Yamaha XT660X(S) manual

2004 XT660R(S) XT660X(S) 5VK1-AE1 SERVICE MANUAL[...]

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EAS00000 XT660R(S)/XT660X(S) 2004 SERVICE MANUAL ©2003 by MBK Industrie First edition, December 2003 All rights reserved. Any reproduction or unauthorized use without the written permission of MBK Industrie is expressly prohibited.[...]

EAS00002 NOTICE This manual was produced by MBK Industrie primarily for use by Yamaha dealers and their quali- fied mechanics. It is not possible to include all the knowledge of a mechanic in one manual. There- fore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles sh ould have a basic understanding of mechanics and t[...]

EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for t he mechanic. Co mprehensive explanations of all installation, removal, disassembly, assembly, rep air and check procedures are laid out with the individual steps in sequen tial order. 1 The manual is divided into chap ters. An abbreviation and symb[...]

EAS00008 SYMBOLS The following symbols ar e not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adju stments 4 Chassis 5 Engine 6 Cooling syst em 7 Fuel injection system 8 Electrical s ystem 9 Troubleshootin g Symbols 0 to G indicate the following. 0 Servic[...]

EAS00010 TABLE OF CONTENTS GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 CHASSIS CHAS 4 ENGINE ENG 5 COOLING SYSTEM COOL 6 FUEL INJECTION SYSTEM FI 7 ELECTRICAL SYSTEM ELEC 8 TROUBLESHOOTING TRBL SHTG 9 – +[...]

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GEN INFO 1[...]

GEN INFO CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION .................... .............................................. 1-1 VEHICLE IDENTIFICATION NUMBER ................................................. .... 1-1 MODEL LABEL...................................................................................... .... 1-1 FEATURES ... ....[...]

GEN INFO[...]

1 - 1 GEN INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. EAS00018 MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts. MOTORCYCLE IDENTIFICATION[...]

1 - 2 GEN INFO FEATURES EAS00019 FEATURES EAS00896 OUTLINE The main function of a fuel supply system is to provide fuel to the combu stion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture. In a conventiona l carburetor system, the air-fuel ratio of the mixture that is suppl[...]

1 - 3 GEN INFO FEATURES EAS00897 FI SYSTEM The fuel pump delivers fuel to the in jector via the fuel filter. The pressure regu lator maintains the fuel pressure that is applied to the injector at 324 kPa (3.24 kg/cm 2 , 46.1 psi) higher than the in take manifold pressure. Accordingly, when the ene rgizing signal from the ECU energizes the injector,[...]

1 - 4 GEN INFO IMPORTANT INFORMATION EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Bef ore remo v al and disassemb ly , remo v e all dir t, mud, dust and f oreign mater ial. 2. Use only the proper tools and clea ning equipment. Refer to “ SPECIAL TOOLS ” . 3. When disassemb ling, alwa ys keep mated par ts together . [...]

1 - 5 GEN INFO IMPORTANT INFORMATION EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lo ck tabs along a flat of the bolt o r nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu- facturer[...]

1 - 6 GEN INFO CHECKING THE CONNECTIONS EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connect ors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Chec k: • lead • coupler • connector Moisture → Dry with an air b lower. Rust/stains → Conn ect and disconnect sev- eral times. 3. Chec k[...]

1 - 7 GEN INFO SPECIAL TOOLS EAS00027 SPECIAL TOOLS The following special too ls are necessary for complete and accurate tune-up a nd assembly. Use only the appropriate special to ols as this will help preven t damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the[...]

1 - 8 GEN INFO SPECIAL TOOLS T-handle 90890-01326 Holder 90890-01460 T-handle Damper rod holder These tools are used to hold the da mper rod holder when removing or installing the damper ro d. 90890-01352 Radiator cap t ester adaptor This tool is used to ch eck the cooling sys- tem. 90890-01362 Flywheel puller This tool is used to remove the A.C. m[...]

1 - 9 GEN INFO SPECIAL TOOLS 90890-03079 Thickness gauge This tool is used to measure t he valve clearance. 90890-03081 Compression gauge These tools are use d to measure the engine compressio n. 90890-03112 Pocket tester This tool is used to check t he electrical system. 90890-03141 Timing light This tool is used to check t he ignition tim- ing. 9[...]

1 - 10 GEN INFO SPECIAL TOOLS 90890-04064 Valve guide r emover ( ø 6) This tool is needed to re move and install the valve guides. 90890-04065 Valve guide installer ( ø 6) This tool is needed to install th e valve guides. 90890-04066 Valve guide r eamer ( ø 6) This tool is needed t o rebore the new valve guides. 90890-04082 Adaptor (Compr ession[...]

1 - 11 GEN INFO SPECIAL TOOLS 90890-85505 Yamaha bond No. 121 5 This bond is used to seal two matin g sur- faces (e.g., crankcase m ating surface s). Tool No. Tool name/Function Illustration[...]

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SPEC 2[...]

SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS .................................... .................................... 2-1 ENGINE SPECIFICATIONS ......... ..................................................... .............. 2-2 CHASSIS SPECIFICATIONS ........................................................................ 2-11 ELECTRICAL SP[...]

SPEC[...]

2 - 1 SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code XT660R: 5VK1 (Europe) 5VK2 (AUS) 5VK3 (GB) XT660X: 1D21 (Europe) 1D22 (AUS) 1D23 (GB) ---- ---- ---- ---- ---- ---- Dimensions Overall length 2,240 mm (88.2 in) (XT660R) 2,150 mm (84.6 in) (XT660X) ---- ---- Overall width 845 mm (33.3 in) (XT660R) 865 mm (34.1 in) (XT66[...]

2 - 2 SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, SOHC ---- Displacement 660 cm 3 (40.27 cu · in) ---- Cylinder arrangement Forward-inclined single cylinder ---- Bore × stroke 100.0 × 84.0 mm (3.94 × 3.31 in) ---- Compression ratio 10.00 : 1 ---- Engine idling speed 1,300 ~ 1,[...]

2 - 3 SPEC ENGINE SPECIFICATIONS Oil pump Oil pump type Trochoid ---- Inner-rotor-to-outer-rotor-tip clear- ance 0.07 ~ 0.12 mm (0.0028 ~ 0.0047 in) 0.2 mm (0.008 in) Outer-rotor-to-oil-pump-housing clearance 0.03 ~ 0.08 mm (0.0012 ~ 0.0031 in) 0.15 mm (0.0059 in) Oil-pump-housing-to-inner-rotor-and- outer-rotor clearance 0.03 ~ 0.08 mm (0.0012 ~ 0[...]

2 - 4 SPEC ENGINE SPECIFICATIONS Camshaft Drive system Chain drive (left) ---- Intake camshaft lobe dimensions Measurement A 43.488 ~ 43.588 mm (1.7121 ~ 1.7161 in) 43.338 mm (1.7062 in) Measurement B 36.959 ~ 37.059 mm (1.4551 ~ 1.4590 in) 36.840 mm (1.4504 in) Exhaust camshaft lobe dimensions Measurement A 43.129 ~ 43.229 mm (1.6980 ~ 1.7019 in) [...]

2 - 5 SPEC ENGINE SPECIFICATIONS Rocker arm/rocker arm shaft Rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) 12.036 mm (0.4739 in) Shaft outside dia meter 11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in) 11.955 mm (0.4707 in) Arm-to-shaft clearance 0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.081 mm (0.0032 in) Valves, valve seats, valve guid [...]

2 - 6 SPEC ENGINE SPECIFICATIONS Valve-stem-to-valve-guide clearance Intake 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.08 mm (0.0031 in) Exhaust 0.025 ~ 0.052 mm (0.0010 ~ 0 .0020 in) 0.10 mm (0.0039 in) Valve stem runout ---- 0.010 mm (0.0004 in) Valve seat wi dth Intake 1.00 ~ 1.20 mm (0.0394 ~ 0.0472 in) 1.6 mm (0.06 in) Exhaust 1.00 ~ 1.20 mm (0.0[...]

2 - 7 SPEC ENGINE SPECIFICATIONS Cylinder Cylinder arrangement Forward-inclined single cylinder ---- Bore × stroke 100.0 × 84.0 mm (3.94 × 3.31 in) ---- Compression ratio 10 : 1 ---- Bore 100.000 ~ 100.010 (3.9370 ~ 3. 9374 in) 100.080 mm (3.9402 in) Maximum taper ---- 0.05 mm (0.002 in) Maximum out-of-round ---- 0.05 mm (0.002 in) Piston Piston[...]

2 - 8 SPEC ENGINE SPECIFICATIONS 2nd ring Ring type Taper ---- Dimensions (B × T) 1.2 0 × 4.00 mm (0.047 × 0.157 in) ---- End gap (installed) 0.35 ~ 0.50 mm (0.0138 ~ 0.0197 in) 0.85 mm (0.0335 in) Ring side clearance 0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in) 0.11 mm (0.0043 in) Oil ring Dimensions (B × T) 2.5 0 × 3.40 mm (0.098 × 0.134 in) ---- [...]

2 - 9 SPEC ENGINE SPECIFICATIONS Clutch Clutch type Wet, multiple disc ---- Clutch release method Outer pull, rack and pinion pull ---- Operation Left-hand operation ---- Clutch cable free play (at the end of the clutch lever) 10.0 ~ 15.0 mm (0.39 ~ 0.59 in) ---- Friction plates 1 (inside dia.: 120 mm) Thickness 2.90 ~ 3.10 mm (0.114 ~ 0.122 in) 2.[...]

2 - 10 SPEC ENGINE SPECIFICATIONS Maximum main axle runout ---- 0.08 mm (0.0031 in) Maximum drive axle runout ---- 0.08 mm (0.0031 in) Shifting mechanism Shift mechanism type Shift drum and guide bar ---- Decompression device Device type Auto decomp ---- Air filter type Oil-coated paper element ---- Fuel pump Pump type Electrical ---- Model/manufac[...]

2 - 11 SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Diamond ---- Caster angle 27.25 ° (XT660R) 26 ° (XT660X) ---- ---- Trail 107 mm (4.21 in) (XT660R) 94 mm (3.70 in) (XT660X) ---- ---- Front wheel Wheel type Spoke wheel ---- Rim Size 21 × 1.85 (XT660R) 17M/C × MT3.50 (XT660X) ---- ---- Material Alumin[...]

2 - 12 SPEC CHASSIS SPECIFICATIONS Front tire Tire type With tube ---- Size 90/90-21M/C 54S, 90/90-21M/C 54T (XT660R) 120/70R 17M/C 58 H (XT660X) ---- ---- Model/manufacturer TOURANCE FRONT/METZELER, SIRAC/MICHELIN (XT660R) DRAGON/PIRELLI (XT660X) ---- ---- Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 200 kPa (2.00 kgf/cm, 29 psi) (XT660R) 210 kPa ([...]

