2007 Yamaha R1

Contents
Table of Contents
Troubleshooting
Bookmarks

Quick Links

7
Table of Contents
31
Specifications
85
Periodic Checks and Adjustments
- 88
  Periodic Maintenance
- 91
  Engine
- 110
  Chassis
127
Chassis
- 136
  General Chassis
- 137
  Front Wheel
- 143
  Rear Wheel
- 149
  Front Brake
- 162
  Rear Brake
- 176
  Handlebars
- 179
  Front Fork
- 188
  Steering Head
- 192
  Rear Shock Absorber Assembly
- 195
  Swingarm
- 200
  Chain Drive
205
Engine
- 208
  Engine Removal
- 216
  Camshafts
- 225
  Cylinder Head
- 229
  Valves and Valve Springs
- 237
  Generator
- 241
  Starter Clutch
- 244
  Crankshaft Position Sensor
- 246
  Electric Starter
- 251
  Clutch
- 261
  Shift Shaft
- 264
  Oil Pump
- 272
  Crankcase
- 276
  Crankshaft
- 291
  Transmission
301
Cooling System
- 304
  Radiator
- 305
  Oil Cooler
- 307
  Thermostat
- 310
  Water Pump
313
Fuel System
- 315
  Fuel Tank
- 318
  Throttle Bodies
- 323
  Air Induction System
325
Electrical System
- 328
  Ignition System
- 332
  Electric Starting System
- 338
  Charging System
- 342
  Lighting System
- 346
  Signaling System
- 352
  Cooling System
- 356
  Fuel Injection System
- 394
  Fuel Pump System
- 398
  Immobilizer System
- 408
  Electrical Components

Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys

2007

YZF-R1(W)

SERVICE MANUAL

4C8-28197-E0

email: info@motomatrix.co.uk

Chapters

7
Table of Contents
31
Specifications
85
Periodic Checks and Adjustments
- 88
  Periodic Maintenance
- 91
  Engine
- 110
  Chassis
127
Chassis
- 136
  General Chassis
- 137
  Front Wheel
- 143
  Rear Wheel
- 149
  Front Brake
- 162
  Rear Brake
- 176
  Handlebars
- 179
  Front Fork
- 188
  Steering Head
- 192
  Rear Shock Absorber Assembly
- 195
  Swingarm
- 200
  Chain Drive
205
Engine
- 208
  Engine Removal
- 216
  Camshafts
- 225
  Cylinder Head
- 229
  Valves and Valve Springs
- 237
  Generator
- 241
  Starter Clutch
- 244
  Crankshaft Position Sensor
- 246
  Electric Starter
- 251
  Clutch
- 261
  Shift Shaft
- 264
  Oil Pump
- 272
  Crankcase
- 276
  Crankshaft
- 291
  Transmission
301
Cooling System
- 304
  Radiator
- 305
  Oil Cooler
- 307
  Thermostat
- 310
  Water Pump
313
Fuel System
- 315
  Fuel Tank
- 318
  Throttle Bodies
- 323
  Air Induction System
325
Electrical System
- 328
  Ignition System
- 332
  Electric Starting System
- 338
  Charging System
- 342
  Lighting System
- 346
  Signaling System
- 352
  Cooling System
- 356
  Fuel Injection System
- 394
  Fuel Pump System
- 398
  Immobilizer System
- 408
  Electrical Components

