Yamaha MT-01 T 2005 Manuals

Yamaha MT-01 T 2005 Manuals

Manuals and User Guides for Yamaha MT-01 T 2005. We have 2 Yamaha MT-01 T 2005 manuals available for free PDF download: Service Manual

Yamaha MT-01 T 2005 Service Manual

Yamaha MT-01 T 2005 Service Manual (864 pages)

Brand: Yamaha | Category: Motorcycle | Size: 148.85 MB

Table of Contents

Table of Contents

6
- General Information
  8
  - Identification
    10
  - Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    Outline of the Fi System
    11
    
    Fi System
    12
    
    Instrument Functions
    13
  - Important Information
    16
    
    Gaskets, Oil Seals and O-Rings
    16
    
    Lock Washers/Plates and Cotter Pins
    16
    
    Preparation for Removal and Disassembly
    16
    
    Replacement Parts
    16
    
    Bearings and Oil Seals
    17
    
    Circlips
    17
  - Checking the Connections
    18
  - Special Tools
    19
Specifications

25
- General Specifications
  27
- Engine Specifications
  28
- Chassis
  36
  - Chassis Specifications
    36
  - Electrical Specifications
    40
  - Tightening Torques
    43
    
    General Tightening Torque Specifications
    43
    
    Engine Tightening Torques
    44
    
    Chassis Tightening Torques
    49
  - Lubrication Points and Lubricant Types
    54
    
    Engine
    54
    
    Chassis
    56
  - Lubrication System Chart and Diagrams
    57
    
    Engine Oil Lubrication Chart
    57
    
    Lubrication Diagrams
    59
  - Cable Routing
    67
- Engine
  70
Periodic Checks and Adjustments

84
- Periodic Maintenance
  
  86
  - Introduction
    86
  - Periodic Maintenance and Lubrication Chart
    86
- Engine
  
  88
- Chassis
  
  105
  - Adjusting the Front Disc Brake
    105
  - Adjusting the Rear Disc Brake
    105
  - Checking the Brake Fluid Level
    106
  - Checking the Front Brake Pads
    106
  - Checking the Rear Brake Pads
    107
  - Checking the Front Brake Hoses
    107
  - Checking the Rear Brake Hose
    107
  - Adjusting the Rear Brake Light Switch
    107
  - Bleeding the Hydraulic Brake System
    108
  - Adjusting the Shift Pedal
    109
  - Adjusting the Drive Chain Slack
    109
  - Lubricating the Drive Chain
    110
  - Checking and Adjusting the Steering Head
    110
  - Checking the Front Fork
    111
  - Adjusting the Front Fork Legs
    112
  - Adjusting the Rear Shock Absorber Assembly
    113
  - Specifications
    114
    
    Checking the Tires
    115
    
    Checking the Wheels
    116
    
    Checking and Lubricating the Cables
    117
    
    Lubricating the Levers
    117
    
    Lubricating the Pedal
    117
    
    Lubricating the Rear Suspension
    117
    
    Lubricating the Sidestand
    117
  - Electrical System
    118
Chassis

121
- General Chassis
  
  123
  - Checking the Air Filter Case Valve
    127
- Front Wheel
  
  128
  - Removing the Front Wheel
    130
  - Disassembling the Front Wheel
    130
  - Checking the Front Wheel
    130
  - Assembling the Front Wheel
    131
  - Adjusting the Front Wheel Static Balance
    131
  - Checking the Front Brake Discs
    132
  - Installing the Front Wheel (Front Brake Discs)
    132
- Rear Wheel
  
  134
  - Removing the Rear Wheel
    137
  - Disassembling the Rear Wheel
    137
  - Checking the Rear Wheel
    137
  - Checking the Rear Wheel Drive Hub
    137
  - Checking and Replacing the Rear Wheel Sprocket
    137
  - Assembling the Rear Wheel
    138
  - Adjusting the Rear Wheel Static Balance
    138
  - Checking the Rear Brake Disc
    138
  - Installing the Rear Wheel (Rear Brake Disc)
    138
- Front Brake
  