2 - 13 SPEC CHASSIS SPECIFICATIONS Front brakes Brake type Single-disc brake ---- Operation Right-hand operation ---- Recommended fluid DOT 4 ---- Brake discs Diameter × thickness 298.0 × 4.5 mm (11.73 × 0.18 in) (XT660R) 320.0 × 4.5 mm (12.60 × 0.18 in) (XT660X) ---- ---- Minimum thickness ---- 4.0 mm (0.16 in) Maximum deflection ---- 0.15 mm[...]

2 - 14 SPEC CHASSIS SPECIFICATIONS Steering Steering bearing type Taper roller bearing ---- Lock to lock angle (left) 44.0 ° ---- Lock to lock angle (right) 44.0 ° ---- Front suspension Suspension type Telescopic fork ---- Front fork type Coil spring/oil damper ---- Front fork travel 225.0 mm (8.86 in) (XT660R) 200.0 mm (7.87 in) (XT660X) ---- --[...]

2 - 15 SPEC CHASSIS SPECIFICATIONS Rear suspension Suspension type Swingarm (monocross) ---- Rear shock absorber assembly type Coil spring/gas-oil damper ---- Rear shock absorber assembly travel 65.0 mm (2.56 in) ---- Spring Free length 216.0 mm (8.50 in) 205 mm (8.07 in) Installed length 206.0 mm (8.11 in) ---- Spring rate (K1) 125.00 N/mm (12.75 [...]

2 - 16 SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V ---- Ignition system Ignition system type Transistorized coil ignition (digital) ---- Ignition timing 9.0 ° BTDC at 1,400 r/min ---- Advancer type Electric ---- Crankshaft position senor resistance/ color 192 ~ 288 Ω at 20 ° C (68 ° F) blue/[...]

2 - 17 SPEC ELECTRICAL SPECIFICATIONS Bulbs (voltage/wattage × quantity) Headlight 12 V 55.0 W/60.0 W × 1 ---- Auxiliary light 12 V 5.0 W × 1 ---- Tail/brake light 12 V 5.0 W/21.0 W × 1 ---- Front turn signal light 12 V 10.0 W × 2 ---- Rear turn signal light 12 V 10.0 W × 2 ---- Meter lighting EL ---- Electric starting system System type Cons[...]

2 - 18 SPEC ELECTRICAL SPECIFICATIONS Headlight relay Model/manufacturer ACM33211 M04/MATSUSHITA ---- Radiator fan Model/manufacturer 5VW/KTM ---- Fan motor relay Model/manufacturer ACM33211 M04/MATSUSHITA ---- Intake air pressure senso r Thermostat type/manufacturer 5PS1/DENSO ---- Output voltage 3.4 ~ 3.8 V ---- Intake air temperature sensor Mode[...]

2 - 19 SPEC CONVERSION TABLE/ GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00028 CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. CONVERSION TABLE EAS00030 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for sta[...]

2 - 20 SPEC TIGHTENING TORQUE TIGHTENING TORQUE ENGINE TIGHTENING TORQUE Part to be tightened Part name Thread size Q ’ ty Tightening torque Remarks Nm m · kg ft · lb Cylinder head (exhaust pipe) Stud b olt M8 4 15 1.5 11 Cylinder head (left side) = 145 mm (5.71 in) Bolt M9 2 50 5.0 36 E Cylinder head (right side) = 135 mm (5.31 in) Bolt M9 2 5[...]

2 - 21 SPEC TIGHTENING TORQUE Oil strainer Bolt M6 3 10 1.0 7.2 LT Oil pump Screw M6 3 10 1.0 7.2 Oil baffle plate 2 Bolt M5 2 4 0.4 2.9 LT Oil pump as sembly Screw M6 1 7 0.7 5.1 Engine oil drain bolt (crankcase) Bolt M14 1 30 3.0 22 Oil filter element cover Bolt M6 2 10 1.0 7.2 Oil filter drain bolt Bolt M 6 1 10 1.0 7.2 Engine oil drain bolt (oi[...]

2 - 22 SPEC TIGHTENING TORQUE Starter clutch Bolt M8 3 30 3.0 22 LT Stator coil Bolt M6 3 10 1.0 7.2 LT Crankshaft position sensor Bolt M5 2 7 0.7 5.1 LT Starter motor and crankcase Bolt M6 2 10 1.0 7.2 Starter motor lead Nut M6 1 5 0.5 3.6 Brush holder and starter motor yoke Nut M6 1 11 1.1 8 Starter motor assembly Bolt M5 2 5 0.5 3.6 Drive axle o[...]

2 - 23 SPEC TIGHTENING TORQUE CHASSIS TIGHTENING TORQUES Part to be tightened Thread size Tightening torque Remarks Nm m · kg ft · lb Engine mounting: Engine upper bracket and frame M10 73 7.3 53 Engine upper bracket and engin e M10 55 5.5 40 Engine front bracket and frame M10 73 7.3 53 Engine front bracket and engine M10 73 7.3 53 Engine and fra[...]

2 - 24 SPEC TIGHTENING TORQUE NOTE: 1. First, tighten the lo wer ring nut appro ximately 43 Nm (4.3 m · kg, 31 ft · lb) by usin g the torque wrench, then loosen the ring nut complet ely . 2. Retighten the lo wer ring nut 7 Nm (0.7 m · kg, 5.1 ft · lb) b y using the torque wrench. Fuel tank and frame M6 10 1.0 7.2 Fuel pump and fuel tank M5 4 0.[...]

2 - 25 SPEC EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point Symbol Oil seal lips LS O-rings LS Bearings E Cylinder head tightening bolts E Cylinder tightening bolts E Crankshaft pin E Timing chain sprocket inner surface M Connecting rod big end thrust surface E Piston pin E Piston and ring groove E Balancer weight tightenin[...]

2 - 26 SPEC LUBRICATION POINTS AND LUBRICANT TYPES Crankcase mating su rface Yamaha bond No.1215 A.C. magnet lead grommet (A.C. magneto cover) Yamaha bond No.1215 Oil seal holder tightening bolt Yamaha bond No.1215 Oil delivery hose 2 tightening bolt Yamaha bond No.1215 Lubrication Point Symbol[...]

2 - 27 SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication Point Symbol Front wheel oil seal lips (left and right) LS Rear wheel oil seal lips (le ft and right) LS Rear wheel drive hub contact surface LS Rear arm pivot shaft oute r surface and bush outer surface and oil seal lip LS Dust cover thrust surface LS Relay arm and rea[...]

2 - 28 SPEC COOLING SYSTEM DIAGRAMS EAS00033 COOLING SYSTEM DIAGRAMS 1 Water jacket joint 2 Water pump ou tlet hose 3 Water pump ou tlet pipe 4 Water pump È From the radiato r É To the cylinder 5VK 5VK00 È È É A 1 1 2 3 2 3 4 A 4[...]

2 - 29 SPEC COOLING SYSTEM DIAGRAMS 1 Fast idle plunger outl et hose 2 Coolant reserv oir breather hose 3 Coolant re servoir hose 4 Radiator cap 5 Radiator 6 Coolant rese rvoir cap 7 Coolant re servoir 8 Radiator outlet ho se 9 Water pump 0 Radiator fan A Radiator in let hose È From the fast idle plun ger É To the cylinder Ê From the thermost at[...]

2 - 30 SPEC LUBRICATION CHART LUBRICATION CHART : Pressure feed : Splashed scavenge Oil strainer Oil pump rotor 2 Check ball Oil filter Cylinder head Drive axle Crankshaft Camshaft Oil tank Main axle Oil pan Oil pump rotor 1 Connecting rod[...]

2 - 31 SPEC LUBRICATION DIAGRAMS EAS00034 LUBRICATION DIAGRAMS 1 Oil delivery hose 2 2 Oil strainer 3 Oil delivery hose 1 A-A A A 1 3 2 2[...]

2 - 32 SPEC LUBRICATION DIAGRAMS 1 Oil delivery pipe 2 2 Oil delivery pipe 1 3 Oil filter 4 Oil pump A-A A 1 4 3 3 2 A[...]

2 - 33 SPEC LUBRICATION DIAGRAMS 1 Oil delivery hose 2 2 Oil delivery pipe 2 3 Oil filter 4 Oil pump rotor 1 5 Oil pump rotor 2 6 Main axle 7 Oil delivery pipe 3 È To oil tank 1 7 3 2 6 4 5 È[...]

2 - 34 SPEC LUBRICATION DIAGRAMS 1 Camshaft 2 Oil delivery pipe 1 3 Oil filter 4 Main axle 5 Drive axle 6 Cranksh aft 2 3 5 4 1 6[...]

2 - 35 SPEC CABLE ROUTING EAS00035 CABLE ROUTING 1 Left handlebar switch lead 2 Clutch switch lead 3 Clutch cable 4 Front brake light switch lead 5 Right handlebar swit ch lead 6 Throttle ca ble 7 Headlight lead 8 Meter assembly lead 9 Main switch lead 0 Immobilizer unit lead[...]

2 - 36 SPEC CABLE ROUTING È When fastening the f ront brake light switch lea d, leave some slack in the lead at th e area shown. É Fasten the righ t handlebar switch lead, front brake light switch lead, and th rottle cables with a plastic ba nd. Face th e end of the plastic ban d forward. Ê Fasten the clutch cable with a cable holder . Ë Fasten[...]

2 - 37 SPEC CABLE ROUTING 1 Front turn signal light lead (right) 2 Meter assembly lead 3 Auxiliary light lead 4 Front turn signal light le ad (left) 5 Headlight lead 6 Sub-wire harness È Fasten the sub-wir e harness and meter asse m- bly lead with a plastic band. Fasten the sub-wire harness at the whi te tape. Face the end of the plastic band forw[...]

2 - 38 SPEC CABLE ROUTING Ë Fasten the left and ri ght front turn signal lig ht leads to the headlight stay wit h a plastic locking tie. Ì Pass the left and right front turn signal light lea ds in front of the he adlight stay. Í Only the left side is shown in this illustration. Route the r ight front turn sig nal light lead in th e same way. Î [...]

2 - 39 SPEC CABLE ROUTING 1 Ignition coil le ad 2 Main switch coupler 3 Immobilizer unit coupler 4 Air induction system lead 5 Horn lead 6 Horn 7 Ignition coil 8 Spark plug lead 9 Clutch cable 0 Oil delivery pipe 1 A Wire harness B Fast idle plunger outlet hose È Fasten the fast idle plunger outlet hose and igni- tion coil leads with a hose holder[...]