Troubleshooting

Related Manuals for Yamaha YZF-R1 2007

Summary of Contents for Yamaha YZF-R1 2007

Page 1 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 2007 YZF-R1(W) SERVICE MANUAL 4C8-28197-E0 email: info@motomatrix.co.uk...
Page 2 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS20040 YZF-R1(W) SERVICE MANUAL ©2006 by Yamaha Motor Co., Ltd. First edition, October 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
Page 4: How To Use This Manual
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 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 / The Solution For Lost Motorcycle Coded Keys EAS20100 16.Replace the part SYMBOLS The following symbols are used in this manual for easier understanding. NOTE: The following symbols are not relevant to every vehicle. 1. Serviceable with engine mounted 2.
Page 6 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
Page 7: Table Of Contents
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING email: info@motomatrix.co.uk...
Page 8 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
Page 9: General Information
VEHICLE IDENTIFICATION NUMBER...........1-1 MODEL LABEL ..................1-1 FEATURES ....................1-2 FI SYSTEM .....................1-3 YCC-T (Yamaha Chip Controlled Throttle) YCC-I (Yamaha Chip Controlled Intake) ..........1-4 IMPORTANT INFORMATION ..............1-12 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-12 REPLACEMENT PARTS...............1-12 GASKETS, OIL SEALS AND O-RINGS..........1-12 LOCK WASHERS/PLATES AND COTTER PINS .........1-12 BEARINGS AND OIL SEALS ...............1-13...
Page 10: Identification
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number "1" is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label "1" is affixed to the frame. This information will be needed to order spare parts.
Page 11: Features
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES EAS20170 FEATURES OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.
Page 12: Fi System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES EAS4C81010 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 324 kPa (3.24 kg/cm , 46.1 psi).
Page 13: Ycc-T (Yamaha Chip Controlled Throttle) Ycc-I (Yamaha Chip Controlled Intake)
Yamaha developed the YCC-T and YCC-I system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles, but Yamaha has developed a faster, more compact system specifically for the needs of a sports motorcycle. The Yamaha-devel- oped system has a high-speed calculating capacity that produces computations of running condi- tions every 1/1000th of a second.
Page 14 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES Aims and advantages of using YCC-I system • Improvement of the engine power characteristics The high power design in all ranges is now provided by having both two features of the short intake function to ensure the power at the high speed revolution of engine, and the long intake function to ensure the power in the practical use range.
Page 15 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES YCC-T/YCC-I system outline 19.Intake funnel servo motor driver 1. Throttle position sensor (for throttle cable pulley) 20.Intake funnel servo motor 2. Throttle servo motor 3. Throttle position sensor (for throttle valves) 4.
Page 16 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES YCC-T/YCC-I control outline 15.Throttle servo motor 1. Throttle position sensor (for throttle cable pulley) 16.ECU (engine control unit) 2. Throttle position sensor (for throttle valves) 17.Base map 3.
Page 17 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES EAS4C81024 kilometers and miles, press the "SELECT" INSTRUMENT FUNCTIONS button for at least one second. Multi-function meter unit Tachometer 1. Clock 1. Tachometer 2. Speedometer 2. Tachometer red zone 3.
Page 18 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES 5. Push the "SELECT" button and then Split-time measurement release it to start the clock. 1. Push the "RESET" button to start the stop- watch. Odometer, tripmeter, and stopwatch modes 2.
Page 19 Yamaha dealer and have the standard • When the key is turned to "ON", the coolant keys re-registered. temperature is automatically displayed, even...
Page 20 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES This mode cycles through five control func- setting is selected when the indicator light tions, allowing you to make the following set- flashes once every two seconds.) tings in the order listed below.
Page 21: Important Information
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 22: Bearings And Oil Seals
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 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 23: Checking The Connections
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 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: •...
Page 24 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 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 inappropri- ate tools or improvised techniques.
Page 25 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod holder 4-52, 4-57 90890-01434 Damper rod holder double ended YM-01434 Rod puller 4-56, 4-57 90890-01437 Universal damping rod bleeding tool set YM-A8703 Rod puller attachment (M12) 4-56, 4-57...
Page 26 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve spring compressor 5-23, 5-29 90890-04019 YM-04019 Valve spring compressor attachment 5-23, 5-29 90890-04108 Valve spring compressor adapter (22 mm) YM-04108 Middle driven shaft bearing driver 6-11...
Page 27 Valve guide reamer (ø4.5) 5-25 90890-04118 Valve guide reamer (4.5mm) YM-04118 Ignition checker 8-95 90890-06754 Opama pet-4000 spark checker YU-34487 Yamaha bond No.1215 5-67, 6-11 (Three Bond No.1215) 90890-85505 Pivot shaft wrench 90890-01471 Frame spanner socket YM-01471 Pivot shaft wrench adapter 90890-01476 1-18 email: info@motomatrix.co.uk...
Page 28: Special Tools
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pocket tester 1-14, 5-41, 8- 90890-03112 87, 8-88, 8-89, Analog pocket tester 8-92, 8-93, 8- YU-03112-C 94, 8-95, 8-96, 8-97, 8-98, 8- 99, 8-100, 8- 101, 8-102, 8-...
Page 29 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Damper rod holder (22 mm) 4-69, 4-70 90890-01365 1-20 email: info@motomatrix.co.uk...
Page 30 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS 1-21 email: info@motomatrix.co.uk...
Page 31: Specifications
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-9 ELECTRICAL SPECIFICATIONS...............2-11 TIGHTENING TORQUES................2-13 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-13 ENGINE TIGHTENING TORQUES ............2-14 CHASSIS TIGHTENING TORQUES ............2-18 LUBRICATION POINTS AND LUBRICANT TYPES ........2-21 ENGINE ....................2-21 CHASSIS ....................2-22 LUBRICATION SYSTEM CHART AND DIAGRAMS .........2-23...
Page 32: General Specifications
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 4C81 (EUR) 4C82 (FRA, BEL) 4C83 (AUS) Dimensions Overall length 2060 mm (81.1 in) Overall width 720 mm (28.3 in) Overall height 1110 mm (43.7 in) Seat height...
Page 33: Engine Specifications
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 998.0 cm³ Cylinder arrangement Forward-inclined parallel 4-cylinder Bore × stroke 77.0 × 53.6 mm (3.03 × 2.11 in) Compression ratio 12.70 :1 Standard compression pressure (at sea level)
Page 34 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Spark plug (s) Manufacturer/model NGK/CR9EK Spark plug gap 0.6–0.7 mm (0.024–0.028 in) Cylinder head Volume 14.00–14.80 cm³ (0.85–0.90 cu.in) Warpage limit* 0.10 mm (0.0039 in) Camshaft Drive system Chain drive (right)
Page 35 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Valve head diameter A (exhaust) 24.90–25.10 mm (0.9803–0.9882 in) Valve face width B (intake) 1.200–2.480 mm (0.0472–0.0976 in) Valve face width B (exhaust) 1.625–2.900 mm (0.0640–0.1142 in) Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in) Valve seat width C (exhaust)
Page 36 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Installed length (intake) 35.50 mm (1.40 in) Installed length (exhaust) 33.00 mm (1.30 in) Spring rate K1 (intake) 42.91 N/mm (245.02 lb/in) (4.38 kgf/mm) Spring rate K2 (intake) 56.23 N/mm (321.07 lb/in) (5.73 kgf/mm) Spring rate K1 (exhaust) 40.10 N/mm (228.97 lb/in) (4.09 kgf/mm)
Page 37 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Piston ring Top ring Ring type Barrel Dimensions (B × T) 0.90 × 2.75 mm (0.04 × 0.11 in) End gap (installed) 0.15–0.25 mm (0.0059–0.0098 in) Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) 2nd ring...
Page 38 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Clutch Clutch type Wet, multiple-disc Clutch release method Outer pull, rack and pinion pull Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) Friction plate thickness 2.90–3.10 mm (0.114–0.122 in) Wear limit 2.80 mm (0.1102 in)
Page 39 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Gear ratio 38/15 (2.533) 33/16 (2.063) 37/21 (1.762) 35/23 (1.522) 30/22 (1.364) 33/26 (1.269) Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit 0.08 mm (0.0032 in) Shifting mechanism Shift mechanism type...
Page 40: Chassis Specifications
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond 24.00 ° Caster angle Trail 102.0 mm (4.02 in) Front wheel Wheel type Cast wheel Rim size 17M/C x MT3.50 Rim material Aluminum Wheel travel...
Page 41 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS SPECIFICATIONS Master cylinder inside diameter 16.00 mm (0.63 in) 24.05 mm × 3 (0.95 in × 3) Caliper cylinder inside diameter Recommended fluid DOT 4 Rear brake Type Single disc brake Operation...
Page 42: Electrical Specifications
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Transistorized coil ignition (digital) 5.0 °/1050 r/min Ignition timing (B.T.D.C.) Engine control unit Model/manufacturer TBDF37/DENSO (4C81, 4C83) TBDF41/DENSO (4C82)
Page 43 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SPECIFICATIONS Electric starting system System type Constant mesh Starter motor Model/manufacturer 4C8/YAMAHA Power output 0.90 kW 0.0090–0.0110 Ω Armature coil resistance Brush overall length 10.8 mm (0.43 in) Limit 7.19 mm (0.28 in)
Page 44: Tightening Torques
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFI- CATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual.
Page 45: Engine Tightening Torques
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Threa Item Q'ty Tightening torque Remarks d size Spark plugs 13 Nm (1.3 m·kg, 9.4 ft·lb) Cylinder head nut (2pieces) See NOTE Cylinder head nut (8pieces) See NOTE Cylinder head bolt...
Page 46 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES Threa Item Q'ty Tightening torque Remarks d size Exhaust pipe and muffler bolt 20 Nm (2.0 m·kg, 14 ft·lb) Exhaust pipe and EXUP valve 12 Nm (1.2 m·kg, 8.7 ft·lb) bolt Exhaust valve pipe bracket bolt 20 Nm (2.0 m·kg, 14 ft·lb)
Page 47 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES Threa Item Q'ty Tightening torque Remarks d size Oil return pipe bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Oil return plug 24 Nm (2.4 m·kg, 17 ft·lb) AC magneto lead bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Stator coil screw...
Page 48 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES 3. Final, tighten the bolts to 40 Nm (4.0 m·kg, 29 ft·lb) with a torque wrench following the tighten- ing order. • Crankcase bolt (main journal) 1.
Page 49: Chassis Tightening Torques
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Threa Item Q'ty Tightening torque Remarks d size Upper bracket pinch bolt 26 Nm (2.6 m·kg, 19 ft·lb) Steering stem nut 113 Nm (11.3 m·kg, 82 ft·lb) Handlebar pinch bolt 17 Nm (1.7m·kg, 12 ft·lb)
Page 50 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES Threa Item Q'ty Tightening torque Remarks d size Connecting arm nut (connecting 44 Nm (4.4 m·kg, 32 ft·lb) arm and frame) Relay arm nut (relay arm and 44 Nm (4.4 m·kg, 32 ft·lb) connecting arm) Relay arm nut (relay arm and...
Page 51 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES • Front wheel axle pinch bolt 1. Insert the front wheel axle from the right side and tighten it with the flange bolt from the left side to 91 Nm (9.1 m·kg, 65.8 ft·lb).
Page 52: Lubrication Points And Lubricant Types
Starter clutch assembly Primary driven gear Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Yamaha bond No. Cylinder head cover mating surface 1215 Yamaha bond No. Cylinder head cover semicircular 1215 Yamaha bond No.
Page 53: Chassis
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Throttle grip inner surface Brake lever pivoting point and metal-to-metal moving parts Clutch lever pivoting point and metal-to-metal moving parts Engine mount bolts (rear upper and lower) Relay arm, connecting rod and rear shock absorber collar...
Page 54: Lubrication System Chart And Diagrams
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-23 email: info@motomatrix.co.uk...
Page 55 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Oil filter 6. Main gallery 7. AC magneto drive gear shower 8.
Page 56: Lubrication Diagrams
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-25 email: info@motomatrix.co.uk...
Page 57 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Oil filter cartridge 4. Oil level switch 2-26 email: info@motomatrix.co.uk...
Page 58 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27 email: info@motomatrix.co.uk...
Page 59 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Crankshaft 4. Oil cooler 5. Relief valve 6. Oil pipe 7. Oil strainer 8. Oil pump 2-28 email: info@motomatrix.co.uk...
Page 60 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29 email: info@motomatrix.co.uk...
Page 61 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter cartridge 2. Oil level switch 3. Oil pump 4. Oil strainer 5. Oil pipe 6. Oil cooler 2-30 email: info@motomatrix.co.uk...
Page 62 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31 email: info@motomatrix.co.uk...
Page 63 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil delivery pipe 3. Drive axle 2-32 email: info@motomatrix.co.uk...
Page 64 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33 email: info@motomatrix.co.uk...
Page 65 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Crankshaft 2-34 email: info@motomatrix.co.uk...
Page 66: Cooling System Diagrams
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-35 email: info@motomatrix.co.uk...
Page 67 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM DIAGRAMS 1. Water pump 2. Radiator 3. Radiator fan 2-36 email: info@motomatrix.co.uk...
Page 68 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM DIAGRAMS 2-37 email: info@motomatrix.co.uk...
Page 69 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator 3. Oil cooler 4. Thermostat 2-38 email: info@motomatrix.co.uk...
Page 70: Cable Routing
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING EAS20430 CABLE ROUTING 2-39 email: info@motomatrix.co.uk...
Page 71 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Ground lead 2. Meter lead 3. Headlight stay 4. Right headlight lead (high beam) 5. Right auxiliary light lead 6. Intake air temperature sensor coupler 7.
Page 72 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-41 email: info@motomatrix.co.uk...
Page 73 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Right handlebar switch lead 2. Clutch cable 3. Main switch lead 4. Left handlebar switch lead 5. Horn lead 6. Horn 7. Throttle cables 8.
Page 74 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-43 email: info@motomatrix.co.uk...
Page 75 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING J. Cut the clamp tip leaving 2 to 4 mm (0.08 1. Wire harness to 0.16 in). 2. Crankshaft position sensor lead K. Route the rear brake light switch lead by 3.
Page 76 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-45 email: info@motomatrix.co.uk...
Page 77 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING I. 40 to 60mm (1.57 to 2.36 in) 1. Left radiator fan motor lead J. Route the sidestand switch lead by the 2. Heat protector inside of the water hose and water pipe.
Page 78 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-47 email: info@motomatrix.co.uk...
Page 79 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING N. All hoses and leads should be routed over 1. Throttle cables the vehicle's upper side above the heat 2. Rectifier/regulator protector. 3. Rectifier/regulator lead O.
Page 80 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-49 email: info@motomatrix.co.uk...
Page 81 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Starter relay lead 2. Starter motor lead 3. Battery positive lead 4. Lean angle sensor 5. Turn signal/hazard relay 6. Main fuse 7. Turn signal light/license plate light lead 8.
Page 82 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-51 email: info@motomatrix.co.uk...
Page 83 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Fuel tank 2. O-ring 3. Fuel hose 4. Fuel tank drain hose 5. Fuel tank breather hose 6. Air filter stay 7. Clip 8. Fuel tank bracket 9.
Page 84 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-53 email: info@motomatrix.co.uk...
Page 85: Periodic Checks And Adjustments
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE .................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE AND LUBRICATION CHART.....3-1 ENGINE......................3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 SYNCHRONIZING THE THROTTLE BODIES ........3-7 ADJUSTING THE EXHAUST GAS VOLUME.........3-8 ADJUSTING THE THROTTLE CABLE FREE PLAY ......3-9 CHECKING THE SPARK PLUGS............3-10 MEASURING THE COMPRESSION PRESSURE .......3-11...