  140
- Rear Brake
  
  153
  - Introduction
    158
  - Checking the Rear Brake Disc
    158
  - Replacing the Rear Brake Pads
    158
  - Removing the Rear Brake Caliper
    159
  - Disassembling the Rear Brake Caliper
    159
  - Checking the Rear Brake Caliper
    160
  - Assembling the Rear Brake Caliper
    160
  - Installing the Rear Brake Caliper
    161
  - Removing the Rear Brake Master Cylinder
    162
  - Checking the Rear Brake Master Cylinder
    162
  - Assembling the Rear Brake Master Cylinder
    162
  - Installing the Rear Brake Master Cylinder
    162
- Handlebar
  
  164
  - Removing the Handlebar
    166
  - Checking the Handlebar
    166
  - Installing the Handlebar
    166
- Front Fork
  
  169
  - Removing the Front Fork Legs
    172
  - Disassembling the Front Fork Legs
    172
  - Checking the Front Fork Legs
    173
  - Assembling the Front Fork Legs
    174
  - Installing the Front Fork Legs
    178
- Steering Head
  
  179
  - Removing the Lower Bracket
    181
  - Checking the Steering Head
    181
  - Installing the Steering Head
    181
- Rear Shock Absorber Assembly
  
  183
- Swingarm
  
  187
  - Removing the Swingarm
    189
  - Checking the Swingarm
    189
  - Installing the Swingarm
    189
- Chain Drive
  
  191
  - Removing the Drive Chain
    192
  - Checking the Drive Chain
    192
  - Checking the Drive Sprocket
    193
  - Checking the Rear Wheel Sprocket
    193
  - Checking the Rear Wheel Drive Hub
    193
  - Installing the Drive Chain
    193
Engine

196
- Engine Removal
  
  200
  - Checking the Oil Pipes
    201
  - Checking the Oil Strainer
    201
  - Installing the Oil Tank
    201
  - Removing the Muffler End Covers
    203
  - Installing the Muffler End Covers
    203
  - Removing the Engine
    212
  - Installing the Engine
    212
- Camshafts
  
  215
  - Removing the Rocker Arms, Push Rods and Valve Lifters
    220
  - Removing the Camshafts
    220
  - Checking the Camshafts
    221
  - Checking the Rocker Arms and Rocker Arm Shafts
    223
  - Checking the Rocker Arm Bases
    223
  - Checking the Push Rods
    223
  - Checking the Valve Lifters and Valve Lifter Cases
    224
  - Checking the Push Rod Cover
    224
  - Checking the Decompression System
    225
  - Checking the Oil Delivery Pipe
    225
  - Installing the Camshafts
    225
  - Bleeding a Valve Lifter
    226
  - Installing the Valve Lifters
    228
  - Installing the Rocker Arms and Push Rods
    228
  - Installing the Cylinder Head Covers
    229
- Cylinder Heads
  
  230
  - Removing the Cylinder Heads
    231
  - Checking the Cylinder Heads
    231
  - Checking the Oil Pipe
    231
  - Installing the Cylinder Heads
    232
- Valves and Valve Springs
  
  234
  - Removing the Valves
    234
  - Checking the Valves and Valve Guides
    234
  - Checking the Valve Seats
    236
  - Checking the Valve Springs
    237
  - Installing the Valves
    238
- Cylinders and Pistons
  
  240
  - Removing the Pistons
    241
  - Checking the Cylinders and Pistons
    241
  - Checking the Piston Rings
    242
  - Checking the Piston Pins
    243
  - Installing the Pistons and Cylinders
    243
- Clutch
  
  245
  - Removing the Clutch
    254
  - Removing the Primary Drive Gear
    254
  - Checking the Friction Plates
    254
  - Checking the Clutch Plates
    255
  - Checking the Clutch Spring Plate
    255
  - Checking the Clutch Housing
    255
  - Checking the Clutch Boss
    255
  - Checking the Pressure Plate
    255
  - Checking the Clutch Push Rods
    256
  - Checking the Primary Drive Gear
    256
  - Checking the Primary Driven Gear
    256
  - Installing the Crankshaft Position Sensor
    256
  - Installing the Primary Drive Gear
    256
  - Installing the Clutch
    257
  - Disassembling the Clutch Master Cylinder
    258
  - Checking the Clutch Master Cylinder
    259
  - Assembling the Clutch Master Cylinder
    259
  - Installing the Clutch Master Cylinder
    259
  - Removing the Clutch Release Cylinder
    260
  - Checking the Clutch Release Cylinder
    260
  - Assembling the Clutch Release Cylinder
    261
  - Installing the Clutch Release Cylinder
    261
- Shift Shaft
  