2 - 40 SPEC CABLE ROUTING Ê Fasten the main switch lead, immobilizer unit lead, and horn switch lead wit h a plastic locking tie. To faste n the leads, connect th e couplers, and then turn the handlebar complet ely to the left. Ë Fasten the main switch lead, immobilizer unit lead, and clutch cable with a plastic ba nd under the engine oil filler [...]

2 - 41 SPEC CABLE ROUTING 1 Rear brake l ight switch lead 2 Negative battery lead 3 Lean angle cut-off swit ch lead 4 Throttle position sensor le ad 5 Coolant temperat ure sensor lead 6 Turn signal/hazard relay 7 Headlight relay 8 Radiator fan mo tor relay 9 Relay unit È Fasten the wire har ness, negative batt ery lead, and rear brak e light switc[...]

2 - 42 SPEC CABLE ROUTING 1 Neutral switch connector 2 Crankshaft po sition sensor coupler 3 A.C. magneto coup ler 4 Speed sensor lead 5 Intake air temper ature sensor lead 6 ECU lead 7 Starter mo tor lead 8 Sidestand switch lead 9 Speed sensor 0 A.C. magneto lea d A Oil tank breather ho se B Oil delivery hose 2 C Radiator fan motor le ad D Throttl[...]

2 - 43 SPEC CABLE ROUTING È Fasten the left handleba r switch lead, right han- dlebar switch lead, h eadlight lead, meter assem- bly lead, front brake lig ht switch lead, and clut ch switch lead to the frame with a plasti c locking tie. To fasten the leads, co nnect the couplers , and then turn the ha ndlebar completely to the right. É Fasten the[...]

2 - 44 SPEC CABLE ROUTING Ë Fasten the w ire harness to the fram e at the white tape with a plastic lockin g tie. Ì Fasten the st arter motor lead to the f rame with a plastic locking tie. Í Fasten the sidestand switch lea d to the frame with a plastic locking tie. Î Route the sidest and switch lead at the front end of the left side heel plat e[...]

2 - 45 SPEC CABLE ROUTING Ò Fasten the wire harness, air-filt er-to-air-cut-off- valve hose, and oil d elivery hose 2 with a plastic clamp. Ó Fasten the left handleba r switch lead, right han- dlebar switch lead, h eadlight lead, meter assem- bly lead, front brake lig ht switch lead, and clut ch switch lead with a plastic band. B B C C E D E F F [...]

2 - 46 SPEC CABLE ROUTING 1 Starter mo tor lead 2 Fuse box 1 lead 3 Fuse box 2 lead 4 Tail/brake light lead 5 Rear turn signal light lea d 6 Seat lock cable 7 Positive battery lead 8 Starter relay lead 9 Rectifier/regulator lead È Fasten the wire harne ss and starter motor lead to the frame with a plastic locking t ie. É 45 ° Ê Fasten the wire [...]

2 - 47 SPEC 1 Immobilizer unit coupler 2 Intake air temper ature sensor 3 Fuel injector lead 4 Fuel pump lead 5 Fuel sender lead 6 Oil tank breather hose È 0 ~ 10 mm (0 ~ 0.39 in) É 30 ~ 40 mm (1.18 ~ 1.57 in) Ê 5 ~ 15 mm (0.20 ~ 0 .59 in) Ë Fasten the wire harness to th e frame with a plas- tic locking tie. Ì To the fuel tank Í 0 ~ 5 mm (0 ~[...]

2 - 48 SPEC 1 Battery 2 Negative battery lead 3 Tail/brake light coupler 4 Rear turn signal light conn ector 5 Seat lock cable 6 Anti-theft ala rm coupler 7 Fuse box 2 8 Positive battery lead 9 Fuse box 1 0 Rear fe nder A Rear fende r cover È Fasten the tail/brake light lead with two plasti c locking ties so that the couple r is positioned to the [...]

2 - 49 SPEC CABLE ROUTING Ë Connect the co uplers so that the y are not pinched between the rear fen der and rear f ender cover. Ì Fasten the wire harness to the fram e with a plas- tic locking tie. Í 0 ~ 5 mm (0 ~ 0 .20 in) Î 0 ~ 10 mm (0 ~ 0.39 in) Ï The tail/brake ligh t coupler and th e rear turn sig- nal light lead should no t be lower th[...]

2 - 50 SPEC CABLE ROUTING 1 Front brake hose 2 Front brake master cylinder 3 Front mu d guard 4 Front brake calipe r 5 Front fork boss È To install the b rake hose holders, align t he edge of each holder with the upper edge of the r ecess in the brake hose. É Route the f ront brake hose so that its alignment mark is facing towar d the rear of the[...]

2 - 51 SPEC CABLE ROUTING Ì Route the f ront brak e hose between t he front fork and fron t mud guard a nd between the bosses on th e front for k. Í When installing the brake hose onto the brake caliper, make sure that the brake pipe touches the brake caliper as shown. Î When installing the brake hose onto the brake caliper, make sure that the b[...]

2 - 52 SPEC CABLE ROUTING 1 Brake fluid rese rvoir 2 Brake fluid rese rvoir hose 3 Rear brake lig ht switch 4 Rear brake mast er cylinder 5 Rear brak e hose 6 Rear brake calip er È When installing the brake hose onto the brake master cylinder, m ake sure that th e brake pipe touches the brake ma ster cylinder as shown. É Fasten the rear brake hos[...]

CHK ADJ 3[...]

CHK ADJ CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION .......................................................... .................................... 3-1 PERIODIC MAINTENANCE AND LUBRICATION CHART ............................ 3-1 COWLING AND COVER ........................................................ ......................... 3-3 COVER [...]

CHK ADJ CHASSIS ................................................ ..................................................... .. 3-36 ADJUSTING THE REAR BRAKE PEDAL ............................................... 3-36 CHECKING THE BRAKE FLUID LEVEL................................................. 3-37 CHECKING THE FRONT AND REAR BRAKE PAD S AND BRAKE PAD [...]

3 - 1 CHK ADJ EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all informa tion necessary to perfo rm recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable veh icle operation, a longer service life and reduce the need for costly overhaul work. This information a[...]

3 - 2 CHK ADJ PERIODIC MAINTENANCE AND LUBRICATION CHART NOTE: • Replace the air filter element more frequently if you are riding in unusually wet or dusty areas. • Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid le vel. • Every two years replace the internal components of the brake ma ster cylinder, and[...]

3 - 3 CHK ADJ COWLING AND COVER COWLING AND COVER COVER 3 1 4 5 4 2 T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the cover Remove the parts in the ord er listed. 1 Seat 1 2 Left side panel 1 3 Right side panel 1 4 Grab bar 2 [...]

3 - 4 CHK ADJ COWLING AND COVER COWLING T R . . 8 Nm (0.8 m • kg, 5.8 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) 3 4 5 2 1 Order Job/Part Q ’ ty Remarks Removing the cowling Remove the parts in the order listed . Seat/side panels (left and right) Refer to “ COWLING AND COVER ” . Fuel tank Refer to “ FUEL TANK ” . 1 Front fend[...]

3 - 5 CHK ADJ EAS00040 FUEL TANK T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 7 6 8 10 5 4 9 3 2 Order Job/Part Q ’ ty Remarks Removing the fuel tank Remove the parts in the ord er listed. Seat/side panels (left and right) Refer to “ COWLING AND COVER ” . Fuel Drain. 1 Fuel tank left side cover 1 2 Fuel tank right side cover 1 3 Intake air g[...]

3 - 6 CHK ADJ REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tan k through the fuel tank filler tube with a pump . 2. Remov e: • fuel hose CAUTION: Although the fuel has been removed from the fuel tank be careful when removing the fuel hose, since there may be fuel remain- ing in it. NOTE: • To remove the fuel hose from the fuel injec- [...]

3 - 7 CHK ADJ INSTALLING THE FUEL PUMP 1. Install: • fuel pump NOTE: • Do not damage the installation surfaces of the fuel tank when installing the fuel pump. • Always use a new fuel pump gaske t. • Align the projection a on the fuel pump with the slot in the fuel pump bracket. • Tighten the bolts to the specified torq ue in the proper ti[...]

3 - 8 CHK ADJ AIR FILTER CASE REAR MUD GUARD AND REAR FENDER 2 2 1 3 8 4 5 6 7 T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the rear mud guard and rear fender Remove the parts in the[...]

3 - 9 CHK ADJ AIR FILTER CASE 2 2 1 3 8 4 5 6 7 T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order Job/Part Q ’ ty Remarks 6 Fuse box 2 1 7 Rear mud guard 1 8 Rear fender 1 For installation, rever se the removal pro- cedu[...]

3 - 10 CHK ADJ EAS00043 AIR FILTER CASE T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 4 Nm (0.4 m • kg, 2.9 ft • Ib) LS 15 (4) 7 14 16 12 11 10 9 17 3 13 2 4 5 8 6 1 [...]

3 - 11 CHK ADJ T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 4 Nm (0.4 m • kg, 2.9 ft • Ib) LS 15 (4) 7 14 16 12 11 10 9 17 3 13 2 4 5 8 6 1 Order Job/Part Q ’ ty R[...]

3 - 12 CHK ADJ INSTALLING THE AIR FILTER CASE JOINT CLAMP 1. Install: • air filter case joint clamp 1 NOTE: To install the air filter case joint clamp, align its slot a with the projection b on the air filter case. 1 a b AIR FILTER CASE[...]

3 - 13 CHK ADJ ADJUSTING THE VALVE CLEARANCE EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: _ • Valve clearance adjustment should be made on a cold engine, at room te mperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the [...]

3 - 14 CHK ADJ ADJUSTING THE VALVE CLEARANCE 6. Measure: • valve clearance Out of specification → Adjust. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. T urn the crankshaft countercloc kwise . b . When the piston is at the top dead center (TDC) on the compression strok e , a[...]

3 - 15 CHK ADJ ADJUSTING THE VALVE CLEARANCE d. Hold the adjusting scre w to pre vent it from moving and tighten the loc kn ut to the speci- fied torque. e. Measure the v alv e cle arance again. f . If the v alv e clearance is still out of spe cifica- tion, repeat all of the v alv e clearance adjust- ment steps until the sp ecified clearance is obt[...]

3 - 16 CHK ADJ ADJUSTING THE EXHAUST GAS VOLUME EAS00869 ADJUSTING THE EXHAUST GAS VOLUME NOTE: _ Be sure to set the CO density level to stan- dard, and then adjust the exha ust gas volume. 1. T ur n the main s witch to “ OFF ” and set the engine stop s witch to “” . 2. Simultaneously press and hold the “ SELECT ” and “ RESET ” b ut[...]

3 - 17 CHK ADJ ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00054 ADJUSTING THE ENGINE IDLING SPEED NOTE: _ Prior to adjusting the engine idling speed, the air filter element should be cleaned, and the engine should have a dequate compression. 1. Star t the engine and let it w ar m up f or se v- eral minutes . 2. Che[...]