Page 86 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATING THE REAR SUSPENSION ..........3-36 ELECTRICAL SYSTEM................3-37 CHECKING AND CHARGING THE BATTERY........3-37 CHECKING THE FUSES..............3-37 REPLACING THE HEADLIGHT BULBS..........3-37 ADJUSTING THE HEADLIGHT BEAMS ..........3-38 email: info@motomatrix.co.uk...
Page 87 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
Page 88: 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. ODOMETER READ- Annual ING (×...
Page 89 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE ODOMETER READ- Annual ING (× 1000 km) ITEM CHECK OR MAINTENANCE JOB check 10 20 30 40 • Check operation and for excessive √ √ √...
Page 90 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE ODOMETER READ- Annual ING (× 1000 km) ITEM CHECK OR MAINTENANCE JOB check 10 20 30 40 • Check operation and free play. Throttle grip •...
Page 91: Engine
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE EAS20470 ENGINE EAS20490 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. •...
Page 92 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE • When removing the timing chain and cam- Valve clearance measuring sequence shafts, fasten the timing chain with a wire to Cylinder #1 → #2 → #4 → #3 retrieve it if it falls into the crankcase.
Page 93 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE NOTE: • The thickness "a" of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. • Since valve pads of various sizes are origi- nally installed, the valve pad number must be rounded in order to reach the closest equiva- lent to the original.
Page 94: Synchronizing The Throttle Bodies
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE EAS20570 5. Install: SYNCHRONIZING THE THROTTLE BODIES • Fuel tank NOTE: Refer to "FUEL TANK" on page 7-1. Prior to synchronizing the throttle bodies, the 6. Start the engine and let it warm up for sev- valve clearance should be properly adjusted eral minutes.
Page 95: Adjusting The Exhaust Gas Volume
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE • If an air screw was removed, turn the screw NOTE: 3/4 turn in and be sure to synchronize the • If more than one throttle body has a bypass throttle body.
Page 96: Adjusting The Throttle Cable Free Play
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE 7. Change the CO adjustment volume by NOTE: pressing the "SELECT" and "RESET" but- "dIAG" appears on the odometer, tripmeter and tons. fuel reserve trip LCD. NOTE: 3.
Page 97: Checking The Spark Plugs
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE Direction "a" Manufacturer/model Throttle cable free play is increased. NGK/CR9EK Direction "b" Throttle cable free play is decreased. 6. Check: • Electrode "1" c. Tighten the locknut "1". Damage/wear →...
Page 98: Measuring The Compression Pressure
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE EAS20710 MEASURING THE COMPRESSION PRES- Standard compression pres- SURE sure (at sea level) The following procedure applies to all of the 1480 kPa/350 r/min (210.5 psi/ cylinders.
Page 99: Checking The Engine Oil Level
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE 8. Connect: cause clutch slippage. Therefore, do not • Ignition coils add any chemical additives or use engine oils with a grade of CD "a" or higher and EAS20730 do not use oils labeled "ENERGY CON- CHECKING THE ENGINE OIL LEVEL...
Page 100: Measuring The Engine Oil Pressure
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE Oil filter cartridge 17 Nm (1.7 m·kg, 12 ft·lb) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Check: • Engine oil drain bolt gasket 8. Install: • Engine oil drain bolt (along with the gasket) 5.
Page 101: Adjusting The Clutch Cable Free Play
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE 5. Measure: 2. Start the engine, warm it up for several • Engine oil pressure minutes, and then turn it off. (at the following conditions) ECA13410 Out of specification →...
Page 102: Replacing The Air Filter Element
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) 2. Adjust: • Clutch cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Handlebar side a. Turn the adjusting bolt "1" in direction "b" or "c"...
Page 103: Checking The Throttle Body Joints
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE NOTE: When installing the air filter element into the air filter case cover, make sure that the sealing surfaces are aligned to prevent any air leaks. 6.
Page 104: Checking The Crankcase Breather Hose
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE NOTE: Before removing the fuel hoses, place a few rags in the area under where it will be remov- ing. ECA14940 CAUTION: Make sure the fuel tank breather hose is routed correctly.
Page 105: Adjusting The Exup Cables
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE EAS21100 Exhaust pipe nut ADJUSTING THE EXUP CABLES 20 Nm (2.0 m·kg, 14 ft·lb) 1. Remove: Exhaust pipe and exhaust valve • Lower cowlings pipe bolt Refer to "GENERAL CHASSIS"...
Page 106: Checking The Exup Servo Motor
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE EAS21110 CHECKING THE COOLANT LEVEL 1. Stand the vehicle on a level surface. NOTE: • Place the vehicle on a suitable stand. • Make sure the vehicle is upright. 2.
Page 107: Checking The Cooling System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE EAS21120 • Side cowlings CHECKING THE COOLING SYSTEM • Lower cowlings 1. Remove: Refer to "GENERAL CHASSIS" on page 4- • Lower cowlings • Side cowling Refer to "GENERAL CHASSIS"...
Page 108 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Radiator capacity (including all routes) 2.76 L (2.92 US qt) (2.43 Imp.qt) 7.
Page 109 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE 15. Install: • Coolant reservoir cap 16. Start the engine, warm it up for several minutes, and then stop it. 17. Check: • Coolant level Refer to "CHECKING THE COOLANT LEVEL"...
Page 110: Chassis
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS EAS21140 (distance "a" from the center of the footrest CHASSIS bracket bolt to the center of the brake pedal) EAS21160 Out of specification → Adjust. ADJUSTING THE FRONT DISC BRAKE 1.
Page 111: Checking The Brake Fluid Level
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS EWA13050 WARNING A soft or spongy feeling in the brake lever 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 112: Checking The Rear Brake Pads
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS 3. Hold the vehicle upright and apply the brake several times. 4. Check: • Brake hose Brake fluid leakage → Replace the dam- aged hose. Refer to "FRONT BRAKE" on page 4-20. EAS21290 CHECKING THE REAR BRAKE HOSE 1.
Page 113: Bleeding The Hydraulic Brake System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS a. Hold the main body "1" of the rear brake b. Install the brake fluid reservoir diaphragm. light switch so that it does not rotate and c.
Page 114: Adjusting The Shift Pedal
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS g. Loosen the bleed screw. EAS21410 ADJUSTING THE DRIVE CHAIN SLACK NOTE: NOTE: Loosening the bleed screw will release the The drive chain slack must be checked at the pressure and cause the brake lever to contact tightest point on the chain.
Page 115: Lubricating The Drive Chain
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS Recommended lubricant Direction "a" Drive chain is tightened. Engine oil or chain lubricant Direction "b" suitable for O-ring chains Drive chain is loosened. EAS21500 CHECKING AND ADJUSTING THE STEER- ING HEAD 1.
Page 116 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS Steering nut wrench 90890-01403 Spanner wrench YU-33975 Lower ring nut (initial tightening torque) 52 Nm (5.2 m·kg, 38 ft·lb) c. Loosen the lower ring nut "4" completely, then tighten it to specification.
Page 117: Checking The Front Fork
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS 4. Check: • Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement → Repair. Refer to "FRONT FORK"...
Page 118 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS Rebound damping adjust posi- tions Minimum 26 click(s) out* Standard 10 click(s) out* Maximum 1 click(s) out* * With the adjusting screw fully turned in. Spring preload adjusting posi- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 119: Adjusting The Rear Shock Absorber Assembly
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS Spring preload adjusting posi- tions Minimum Standard Maximum ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Rebound damping ECA13590 EAS21610 CAUTION: ADJUSTING THE REAR SHOCK Never go beyond the maximum or minimum ABSORBER ASSEMBLY adjustment positions.
Page 120: Checking The Tires
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS Compression damping (fast compression ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ damping) a. Turn the adjusting knob "1" in direction "a" or "b". ECA13590 CAUTION: Direction "a" Never go beyond the maximum or minimum Compression damping is increased adjustment positions.
Page 121 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS Damage/wear → Replace the tire. EWA13180 WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. •...
Page 122: Checking The Wheels
EWA13260 concerning handling characteristics can be WARNING given if a tire combination other than one Never attempt to make any repairs to the approved by Yamaha is used on this vehi- wheel. cle. NOTE: Front tire After a tire or wheel has been changed or Size replaced, always balance the wheel.
Page 123: Lubricating The Pedal
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal-to-metal moving parts of the pedal. Recommended lubricant Lithium-soap-based grease EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand.
Page 124 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SYSTEM EAS21750 4. Remove: ELECTRICAL SYSTEM • Headlight bulb holders "3" EAS21760 CHECKING AND CHARGING THE BATTERY Refer to "ELECTRICAL COMPONENTS" on page 8-81. EAS21770 CHECKING THE FUSES Refer to "ELECTRICAL COMPONENTS"...
Page 125 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SYSTEM 9. Install: Right headlight • Headlight bulb cover Direction "a" 10. Connect: Headlight beam moves to the left. • Headlight bulb coupler (high beam) Direction "b" 11.
Page 126 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SYSTEM 3-39 email: info@motomatrix.co.uk...
Page 127 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE COVER...............4-7 INSTALLING THE COVER ..............4-7 FRONT WHEEL ....................4-8 REMOVING THE FRONT WHEEL ............4-10 CHECKING THE FRONT WHEEL............4-10 ADJUSTING THE FRONT WHEEL STATIC BALANCE .......4-11 INSTALLING THE FRONT WHEEL ............4-12 REAR WHEEL ....................4-14 REMOVING THE REAR WHEEL ............4-17...
Page 128 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REMOVING THE HANDLEBAR ............4-47 CHECKING THE HANDLEBARS ............4-47 INSTALLING THE HANDLEBARS............4-47 CHECKING THE STEERING DAMPER ..........4-48 FRONT FORK.....................4-50 REMOVING THE FRONT FORK LEGS ..........4-52 DISASSEMBLING THE FRONT FORK LEGS ........4-52 CHECKING THE FRONT FORK LEGS..........4-53 ASSEMBLING THE FRONT FORK LEGS ...........4-54 INSTALLING THE FRONT FORK LEGS ..........4-58...
Page 129 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
Page 130 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat and battery Order Job/Parts to remove Q'ty Remarks Rider seat Passenger seat Battery negative lead Battery positive lead ECU (engine control unit) ECU lead coupler Disconnect.
Page 131 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the front cowling and side cowlings Order Job/Parts to remove Q'ty Remarks Side cowling inner panel Side cowling Front turn signal light lead coupler Disconnect.
Page 132 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the rear fender Order Job/Parts to remove Q'ty Remarks Rider seat Refer to "GENERAL CHASSIS" on page 4-1. Passenger seat Refer to "GENERAL CHASSIS" on page 4-1. Muffler Refer to "ENGINE REMOVAL"...
Page 133 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the air filter case Order Job/Parts to remove Q'ty Remarks Rider seat Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank Refer to "FUEL TANK" on page 7-1. Air filter case cover Air filter Intake funnel servo motor rod assembly...
Page 134 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS EAS4C81025 surface between upper stopper and lower CHECKING THE INTAKE FUNNEL seating position when it is moved by 1. Check: hand. • Intake funnel • Make sure that the intake funnel smoothly Cracks/damage →...
Page 135 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Activate the diagnostic mode and select the diagnostic code number "34". Refer to "FUEL INJECTION SYSTEM" on page 8-29. b. Set the engine stop switch to " ".
Page 136: General Chassis
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS EAS21840 REMOVING THE COVER 1. Remove: • Tail cover • Rear fender NOTE: To remove the quick fastener, push its center with a screwdriver, then pull the fastener out. EAS21850 INSTALLING THE COVER 1.
Page 137: Front Wheel
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs Order Job/Parts to remove Q'ty Remarks Left brake hose holder Right brake hose holder Left front brake caliper Right front brake caliper Front wheel axle pinch bolt Front wheel axle bolt...
Page 138 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q'ty Remarks Oil seal (left and right) Wheel bearing (left and right) Spacer For assembly, reverse the disassembly pro- cedure.
Page 139: Removing The Front Wheel
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL EAS21900 Refer to "CHECKING THE TIRES" on page REMOVING THE FRONT WHEEL 3-33 and "CHECKING THE WHEELS" on 1. Stand the vehicle on a level surface. page 3-35.
Page 140: Adjusting The Front Wheel Static Balance
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL • Adjust the front wheel static balance with the brake disc installed. 1. Remove: • Balancing weight(s) 2. Find: • Front wheel's heavy spot NOTE: Place the front wheel on a suitable balancing stand.
Page 141: Installing The Front Wheel
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL 1. Lubricate: NOTE: • Wheel axle Start with the lightest weight. • Oil seal lips Recommended lubricant Lithium-soap-based grease 2. Lift the wheel up between the fork legs. 3.
Page 142 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL NOTE: Make sure that there is enough space between the brake pads before installing the brake cali- pers on to the brake discs. 4-13 email: info@motomatrix.co.uk...
Page 143: Rear Wheel
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel Order Job/Parts to remove Q'ty Remarks Rear brake caliper Locknut (left and right) Loosen. Adjusting bolt (left and right) Loosen.
Page 144 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL Removing the brake disc and rear wheel sprocket Order Job/Parts to remove Q'ty Remarks Rear brake disc Rear wheel sprocket Collar Dust cover Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper...
Page 145 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 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. 4-16 email: info@motomatrix.co.uk...
Page 146: Removing The Rear Wheel
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL EAS22040 REMOVING THE REAR WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.
Page 147: Checking The Rear Wheel Drive Hub
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL EAS22110 NOTE: CHECKING THE REAR WHEEL DRIVE HUB Tighten the self-locking nuts in stages and in a 1. Check: crisscross pattern. • Rear wheel drive hub "1" Cracks/damage →...
Page 148 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL Rear wheel axle nut 150 Nm (15.0 m·kg, 108 ft·lb) Rear brake caliper bolt (front side) 27 Nm (2.7 m·kg, 20 ft·lb) Rear brake caliper bolt (rear side) 22 Nm (2.2 m·kg, 16 ft·lb) EWA13500...
Page 149: Front Brake
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q'ty Remarks Brake hose holder Front brake caliper Brake pad clip Brake pad pin Brake pad spring Brake pad Bleed screw...
Page 150 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Removing the front brake master cylinder Order Job/Parts to remove Q'ty Remarks Drain. Brake fluid Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-26. Stopper Brake fluid reservoir cap Brake fluid reservoir diaphragm holder...
Page 151 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 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 pro- cedure.
Page 152 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Removing the front brake calipers Order Job/Parts to remove Q'ty Remarks Drain. Brake fluid Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-26. Union bolt Copper washer Brake hose Brake caliper...
Page 153 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Disassembling the front brake calipers Order Job/Parts to remove Q'ty Remarks Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro-...
Page 154: Introduction
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE EAS22220 INTRODUCTION EWA14100 WARNING Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. •...
Page 155: Replacing The Front Brake Pads