  263
  - Checking the Shift Shaft
    264
  - Checking the Stopper Lever
    264
  - Installing the Shift Shaft
    264
- Generator and Starter Clutch
  
  265
  - Removing the Generator
    267
  - Checking the Starter Clutch
    267
  - Installing the Generator
    267
- Electric Starter
  
  269
  - Checking the Starter Motor
    271
  - Assembling the Starter Motor
    272
- Crankcase
  
  273
  - Disassembling the Crankcase
    276
  - Checking the Crankcase
    277
  - Checking the Bearings and Oil Seal
    277
  - Checking the Oil Pipe
    277
  - Checking the Oil Pump Drive
    277
  - Installing the Bearing Retainer
    277
  - Assembling the Crankcase
    277
- Oil Pump
  
  280
  - Checking the Oil Pump
    283
  - Checking the Relief Valve
    283
  - Checking the Oil Strainer
    283
  - Assembling the Oil Pump
    283
  - Installing the Oil Pump
    284
- Crankshaft
  
  285
- Transmission
  
  291
Fuel System

297
- Fuel Tank
  
  299
  - Removing the Fuel Tank
    300
  - Removing the Fuel Pump
    300
  - Checking the Fuel Pump Body
    300
  - Checking the Fuel Pump Operation
    300
  - Installing the Fuel Pump
    300
  - Installing the Fuel Tank
    300
- Throttle Bodies
  
  302
  - Checking the Injectors
    307
  - Checking the Throttle Bodies
    307
  - Checking the Rollover Valves
    307
  - Checking the Pressure Regulator
    307
  - Checking the Pressure Regulator Operation
    307
  - Adjusting the Throttle Position Sensor
    308
  - Installing the Fuel Pipe
    308
- Isc (Idle Speed Control) Unit
  
  309
  - Checking the Isc (Idle Speed Control) System
    311
Electrical System

314
- Ignition System
  
  316
  - Circuit Diagram
    316
  - Troubleshooting
    318
- Electric Starting System
  
  320
  - Circuit Diagram
    320
  - Starting Circuit Cut-Off System Operation
    322
  - Troubleshooting
    324
- Charging System
  
  326
  - Circuit Diagram
    326
  - Troubleshooting
    328
- Lighting System
  
  330
  - Circuit Diagram
    330
  - Troubleshooting
    332
- Signaling System
  
  334
  - Circuit Diagram
    334
  - Troubleshooting
    336
- Fuel Injection System
  
  340
  - Circuit Diagram
    340
  - Ecu Self-Diagnostic Function
    342
  - Self-Diagnostic Function Table
    343
  - Troubleshooting Method
    346
  - Diagnostic Mode
    346
  - Troubleshooting Details
    354
- Fuel Pump System
  
  382
  - Circuit Diagram
    382
  - Troubleshooting
    384
- Muffler Cooling System
  
  386
  - Circuit Diagram
    386
  - Troubleshooting
    388
- Immobilizer System
  
  390
  - Circuit Diagram
    390
  - General Information
    392
  - Part Replacement and Key Code Registration Requirements
    392
  - Troubleshooting
    396
  - Self-Diagnosis Fault Code Indication
    396
- Electrical Components
  