3 - 18 CHK ADJ ADJUSTING THE THROTTLE CABLE FREE PLAY 1. Chec k: • throttle cable free play a Out of specification → Adjust. Throttle cable free play (at the flange of the throttle grip) 3.0 ~ 5.0 mm (0.12 ~ 0.20 in) 2. Adjust: • throttle cable free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼[...]

3 - 19 CHK ADJ ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUG c. Tighten the loc kn ut. W ARNING _ After adjusting the throttle ca ble free play, start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the e ngine idling speed to change. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ [...]

3 - 20 CHK ADJ CHECKING THE SPARK PLUG/ CHECKING THE IGNITION TIMING 7. Install: • spark plug NOTE: _ Before installing the spark plug, clea n the spark plug and gasket surface. 8. Connect: • spark plug cap T R . . 13 Nm (1.3 m · kg, 9.4 ft · lb) EAS00064 CHECKING THE IGNITION TIMING NOTE: _ Prior to checking the ignition timing, check the wi[...]

3 - 21 CHK ADJ CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE 4. Detach: • timing light 5. Install: • timing mark accessing screw EAS00067 MEASURING THE COMPRESSION PRESSURE NOTE: _ Insufficient compres sion pressure will result in a loss of performance. 1. Measure: • valve clearance Out of specification → Adjust. Refer to[...]

3 - 22 CHK ADJ MEASURING THE COMPRESSION PRESSURE 6. Measure: • compression pressure Out of specification → Refer to steps (c) and (d). ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Set the main s witch to “ ON ” and the engine stop s witch to “” . b . With the throt[...]

3 - 23 CHK ADJ MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL 7. Install: • spark plug 8. Connect: • spark plug cap EAS00069 CHECKING THE ENGINE OIL LEVEL 1. Stand the motorcycle on a le vel surf ace . NOTE: _ • Place the motorcycle on a suitable stand. • Make sure the motorcycle is upright. 2. Star t the engine , warm it[...]

3 - 24 CHK ADJ CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL 4. Star t the engine, w arm it up f or se v er al min- utes, an d then turn it off . 5. Chec k the engine oil le v el again. NOTE: _ Before checking the engine oil level, wait a few minutes until the oil has settled. EAS00076 CHANGING THE ENGINE OIL 1. Star t the engine, w arm it[...]

3 - 25 CHK ADJ CHANGING THE ENGINE OIL 9. If the oil filter element is also to be replaced, perf orm the fo llowing pro cedure. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remov e the oil filter element co v er 1 and oil filter element 2 . b . Check the O-rings 3 and replace t[...]

3 - 26 CHK ADJ CHANGING THE ENGINE OIL 13.Install: • engine oil filler cap • camshaft sprocket c over 14.Star t the engine, warm it up f or se v er al min- utes, an d then turn it off . 15.Chec k: • engine (for engine oil leaks) 16.Chec k: • engine oil level Refer to “ CHECKING THE ENGINE OIL LEVEL ” . T R . . 10 Nm (1.0 m · kg, 7.2 ft[...]

3 - 27 CHK ADJ ADJUSTING THE CLUTCH CABLE FREE PLAY EAS00078 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Chec k: • clutch cable free pla y a Out of specification → Adjust. 2. Adjust: • clutch cable free pla y ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ Handlebar end a. Slide ba[...]

3 - 28 CHK ADJ CHECKING THE AIR FILTER ELEMENT EAS00086 CHECKING THE AIR FILTER ELEMENT NOTE: There is a check hose 1 at the bottom of the air filter case. If dust and/or water collects in this hose, clean the air filter element and air fil- ter case. 1. Remov e: • seat • right side panel Refer to “ COWLING AND COVER ” . 2. Remov e: • air[...]

3 - 29 CHK ADJ CHECKING THE AIR FILTER ELEMENT/ CHECKING THE THROTTLE BODY JOINT/ CHECKING THE FUEL HOSE 6. Install: • right side panel • seat Refer to “ COWLING AND COVER ” . EAS00094 CHECKING THE THROTTLE BODY JOINT 1. Chec k: • throttle body joint 1 Cracks/damage → Replace. Refer to “ FUEL INJECTION SYSTEM ” in chapter 7. 1 EAS00[...]

3 - 30 CHK ADJ CHECKING THE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM EAS00098 CHECKING THE BREATHER HOSE 1. Chec k: • crankcase-to-crankcase-breather -chamber hose 1 • air-filter-to-crankcase- breather-chamber hose 2 Cracks/damage → Replace. Loose connection → Connect properly. CAUTION: _ Make sure the breather hoses are routed correctly.[...]

3 - 31 CHK ADJ CHECKING THE COOLANT LEVEL/ CHECKING THE COOLING SYSTEM EAS00102 CHECKING TH E COOLANT L EVEL 1. Stand the motorcycle on a le vel surf ace . NOTE: _ • Place the motorcycle on a suitable stand. • Make sure the motorcycle is upright. 2. Chec k: • coolant level The coolant level should be between the maximum level mark a and minim[...]

3 - 32 CHK ADJ CHECKING THE COOLING SYSTEM/ CHANGING THE COOLANT 2. Chec k: • radiator 1 • radiator outlet hose 2 • radiator inlet hose 3 • water pump asse mbly 4 • water pump outlet pipe 5 • water pump outlet hose 6 Cracks/damage → Replace. Refer to “ COOLING SYSTEM ” in chapter 6. 3. Install: • fuel tank Refer to “ FUEL TANK[...]

3 - 33 CHK ADJ CHANGING THE COOLANT 2. Remov e: • radiator cap retainer 1 • radiator cap 2 W ARNING _ A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause seri- ous injury. When the engine has cooled, open the radiator cap as follows:[...]

3 - 34 CHK ADJ CHANGING THE COOLANT 10.Fill: • cooling syste m (with the specified amount of the recom- mended coolant) Handling notes for coolant Coolant is potentially harmful and should be handled with special care. W ARNING _ • If coolant splashe s in your eyes, th or- oughly wash them with water and consult a doctor. • If coolant splashe[...]

3 - 35 CHK ADJ CHANGING THE COOLANT 11.Install: • radiator cap • radiator cap retainer 12.Fill: • coolant reservoir (with the recommended coolant to the maxi- mum level mark a ) 13.Install: • coolant reservoir cap 14.Star t the engine, warm it up f or se v er al min- utes, an d then turn it off . 15.Chec k: • coolant level Refer to “ CH[...]

3 - 36 CHK ADJ ADJUSTING THE REAR BRAKE PEDAL EAS00110 CHASSIS ADJUSTING THE REAR BRAKE PEDAL 1. Chec k: • brake pedal position (distance a from the top of the rider foot- rest to the top of the brake pedal) Out of specification → Adjust. 2. Adjust: • brake pedal position ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼[...]

3 - 37 CHK ADJ ADJUSTING THE REAR BRAKE PEDAL/ CHECKING THE BRAKE FLUID LEVEL 3. Adjust: • rear brake lig ht switch Refer to “ ADJUSTING THE REAR BRAKE LIGHT SWITCH ” . EAS00115 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a le vel surf ace . NOTE: _ • Place the motorcycle on a suitable stand. • Make sure the motorcycle is up[...]

3 - 38 CHK ADJ CHECKING THE FRONT AND REAR BRAKE PAD S AND BRAKE PAD PINS/ADJUSTING THE REAR BRAKE LIGHT SWITCH EAS00118 CHECKING THE FRONT AN D REAR BRAKE PADS AND BRAKE PAD PINS The following procedure applies to all of the brake pads. 1. Operate the brak e . 2. Chec k: • front brake pads XT660R Wear indicator grooves 1 have almost dis- appeare[...]

3 - 39 CHK ADJ ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE FRONT AND REAR BRAKE HOSES 1. Chec k: • rear brake light operat ion timing Incorrect → Adjust. 2. Adjust: • rear brake light operat ion timing ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Hold the main bod[...]

3 - 40 CHK ADJ BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00134 BLEEDING THE HYDRAULIC BRAKE SYSTEM W ARNING _ Bleed the hydraulic brake sy stem when- ever: • the system is disassembled. • a brake hose is loos ened, disconnected or replaced. • the brake fluid level is very low. • brake operation is faulty. NOTE: _ • Be careful not to spill an[...]

3 - 41 CHK ADJ BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SHIFT PEDAL g. Loosen the b leed scre w . NOTE: _ Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. h. Tighten the b leed scre w , and then release the brak e le ver or br ak e pedal. i. Repe[...]

3 - 42 CHK ADJ ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK 2. Adjust: • shift pedal position ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remov e the bolt 1 . b . Remov e the shift pedal 2 . c. Install the shift pedal at the correct po sition. d. Install the bo[...]

3 - 43 CHK ADJ ADJUSTING THE DRIVE CHAIN SLACK 3. Chec k: • drive chain slack a Out of specification → Adjust. Drive chain slack 40.0 ~ 55.0 mm (1.57 ~ 2.17 in) 4. Adjust: • drive chain slack ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loosen the wheel axle nu t 1 . b . [...]

3 - 44 CHK ADJ LUBRICATING THE DRIVE CHAIN/ CHECKING AND ADJUSTING THE STEERING HEAD EAS00142 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not mainta ined prop- erly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the motorcycle is used in dusty areas[...]

3 - 45 CHK ADJ CHECKING AND ADJUSTING THE STEERING HEAD 3. Remov e: • handlebar protector cover (XT660X) • handlebar protector (XT660X) • handlebar holder caps • upper handlebar holders 1 • handlebar 2 1 1 2 4. Loosen: • upper bracket pinch bolts 1 5. Remov e: • steering stem nut 2 • washer • upper bracket 3 1 2 3 6. Adjust: • s[...]

3 - 46 CHK ADJ CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK d. Chec k the steering head f or lo oseness or binding b y tur ning the front f ork all the wa y in both directions . If an y bind ing is f elt, remov e the lo wer brac k et and chec k the upper and low er bearings. Refer to “ STEERING HEAD ” in chapter 4. e. Insta[...]

3 - 47 CHK ADJ CHECKING THE FRONT FORK/ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3. Hold the motorcycle upright and apply the front brak e . 4. Chec k: • front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement → Repair. Refer to “ FRONT FORK ” in chapter 4. EAS00156 A[...]

3 - 48 CHK ADJ CHECKING THE TIRES EAS00166 CHECKING THE TIRES The following procedure ap plies to both of the tires. 1. Chec k: • tire pressure Out of specification → Regulate. W ARNING _ • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. • The tire pressure and the suspens[...]

3 - 49 CHK ADJ CHECKING THE TIRES XT660X * Total weight of rider, passenger, car go and accesso ries W ARNING _ It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately. 2. Chec k: • tire surfaces Damage/wear → Replace the tire. 1 Tire trea d depth 2 Sidewall 3 Wear indicator W ARNIN[...]