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Front brake disc bolt 18 Nm (1.8 m·kg, 13 ft·lb) LOCTITE® 3. Remove: • Brake pads "1" d. Measure the brake disc deflection. e. If out of specification, repeat the adjust- ment steps until the brake disc deflection is within specification.
Page 156: Removing The Front Brake Calipers
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Below the minimum level mark "a" → Add NOTE: the recommended brake fluid to the proper Always install new brake pads and a new level. brake pad spring as a set.
Page 157: Disassembling The Front Brake Calipers
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE EAS22360 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ DISASSEMBLING THE FRONT BRAKE CALIPERS EAS22390 CHECKING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. Recommended brake component replace- 1.
Page 158: Installing The Front Brake Calipers
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE • Whenever a brake caliper is disassem- bled, replace the brake caliper piston seals. Recommended fluid DOT 4 EAS22450 INSTALLING THE FRONT BRAKE CALI- PERS The following procedure applies to both of the 3.
Page 159: Removing The Front Brake Master Cylinder
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE EAS22510 CHECKING THE FRONT BRAKE MASTER CYLINDER 1. Check: • Brake master cylinder Damage/scratches/wear → Replace. • Brake fluid delivery passages (brake master cylinder body) Obstruction →...
Page 160: Assembling The Front Brake Master Cylinder
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE 2. Install: EAS22520 ASSEMBLING THE FRONT BRAKE MAS- • Copper washers TER CYLINDER • Brake hose EWA13520 • Union bolt WARNING Front brake hose union bolt •...
Page 161 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE EWA13090 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. •...
Page 162: Rear Brake
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q'ty Remarks Screw plug Brake pad pin Rear brake caliper Brake pad shim Brake pad Bleed screw Brake pad spring...
Page 163 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q'ty Remarks Drain. Brake fluid Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-26. Footrest plate Brake fluid reservoir cap Rear brake fluid reservoir diaphragm holder...
Page 164 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q'ty Remarks Brake master cylinder kit Hose joint Bush Brake master cylinder body For assembly, reverse the disassembly pro- cedure.
Page 165 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Removing the rear brake calipers Order Job/Parts to remove Q'ty Remarks Drain. Brake fluid Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-26. Union bolt Copper washer Brake hose Brake caliper...
Page 166 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Disassembling the rear brake calipers Order Job/Parts to remove Q'ty Remarks Screw plug Brake pad pin Brake pad Brake pad shim Brake pad spring Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro-...
Page 167: Introduction
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14100 4.5 mm (0.18 in) WARNING 5. Adjust: Disc brake components rarely require dis- • Brake disc deflection assembly. Therefore, always follow these Refer to "CHECKING THE FRONT BRAKE preventive measures: DISCS"...
Page 168 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE 3. Measure: c. Tighten the bleed screw. • Brake pad wear limit "a" Out of specification → Replace the brake Bleed screw 6 Nm (0.6 m·kg, 4.3 ft·lb) pads as a set.
Page 169: Removing The Rear Brake Caliper
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE EAS22590 • Never try to pry out the brake caliper pis- REMOVING THE REAR BRAKE CALIPER ton. NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1.
Page 170: Assembling The Rear Brake Caliper
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE EWA13610 ECA14170 WARNING CAUTION: Whenever a brake caliper is disassembled, When installing the brake hose onto the replace the brake caliper piston seals. brake caliper "1", make sure the brake pipe "a"...
Page 171: Removing The Rear Brake Master Cylinder
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR 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.
Page 172: Assembling The Rear Brake Master Cylinder
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE EWA13530 WARNING Proper brake hose routing is essential to insure safe vehicle operation. Refer to "CABLE ROUTING" on page 2-39. ECA14160 CAUTION: When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection "a"...
Page 173 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR 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.
Page 174 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBARS EAS22850 HANDLEBARS Removing the handlebars Order Job/Parts to remove Q'ty Remarks Front cowling Refer to "GENERAL CHASSIS" on page 4-1. Side cowling Refer to "GENERAL CHASSIS" on page 4-1. Grip end Handlebar grip Clutch switch connector...
Page 175 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBARS Removing the handlebars Order Job/Parts to remove Q'ty Remarks Upper bracket bolt Loosen. Upper bracket pinch bolt Loosen. Steering stem nut Loosen. Upper bracket Left handlebar Right handlebar For installation, reverse the removal proce- dure.
Page 176: Handlebars
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBARS EAS22870 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.
Page 177: Checking The Steering Damper
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBARS 7. Install: 4. Install: • Handlebar grip • Throttle grip • Throttle cable housing "1" ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a thin coat of rubber adhesive onto • Throttle cables the end of the left handlebar.
Page 178 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBARS • Bearing Damage/pitting → Replace. (It replace with the assembly.) 4-49 email: info@motomatrix.co.uk...
Page 179: Front Fork
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q'ty Remarks Front wheel Refer to "FRONT WHEEL" on page 4-8. Front brake caliper Refer to "FRONT BRAKE"...
Page 180 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q'ty Remarks Cap bolt O-ring Damper adjusting rod Damper adjusting rod locknut Washer Spacer Fork spring Dust seal Oil seal clip Oil seal...
Page 181: Removing The Front Fork Legs
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK EAS22970 • Front fork leg REMOVING THE FRONT FORK LEGS The following procedure applies to both of the EAS22990 DISASSEMBLING THE FRONT FORK LEGS front fork legs. The following procedure applies to both of the 1.
Page 182: Checking The Front Fork Legs
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK 1. Check: • Inner tube "1" • Outer tube "2" Bends/damage/scratches → Replace. EWA13650 WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 3.
Page 183: Assembling The Front Fork Legs
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK 4. Check: • Cap bolt O-ring "1" Damage/wear → Replace. 2. Lubricate: • Inner tube's outer surface Recommended oil Suspension oil 01 or equiva- lent 3.
Page 184 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK • Oil seal clip "2" • Oil seal "3" • Washer "4" ECA14220 CAUTION: Make sure the numbered side of the oil seal faces up. NOTE: •...
Page 185 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK Rod puller 90890-01437 Universal damping rod bleeding tool set YM-A8703 Rod puller attachment (M12) 90890-01435 Universal damping rod bleeding tool set YM-A8703 11. Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed.
Page 186 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK a. Remove the rod puller attachment. b. Install the nut. c. Install the fork spring and spacer. NOTE: Install the spring with the smaller pitch "a" fac- ing up "A".
Page 187: Installing The Front Fork Legs
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK EWA4C81003 WARNING • The fork spring is compressed. • Always use a new cap bolt O-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.
Page 188: Steering Head
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q'ty Remarks Front cowling Refer to "GENERAL CHASSIS" on page 4-1. Side cowling Refer to "GENERAL CHASSIS" on page 4-1. Front wheel Refer to "FRONT WHEEL"...
Page 189 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q'ty Remarks Bearing cover Bearing inner race Upper bearing Lower bearing Dust seal Bearing outer race For installation, reverse the removal proce- dure.
Page 190: Removing The Lower Bracket
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STEERING HEAD EAS23110 • Bearings REMOVING THE LOWER BRACKET • Bearing races 1. Stand the vehicle on a level surface. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ EWA13120 a. Remove the bearing races "1" from the WARNING steering head pipe with a long rod "2"...
Page 191 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STEERING HEAD • Bearing races Recommended lubricant Lithium-soap-based grease 2. Install: • Lower ring nut "1" • Rubber washer "2" • Upper ring nut "3" • Lock washer "4" Refer to "CHECKING AND ADJUSTING THE STEERING HEAD"...
Page 192: Rear Shock Absorber Assembly
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q'ty Remarks Rider seat Refer to "GENERAL CHASSIS" on page 4-1. Passenger seat Refer to "GENERAL CHASSIS"...
Page 193: Handling The Rear Shock Absorber
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR SHOCK ABSORBER ASSEMBLY EAS23180 2. Remove: HANDLING THE REAR SHOCK ABSORBER • Rear shock absorber assembly lower bolt EWA13740 "1" WARNING • Relay arm-to-swingarm bolt "2" This rear shock absorber contains highly NOTE: compressed nitrogen gas.
Page 194: Checking The Connecting Arm And Relay Arm
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR SHOCK ABSORBER ASSEMBLY • Dust seals Installed depth "a" Damage/wear → Replace. 1.0 mm (0.04 in) • Bolts Installed depth "b" Bends/damage/wear → Replace. 4.0 mm (0.16 in) EAS23260 A.
Page 195: Swingarm
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q'ty Remarks Rear wheel Refer to "REAR WHEEL" on page 4-14. Refer to "REAR SHOCK ABSORBER Rear shock absorber assembly ASSEMBLY"...
Page 196 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SWINGARM Removing the swingarm Order Job/Parts to remove Q'ty Remarks For installation, reverse the removal proce- dure. 4-67 email: info@motomatrix.co.uk...
Page 197: Removing The Swingarm
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SWINGARM EAS23350 REMOVING THE SWINGARM Swingarm side play (at the end 1. Stand the vehicle on a level surface. of the swingarm) EWA13120 1.0 mm (0.04 in) WARNING d.
Page 198: Checking The Swingarm
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SWINGARM • Washers NOTE: • Bearings Loosen the swingarm pivot shaft with the damper rod holder (22 mm) "2". Recommended cleaning solvent Kerosene Damper rod holder (22 mm) 4.
Page 199 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SWINGARM 5. Swingarm 6. Pivot shaft A. Left side B. Right side 3. Install: • Pivot shaft "1" Pivot shaft 7 Nm (0.7 m·kg, 5.1 ft·lb) NOTE: 5.
Page 200: Chain Drive
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive chain Order Job/Parts to remove Q'ty Remarks Swingarm Refer to "SWINGARM" on page 4-66. Drive chain guard Drive chain For installation, reverse the removal proce- dure.
Page 201: Removing The Drive Chain
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 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: 2.
Page 202: Checking The Rear Wheel Sprocket
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAIN DRIVE b. Correct 1. Drive chain roller 2. Drive chain sprocket EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to "CHECKING AND REPLACING THE REAR WHEEL SPROCKET" on page 4-18 EAS23480 CHECKING THE REAR WHEEL DRIVE HUB Refer to "CHECKING THE REAR WHEEL...
Page 203 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAIN DRIVE ECA14300 CAUTION: Never install a new drive chain onto worn drive chain sprockets; this will dramatically shorten the drive chain's life. 3. Adjust: • Drive chain slack Refer to "ADJUSTING THE DRIVE CHAIN SLACK"...
Page 204 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAIN DRIVE 4-75 email: info@motomatrix.co.uk...
Page 205: Engine
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE ENGINE ..............5-7 CAMSHAFTS....................5-9 REMOVING THE CAMSHAFTS ............5-11 CHECKING THE CAMSHAFTS ............5-12 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET..5-13 CHECKING THE TIMING CHAIN GUIDES ..........5-13 CHECKING THE TIMING CHAIN TENSIONER ........5-13 INSTALLING THE CAMSHAFTS ............5-15 CYLINDER HEAD..................5-18...
Page 206 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE CLUTCH PLATES.............5-48 CHECKING THE CLUTCH SPRINGS ..........5-49 CHECKING THE CLUTCH HOUSING ..........5-49 CHECKING THE CLUTCH BOSS ............5-49 CHECKING THE PRESSUR PLATE 2 ..........5-50 CHECKING THE PRESSURE PLATE 1 ..........5-50 CHECKING THE PUSH LEVER SHAFT AND PUSH ROD....5-50 INSTALLING THE CLUTCH..............5-50 SHIFT SHAFT .....................5-54...
Page 207 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE TRANSMISSION ............5-90 INSTALLING THE TRANSMISSION.............5-91 email: info@motomatrix.co.uk...
Page 208: Engine Removal
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the drive sprocket Order Job/Parts to remove Q'ty Remarks Lower cowlings Refer to "GENERAL CHASSIS" on page 4-1. Loosen. Drive chain Refer to "ADJUSTING THE DRIVE CHAIN SLACK"...
Page 209 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Removing the exhaust pipe Order Job/Parts to remove Q'ty Remarks Rider seat Refer to "GENERAL CHASSIS" on page 4-1. Passenger seat Refer to "GENERAL CHASSIS" on page 4-1. Side cowlings Refer to "GENERAL CHASSIS"...
Page 210 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Removing the exhaust pipe Order Job/Parts to remove Q'ty Remarks For installation, reverse the removal proce- dure. email: info@motomatrix.co.uk...
Page 211 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Disassembling the exhaust valve pipe Order Job/Parts to remove Q'ty Remarks Washer Pulley Collar Plate Spring EXUP pulley bracket Housing Gasket Collar Shaft arm Exhaust valve pipe For assembly, reverse the disassembly pro- cedure.
Page 212 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q'ty Remarks Fuel tank Refer to "FUEL TANK" on page 7-1. Air filter case Refer to "GENERAL CHASSIS" on page 4-1. Throttle body Refer to "THROTTLE BODIES"...
Page 213 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q'ty Remarks Engine mounting bolt (front right side) Engine mount collar (outer) Engine mount collar (center) Engine mount collar (inner) Engine mounting bolt (front left side) Locknut Engine mounting bolt (rear lower side)
Page 214: Installing The Engine
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE 1. Install: • Engine mounting adjust bolts (temporary tighten) 2. Install: • Engine 3. Install: • Engine mounting bolt (rear lower side) "1" •...
Page 215 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Upper locknut Engine mounting bolt (front 51 Nm (5.1 m·kg, 37 ft·lb) right side) Lower locknut 45 Nm (4.5 m·kg, 33 ft·lb) 51 Nm (5.1 m·kg, 37 ft·lb) NOTE: First tighten the lower locknut, and then tighten the upper locknut.
Page 216: Camshafts
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover Order Job/Parts to remove Q'ty Remarks Fuel tank Refer to "FUEL TANK" on page 7-1. Side cowlings Refer to "GENERAL CHASSIS" on page 4-1. Lower cowlings Refer to "GENERAL CHASSIS"...
Page 217 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q'ty Remarks Refer to "CRANKSHAFT POSITION SEN- Pickup rotor cover SOR" on page 5-37. Camshaft sprocket bolt Loosen. Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap Dowel pin...
Page 218: Removing The Camshafts
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Remove: • Pickup rotor cover Refer to "CRANKSHAFT POSITION SEN- SOR" on page 5-37. 2. Align: • "T" mark "a" on the pickup rotor (with the crankcase mating surface "b") ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 219: Checking The Camshafts
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS 3. Measure: • Camshaft runout EAS23850 CHECKING THE CAMSHAFTS Out of specification → Replace. 1. Check: • Camshaft lobes Camshaft runout limit Blue discoloration/pitting/scratches → 0.030 mm (0.0012 in) Replace the camshaft.
Page 220: Checking The Timing Chain And Camshaft Sprocket
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS 2. Check: • Camshaft sprocket More than 1/4 tooth wear "a" → Replace the camshaft sprocket and the timing chain as a set. a. 1/4 tooth ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 221 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS NOTE: NOTE: Squeeze the timing chain tensioner clip, and When the timing chain tensioner rod "3" is then remove the timing chain tensioner spring pushed while holding the grip of the timing and timing chain tensioner rod.
Page 222: Installing The Camshafts
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS EAS24000 INSTALLING THE CAMSHAFTS 1. Align: • "T" mark "a" on the pickup rotor (with the crankcase mating surface "b") ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. b.
Page 223 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS ECA4C81004 CAUTION: • Lubricate the camshaft cap bolts with the engine oil. • The camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft caps, and camshafts will result.
Page 224 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS 11. Measure: • Valve clearance Out of specification → Adjust. Refer to "ADJUSTING THE VALVE CLEARANCE" on page 3-4. 12. Install: • Pickup coil rotor cover "CRANKSHAFT POSITION SENSOR"...
