/L R/G B2 Br/B R/W Lg R/W...

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Table of Contents

Specifications

Periodic Checks and Adjustments

Periodic Maintenance

Engine

Chassis

Chassis

General Chassis

Front Wheel

Rear Wheel

Front Brake

Rear Brake

Handlebar

Front Fork

Steering Head

Rear Shock Absorber Assembly

Swingarm

Chain Drive

Engine

Engine Removal

Camshafts

Cylinder Heads

Valves and Valve Springs

Cylinders and Pistons

Clutch

Shift Shaft

Generator and Starter Clutch

Electric Starter

Crankcase

Oil Pump

Crankshaft

Transmission

Fuel System

Fuel Tank

Throttle Bodies

Isc (Idle Speed Control) Unit

Electrical System

Ignition System

Electric Starting System

Charging System

Lighting System

Signaling System

Fuel Injection System

Fuel Pump System

Muffler Cooling System

Immobilizer System

Electrical Components

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Yamaha MT-01