  400
  - Checking the Switches
    404
  - Checking the Bulbs and Bulb Sockets
    407
  - Checking the Fuses
    408
  - Checking and Charging the Battery
    409
  - Checking the Relays
    411
  - Checking the Relay Unit (Diode)
    413
  - Checking the Spark Plug Caps
    414
  - Checking the Ignition Coils
    414
  - Checking the Ignition Spark Gap
    415
  - Checking the Crankshaft Position Sensor
    415
  - Checking the Lean Angle Cut-Off Switch
    415
  - Checking the Stator Coil
    416
  - Checking the Rectifier/Regulator
    416
  - Checking the Horn
    417
  - Checking the Engine Temperature Sensor
    417
  - Checking the Fuel Sender
    418
  - Checking the Speed Sensor
    418
  - Checking the Throttle Position Sensor
    419
  - Checking the Fuel Pump
    419
  - Checking the Exup Servo Motor
    420
  - Checking the Decompression Solenoid
    420
  - Checking the Intake Air Pressure Sensors
    421
  - Checking the Air Temperature Sensor
    422
  - Checking the Intake Solenoid
    422
  - Checking the Muffler Cooling Fan Motor
    422
  - Checking the Muffler Cooling Fan Temperature Sensor
    423
Troubleshooting

425
- Troubleshooting
  427
  - General Information
    427
  - Incorrect Engine Idling Speed
    427
  - Starting Failures
    427
  - Faulty Clutch
    428
  - Faulty Gear Shifting
    428
  - Jumps out of Gear
    428
  - Poor Medium and High-Speed Performance
    428
  - Shift Pedal Does Not Move
    428
  - Faulty Front Fork Legs
    429
  - Faulty Lighting or Signaling System
    429
  - Overheating
    429
  - Poor Braking Performance
    429
  - Unstable Handling
    429
Table of Contents

442
- General Information
  444
  - Identification
    445
  - Vehicle Identification Number
    445
    
    Model Label
    445
  - Features
    446
    
    Outline of the Fi System
    446
    
    Fi System
    447
    
    Instrument Functions
    448
  - Important Information
    451
    
    Gaskets, Oil Seals and O-Rings
    451
    
    Lock Washers/Plates and Cotter Pins
    451
    
    Preparation for Removal and Disassembly
    451
    
    Replacement Parts
    451
    
    Bearings and Oil Seals
    452
    
    Circlips
    452
  - Checking the Connections
    453
  - Special Tools
    454
Specifications

460
- General Specifications
  461
- Engine Specifications
  462
- Chassis Specifications
  470
- Electrical Specifications
  473
- Tightening Torques
  476
- Lubrication Points and Lubricant Types
  487
  - Engine
    487
  - Chassis
    489
- Lubrication System Chart and Diagrams
  491
  - Engine Oil Lubrication Chart
    491
  - Lubrication Diagrams
    493
- Cable Routing
  501
Periodic Checks and Adjustments

518
- Periodic Maintenance
  
  521
  - Introduction
    521
  - Periodic Maintenance and Lubrication Chart
    521
- Engine
  
  523
  - Adjusting the Valve Clearance
    523
  - Synchronizing the Throttle Bodies
    525
  - Adjusting the Throttle Cable Free Play
    527
  - Checking the Spark Plugs
    528
  - Checking the Ignition Timing
    528
  - Measuring the Compression Pressure
    529
  - Checking the Engine Oil Level
    531
  - Changing the Engine Oil
    531
  - Adjusting the Clutch Lever
    533
  - Checking the Clutch Fluid Level
    534
  - Bleeding the Hydraulic Clutch System
    534
  - Replacing the Air Filter Element
    535
  - Checking the Throttle Body Joints
    536
  - Checking the Fuel Line
    536
  - Checking the Cylinder Head Breather Hoses
    536
  - Checking the Oil Tank Breather Hose
    537
  - Checking the Exhaust System
    537
  - Adjusting the Exup Cables
    538
- Chassis
  