Page 225: Cylinder Head
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q'ty Remarks Engine Refer to "ENGINE REMOVAL" on page 5-1. Intake camshaft Refer to "CAMSHAFTS" on page 5-9. Exhaust camshaft Refer to "CAMSHAFTS"...
Page 226: Removing The Cylinder Head
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD EAS24120 REMOVING THE CYLINDER HEAD Warpage limit 1. Remove: 0.10 mm (0.0039 in) • Intake camshaft • Exhaust camshaft Refer to "REMOVING THE CAMSHAFTS" on page 5-11. 2.
Page 227 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD NOTE: • First, tighten the nuts "1" – "10" to approxi- mately 10 Nm (1.0 m·kg, 7.2 ft·lb) with a torque wrench, and then tighten the 25 Nm (2.5 m·kg, 18 ft·lb).
Page 228 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q'ty Remarks Cylinder head Refer to "CYLINDER HEAD" on page 5-18. Intake valve lifter Intake valve pad Intake valve cotter...
Page 229: Valves And Valve Springs
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q'ty Remarks For installation, reverse the removal proce- dure. 5-22 email: info@motomatrix.co.uk...
Page 230: Removing The Valves
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS EAS24280 • Valve cotters "1" REMOVING THE VALVES NOTE: The following procedure applies to all of the Remove the valve cotters by compressing the valves and related components.
Page 231 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS 1. Measure: a. Remove the valve guide with the valve • Valve-stem-to-valve-guide clearance guide remover "1". Out of specification → Replace the valve guide.
Page 232: Checking The Valve Seats
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS Valve guide remover (ø4.5) 90890-04116 Valve guide remover (4.5 mm) YM-04116 Valve guide remover (ø5) 90890-04097 Valve guide remover (5.0 mm) YM-04097 Valve guide installer (ø4.5) 90890-04117 Valve guide installer (4.5 mm) 6.
Page 233 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS ECA4C81012 Valve seat width CAUTION: Valve seat width C (intake) This model uses titanium intake valves. 0.90–1.10 mm (0.0354–0.0433 Titanium valves that have been used to lap the valve seats must not be used.
Page 234: Checking The Valve Springs
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS Out of specification → Replace the valve spring. Valve spring free length Free length (intake) 39.79 mm (1.57 in) Limit 37.80 mm (1.49 in) Free length (exhaust) 38.42 mm (1.51 in) Limit...
Page 235: Checking The Valve Lifters
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS 3. Measure: • Valve spring tilt "a" Out of specification → Replace the valve spring. Spring tilt limit Spring tilt (intake) 2.5 °/1.7 mm Spring tilt (exhaust) 2.5 °/1.7 mm 2.
Page 236 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys VALVES AND VALVE SPRINGS b. Smaller pitch 6. Lubricate: 4. Install: • Valve pad "1" • Valve cotters "1" • Valve lifter "2" (with the recommended lubricant) NOTE: Install the valve cotters by compressing the Recommended lubricant...
Page 237: Generator
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERATOR EAS24480 GENERATOR Removing the generator Order Job/Parts to remove Q'ty Remarks Rider seat Refer to "GENERAL CHASSIS" on page 4-1. Passenger seat Refer to "GENERAL CHASSIS" on page 4-1. Side cowlings Refer to "GENERAL CHASSIS"...
Page 238 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERATOR Removing the generator Order Job/Parts to remove Q'ty Remarks Stator coil assembly lead holder Idler gear Idler gear shaft Washer Bearing For installation, reverse the removal proce- dure.
Page 239: Removing The Generator
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERATOR EAS24490 EAS24500 REMOVING THE GENERATOR INSTALLING THE GENERATOR 1. Remove: 1. Install: • Plug • Idle gear shaft • Generator rotor cover "1" • Idle gear "1" •...
Page 240 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERATOR NOTE: • First tighten the M8 bolts and then tighten the M6 bolts. • Tighten the generator rotor cover bolts in stages and in a crisscross pattern. 5-33 email: info@motomatrix.co.uk...
Page 241: Starter Clutch
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STARTER CLUTCH EAS24550 STARTER CLUTCH Removing the starter clutch Order Job/Parts to remove Q'ty Remarks Generator rotor Damper Driven gear Washer Starter clutch drive gear Collar Washer Spacer O-ring For assembly, reverse the removal proce-...
Page 242: Removing The Starter Clutch
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STARTER CLUTCH EAS24560 REMOVING THE STARTER CLUTCH 1. Remove: • Spacer "1" • O-ring "2" • Washer "3" EAS24570 CHECKING THE STARTER CLUTCH 1. Check: • Starter clutch rollers "1" Damage/wear →...
Page 243: Installing The Starter Clutch
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STARTER CLUTCH b. When turning the starter clutch drive gear clockwise "A", the starter clutch and the starter clutch drive gear should engage, otherwise the starter clutch is faulty and must be replaced.
Page 244: Crankshaft Position Sensor
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT POSITION SENSOR EAS24520 CRANKSHAFT POSITION SENSOR Removing the crankshaft position sensor Order Job/Parts to remove Q'ty Remarks Rider seat Refer to "GENERAL CHASSIS" on page 4-1. Side cowlings Refer to "GENERAL CHASSIS"...
Page 245: Removing The Crankshaft Position Sensor
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT POSITION SENSOR EAS24530 • Crankshaft position sensor lead coupler REMOVING THE CRANKSHAFT POSITION SENSOR 1. Disconnect: • Crankshaft position sensor lead coupler 2. Remove: • Crankshaft position sensor •...
Page 246: Electric Starter
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q'ty Remarks Rider seat Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank Refer to "FUEL TANK" on page 7-1. Air filter case Refer to "GENERAL CHASSIS"...
Page 247 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q'ty Remarks O-ring Front cover Lock washer Washer Starter motor yoke Armature assembly Gasket Brush holder Rear cover For assembly, reverse the removal proce- dure.
Page 248: Checking The Starter Motor
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR Pocket tester 1. Check: 90890-03112 • Commutator Analog pocket tester Dirt → Clean with 1000 grit sandpaper. YU-03112-C 2. Measure: •...
Page 249: Assembling The Starter Motor
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTER NOTE: Align the tab "a" on the brush holder "2" with the tab "b" in the starter motor rear cover. 7. Check: • Gear teeth Damage/wear →...
Page 250: Installing The Starter Motor
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTER EAS24810 INSTALLING THE STARTER MOTOR 1. Install: • Starter motor "1" • Starter motor bolts "2" Starter motor bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) 2.
Page 251: Clutch
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH EAS25060 CLUTCH Removing the clutch cover Order Job/Parts to remove Q'ty Remarks Right side cowling Refer to "GENERAL CHASSIS" on page 4-1. Bottom cowlings Refer to "GENERAL CHASSIS" on page 4-1. Drain.
Page 252 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH Removing the push lever shaft Order Job/Parts to remove Q'ty Remarks Circlip Pull lever Pull lever spring Pull lever shaft Oil seal Bearing For installation, reverse the removal proce- dure.
Page 253 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH Removing the clutch Order Job/Parts to remove Q'ty Remarks Compression spring Pressure plate 1 Push rod Bearing Friction plate 1 Clutch plate 1 Friction plate 2 Clutch plate 2 Clutch plate 3 Friction plate 3...
Page 254: Removing The Clutch
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH EAS25080 • Friction plate 2 REMOVING THE CLUTCH • Clutch plate 2 1. Remove: • Clutch plate 3 • Clutch cover "1" • Friction plate 3 •...
Page 255: Checking The Friction Plates
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH • Springs • Pressure plate 2 • Conical spring washer • Thrust plate 2 EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates.
Page 256: Checking The Clutch Springs
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH Clutch plate "2" EAS25150 CHECKING THE CLUTCH HOUSING Part No. Thickness 1. Check: 5VY-16325-00 2.0 mm (0.079 in) • Clutch housing dogs Damage/pitting/wear → Deburr the clutch 4B1-16325-00 2.3 mm (0.091 in) housing dogs or replace the clutch hous-...
Page 257: Checking The Pressur Plate 2
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH EAS4C81005 2. Check: CHECKING THE PRESSUR PLATE 2 • Push rod bearing 1. Check: Damage/wear → Replace. • Pressure plate 2 Cracks / damage → Replace. EAS25170 EAS25240 CHECKING THE PRESSURE PLATE 1...
Page 258 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH 3. Install: • Spring "1" • Clutch boss nut "2" Clutch boss nut 115 Nm (11.5 m·kg, 83 ft·lb) NOTE: • Put the spring detent "a" into the groove of the pressure plate 2.
Page 259 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH NOTE: Clutch spring bolt Assemble the friction plates and clutch plates 10 Nm (1.0 m·kg, 7.2 ft·lb) according to the installation order. NOTE: Tighten the clutch spring bolts in stages and in a crisscross pattern.
Page 260 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CLUTCH 12. Tighten: • Clutch cover bolts "1" • Clutch cover bolt "2" Clutch cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Clutch cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) LOCTITE®...
Page 261: Shift Shaft
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q'ty Remarks Shift arm Refer to "ENGINE REMOVAL" on page 5-1 Clutch assembly Refer to "CLUTCH"...
Page 262: Removing The Shift Shaft
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHIFT SHAFT EAS4C81008 REMOVING THE SHIFT SHAFT 1. Remove: • Clutch assembly Refer to "CLUTCH" on page 5-44 2. Remove: • Shift arm • Shift rod Refer to "ENGINE REMOVAL" on page 5-1 3.
Page 263 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SHIFT SHAFT • Stopper lever spring "3" • Shift rod • Shift arm Refer to "ENGINE REMOVAL" on page 5- 5. Install: • Clutch assembly Refer to "CLUTCH" on page 5-44. 2.
Page 264: Oil Pump
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP EAS24920 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q'ty Remarks Side cowlings Refer to "GENERAL CHASSIS" on page 4-1. Lower cowlings Refer to "GENERAL CHASSIS"...
Page 265 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q'ty Remarks Oil strainer Oil pipe Oil delivery pipe Relief valve assembly Oil/water pump assembly drive chain guide Collar Oil/water pump assembly drive sprocket Washer...
Page 266 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q'ty Remarks Oil/water pump driven sprocket Collar Oil pump housing Bearing Oil pump outer rotor Oil pump inner rotor For assembly, reverse the disassembly pro- cedure.
Page 267: Removing The Oil Pan
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP EAS24930 EAS24960 REMOVING THE OIL PAN CHECKING THE OIL PUMP 1. Remove: 1. Check: • Oil level switch "1" • Oil pump driven gear "1" •...
Page 268: Checking The Relief Valve
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP EAS24980 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes. 1. Check: • Oil delivery pipe "1" • Oil pipe "2" Damage →...
Page 269: Assembling The Oil Pump
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP • O-ring "2" Oil/water pump driven sprocket Damage/wear → Replace. bolt • Oil nozzle passage 15 Nm (1.5 m·kg, 11 ft·lb) Obstruction → Blow out with compressed LOCTITE®...
Page 270: Installing The Oil Pan
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP NOTE: Install the oil/water pump assembly drive chain "1" onto the oil/water pump assembly drive sprocket "2". ECA4C81007 CAUTION: After installing the oil/water pump assem- bly drive chain and drive sprocket, make sure the oil/water pump turns smoothly.
Page 271 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL PUMP Engine oil drain bolt 43 Nm (4.3 m·kg, 31 ft·lb) EWA12820 WARNING Always use new copper washers. NOTE: • Tighten the oil pan bolts in stages and in a crisscross pattern.
Page 272: Crankcase
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE EAS25540 CRANKCASE Separating the crankcase Order Job/Parts to remove Q'ty Remarks Air filter case Refer to "GENERAL CHASSIS" on page 4-1. Throttle body assembly Refer to "THROTTLE BODIES" on page 7-4. Engine Refer to "ENGINE REMOVAL"...
Page 273 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE Separating the crankcase Order Job/Parts to remove Q'ty Remarks Lower crankcase Dowel pin Damper For installation, reverse the removal proce- dure. 5-66 email: info@motomatrix.co.uk...
Page 274: Disassembling The Crankcase
Engine oil 2. Apply: 3. Remove: • Sealant • Lower crankcase ECA13900 Yamaha bond No. 1215 CAUTION: (Three Bond No.1215®) Tap on one side of the crankcase with a 90890-85505 soft-face hammer. Tap only on reinforced portions of the crankcase, not on the...
Page 275 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKCASE Crankcase bolt Bolt "1"–"10" 1st: 20 Nm (2.0 m·kg, 14 ft·lb) 2nd*: 20 Nm (2.0 m·kg, 14 ft·lb) 3rd: +60° Bolt "11"–"16" 24 Nm (2.4 m·kg, 17 ft·lb) Bolt "17"–"26"...
Page 276: Crankshaft
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT EAS25960 CRANKSHAFT Removing the connecting rods and pistons Order Job/Parts to remove Q'ty Remarks Lower crankcase Refer to "CRANKCASE" on page 5-65. Connecting rod cap Big end lower bearing Big end upper bearing Piston pin clip Piston pin...
Page 277 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q'ty Remarks Lower crankcase Refer to "CRANKCASE" on page 5-65. Refer to "REMOVING THE CONNECTING Connecting rod and connecting rod caps RODS AND PISTONS"...
Page 278: Removing The Connecting Rods And Pistons
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT EAS26030 REMOVING THE CONNECTING RODS AND Piston pin puller set PISTONS 90890-01304 The following procedure applies to all of the Piston pin puller connecting rods and pistons. YU-01304 1.
Page 279: Checking The Cylinder And Piston
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT b. If out of specification, rebore or replace the NOTE: cylinder, and replace the piston and piston Identify the position of each crankshaft journal rings as a set. upper bearing so that it can be reinstalled in its c.
Page 280: Checking The Piston Pin
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT Piston ring side clearance Piston ring end gap Top ring Top ring 0.030–0.065 mm (0.0012– 0.15–0.25 mm (0.0059–0.0098 0.0026 in) Limit Limit 0.115 mm (0.0045 in) 0.50 mm (0.0197 in) 2nd ring 2nd ring...
Page 281: Checking The Big End Bearings
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT a. Clean the big end bearings, crankshaft pins, and the inside of the connecting rods halves. b. Install the big end upper bearing into the connecting rod and the big end lower bear- ing into the connecting rod cap.
Page 282 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT j. Loosen the connecting rod bolt, remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in the current condi- tion.
Page 283 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT p. After the installation, check that the section 2. Select: shown "a" is flush with each other by touch- • Big end bearings (P1 – P4) ing the surface.
Page 284: Installing The Connecting Rod And Piston
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT EAS26190 (with the recommended lubricant) INSTALLING THE CONNECTING ROD AND PISTON Recommended lubricant The following procedure applies to all of the Engine oil connecting rods and pistons. 4.
Page 285 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT NOTE: • Install by carrying out the following proce- dures in order to assemble in the most suit- able condition. • First tighten the bolts to 15 Nm (1.5 m·kg, 11 ft·lb) •...
Page 286 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT ECA14980 CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method. a. Clean the connecting rod bolts. b. Tighten the connecting rod bolts. c. Put a mark "1" on the connecting rod bolt "2"...
Page 287: Checking The Crankshaft
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT • If they are not flush with each other, remove the connecting rod bolt and big end bearing and restart from step "9". In this case, make sure to replace the con- necting rod bolt.
Page 288 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT Crankcase bolt Bolt "1"–"10" 1st: 20 Nm (2.0 m·kg, 14 ft·lb) 2nd: 20 Nm (2.0 m·kg, 14 ft·lb) 3rd: +60° Bolt "11"–"16" 24 Nm (2.4m·kg, 17 ft·lb) Bolt "17"–"26"...
Page 289: Installing The Crankshaft
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Select: • Crankshaft journal bearings (J1–J5) NOTE: • The numbers "A" stamped into the crank- shaft web and the numbers "1" stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes.
Page 290 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CRANKSHAFT NOTE: • Align the projections "a" on the crankshaft journal upper bearings with the notches "b" in the upper crankcase. • Be sure to install each crankshaft journal upper bearing in its original place.
Page 291: Transmission
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q'ty Remarks Separate. Lower crankcase Refer to "CRANKCASE" on page 5-65. Drive axle assembly Circlip Oil seal...
Page 292 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q'ty Remarks For installation, reverse the removal proce- dure. 5-85 email: info@motomatrix.co.uk...