3 - 50 CHK ADJ CHECKING THE TIRES • Patching a punctured tube is not recom- mended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement. È Tire É Wheel • After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The fro[...]

3 - 51 CHK ADJ CHECKING THE TIRES/ CHECKING AND TIGHTENING THE SPOKES W ARNING _ New tires have a relatively low grip on the road surface until they ha ve been slightly worn. Therefore, approximately 100 km should be traveled at normal sp eed before any high-speed riding is done. NOTE: _ For tires with a direction of rotation mark 1 : • Install t[...]

3 - 52 CHK ADJ CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS AND BRAKE PEDAL/ LUBRICATING THE SIDESTAND EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables. W ARNING _ Damaged outer cable may cause the cable to corrode and interfere with its movement. Replace damaged outer [...]

3 - 53 CHK ADJ CHECKING AND CHARGING THE BATTERY EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY W ARNING _ Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or work[...]

3 - 54 CHK ADJ CHECKING AND CHARGING THE BATTERY NOTE: _ Since MF batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remov e: • seat Refer to “ COWL[...]

3 - 55 CHK ADJ 5. Charge: • battery (refer to the appropriate charging method illustration) W ARNING _ Do not quick charge a battery. CAUTION: _ • Never remove the MF battery sealing caps. • Do not use a high-rate battery charger since it forces a high-amp erage current into the battery quickly and can cause battery overheating and battery pl[...]

3 - 56 CHK ADJ CHECKING AND CHARGING THE BATTERY Charging method using a variable-curre nt (voltage) charger Measure the ope n-circuit voltage prior to chargin g. Connect a charger and ammeter to the battery and start charging . Is the amperage high er than the standa rd charging amperage writt en on the battery? Adjust the char ging voltage to 20 [...]

3 - 57 CHK ADJ CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger Measure the open-cir cuit voltage prior to chargin g. NOTE: Set the charging ti me to a maxi- mum of 20 hours. Connect a char ger and ammeter to the ba ttery and start char ging. Is the ampera ge higher than the standa rd charg- ing amperage written on[...]

3 - 58 CHK ADJ CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) CAUTION: _ First, connect the positive battery lead 1 , then the negative battery lead 2 . 8. Chec k: • battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. 9. [...]

3 - 59 CHK ADJ CHECKING THE FUSES 2. Chec k: • fuse 1 • fuse box 1 2 • fuse box 2 3 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pock et tester to th e fuse and chec k the continuity . NOTE: _ Set the pocket tester sel ector to “ Ω × 1 ” . b . If the po[...]

3 - 60 CHK ADJ CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULB W ARNING _ Never use a fuse with an amp erage rating other than that specified. Improvising or using a fuse with the wrong amperage rat- ing may cause extensive dama ge to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. ▲[...]

3 - 61 CHK ADJ REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM 5. Install: • headlight bulb • headlight bulb holder • headlight bulb holder cover CAUTION: _ Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adve[...]

3 - 62 CHK ADJ SETTING THE DIGITAL CLOCK EAS00187 SETTING THE DIGITAL CLOCK 1. Set: • digital clock 1 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Set the main s witch to “ ON ” . b . Push the “ SELECT ” b utton 2 and “ RESET ” bu tton 3 together f or at least tw [...]

CHAS 4[...]

CHAS CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISC ................................................. .............. 4-1 FRONT WHEEL .......................................................................... .............. 4-2 REMOVING THE FRONT WHEEL .............................................. .............. 4-3 CHECKING THE FRONT WHEEL .........[...]

CHAS FRONT FORK ......................................... ..................................................... .. 4-51 REMOVING THE FRONT FORK LEGS ........................... ....................... 4-55 DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-55 CHECKING THE FRONT FORK LEGS ...................................[...]

4 - 1 CHAS EAS00512 CHASSIS FRONT WHEEL AND BRAKE DISC T R . . 18 Nm (1.8 m • kg, 13 ft • Ib) T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 59 Nm (5.9 m • kg, 43 ft • Ib) LT T R . . 40 Nm (4.0 m • kg, 29 ft • Ib) 6 4 7 5 1 2 3 (6) Order Job/Part Q ’ ty Remarks Removing the front wheel and brake disc Remove the parts in the order [...]

4 - 2 CHAS FRONT WHEEL AND BRAKE DISC EAS00518 FRONT WHEEL LS LS New New 1 2 3 2 1 Order Job/Part Q ’ ty Remarks Disassembling the front wheel Remove the parts in the order listed. 1 Oil seal 2 2 Bearing 2 3 Spacer 1 For assembly, reverse the disassembly procedure.[...]

4 - 3 CHAS FRONT WHEEL AND BRAKE DISC EAS00519 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a le vel surf ace . W ARNING _ Securely support the mo torcycle so that there is no danger of it falling over. NOTE: _ Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Remov e: • brake caliper NOTE: _ Do not apply the[...]

4 - 4 CHAS FRONT WHEEL AND BRAKE DISC 3. Chec k: • spokes Bends/damage → Replace. Loose → Tighten. Tap the spokes with a screwdriver. NOTE: _ A tight spoke will emit a clear, ringing tone, a loose spoke will sound flat. 4. Tighten: • spokes 1 (with a spoke wrench 2 ) NOTE: _ After tightening the spokes, measure the front wheel runout. T R .[...]

4 - 5 CHAS FRONT WHEEL AND BRAKE DISC 7. Chec k: • wheel bearings Front wheel turns roug hly or is loose → Replace the wheel bearings. • oil seals Damage/wear → Replace. 8. Replace: • oil seals • wheel bearings ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Clean the [...]

4 - 6 CHAS FRONT WHEEL AND BRAKE DISC EAS00527 CHECKING THE FRONT BRAKE DISC 1. Chec k: • brake disc Damage/galling → Replace. 2. Measure: • brake disc deflection Out of specifica tion → Correct the brake disc deflection or replace the brake disc. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼?[...]

4 - 7 CHAS FRONT WHEEL AND BRAKE DISC 4. Adjust: • brake disc deflection ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remov e the brak e disc. b . Rotate the brak e disc b y one bolt hole . c. Install the brak e disc. NOTE: _ Tighten the brake disc bolts in stages and in a cr[...]

4 - 8 CHAS FRONT WHEEL AND BRAKE DISC 2. Tighten: • wheel axle 1 • wheel axle pinch bolts 2 CAUTION: _ Before tightening the wheel axle nut, push down hard on the handlebar several times and check if the front fork rebounds smoothly. NOTE: To tighten the wheel axle pinch bolt, tighten the outer and inner bolt s to the specified torque, and then[...]

4 - 9 CHAS FRONT WHEEL AND BRAKE DISC 2. Find: • front wheel ’ s heavy spo t NOTE: _ Place the front wheel on a su itable balancing stand. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Spin the front wheel. b . When the front wheel stops, put an “ X 1 ” mark at the botto[...]

4 - 10 CHAS REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET EAS00550 REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET REAR WHEEL T R . . 105 Nm (10.5 m • kg, 75 ft • lb) T R . . 16 Nm (1.6 m • kg, 11 ft • Ib) T R . . 16 Nm (1.6 m • kg, 11 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) LS 3 5 1 2 5 4 4 7 6 8 9 10 11 12 13 14 14 T R .[...]

4 - 11 CHAS REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET T R . . 105 Nm (10.5 m • kg, 75 ft • lb) T R . . 16 Nm (1.6 m • kg, 11 ft • Ib) T R . . 16 Nm (1.6 m • kg, 11 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) LS 3 5 1 2 5 4 4 7 6 8 9 10 11 12 13 14 14 T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.[...]

4 - 12 CHAS REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET BRAKE DISC AND REAR WHEEL SPROCKET 6 6 LT LS T R . . 13 Nm (1.3 m • kg, 9.4 ft • Ib) T R . . 69 Nm (6.9 m • kg, 50 ft • Ib) LS 7 5 2 4 3 1 (6) (6) New Order Job/Part Q ’ ty Remarks Removing the brake disc and rear wheel sprocket Remove the parts in the order listed . 1 Oil seal 1[...]

4 - 13 CHAS REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET Order Job/Part Q ’ ty Remarks Disassembling the rear wheel Remove the parts in the order listed. 1 Bearing 2 2 Oil seal 1 3 Spacer 1 For assembly, reverse the disassembly procedure.[...]

4 - 14 CHAS REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET EAS00561 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a le vel surf ace . W ARNING _ Securely support the mo torcycle so that there is no danger of it falling over. NOTE: _ Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Loosen: • locknut 1 • adjus[...]

4 - 15 CHAS REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET 2. Chec k: • tire • rear wheel Damage/wear → Replace. Refer to “ CHECKING THE TIR ES ” in chap- ter 3. 3. Chec k: • spokes Refer to “ CHECKING THE FRONT WHEEL ” . 4. Measure: • radial wheel runout • lateral wheel runout Refer to “ CHECKING THE FRONT WHEEL ” . EAS005[...]

4 - 16 CHAS REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET 3. Measure: • brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification → Replace. Brake disc thickness limit (mini- mum) 4.5 mm (0.18 in) 4. Adjust: • brake disc deflection ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼[...]

4 - 17 CHAS REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET EAS00568 CHECKING AND REPLACIN G THE REAR WHEEL SPROCKET 1. Chec k: • rear wheel sprocket More than 1/4 tooth a wear → Replace the rear wheel sprocket. Bent teeth → Replace the rear wheel sprocket. b Correct 1 Drive chain roller 2 Rear wheel sprocket 2. Replace: • rear wheel sprock[...]

4 - 18 CHAS REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET 2. Install: • rear wheel • washer (O) • rear axle • washer (N) • rear axle nut NOTE: Install the washer with the “ N ” m a r k o n t h e right-hand side of the vehicle and the washer with the “ O ” mark on the left-hand side of the vehicle. Be sure to install both washe r[...]

4 - 19 CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS (XT660R) T R . . 40 Nm (4.0 m • kg, 29 ft • Ib) T R . . 14 Nm (1.4 m • kg, 10 ft • Ib) 1 1 5 4 5 2 6 3 Order Job/Part Q ’ ty Remarks Removing the front brake pads Remove t he parts in the order listed. 1 Brake caliper bolt 2 Refer to “ REPLACING THE FRONT [...]

4 - 20 CHAS FRONT BRAKE PADS (XT660X) T R . . 40 Nm (4.0 m • kg, 29 ft • Ib) T R . . 14 Nm (1.4 m • kg, 10 ft • Ib) 3 4 5 6 2 1 1 2 Order Job/Part Q ’ ty Remarks Removing the front brake pads Remove the parts in the order listed. 1 Brake caliper bolt 2 Refer to “ REPLACING THE FRONT BRAKE PADS ” . 2 Brake pad clip 2 3 Brake pad pin 2 [...]