  540
  - Adjusting the Front Disc Brake
    540
    
    Adjusting the Rear Disc Brake
    540
    
    Checking the Brake Fluid Level
    541
    
    Checking the Front Brake Hoses
    542
    
    Checking the Front Brake Pads
    542
    
    Checking the Rear Brake Hose
    542
    
    Checking the Rear Brake Pads
    542
    
    Bleeding the Hydraulic Brake System
    543
    
    Adjusting the Shift Pedal
    544
    
    Adjusting the Drive Chain Slack
    545
    
    Checking and Adjusting the Steering Head
    546
    
    Lubricating the Drive Chain
    546
    
    Adjusting the Front Fork Legs
    547
    
    Checking the Front Fork
    547
    
    Adjusting the Rear Shock Absorber Assembly
    549
    
    Checking the Tires
    550
    
    Checking and Lubricating the Cables
    552
    
    Checking the Wheels
    552
    
    Lubricating the Levers
    552
    
    Lubricating the Pedal
    552
    
    Lubricating the Rear Suspension
    552
    
    Lubricating the Sidestand
    552
Chassis

556
- General Chassis
  
  559
  - Checking the Air Filter Case Valve
    563
- Front Wheel
  
  564
  - Removing the Front Wheel
    566
  - Disassembling the Front Wheel
    566
  - Checking the Front Wheel
    566
  - Assembling the Front Wheel
    567
  - Checking the Front Brake Discs
    568
  - Installing the Front Wheel (Front Brake Discs)
    568
- Rear Wheel
  
  570
  - Removing the Rear Wheel
    573
  - Disassembling the Rear Wheel
    573
  - Checking the Rear Wheel
    573
  - Checking the Rear Wheel Drive Hub
    573
  - Checking and Replacing the Rear Wheel Sprocket
    573
  - Assembling the Rear Wheel
    574
  - Checking the Rear Brake Disc
    574
  - Installing the Rear Wheel (Rear Brake Disc)
    574
- Front Brake
  
  576
  - Introduction
    581
  - Checking the Front Brake Discs
    581
  - Replacing the Front Brake Pads
    582
  - Removing the Front Brake Calipers
    583
  - Disassembling the Front Brake Calipers
    583
  - Checking the Front Brake Calipers
    584
  - Assembling the Front Brake Calipers
    584
  - Installing the Front Brake Calipers
    584
  - Checking the Front Brake Master Cylinder
    585
  - Assembling the Front Brake Master Cylinder
    586
  - Installing the Front Brake Master Cylinder
    586
  - Engine
    630
  - Fuel System
    730
  - Electrical System
    744
  - Troubleshooting
    856

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Yamaha MT-01 T 2005 Service Manual

Yamaha MT-01 T 2005 Service Manual (435 pages)

Brand: Yamaha | Category: Motorcycle | Size: 15.17 MB

Table of Contents

Table of Contents

6
- How to Use this Manual
  4
- General Information
  8
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    Outline of the Fi System
    11
    
    Fi System
    12
    
    Instrument Functions
    13
  - Important Information
    16
    
    Preparation for Removal and Disassembly
    16
    
    Replacement Parts
    16
    
    Gaskets, Oil Seals and O-Rings
    16
    
    Lock Washers/Plates and Cotter Pins
    16
    
    Bearings and Oil Seals
    17
    
    Circlips
    17
  - Checking the Connections
    18
  - Special Tools
    19
Specifications

25
- General Specifications
  27
- Engine Specifications
  28
- Chassis Specifications
  36
- Electrical Specifications
  40
- Tightening Torques
  43
- Lubrication Points and Lubricant Types
  54
  - Engine
    54
  - Chassis
    56
- Lubrication System Chart and Diagrams
  57
  - Engine Oil Lubrication Chart
    57
  - Lubrication Diagrams
    59
- Cable Routing
  67
Periodic Checks and Adjustments

84
- Periodic Maintenance
  
  86
  - Introduction
    86
  - Periodic Maintenance and Lubrication Chart
    86
- Engine
  