Page 293 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q'ty Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip...
Page 294 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q'ty Remarks Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar...
Page 295 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q'ty Remarks For assembly, reverse the disassembly pro- cedure. 5-88 email: info@motomatrix.co.uk...
Page 296: Removing The Transmission
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Drive axle assembly "1" • Shift drum retainers "2" • Shift fork guide bars • Shift fork "L" and "R" •...
Page 297: Checking The Shift Drum Assembly
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION Rough movement → Replace the shift forks and shift fork guide bar as a set. EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 2. Measure: 1. Check: • Shift drum groove •...
Page 298 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION EAS26350 INSTALLING THE TRANSMISSION 1. Install: • Bearing "1" NOTE: Make the seal side of bearing face to the out- side and install it close to the right end face of the crankcase.
Page 299 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION 4. Check: • Transmission Rough movement → Repair. NOTE: Oil each gear, shaft, and bearing thoroughly. 5-92 email: info@motomatrix.co.uk...
Page 300 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TRANSMISSION 5-93 email: info@motomatrix.co.uk...
Page 301: Cooling System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM RADIATOR....................6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR ..............6-3 OIL COOLER ....................6-4 CHECKING THE OIL COOLER..............6-5 INSTALLING THE OIL COOLER ............6-5 THERMOSTAT ....................6-6 CHECKING THE THERMOSTAT............6-8 ASSEMBLING THE THERMOSTAT ASSEMBLY ........6-8 INSTALLING THE THERMOSTAT ASSEMBLY ........6-8 WATER PUMP ....................6-9...
Page 302 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys RADIATOR EAS26380 RADIATOR Removing the radiator Order Job/Parts to remove Q'ty Remarks Rider seat Refer to "GENERAL CHASSIS" on page 4-1. Side cowling Refer to "GENERAL CHASSIS" on page 4-1. Drain.
Page 303 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys RADIATOR Removing the radiator Order Job/Parts to remove Q'ty Remarks Radiator fan motor For installation, reverse the removal proce- dure. email: info@motomatrix.co.uk...
Page 304: Radiator
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver.
Page 305: Oil Cooler
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL COOLER EAS26410 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q'ty Remarks Drain. Engine oil Refer to "CHANGING THE ENGINE OIL" on page 3-12. Drain.
Page 306: Checking The Oil Cooler
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys OIL COOLER EAS26420 3. Fill: CHECKING THE OIL COOLER • Cooling system 1. Check: (with the specified amount of the recom- • Oil cooler mended coolant) Cracks/damage → Replace. Refer to "CHANGING THE COOLANT"...
Page 307: Thermostat
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat assembly Order Job/Parts to remove Q'ty Remarks Rider seat Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank Refer to "FUEL TANK" on page 7-1. Air filter case Refer to "GENERAL CHASSIS"...
Page 308 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THERMOSTAT Disassembling the thermostat assembly Order Job/Parts to remove Q'ty Remarks Thermostat housing cover Thermostat Thermostat housing O-ring For assembly, reverse the disassembly pro- cedure. email: info@motomatrix.co.uk...
Page 309: Checking The Thermostat
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THERMOSTAT EAS26450 2. Check: CHECKING THE THERMOSTAT • Thermostat housing cover "1" 1. Check: • Thermostat housing "2" • Thermostat Cracks/damage → Replace. Does not open at 71–85°C (160–185°F) → Replace.
Page 310: Water Pump
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys WATER PUMP EAS26500 WATER PUMP Disassembling the water pump Order Job/Parts to remove Q'ty Remarks Oil/water pump assembly Refer to "OIL PUMP" on page 5-57. Oil pump rotor Refer to "OIL PUMP"...
Page 311: Disassembling The Water Pump
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys WATER PUMP EAS26520 DISASSEMBLING THE WATER PUMP 1. Remove: • Water pump seal "1" • Water pump housing "2" NOTE: Tap out the bearing and oil seal from the out- side of the water pump housing.
Page 312 (4). tools. ECA14090 • Before installing the water pump seal, apply CAUTION: Yamaha bond No.1215 (Three Bond Make sure the rubber damper and rubber No.1215®) "2" to the water pump housing damper holder are flush with the impeller. "3".
Page 313: Fuel System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL SYSTEM FUEL TANK ....................7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP...............7-2 CHECKING THE FUEL PUMP BODY ............7-2 CHECKING THE FUEL PUMP OPERATION .........7-2 INSTALLING THE FUEL PUMP..............7-2 INSTALLING THE FUEL TANK...............7-3 THROTTLE BODIES..................7-4 CHECKING THE INJECTORS ...............7-6...
Page 314 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK EAS26620 FUEL TANK Removing the fuel tank Order Job/Parts to remove Q'ty Remarks Rider seat Refer to "GENERAL CHASSIS" on page 4-1. Passenger seat Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank side cover Fuel sender coupler Fuel pump coupler...
Page 315: Fuel Tank
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK EAS26630 ECA14720 REMOVING THE FUEL TANK CAUTION: 1. Extract the fuel in the fuel tank through the • Do not drop the fuel pump or give it a fuel tank cap with a pump.
Page 316: Installing The Fuel Tank
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK EAS4C81002 INSTALLING THE FUEL TANK 1. Install: • Fuel hose • Fuel hose connector cover ECA14740 CAUTION: When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holders are in the correct posi- tion, otherwise the fuel hose will not be properly installed.
Page 317 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies Order Job/Parts to remove Q'ty Remarks Rider seat Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank Refer to "FUEL TANK" on page 7-1. Air filter case Refer to "GENERAL CHASSIS"...
Page 318: Throttle Bodies
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES Removing the injectors Order Job/Parts to remove Q'ty Remarks Intake air pressure sensor coupler Disconnect. Cylinder #1-injector coupler Disconnect. Cylinder #2-injector coupler Disconnect. Cylinder #3-injector coupler Disconnect.
Page 319: Checking The Injectors
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES EAS26980 CHECKING THE INJECTORS 1. Check: • Injectors Damage → Replace. c. Connect the pressure gauge "2" and adapter "3" to the fuel hose (fuel tank to pri- mary injector fuel rail).
Page 320: Adjusting The Throttle Position Sensor (For Throttle Cable Pulley)
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES • Throttle position sensor (for throttle cable ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Temporary tighten the throttle position sen- pulley) sor (for throttle valves). Refer to "ADJUSTING THE THROTTLE b.
Page 321 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys THROTTLE BODIES ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ email: info@motomatrix.co.uk...
Page 322 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and hoses Order Job/Parts to remove Q'ty Remarks Air cut-off valve coupler Disconnect. Air cut-off valve hose 1 Disconnect.
Page 323: Air Induction System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR INDUCTION SYSTEM EAS27060 A. From the air cleaner CHECKING THE AIR INDUCTION SYSTEM B. To the cylinder head 1. Check: Air injection • Hoses The air induction system burns unburned Loose connections →...
Page 324 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR INDUCTION SYSTEM 7-11 email: info@motomatrix.co.uk...
Page 325: Electrical System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SYSTEM IGNITION SYSTEM..................8-1 CIRCUIT DIAGRAM................8-1 TROUBLESHOOTING ................8-3 ELECTRIC STARTING SYSTEM..............8-5 CIRCUIT DIAGRAM................8-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION......8-7 TROUBLESHOOTING ................8-9 CHARGING SYSTEM .................8-11 CIRCUIT DIAGRAM................8-11 TROUBLESHOOTING ................8-13 LIGHTING SYSTEM ...................8-15 CIRCUIT DIAGRAM................8-15 TROUBLESHOOTING ................8-17...
Page 326 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS..............8-81 CHECKING THE SWITCHES...............8-85 CHECKING THE BULBS AND BULB SOCKETS.........8-88 CHECKING THE FUSES..............8-89 CHECKING AND CHARGING THE BATTERY........8-89 CHECKING THE RELAYS..............8-92 CHECKING THE TURN SIGNAL/HAZARD RELAY ......8-93 CHECKING THE RELAY UNIT (DIODE) ..........8-94 CHECKING THE IGNITION COILS ............8-95 CHECKING THE CRANKSHAFT POSITION SENSOR .......8-96...
Page 327 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
Page 328: Ignition System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM email: info@motomatrix.co.uk...
Page 329 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IGNITION SYSTEM 1. Main switch 4. Main fuse 8. Battery 12.Starting circuit cut-off relay 13.Neutral switch 14.Sidestand switch 19.ECU (engine control unit) 20.Ignition coil #1 21.Ignition coil #2 22.Ignition coil #3 23.Ignition coil #4 24.Spark plug...
Page 330: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IGNITION SYSTEM EAS27150 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following part(s): 1 Rider seat 2 Passenger seat 3 Fuel tank 4 Side cowlings 1 Check the fuses.
Page 331 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IGNITION SYSTEM 8 Check the engine stop switch. NG→ Refer to "CHECKING THE Replace the right handlebar switch. SWITCHES" on page 8-85. OK↓ 9 Check the neutral switch. NG→...
Page 332: Electric Starting System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM email: info@motomatrix.co.uk...
Page 333 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTING SYSTEM 1. Main switch 4. Main fuse 8. Battery 10.Starter relay 11.Starter motor 12.Starting circuit cut-off relay 13.Neutral switch 14.Sidestand switch 58.Engine stop switch 59.Start switch 66.Clutch switch 81.Ignition fuse 91.Ground...
Page 334: Starting Circuit Cut-Off System Operation
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to " " and the main switch is set to "ON" (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
Page 335 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2.
Page 336: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1 Rider seat 2 Passenger seat 3 Fuel tank 4 Air filter case 1 Check the fuses.
Page 337 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRIC STARTING SYSTEM 8 Check the engine stop switch. NG→ Refer to "CHECKING THE Replace the right handlebar switch. SWITCHES" on page 8-85. OK↓ 9 Check the neutral switch. NG→...
Page 338: Charging System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-11 email: info@motomatrix.co.uk...
Page 339 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Main fuse 8. Battery 91.Ground 92.Battery negative lead 8-12 email: info@motomatrix.co.uk...
Page 340: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. NOTE: • Before troubleshooting, remove the following part(s): 1 Rider seat 2 Fuel tank 3 Air filter case 1 Check the fuse.
Page 341 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHARGING SYSTEM 8-14 email: info@motomatrix.co.uk...
Page 342: Lighting System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-15 email: info@motomatrix.co.uk...
Page 343 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LIGHTING SYSTEM 1. Main switch 4. Main fuse 8. Battery 19.ECU (engine control unit) 51.High beam indicator light 54.Meter light 63.Pass switch 64.Dimmer switch 73.Headlight 74.Auxiliary light 76.License plate light 78.Tail/brake light 79.Headlight relay (on/off)
Page 344: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. NOTE: • Before troubleshooting, remove the following part(s): 1 Rider seat 2 Fuel tank 3 Side cowlings...
Page 345 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LIGHTING SYSTEM 8 Check the headlight relay (on/off). NG→ Refer to "CHECKING THE Replace the headlight relay. RELAYS" on page 8-92. OK↓ 9 Check the headlight relay (dimmer). NG→...
Page 346: Signaling System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-19 email: info@motomatrix.co.uk...
Page 347 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM 1. Main switch 4. Main fuse 8. Battery 9. Fuel injection system fuse 12.Starting circuit cut-off relay 13.Neutral switch 15.Fuel pump 19.ECU (engine control unit) 33.Speed sensor 43.Fuel level warning light 44.Oil level warning light...
Page 348: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. NOTE: •...
Page 349 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM 3 Check the entire signaling system's NG→ wiring. Properly connect or repair the signal- Refer to "SIGNALING SYSTEM" on ing system's wiring. page 8-19. OK↓ This circuit is OK.
Page 350 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM 3 Check the hazard switch. NG→ Refer to "CHECKING THE Replace the left handlebar switch. SWITCHES" on page 8-85. OK↓ 4 Check the turn signal relay. NG→...
Page 351 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SIGNALING SYSTEM 2 Check the entire signaling system's NG→ wiring. Properly connect or repair the signal- Refer to "SIGNALING SYSTEM" on ing system's wiring. page 8-19. OK↓ This circuit is OK.
Page 352: Cooling System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-25 email: info@motomatrix.co.uk...
Page 353 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM 1. Main switch 4. Main fuse 8. Battery 19.ECU (engine control unit) 36.Coolant temperature sensor 81.Ignition fuse 86.Radiator fan motor relay 87.Right radiator fan motor fuse 88.Left radiator fan motor fuse 89.Right radiator fan motor 90.Left radiator fan motor...
Page 354: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM EAS27320 TROUBLESHOOTING NOTE: • Before troubleshooting, remove the following part(s): 1 Rider seat 2 Passenger seat 3 Fuel tank 4 Side cowling 1 Check the fuses. NG→...
Page 355 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM 7 Check the entire cooling system's NG→ wiring. Properly connect or repair the cooling Refer to "COOLING SYSTEM" on system's wiring. page 8-25. OK↓ This circuit is OK. 8-28 email: info@motomatrix.co.uk...
Page 356: Fuel Injection System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-29 email: info@motomatrix.co.uk...
Page 357 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM 1. Main switch 4. Main fuse 5. Backup fuse 8. Battery 9. Fuel injection system fuse 12.Starting circuit cut-off relay 13.Neutral switch 14.Sidestand switch 15.Fuel pump 16.Throttle position sensor (for throttle valves) 17.Throttle position sensor (for throttle cable...
Page 358: Ecu Self-Diagnostic Function
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 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 engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Page 359 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM a. Main switch "OFF" b. Main switch "ON" c. Engine trouble warning light off d. Engine trouble warning light on for 1.4 sec- onds 8-32 email: info@motomatrix.co.uk...
Page 360: Fail-Safe Actions (Substitute Characteristics Operation Control)
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS27362 FAIL-SAFE ACTIONS (SUBSTITUTE CHARACTERISTICS OPERATION CONTROL) If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate for the type of malfunction.
Page 361 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Able / Able / Fault Item Symptom unable to unable to code No. start drive Atmospheric pressure Atmospheric pressure sensor- Able Able sensor open or short circuit detected. No normal signal is received from sensor Able...
Page 362 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Able / Able / Fault Item Symptom unable to unable to code No. start drive ECU memory is faulty. (When this ECU internal malfunc- malfunction is detected in the ECU, Able/Unable Able/Unable tion...
Page 363: Troubleshooting Method
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS27400 The engine operation is not normal but the TROUBLESHOOTING METHOD engine trouble warning light does not come The engine operation is not normal and the 1.
Page 364: Diagnostic Mode
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS27421 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to "OFF" and set the engine stop switch to "ON". 2. Disconnect the wire harness coupler from the fuel pump. 3.
Page 365 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM NOTE: If the engine stop switch is set to " ", set it to " ", and then set it to " " again. 9.
Page 366 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Atmospheric pressure sensor hose is clogged. When the main switch is • Intake air pressure sensor hose is clogged, turned to "ON", the atmo- kinked, or pinched.
Page 367 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. Lean angle sensor: • Open or short circuit in wire harness. open or short circuit •...
Page 368 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 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 •...