4 - 21 CHAS FRONT AND REAR BRAKES EAS00578 REAR BRAKE PADS T R . . 14 Nm (1.4 m • kg, 10 ft • Ib) 5 3 4 4 1 2 Order Job/Part Q ’ ty Remarks Removing the rear brake pads Remove t he parts in the order listed. Rear wheel Refer to “ REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET ” . 1 Brake pad pin 1 Refer to “ REPLACING THE REAR BRAKE PA[...]

4 - 22 CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: _ Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be dis assembled, drained,[...]

4 - 23 CHAS FRONT AND REAR BRAKES 2. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. È XT660R É XT660X 3. Chec k: • brake pad pin(s) Damage/wear → Replace. Brake pad wear limit 1.0 mm (0.04 in) È É 4. Install: • brake pad springs • brake pads NOTE: _ Always replace the brake pads and brake p[...]

4 - 24 CHAS d. Install new br ak e pads and ne w brak e pad springs. NOTE: _ The arrow a on the brake pad spring must point in the direction of rotation. È XT660R É XT660X ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5. Install: • brake pad pin • brake pad clip • brake cal[...]

4 - 25 CHAS FRONT AND REAR BRAKES 3. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. 4. Install: • brake pad springs • brake pads NOTE: _ Always replace the brake pads and brake pad springs as a set. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ [...]

4 - 26 CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER T R . . 30 Nm (3.0 m • kg, 22 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 6 Nm (0.6 m • kg, 4.3 ft • Ib) 5 7 8 6 1 4 3 2 9 10 12 11 LS New Order Job/Part Q ’ ty Remarks Removing the front brake master cylinder Remove the parts in the order listed . Brak[...]

4 - 27 CHAS T R . . 30 Nm (3.0 m • kg, 22 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 6 Nm (0.6 m • kg, 4.3 ft • Ib) 5 7 8 6 1 4 3 2 9 10 12 11 LS New Order Job/Part Q ’ ty Remarks 5 Front brake light switch 1 Disconnect. Refer to “ DISASSEM- BLING THE FRONT BRAKE MASTER CYLIN- DER ” and “ ASSEMBLING AND INSTALLING T[...]

4 - 28 CHAS FRONT AND REAR BRAKES EAS00585 Order Job/Part Q ’ ty Remarks Disassembling the front brake mas- ter cylinder Remove the parts in the order listed . 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder 1 For assembly, reverse the disassembly procedure.[...]

4 - 29 CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER T R . . 30 Nm (3.0 m • kg, 22 ft • Ib) T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 18 Nm (1.8 m • kg, 13 ft • Ib) New New LS 9 5 4 1 2 3 10 12 11 6 7 8 13 Order Job/Part Q ’ ty Remarks Removing the rear brake master cyl- inder Remove the parts in the order listed[...]

4 - 30 CHAS T R . . 30 Nm (3.0 m • kg, 22 ft • Ib) T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 18 Nm (1.8 m • kg, 13 ft • Ib) New New LS 9 5 4 1 2 3 10 12 11 6 7 8 13 Order Job/Part Q ’ ty Remarks 10 Cotter pin 1 Refer to “ INSTALLING THE REAR BRAKE MASTER CYLINDER ” . 11 Washer 1 12 Pin 1 13 Master cylinder 1 For installation,[...]

4 - 31 CHAS FRONT AND REAR BRAKES EAS00587 Order Job/Part Q ’ ty Remarks Disassembling the rear brake mas- ter cylinder Remove the parts in the order listed . 1 Hose joint 1 2 Brake master cylinder kit 1 Refer to “ ASSEMBLING THE REAR BRAKE MASTER CYLINDER ” . 3 Brake master cylinder 1 For assembly, reverse the disassembly procedure.[...]

4 - 32 CHAS FRONT AND REAR BRAKES EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: _ Before disassembling the front brake master cylinder, drain the brake fluid fro m the entire brake system. 1. Disconnect: • front brake light switch 1 NOTE: Push the fastener to remove the front brake light switch from the brake master cylinder. 2. Re[...]

4 - 33 CHAS FRONT AND REAR BRAKES EAS00592 CHECKING THE FRONT AN D REAR BRAKE MASTER CYLINDERS The following procedure ap plies to both of the brake master cylinders. 1. Chec k: • brake master cylinder 1 Damage/scratches/wear → Replace. • brake fluid delivery passages (brake master cylinder body) Obstruction → Blow out with compressed air. [...]

4 - 34 CHAS FRONT AND REAR BRAKES 5. Chec k: • brake hoses Cracks/damage/wear → Replace. EAS00598 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER W ARNING _ • Before installation, all internal b rake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components. 1. I[...]

4 - 35 CHAS FRONT AND REAR BRAKES 3. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) W ARNING _ • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is[...]

4 - 36 CHAS FRONT AND REAR BRAKES EAS00608 ASSEMBLING THE REAR BRAKE MASTER CYLINDER W ARNING _ • All internal brake components should be cleaned and lubricated with new brake fluid only before installation. • Whenever a master cylinder is dis assem- bled, replace the piston seals a nd dust seals. 1. Install: • brake master cylinder kit • j[...]

4 - 37 CHAS FRONT AND REAR BRAKES 2. Install: • right side heel plate • copper washers • brake hose 1 • union bolt 2 W ARNING _ Proper brake hose routing is essential to insure safe motorcycle operation. Refer to “ CABLE ROUTING ” in chapter 2. CAUTION: _ When installing the bra ke hose onto the brake master cylinder, make sure the brak[...]

4 - 38 CHAS 4. Bleed: • brake system Refer to “ BLEEDING THE HYDRAULIC BRAKE SYSTEM ” in chapter 3. 5. Chec k: • brake fluid level Below the minimu m level mark a → Add the recommended brake flu id to the proper level. Refer to “ CHECKING THE BRAKE FLUID LEVEL ” in chapter 3. 6. Adjust: • brake pedal position a Refer to “ ADJUSTIN[...]

4 - 39 CHAS FRONT AND REAR BRAKES EAS00612 FRONT BRAKE CALIPER (XT660R) T R . . 30 Nm (3.0 m • kg, 22 ft • Ib) T R . . 40 Nm (4.0 m • kg, 29 ft • Ib) New New 5 3 1 2 4 2 Order Job/Part Q ’ ty Remarks Removing the front brake caliper Remove the parts in the ord er listed. Brake fluid Drain. 1 Union bolt 1 Refer to “ INSTALLING THE FRONT [...]

4 - 40 CHAS FRONT AND REAR BRAKES EAS00614 5 2 1 4 3 4 T R . . 14 Nm (1.4 m • kg, 10 ft • Ib) LS LS Order Job/Part Q ’ ty Remarks Disassembling the front brake cali- per Remove the parts in the order listed . 1 Brake pad clip 1 Refer to “ INSTALLING THE FRONT BRAKE CALIPER ” . 2 Brake pad pin 1 3 Brake pad 2 4 Brake pad spring 2 5 Bleed s[...]

4 - 41 CHAS FRONT BRAKE CALIPER (XT660X) 1 2 3 5 T R . . 40 Nm (4.0 m • kg, 29 ft • Ib) T R . . 30 Nm (3.0 m • kg, 22 ft • Ib) New 4 Order Job/Part Q ’ ty Remarks Removing the front brake caliper Remove t he parts in the order listed. Brake fluid Drain. 1 Union bolt 1 Refer to “ INSTALLING THE FRONT BRAKE CALIPER ” . 2 Copper washer 2[...]

4 - 42 CHAS T R . . 14 Nm (1.4 m • kg, 10 ft • Ib) 3 4 5 1 1 2 Order Job/Part Q ’ ty Remarks Disassembling the front brake cali- per Remove the parts in the order listed . 1 Brake pad clip 2 Refer to “ INSTALLING THE FRONT BRAKE CALIPER ” . 2 Brake pad pin 2 3 Brake pad spring 1 4 Brake pad 2 5 Bleed screw 1 For assembly, reverse the disa[...]

4 - 43 CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER T R . . 30 Nm (3.0 m • kg, 22 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) 5 1 2 3 4 New T R . . 4 Nm (0.4 m • kg, 2.9 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the rear brake caliper Remove t he parts in the order listed. Brake fluid Drain. Rear wheel Refer to “[...]

4 - 44 CHAS FRONT AND REAR BRAKES EAS00617 T R . . 14 Nm (1.4 m • kg, 10 ft • Ib) LS 1 6 4 5 5 3 2 Order Job/Part Q ’ ty Remarks Disassembling the rear brake cali- per Remove the parts in the order listed . 1 Brake caliper bracket 1 2 Brake pad clip 1 Refer to “ INSTALLING THE REAR BRAKE CALIPER ” . 3 Brake pad pin 1 4 Brake pad 2 5 Brake[...]

4 - 45 CHAS FRONT AND REAR BRAKES EAS00619 REMOVING THE FRONT BRAKE CALIPER NOTE: _ Before removing the brake caliper, drain the brake fluid from the entire brake system. 1. Remov e: • union bolt 1 • copper washers 2 • brake hose 3 • brake caliper 4 NOTE: _ Put the end of the brake hose into a cont ainer and pump out the brake fluid carefu [...]

4 - 46 CHAS FRONT AND REAR BRAKES EAS00633 CHECKING THE FRONT AN D REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Brake hoses Every four years Brake fluid Every two ye ars and whenever the brake is disassem- bled 1. Chec k: • brake caliper pistons 1 Rust/scratches/wear → Replace the brake caliper. ?[...]

4 - 47 CHAS FRONT AND REAR BRAKES EAS00634 INSTALLING THE FRONT BRAKE CALIPER 1. Install: • brake pad springs • brake pads • brake pad pin(s) • brake pad clip(s) Refer to “ FRONT BRAKE PADS ” . 2. Install: • brake caliper 1 • brake caliper bolts 2 • copper washers • brake hose 3 • union bolt 4 W ARNING _ Proper brake hose rout[...]

4 - 48 CHAS FRONT AND REAR BRAKES 3. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) W ARNING _ • Use only the designated brake fluid. Other brake fluids may cause the piston seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is[...]

4 - 49 CHAS FRONT AND REAR BRAKES EAS00642 INSTALLING THE REAR BRAKE CALIPER 1. Install: • brake caliper springs • brake pads • brake pad pin • brake pad clip Refer to “ REAR BRAKE PADS ” . 2. Install: • brake caliper • rear wheel Refer to “ REAR WHEEL, BRAKE DISC , AND REAR WHEEL SPROCKET ” . • copper washers • brake hose 1[...]