  88
  - Adjusting the Valve Clearance
    88
    
    Synchronizing the Throttle Bodies
    90
    
    Adjusting the Throttle Cable Free Play
    92
    
    Checking the Spark Plugs
    93
    
    Checking the Ignition Timing
    93
    
    Measuring the Compression Pressure
    94
    
    Checking the Engine Oil Level
    96
    
    Changing the Engine Oil
    96
    
    Adjusting the Clutch Lever
    98
    
    Checking the Clutch Fluid Level
    99
    
    Bleeding the Hydraulic Clutch System
    99
    
    Replacing the Air Filter Element
    100
    
    Checking the Throttle Body Joints
    101
    
    Checking the Fuel Line
    101
    
    Checking the Cylinder Head Breather Hoses
    101
    
    Checking the Oil Tank Breather Hose
    102
    
    Checking the Exhaust System
    102
    
    Adjusting the Exup Cables
    103
- Chassis
  
  105
  - Adjusting the Front Disc Brake
    105
  - Adjusting the Rear Disc Brake
    105
  - Checking the Brake Fluid Level
    106
  - Checking the Front Brake Pads
    106
  - Checking the Rear Brake Pads
    107
  - Checking the Front Brake Hoses
    107
  - Checking the Rear Brake Hose
    107
  - Adjusting the Rear Brake Light Switch
    107
  - Bleeding the Hydraulic Brake System
    108
  - Adjusting the Shift Pedal
    109
  - Adjusting the Drive Chain Slack
    109
  - Lubricating the Drive Chain
    110
  - Checking and Adjusting the Steering Head
    110
  - Checking the Front Fork
    111
  - Adjusting the Front Fork Legs
    112
  - Adjusting the Rear Shock Absorber Assembly
    113
  - Checking the Tires
    115
  - Checking the Wheels
    116
  - Checking and Lubricating the Cables
    117
  - Lubricating the Levers
    117
  - Lubricating the Pedal
    117
  - Lubricating the Sidestand
    117
  - Lubricating the Rear Suspension
    117
  - Electrical System
    118
Chassis

121
- General Chassis
  125
- General Chassis
  
  127
  - Checking the Air Filter Case Valve
    127
- Front Wheel
  
  128
  - Removing the Front Wheel
    130
  - Disassembling the Front Wheel
    130
  - Checking the Front Wheel
    130
  - Assembling the Front Wheel
    131
  - Adjusting the Front Wheel Static Balance
    131
  - Checking the Front Brake Discs
    132
  - Installing the Front Wheel (Front Brake Discs)
    132
- Rear Wheel
  
  134
  - Removing the Rear Wheel
    137
  - Disassembling the Rear Wheel
    137
  - Checking the Rear Wheel
    137
  - Checking the Rear Wheel Drive Hub
    137
  - Checking and Replacing the Rear Wheel Sprocket
    137
  - Assembling the Rear Wheel
    138
  - Adjusting the Rear Wheel Static Balance
    138
  - Checking the Rear Brake Disc
    138
  - Installing the Rear Wheel (Rear Brake Disc)
    138
- Front Brake
  
  140
- Rear Brake
  
  153
  - Introduction
    158
  - Checking the Rear Brake Disc
    158
  - Replacing the Rear Brake Pads
    158
  - Removing the Rear Brake Caliper
    159
  - Disassembling the Rear Brake Caliper
    159
  - Checking the Rear Brake Caliper
    160
  - Assembling the Rear Brake Caliper
    160
  - Installing the Rear Brake Caliper
    161
  - Removing the Rear Brake Master Cylinder
    162
  - Checking the Rear Brake Master Cylinder
    162
  - Assembling the Rear Brake Master Cylinder
    162
  - Installing the Rear Brake Master Cylinder
    162
- Handlebar
  
  164
  - Removing the Handlebar
    166
  - Checking the Handlebar
    166
  - Installing the Handlebar
    166
- Front Fork
  
  169
  - Removing the Front Fork Legs
    172
  - Disassembling the Front Fork Legs
    172
  - Checking the Front Fork Legs
    173
  - Assembling the Front Fork Legs
    174
  - Installing the Front Fork Legs
    178
- Steering Head
  
  179
  - Removing the Lower Bracket
    181
  - Checking the Steering Head
    181
  - Installing the Steering Head
    181
- Rear Shock Absorber Assembly
  
  183
- Swingarm
  
  187
  - Removing the Swingarm
    189
  - Checking the Swingarm
    189
  - Installing the Swingarm
    189
- Chain Drive
  
  191
  - Removing the Drive Chain
    192
  - Checking the Drive Chain
    192
  - Checking the Drive Sprocket
    193
  - Checking the Rear Wheel Sprocket
    193
  - Checking the Rear Wheel Drive Hub
    193
  - Installing the Drive Chain
    193
Engine