Page 369 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Throttle position sensor (for throttle valves) signal 2 • Fully closed position 9–23 Check with throttle valve fully closed.
Page 370 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Malfunction history code erasure • No history — • History exists • Displays the total number of To erase the history, set the malfunctions, including the engine stop switch from...
Page 371 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the cylinder-#4 igni- tion coil five times at one-sec- Check the spark five times. Cylinder-#4 ignition coil ond intervals.
Page 372: Troubleshooting Details
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the radiator fan motor relay five times at one Check the operating sound second intervals. (ON 2 sec- Radiator fan motor relay of the radiator fan motor onds, OFF 3 seconds)
Page 373 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM No normal signals are received from the cylinder identifi- Fault code No. Symptom cation sensor when the engine is started or while the vehicle is being driven. Diagnostic code No.
Page 374 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM No normal signals are received from the crankshaft posi- Fault code No. Symptom tion sensor. Diagnostic code No. — — Orde Item/components and probable Reinstatement Check or maintenance job cause...
Page 375 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Intake air pressure sensor: hose system malfunction Fault code No. Symptom (clogged or detached hose). Diagnostic code No. Intake air pressure sensor Orde Item/components and probable Reinstatement Check or maintenance job cause...
Page 376 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom EXUP servo motor circuit: open or short circuit detected. Diagnostic code No. EXUP servo motor Orde Item/components and probable Reinstatement Check or maintenance job cause method...
Page 377 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Open circuit is detected in the input line from the side- Fault code No. Symptom stand switch to the ECU. Diagnostic code No. Sidestand switch Orde Item/components and probable Reinstatement...
Page 378 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Coolant temperature sensor: open or short circuit Fault code No. Symptom detected. Diagnostic code No. Coolant temperature sensor Orde Item/components and probable Reinstatement Check or maintenance job cause method Connections...
Page 379 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Atmospheric pressure sensor: open or short circuit Fault code No. Symptom detected. Diagnostic code No. Atmospheric pressure sensor Orde Item/components and probable Reinstatement Check or maintenance job cause method Connections...
Page 380 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Latch up detected. Fault code No. Symptom No normal signal is received from the lean angle sensor. Diagnostic code No. Lean angle sensor Orde Item/components and probable Reinstatement Check or maintenance job...
Page 381 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Open circuit detected in the primary lead of the cylinder- Fault code No. Symptom #2 ignition coil. Diagnostic code No. Cylinder-#2 ignition coil Orde Item/components and probable Reinstatement Check or maintenance job...
Page 382 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Open circuit detected in the primary lead of the cylinder- Fault code No. Symptom #3 ignition coil. Diagnostic code No. Cylinder-#3 ignition coil Orde Item/components and probable Reinstatement Check or maintenance job...
Page 383 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Open circuit detected in the primary lead of the cylinder- Fault code No. Symptom #4 ignition coil. Diagnostic code No. Cylinder-#4 ignition coil Orde Item/components and probable Reinstatement Check or maintenance job...
Page 384 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open circuit detected in injector. Injector #1 Injector #2 Diagnostic code No. Injector #3 Injector #4 Orde Item/components and probable Reinstatement Check or maintenance job cause...
Page 385 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Lean angle sensor: open or short circuit detected. Diagnostic code No. Lean angle sensor Orde Item/components and probable Reinstatement Check or maintenance job cause method Connections...
Page 386 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM ANo normal signals are received from the speed sensor. Fault code No. Symptom BOpen circuit is detected in the neutral switch. Speed sensor Diagnostic code No. Neutral switch Orde Item/components and probable...
Page 387 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Power supply to the injectors and fuel pump is not nor- Fault code No. Symptom mal. Diagnostic code No. Fuel system voltage (battery voltage) Orde Item/components and probable Reinstatement...
Page 388 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM An error is detected while reading or writing on EEPROM Fault code No. Symptom (CO adjustment value). Diagnostic code No. EEPROM fault cylinder No. Orde Item/components and probable Reinstatement...
Page 389 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Throttle position sensor (for throttle cable pulley): open or short circuit detected. Fault code No. Symptom Throttle position sensor (for throttle cable pulley): cou- pler connection is loose.
Page 390 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Throttle servo motor: open or short circuit detected. Fault code No. Symptom Defective throttle servo motor. Malfunction in ECU (servo motor driving system). Throttle position sensor (for throttle valves) signal 1 Diagnostic code No.
Page 391 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM No signals are received from the ECU within the specified Fault code No. Er-2 Symptom duration. Diagnostic code No. — — Orde Item/components and probable Reinstatement Check or maintenance job cause...
Page 392 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom Non-registered data has been received from the meter. Diagnostic code No. — — Orde Item/components and probable Reinstatement Check or maintenance job cause method Connections...
Page 393 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM 8-66 email: info@motomatrix.co.uk...
Page 394: Fuel Pump System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-67 email: info@motomatrix.co.uk...
Page 395 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL PUMP SYSTEM 1. Main switch 4. Main fuse 8. Battery 9. Fuel injection system fuse 12.Starting circuit cut-off relay 15.Fuel pump 19.ECU (engine control unit) 48.Multi-function meter 58.Engine stop switch 81.Ignition fuse 91.Ground...
Page 396: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1 Rider seat 2 Passenger seat 3 Fuel tank 4 Side cowlings 1 Check the fuses.
Page 397 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL PUMP SYSTEM 7 Check the entire fuel pump sys- NG→ tem's wiring. Properly connect or repair the fuel Refer to "FUEL PUMP SYSTEM" pump system's wiring. on page 8-67.
Page 398: Immobilizer System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 8-71 email: info@motomatrix.co.uk...
Page 399 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM 1. Main switch 4. Main fuse 5. Backup fuse 6. Immobilizer unit 8. Battery 19.ECU (engine control unit) 42.Immobilizer system indicator light 48.Multi-function meter 91.Ground 92.Battery negative lead 8-72 email: info@motomatrix.co.uk...
Page 400: General Information
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM EAS27671 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: •...
Page 401: Part Replacement And Key Code Registration Requirements
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM EAS27691 PART REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS In the course of use, you may encounter the following cases where replacement of parts and regis- tration of code re-registering/standard keys are required.
Page 402 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM Standby mode d. LED off a. Main switch "ON" e. Standby mode on b. Main switch "OFF" f. Standby mode off c. LED on 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 403 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM Standard key registration h. Second standard key a. Main switch "ON" i. Registration mode b. Main switch "OFF" c. LED on A. Registration of the second standard key is complete.
Page 404: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM EAS27701 TROUBLESHOOTING When the main switch is turned to "ON", the immobilizer system indicator light does not come on nor flashes. 1 Check the fuses. NG→...
Page 405: Self-Diagnosis Fault Code Indication
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM EAS27721 SELF-DIAGNOSIS FAULT CODE INDICATION When a system failure occurs, the error code number is indicated in the LCD display of meter and the immobilizer system indicator light blinks at the same time. The pattern of blinking also shows the error code.
Page 406 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code Undefinition code is Noise interference or dis- 1 Check the wire received. connected lead/cable. harness and con- nector. 2 Replace the main switch/immobi- lizer unit.
Page 407 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMMOBILIZER SYSTEM 8-80 email: info@motomatrix.co.uk...
Page 408: Electrical Components
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 8-81 email: info@motomatrix.co.uk...
Page 409 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 1. Main switch 2. Immobilizer unit 3. Front brake light switch 4. Clutch switch 5. Fuel injection system fuse 6. Starter relay 7. Battery 8. Main fuse 9.
Page 410 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 8-83 email: info@motomatrix.co.uk...
Page 411 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 1. Air temperature sensor 2. Atmospheric pressure sensor 3. Fuel pump 4. Coolant temperature sensor 5. Starting circuit cut-off relay 6. Turn signal/hazard relay 7. ECU (engine control unit) 8.
Page 412: Checking The Switches
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 8-85 email: info@motomatrix.co.uk...
Page 413 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 1. Main switch 2. Horn switch 3. Dimmer switch 4. Pass switch 5. Turn signal switch 6. Hazard switch 7. Clutch switch 8. Sidestand switch 9.
Page 414 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 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".
Page 415: Checking The Bulbs And Bulb Sockets
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS EAS27990 wise the transparency of the glass, the CHECKING THE BULBS AND BULB SOCK- life of the bulb, and the luminous flux will be adversely affected. If the headlight Check each bulb and bulb socket for damage bulb gets soiled, thoroughly it with a cloth or wear, proper connections, and also for conti-...
Page 416: Checking The Fuses
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS d. If the fuse immediately blows again, check NOTE: the electrical circuit. Check each bulb socket for continuity in the same manner as described in the bulb section; Amperage Fuses Q'ty...
Page 417 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS • Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. FIRST AID IN CASE OF BODILY CONTACT: EXTERNAL • Skin — Wash with water. •...
Page 418 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS into the battery quickly and can cause c. Make sure that the current is higher than battery overheating and battery plate the standard charging current written on damage.
Page 419: Checking The Relays
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS Out of specification → Replace. battery charger cannot charge the MF battery. A variable voltage charger is recommended. d. Charge the battery until the battery's charg- ing voltage is 15 V.
Page 420: Checking The Turn Signal/Hazard Relay
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS Headlight relay (on/off) 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Result Continuity/No continuity EAS4C81019 CHECKING THE TURN SIGNAL/HAZARD RELAY 1. Check: •...
Page 421: Checking The Relay Unit (Diode)
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Continuity a. Connect the pocket tester (DC 20 V) to the Positive tester probe → Sky turn signal/hazard relay terminal as shown. blue "1" →...
Page 422: Checking The Ignition Coils
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Secondary coil resistance a. Disconnect the relay unit coupler from the 5.02–6.79 kΩ at 20 °C (68 °F) wire harness. b. Connect the pocket tester (Ω × 1) to the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 423: Checking The Crankshaft Position Sensor
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS b. Measure the crankshaft position sensor resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1. Ignition coil EAS28130 c. Set the main switch to "ON". CHECKING THE LEAN ANGLE SENSOR d. Measure the ignition spark gap "a". 1.
Page 424: Checking The Starter Motor Operation
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS d. Measure the lean angle sensor out put volt- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 1) to the age. stator coil coupler as shown. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 425: Checking The Horn
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe Red "1" • Negative tester probe Black "2" c. Measure the horn resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2.
Page 426: Checking The Fuel Sender
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS Pocket tester Pocket tester 90890-03112 90890-03112 Analog pocket tester Analog pocket tester YU-03112-C YU-03112-C Maximum level position "A" • Positive tester probe • Positive tester probe Green/white "1"...
Page 427: Checking The Radiator Fan Motors
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS d. Measure the voltage (DC 5 V) of White/Yel- Coolant temperature sensor low and Black/Blue. With each full rotation resistance of the rear wheel, the voltage reading 0°C (32°F): 5.21–6.37 kΩ...
Page 428: Checking The Throttle Position Sensor (For Throttle Cable Pulley)
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS d. Slowly heat the coolant, and then let it cool • Throttle position sensor (for throttle cable to the specified temperature indicated in pulley) the table. NOTE: e.
Page 429: Checking The Air Induction System Solenoid
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS NOTE: Atmospheric pressure sensor When installing the throttle position sensor (for resistance throttle valves), adjust its angle properly. Refer 3.75–4.25 V to "ADJUSTING THE THROTTLE POSITION SENSOR (FOR THROTTLE VALVES)"...
Page 430: Checking The Intake Air Pressure Sensor
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe White/Black "1" • Negative tester probe Black/Blue "2" b. Set the main switch to "ON". c.
Page 431 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS b. Measure the intake air temperature sensor resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • Intake air temperature sensor Intake air temperature sensor bolt 1.2 Nm (0.12 m·kg, 0.87 ft·lb) 8-104 email: info@motomatrix.co.uk...
Page 432 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL COMPONENTS 8-105 email: info@motomatrix.co.uk...
Page 433: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TROUBLESHOOTING TROUBLESHOOTING ..................9-1 GENERAL INFORMATION ..............9-1 STARTING FAILURES ................9-1 INCORRECT ENGINE IDLING SPEED ..........9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING ..............9-2 SHIFT PEDAL DOES NOT MOVE............9-2 JUMPS OUT OF GEAR ................9-2 FAULTY CLUTCH ...................9-2 OVERHEATING ..................9-2...
Page 434 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 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 •...
Page 435 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 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 •...
Page 436 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TROUBLESHOOTING • Incorrect oil viscosity • Oil or grease on the brake disc • Inferior oil quality • Oil or grease on the brake pad • Incorrect brake fluid level Cooling system 1.
Page 437 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TROUBLESHOOTING 7. Wheel(s) • Incorrect turn signal bulb • Incorrect wheel balance Turn signal remains lit • Deformed cast wheel • Faulty turn signal relay • Damaged wheel bearing •...
Page 438: Wiring Diagram
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS28740 54. Meter light Black/White WIRING DIAGRAM 55. Oil level switch Black/Yellow 56. Right handlebar switch YZF-R1(W) 2007 Br/G Brown/Green 57. Front brake light switch 1. Main switch Br/L Brown/Blue 58.
Page 439 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
Page 440 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN email: info@motomatrix.co.uk...
Page 441 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys YZF-R1(W) 2007 YZF-R1(W) 2007 YZF-R1(W) 2007 YZF-R1(W) 2007 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE YZF-R1(W) 2007 email: info@motomatrix.co.uk...
Page 442 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys YZF-R1(W) 2007 YZF-R1(W) 2007 YZF-R1(W) 2007 YZF-R1(W) 2007 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE YZF-R1(W) 2007 email: info@motomatrix.co.uk...