4 - 50 CHAS FRONT AND REAR BRAKES W ARNING _ • Use only the designated brake fluid. Other brake fluids may cause the piston seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the sy stem. Mixing brake fluids may result in a harmful chemical reaction, leadi ng to poor b[...]

4 - 51 CHAS FRONT FORK EAS00646 FRONT FORK T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 16 Nm (1.6 m • kg, 11 ft • Ib) T R . . 18 Nm (1.8 m • kg, 13 ft • Ib) 5 2 2 1 4 3 9 7 10 8 6 (4) Order Job/Part Q ’ [...]

4 - 52 CHAS T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 16 Nm (1.6 m • kg, 11 ft • Ib) T R . . 18 Nm (1.8 m • kg, 13 ft • Ib) 5 2 2 1 4 3 9 7 10 8 6 (4) Order Job/Part Q ’ ty Remarks 6 Upper bracket pinc[...]

4 - 53 CHAS FRONT FORK EAS00648 T R . . 30 Nm (3.0 m • kg, 22 ft • Ib) New New New New New New LT LS T R . . 18 Nm (1.8 m • kg, 13 ft • Ib) 7 F G 0 E D 5 6 A B C 8 9 4 3 2 1 Order Job/Part Q ’ ty Remarks Disassembling the front fork legs Remove the parts in the order listed . NOTE: The following the procedure applies to both of the front [...]

4 - 54 CHAS T R . . 30 Nm (3.0 m • kg, 22 ft • Ib) New New New New New New LT LS T R . . 18 Nm (1.8 m • kg, 13 ft • Ib) 7 F G 0 E D 5 6 A B C 8 9 4 3 2 1 Order Job/Part Q ’ ty Remarks A Oil seal 1 Refer to “ ASSEMBLING THE FRONT FORK LEGS ” . B Washer 1 C Outer tube bushing 1 D Oil flow stopper 1 E Inner tube bushing 1 F Outer tube 1 [...]

4 - 55 CHAS FRONT FORK EAS00649 REMOVING THE FRONT FORK LEGS The following procedure ap plies to both of the front fork legs. 1. Stand the motorcycle on a le vel surf ace . W ARNING _ Securely support the mo torcycle so that there is no danger of it falling over. NOTE: _ Place the motorcycle on a suitable stand so that the front wheel is elevated. [...]

4 - 56 CHAS FRONT FORK 2. Drain: • fork oil NOTE: Stroke the outer tube several times while draining the fork oil. 3. Remov e: • dust seal 1 • oil seal clip 2 (with a flat-head screwdriver) CAUTION: _ Do not scratch the inner tube. 4. Remov e: • damper rod bolt 1 • copper washer NOTE: _ While holding the damper rod assembly with the dampe[...]

4 - 57 CHAS FRONT FORK • Avoid bottoming the inner tube into the outer tube during the above procedure, as the oil flow stopper will be damaged. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS00657 CHECKING THE FRONT FORK LEGS The following procedure ap plies to both of the fro[...]

4 - 58 CHAS FRONT FORK 3. Chec k: • damper rod 1 Damage/wear → Replace. Obstruction → Blow out all of the o il pas- sages with co mpressed air. • oil flow stopper 2 Damage → Replace. CAUTION: _ • The front fork leg has a built-in damper adjusting rod and a very sophis ticated internal construction, which are particu- larly sensitive to [...]

4 - 59 CHAS FRONT FORK 2. Lubricate: • inner tube ’ s outer surface Recommended lubricant Fork oil 10 W or equivalent 3. Tighten: • damper rod bolt 1 NOTE: _ While holding the damper rod with the damper rod holder 2 and T-handle 3 , tighten the damper rod bolt. T R . . Damper rod bolt 30 Nm (3.0 m · kg, 22 ft · lb) LOCTITE ® Damper rod hol[...]

4 - 60 CHAS FRONT FORK 5. Install: • oil seal 1 (with the fork seal driver weight 2 and fork seal driver attachment 3 ) CAUTION: _ Make sure the numbered side of the o il seal faces up. NOTE: _ • Before installing the oil seal, lubricate its lips with lithium-soap-based grease. • Lubricate the outer surface of the inner tube with fork oil. ?[...]

4 - 61 CHAS FRONT FORK 8. Fill: • front fork leg (with the specified amount of the recom- mended fork oil) 9. Measure: • front fork leg oil level a Out of specification → Correct. NOTE: _ • While filling the front fork leg, keep it upright . • After filling, slowly pump the front fork leg up and down to distribute the fork oil. Quantity ([...]

4 - 62 CHAS EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure ap plies to both of the front fork legs. 1. Install: • front fork leg Temporarily tighten the lower bracket pinch bolts. NOTE: _ To install the front fork leg, align the inner tube a with the lower edge b of the bevel on the upper bracket as shown. b a 2. Tighten: • low[...]

4 - 63 CHAS HANDLEBAR EAS00664 HANDLEBAR T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) LS LS 8 9 5 3 7 10 6 4 2 16 16 2 17 14 6 15 13 12 11 1 1 Order Job/Part Q ’ ty Remarks Removing the handlebar Remove the parts in the o[...]

4 - 64 CHAS T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) LS LS 8 9 5 3 7 10 6 4 2 16 16 2 17 14 6 15 13 12 11 1 1 Order Job/Part Q ’ ty Remarks 13 Clutch lever 1 Refer to “ INSTA LLING THE HANDLE- BAR ” . 14 Left hand[...]

4 - 65 CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a le vel surf ace . W ARNING _ Securely support the mo torcycle so that there is no danger of it falling over. 2. Remov e: • front brake light switch 1 • clutch switch NOTE: • Push the fastener to remove the front brake light switch from the brake master cylinder[...]

4 - 66 CHAS HANDLEBAR 2. Install: • handlebar 1 • upper handlebar holders 2 • handlebar protector (XT660X) • handlebar protector cover (XT660X) CAUTION: _ • First, tighten the bolts on the front side of the upper handlebar holder, the n the bolts on the rear side. • Turn the handlebar all the way to the left and right. If there is any c[...]

4 - 67 CHAS HANDLEBAR 4. Install: • left handlebar switch 1 NOTE: _ Align the projection a on the left handlebar switch with the hole b in the handlebar. a b 1 5. Install: • clutch lever • clutch lever holder 1 NOTE: _ Align the mating surfaces of the clut ch lever holder with the pu nch mark a on the ha ndle- bar. 1 a T R . . 7 Nm (0.7 m · [...]

4 - 68 CHAS HANDLEBAR 8. Install: • brake master cylinder • brake master cylinder holder Refer to “ FRONT AND REAR BRAKES ” . 9. Adjust: • clutch cable free pla y Refer to “ ADJUSTING THE CLUTCH CABLE FREE PLAY ” in chapter 3. 10.Adjust: • throttle cable free play Refer to “ ADJUSTING THE THROTTLE CABLE FREE PLAY ” in chapter 3.[...]

4 - 69 CHAS STEERING HEAD EAS00675 STEERING HEAD LOWER BRACKET T R . . 130 Nm (13.0 m • kg, 94 ft • lb) T R . . 1st 43 Nm (4.3 m • kg, 31 ft • lb) 2nd 7 Nm (0.7 m • kg, 5.1 ft • lb) T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 23 Nm (2.3 m • kg[...]

4 - 70 CHAS T R . . 130 Nm (13.0 m • kg, 94 ft • lb) T R . . 1st 43 Nm (4.3 m • kg, 31 ft • lb) 2nd 7 Nm (0.7 m • kg, 5.1 ft • lb) T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 32 Nm (3.2 m • kg, 23 ft [...]

4 - 71 CHAS STEERING HEAD EAS00679 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a le vel surf ace . W ARNING _ Securely support the mo torcycle so that there is no danger of it falling over. 2. Remov e: • upper ring nut 1 • rubber washer • lower ring nut 2 • lower bracket NOTE: _ Hold the lower ring nut with the steering nut wrench[...]

4 - 72 CHAS STEERING HEAD 3. Replace: • bearings • bearing races ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remov e the bear ing races f rom the steering head pipe with a long rod 1 and hammer . b . Remo v e the bearing race from the lo wer brac k et with a floor chisel 2[...]

4 - 73 CHAS STEERING HEAD 3. Install: • upper bracket • steering stem nut NOTE: _ Temporarily tighten the steering stem nut. 4. Install: • front fork legs Refer to “ INSTALLING THE FRONT FORK LEGS ” . NOTE: _ Temporarily tighten the lower bracket pinch bolts. 5. Tighten: • steering stem nut 6. Install: • lower handlebar holders • lo[...]

4 - 74 CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY LS LS LS LS LS LS LS T R . . 59 Nm (5.9 m • kg, 43 ft • Ib) T R . . 59 Nm (5.9 m • kg, 43 ft • Ib) T R . . 59 Nm (5.9 m • kg, 43 ft • Ib) T R . . 42 Nm (4.2 m • kg, 30 ft • Ib) 1 5 9 1 1 2 2 6 6 7 7 8 3 10 9 11 11 10 3 4 4 Order Job/Part Q ’ ty Remarks [...]

4 - 75 CHAS LS LS LS LS LS LS LS T R . . 59 Nm (5.9 m • kg, 43 ft • Ib) T R . . 59 Nm (5.9 m • kg, 43 ft • Ib) T R . . 59 Nm (5.9 m • kg, 43 ft • Ib) T R . . 42 Nm (4.2 m • kg, 30 ft • Ib) 1 5 9 1 1 2 2 6 6 7 7 8 3 10 9 11 11 10 3 4 4 Order Job/Part Q ’ ty Remarks 4 Self-locking nut/washer/nut 1/1/1 Refer to “ REMOVING THE REAR [...]

4 - 76 CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00686 HANDLING THE REAR SHOCK ABSORBER W ARNING _ This rear shock absorber con tains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following informa- tion. The manufacturer cannot be held responsible for property damage or per- sonal injury [...]

4 - 77 CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00690 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the motorcycle on a le vel surf ace . W ARNING _ Securely support the mo torcycle so that there is no danger of it falling over. NOTE: _ Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remov e: • connecting arm bolt[...]

4 - 78 CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Chec k: • rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly. • rear shock absorber Gas leaks/oil leaks → Replace the rear shock absorber assembly. • spring Damage/wear → Repla ce the rear sh ock absorber assembly.[...]

4 - 79 CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00697 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: • bearings • bolts 2. Install: • rear shock absorber assembly NOTE: _ When installing the rear sh ock absorber assembly, lift up the swingarm. 3. Tighten: • rear shock absorber assembly upper nut • rear shock absorber assembly lower[...]

4 - 80 CHAS SWINGARM AND DRIVE CHAIN EAS00700 SWINGARM AND DRIVE CHAIN 11 12 13 T R . . 120 Nm (12.0 m • kg, 85 ft • lb) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 92Nm (9.2 m • kg, 66 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 23 [...]