196
- Engine Removal
  
  200
  - Checking the Oil Pipes
    201
  - Checking the Oil Strainer
    201
  - Installing the Oil Tank
    201
  - Removing the Muffler End Covers
    203
  - Installing the Muffler End Covers
    203
  - Removing the Engine
    212
  - Installing the Engine
    212
- Camshafts
  
  215
  - Removing the Rocker Arms, Push Rods and Valve Lifters
    220
  - Removing the Camshafts
    220
  - Checking the Camshafts
    221
  - Checking the Rocker Arms and Rocker Arm Shafts
    223
  - Checking the Rocker Arm Bases
    223
  - Checking the Push Rods
    223
  - Checking the Valve Lifters and Valve Lifter Cases
    224
  - Checking the Push Rod Cover
    224
  - Checking the Decompression System
    225
  - Checking the Oil Delivery Pipe
    225
  - Installing the Camshafts
    225
  - Bleeding a Valve Lifter
    226
  - Installing the Valve Lifters
    228
  - Installing the Rocker Arms and Push Rods
    228
  - Installing the Cylinder Head Covers
    229
- Cylinder Heads
  
  230
  - Removing the Cylinder Heads
    231
  - Checking the Cylinder Heads
    231
  - Checking the Oil Pipe
    231
  - Installing the Cylinder Heads
    232
- Valves and Valve Springs
  
  234
  - Removing the Valves
    234
  - Checking the Valves and Valve Guides
    234
  - Checking the Valve Seats
    236
  - Checking the Valve Springs
    237
  - Installing the Valves
    238
- Cylinders and Pistons
  
  241
  - Removing the Pistons
    241
  - Checking the Cylinders and Pistons
    241
  - Checking the Piston Rings
    242
  - Checking the Piston Pins
    243
  - Installing the Pistons and Cylinders
    243
- Clutch
  
  254
  - Removing the Clutch
    254
  - Removing the Primary Drive Gear
    254
  - Checking the Friction Plates
    254
  - Checking the Clutch Plates
    255
  - Checking the Clutch Spring Plate
    255
  - Checking the Clutch Housing
    255
  - Checking the Clutch Boss
    255
  - Checking the Pressure Plate
    255
  - Checking the Clutch Push Rods
    256
  - Checking the Primary Drive Gear
    256
  - Checking the Primary Driven Gear
    256
  - Installing the Crankshaft Position Sensor
    256
  - Installing the Primary Drive Gear
    256
  - Installing the Clutch
    257
  - Disassembling the Clutch Master Cylinder
    258
  - Checking the Clutch Master Cylinder
    259
  - Assembling the Clutch Master Cylinder
    259
  - Installing the Clutch Master Cylinder
    259
  - Removing the Clutch Release Cylinder
    260
  - Checking the Clutch Release Cylinder
    260
  - Assembling the Clutch Release Cylinder
    261
  - Installing the Clutch Release Cylinder
    261
- Shift Shaft
  
  263
  - Checking the Shift Shaft
    264
  - Checking the Stopper Lever
    264
  - Installing the Shift Shaft
    264
- Generator and Starter Clutch
  
  265
  - Removing the Generator
    267
  - Checking the Starter Clutch
    267
  - Installing the Generator
    267
- Electric Starter
  
  269
  - Checking the Starter Motor
    271
  - Assembling the Starter Motor
    272
- Crankcase
  
  273
  - Disassembling the Crankcase
    276
  - Checking the Crankcase
    277
  - Checking the Bearings and Oil Seal
    277
  - Checking the Oil Pipe
    277
  - Checking the Oil Pump Drive
    277
  - Installing the Bearing Retainer
    277
  - Assembling the Crankcase
    277
- Oil Pump
  
  280
  - Checking the Oil Pump
    283
  - Checking the Relief Valve
    283
  - Checking the Oil Strainer
    283
  - Assembling the Oil Pump
    283
  - Installing the Oil Pump
    284
- Crankshaft
  