2007 Yamaha R1

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2007 Yamaha R1

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7 Table of Contents

31 Specifications

85 Periodic Checks and Adjustments

88 Periodic Maintenance

91 Engine

110 Chassis

127 Chassis

136 General Chassis

137 Front Wheel

143 Rear Wheel

149 Front Brake

162 Rear Brake

176 Handlebars

179 Front Fork

188 Steering Head

192 Rear Shock Absorber Assembly

195 Swingarm

200 Chain Drive

205 Engine

208 Engine Removal

216 Camshafts

225 Cylinder Head

229 Valves and Valve Springs

237 Generator

241 Starter Clutch

244 Crankshaft Position Sensor

246 Electric Starter

251 Clutch

261 Shift Shaft

264 Oil Pump

272 Crankcase

276 Crankshaft

291 Transmission

301 Cooling System

304 Radiator

305 Oil Cooler

307 Thermostat

310 Water Pump

313 Fuel System

315 Fuel Tank

318 Throttle Bodies

323 Air Induction System

325 Electrical System

328 Ignition System

332 Electric Starting System

338 Charging System

342 Lighting System

346 Signaling System

352 Cooling System

356 Fuel Injection System

394 Fuel Pump System

398 Immobilizer System

408 Electrical Components

Chapters

7 Table of Contents

31 Specifications

85 Periodic Checks and Adjustments

88 Periodic Maintenance

91 Engine

110 Chassis

127 Chassis

136 General Chassis

137 Front Wheel

143 Rear Wheel

149 Front Brake

162 Rear Brake

176 Handlebars

179 Front Fork

188 Steering Head

192 Rear Shock Absorber Assembly

195 Swingarm

200 Chain Drive

205 Engine

208 Engine Removal

216 Camshafts

7
Table of Contents

31
Specifications

85
Periodic Checks and Adjustments

88
Periodic Maintenance

91
Engine

110
Chassis

127
Chassis

136
General Chassis

137
Front Wheel

143
Rear Wheel

149
Front Brake

162
Rear Brake

176
Handlebars

179
Front Fork

188
Steering Head

192
Rear Shock Absorber Assembly

195
Swingarm

200
Chain Drive

205
Engine

208
Engine Removal

216
Camshafts

225
Cylinder Head

229
Valves and Valve Springs

237
Generator

241
Starter Clutch

244
Crankshaft Position Sensor

246
Electric Starter

251
Clutch

261
Shift Shaft

264
Oil Pump

272
Crankcase

276
Crankshaft

291
Transmission

301
Cooling System

304
Radiator

305
Oil Cooler

307
Thermostat

310
Water Pump

313
Fuel System

315
Fuel Tank

318
Throttle Bodies

323
Air Induction System

325
Electrical System

328
Ignition System

332
Electric Starting System

338
Charging System

342
Lighting System

346
Signaling System

352
Cooling System

356
Fuel Injection System

394
Fuel Pump System

398
Immobilizer System

408
Electrical Components

7
Table of Contents

31
Specifications

85
Periodic Checks and Adjustments

88
Periodic Maintenance

91
Engine

110
Chassis

127
Chassis

136
General Chassis

137
Front Wheel

143
Rear Wheel

149
Front Brake

162
Rear Brake

176
Handlebars

179
Front Fork

188
Steering Head

192
Rear Shock Absorber Assembly

195
Swingarm

200
Chain Drive

205
Engine

208
Engine Removal

216
Camshafts

225
Cylinder Head

229
Valves and Valve Springs

237
Generator

241
Starter Clutch

244
Crankshaft Position Sensor

246
Electric Starter