  285
- Transmission
  
  291
Fuel System

297
- Fuel Tank
  299
- Fuel Tank
  
  300
  - Removing the Fuel Tank
    300
  - Removing the Fuel Pump
    300
  - Checking the Fuel Pump Body
    300
  - Checking the Fuel Pump Operation
    300
  - Installing the Fuel Pump
    300
  - Installing the Fuel Tank
    300
- Throttle Bodies
  
  302
  - Checking the Injectors
    307
  - Checking the Throttle Bodies
    307
  - Checking the Rollover Valves
    307
  - Checking the Pressure Regulator
    307
  - Checking the Pressure Regulator Operation
    307
  - Adjusting the Throttle Position Sensor
    308
  - Installing the Fuel Pipe
    308
- Isc (Idle Speed Control) Unit
  
  309
  - Checking the Isc (Idle Speed Control) System
    311
Electrical System

314
- Ignition System
  
  316
  - Circuit Diagram
    316
  - Troubleshooting
    318
- Electric Starting System
  
  320
  - Circuit Diagram
    320
  - Starting Circuit Cut-Off System Operation
    322
  - Troubleshooting
    324
- Charging System
  
  326
  - Circuit Diagram
    326
  - Troubleshooting
    328
- Lighting System
  
  330
  - Circuit Diagram
    330
  - Troubleshooting
    332
- Signaling System
  
  334
  - Circuit Diagram
    334
  - Troubleshooting
    336
- Fuel Injection System
  
  340
  - Circuit Diagram
    340
  - Ecu Self-Diagnostic Function
    342
  - Self-Diagnostic Function Table
    343
  - Troubleshooting Method
    346
  - Diagnostic Mode
    346
  - Troubleshooting Details
    354
- Fuel Pump System
  
  382
  - Circuit Diagram
    382
  - Troubleshooting
    384
- Muffler Cooling System
  
  386
  - Circuit Diagram
    386
  - Troubleshooting
    388
- Immobilizer System
  
  390
  - Circuit Diagram
    390
  - General Information
    392
  - Part Replacement and Key Code Registration Requirements
    392
  - Troubleshooting
    396
  - Self-Diagnosis Fault Code Indication
    396
- Electrical Components
  
  400
  - Checking the Switches
    404
  - Checking the Bulbs and Bulb Sockets
    407
  - Checking the Fuses
    408
  - Checking and Charging the Battery
    409
  - Checking the Relays
    411
  - Checking the Turn Signal/Hazard Relay
    412
  - Checking the Relay Unit (Diode)
    413
  - Checking the Spark Plug Caps
    414
  - Checking the Ignition Coils
    414
  - Checking the Ignition Spark Gap
    415
  - Checking the Crankshaft Position Sensor
    415
  - Checking the Lean Angle Cut-Off Switch
    415
  - Checking the Stator Coil
    416
  - Checking the Rectifier/Regulator
    416
  - Checking the Horn
    417
  - Checking the Engine Temperature Sensor
    417
  - Checking the Fuel Sender
    418
  - Checking the Speed Sensor
    418
  - Checking the Throttle Position Sensor
    419
  - Checking the Fuel Pump
    419
  - Checking the Exup Servo Motor
    420
  - Checking the Decompression Solenoid
    420
  - Checking the Intake Air Pressure Sensors
    421
  - Checking the Air Temperature Sensor
    422
  - Checking the Intake Solenoid
    422
  - Checking the Muffler Cooling Fan Motor
    422
  - Checking the Muffler Cooling Fan Temperature Sensor
    423
Troubleshooting

425
- General Information
  427
- Incorrect Engine Idling Speed
  427
- Starting Failures
  427
- Troubleshooting
  427
- Faulty Clutch
  428
- Faulty Gear Shifting
  428
- Jumps out of Gear
  428
- Poor Medium and High-Speed Performance
  428
- Shift Pedal Does Not Move
  428
- Faulty Front Fork Legs
  429
- Faulty Lighting or Signaling System
  429
  - Wiring Diagram
    431
- Overheating
  429
- Poor Braking Performance
  429
- Unstable Handling
  429

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