4 - 81 CHAS 11 12 13 T R . . 120 Nm (12.0 m • kg, 85 ft • lb) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 92Nm (9.2 m • kg, 66 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 59 Nm (5.9 m • kg[...]

4 - 82 CHAS SWINGARM AND DRIVE CHAIN EAS00703 REMOVING THE SWINGARM 1. Stand the motorcycle on a le vel surf ace . W ARNING _ Securely support the mo torcycle so that there is no danger of it falling over. NOTE: _ Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Measure: • swingarm side play • swingarm vertical mo[...]

4 - 83 CHAS SWINGARM AND DRIVE CHAIN REMOVING THE DRIVE SPROCKET NOTE: Loosen the drive spro cket nut before removing the rear wheel. 1. Remov e: • drive sprocket cover • chain guard 2. Straighten the loc k w asher tab a 3. Remov e: • drive sprocket nut 1 • lock washer 2 • drive sprocket 3 3 2 1 a EAS00704 REMOVING THE DRIVE CHAIN 1. Stan[...]

4 - 84 CHAS SWINGARM AND DRIVE CHAIN 2. Chec k: • pivot shaft Roll the pivot shaft on a flat surface. Bends → Replace. W ARNING _ Do not attempt to straighten a bent pivot shaft. 3. W ash: • pivot shaft • dust covers • spacer • bushing • bearings 4. Chec k: • dust covers • spacers • oil seals Damage/wear → Replace. • bearing[...]

4 - 85 CHAS SWINGARM AND DRIVE CHAIN 2. Chec k: • drive chain Stiffness → Clean and lubricate or replace. 3. Clean: • drive chain ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Wipe the driv e chain with a clean cloth. b . Put the drive chain in k erosene and remo v e any r[...]

4 - 86 CHAS SWINGARM AND DRIVE CHAIN 5. Lubricate: • drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 6. Chec k: • drive sprocket • rear wheel sprocket More than 1/4 tooth a wear → Replace the drive chain sprockets as a set. Bent teeth → Replace the dri ve chain sprockets as a set. b Correct 1 Dri[...]

4 - 87 CHAS SWINGARM AND DRIVE CHAIN 3. Install: • swingarm • pivot shaft • pivot shaft nut 4. Install: • connecting arm bolt • washer • connecting arm nut • rear wheel Refer to “ INSTALLING THE REAR WHEEL ” . 5. Install: • drive sprocket 1 • lock washer 2 • drive sprocket nut 3 NOTE: • Install the drive sprocket 1 and dri[...]

[...]

ENG 5[...]

ENG CHAPTER 5 ENGINE ENGINE REMOVAL .......................................... .............................................. 5-1 EXHAUST PIPES AND MUFFLERS ......................................................... 5-1 LEADS, CABLES, HOSES, AND IGNITION COIL .................................... 5-2 ENGINE ....................... ...................[...]

ENG CLUTCH ................................................. ..................................................... .. 5-40 CLUTCH COVER .................................................................................. .. 5-40 PULL LEVER SHAFT .............................................................................. 5-41 CLUTCH ...............[...]

ENG CRANKCASE .............................................................. .................................. 5-69 CRANKCASE BEARINGS ....................................................................... 5-71 SEPARATING THE CRANKCASE ................................... ....................... 5-72 CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE[...]

ENG[...]

5 - 1 ENG EAS00188 ENGINE ENGINE REMOVAL EXHAUST PIPES AND MUFFLERS LS LS LT LT New New New New New LT T R . . 27 Nm (2.7 m • kg, 19 ft • Ib) T R . . 27 Nm (2.7 m • kg, 19 ft • Ib) T R . . 20 Nm (2.0 m • kg, 14 ft • Ib) T R . . 20 Nm (2.0 m • kg, 14 ft • Ib) T R . . 20 Nm (2.0 m • kg, 14 ft • Ib) T R . . 27 Nm (2.7 m • kg, 19 [...]

5 - 2 ENG LEADS, CABLES, HOSES, AND IGNITION COIL T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 16 Nm (1.6 m • kg, 11 ft • Ib) LT LS LS New New ∗ 5 10 9 11 13 12 14 2 1 3 4 6 6 7 7 8 8 * Apply sealant Yamaha bond No. 1215 90890-85505 Order Job/Part Q ’ ty Remarks Removing the leads, cables, h[...]

5 - 3 ENG ENGINE REMOVAL T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 16 Nm (1.6 m • kg, 11 ft • Ib) LT LS LS New New ∗ 5 10 9 11 13 12 14 2 1 3 4 6 6 7 7 8 8 * Apply sealant Yamaha bond No. 1215 90890-85505 Order Job/Part Q ’ ty Remarks Starter motor Refer to “ STARTER MOTOR ” in chapte[...]

5 - 4 ENG T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 16 Nm (1.6 m • kg, 11 ft • Ib) LT LS LS New New ∗ 5 10 9 11 13 12 14 2 1 3 4 6 6 7 7 8 8 * Apply sealant Yamaha bond No. 1215 90890-85505 Order Job/Part Q ’ ty Remarks 3 Oil delivery hose 2 1 Disconnect. 4 Oil tank breather hose 1 Discon[...]

5 - 5 ENG ENGINE REMOVAL EAS00191 ENGINE T R . . 73 Nm (7.3 m • kg, 53 ft • lb) T R . . 73 Nm (7.3 m • kg, 53 ft • lb) T R . . 73 Nm (7.3 m • kg, 53 ft • lb) T R . . 55 Nm (5.5m • kg, 40 ft • Ib) 5 5 7 6 2 8 6 5 5 2 3 1 1 4 4 1 1 9 Order Job/Part Q ’ ty Remarks Removing the engine Remove the parts in the ord er listed. NOTE: _ Pla[...]

5 - 6 ENG ENGINE REMOVAL T R . . 73 Nm (7.3 m • kg, 53 ft • lb) T R . . 73 Nm (7.3 m • kg, 53 ft • lb) T R . . 73 Nm (7.3 m • kg, 53 ft • lb) T R . . 55 Nm (5.5m • kg, 40 ft • Ib) 5 5 7 6 2 8 6 5 5 2 3 1 1 4 4 1 1 9 Order Job/Part Q ’ ty Remarks 7 Engine upper bracket (right) 1 Refer to “ INSTALL- ING THE ENGINE ” . 8 Engine u[...]

5 - 7 ENG ENGINE REMOVAL EAS00192 INSTALLING THE ENGINE 1. Install: • engine front bracket 1 • engine front bracket bolt/nut 2 • engine front mounting bolt/nut 3 • engine rear mounting bolt/nut 4 • engine front bracket bolt/nut 5 • engine front mounting bolt/nut 6 • engine upper bracket (left) 7 • engine upper bracket (right) 8 • [...]

5 - 8 ENG CYLINDER HEAD EAS00221 CYLINDER HEAD T R . . 50 Nm (5.0 m • kg, 36 ft • Ib) T R . . 13 Nm (1.3 m • kg, 9.4 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 20 Nm (2.0 m • kg, 14 ft • Ib) T R . . 20 Nm (2.0 m • kg, 14 ft • Ib[...]

5 - 9 ENG T R . . 50 Nm (5.0 m • kg, 36 ft • Ib) T R . . 13 Nm (1.3 m • kg, 9.4 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 20 Nm (2.0 m • kg, 14 ft • Ib) T R . . 20 Nm (2.0 m • kg, 14 ft • Ib) T R . . 20 Nm (2.0 m • kg, 14 ft [...]

5 - 10 ENG CYLINDER HEAD EAS00225 REMOVING THE CYLINDER HEAD 1. Align: •“ I ” mark a on the A.C. magneto rotor (with the stationary pointer b on the A.C. magneto cover) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. T ur n the crankshaft countercloc kwise . b . When the pis[...]

5 - 11 ENG CYLINDER HEAD EAS00229 CHECKING THE CYLINDER HEAD 1. Eliminate: • combustion chamber carbo n deposits (with a rounded scraper) NOTE: _ Do not use a sharp instrument to avoid damag- ing or scratching: • spark plug bore threads • valve seats 2. Chec k: • cylinder head Damage/scratches → Replace. • cylinder head water jacket Min[...]

5 - 12 ENG CYLINDER HEAD EAS00212 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER 1. Chec k: • tappet covers 1 • camshaft sprocket c over 2 • O-rings 3 Damage/wear → Replace the defect ive part(s). 2 1 3 3 EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Chec k: • timing chain tensioner Cracks/damage → Replace. 2. Chec k: • one-[...]

5 - 13 ENG CYLINDER HEAD 2. Install: • cylinder head • washers • cylinder head bolts NOTE: • Lubricate the cylinder head bolt threads and muting surface with engine oil. • Install the washers with t heir blunt surface facing the bolt seat. 3. Tighten: • cylinder head bolts 1 = 135 mm (5.31 in) • cylinder head bolts 2 = 145 mm (5.71 in[...]

5 - 14 ENG CYLINDER HEAD c. Install the timing chain 1 onto the camshaft sproc k et 2 , then the camshaft sprock et onto the camshaft, and then finger tighten the camshaft sproc k et bolts . NOTE: To install the camshaft sprocket sprocket, install the projection 3 on the camshaft sprocket into the slot a in the decompression lever. d. Mak e sure th[...]

5 - 15 ENG CYLINDER HEAD d. Install the spring and timing chain tensioner cap bolt. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 6. T ur n: • crankshaft (several turns counterclockwise) 7. Chec k: •“ I ” mark a NOTE: Check that the “ I ” mark on th e A.C. magneto rotor[...]

5 - 16 ENG ROCKER ARMS AND CAMSHAFT E E E M LT T R . . 14 Nm (1.4 m • kg, 10 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 14 Nm (1.4 m • kg, 10 ft • Ib) 4 4 3 3 2 8 2 7 5 6 1 4 4 M M Order Job/Part Q ’ ty Remarks Removing the rocker arms and cam- shaft Remove the parts in the order listed . Cylinder head Refer to “ CYLIN[...]

5 - 17 ENG E E E M LT T R . . 14 Nm (1.4 m • kg, 10 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 14 Nm (1.4 m • kg, 10 ft • Ib) 4 4 3 3 2 8 2 7 5 6 1 4 4 M M Order Job/Part Q ’ ty Remarks 7 Decompressor lever pin 1 Refer to “ REMOVING THE ROCKER ARMS AND CA MSHAFT ” and “ INSTALLING THE CAMSHAFT AND ROCKER ARMS ” .[...]

5 - 18 ENG ROCKER ARMS AND CAMSHAFT EAS00202 REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Loosen: • locknuts • adjusting screws 2. Remov e: • camshaft retainer 1 1 3. Remov e: • intake rocker arm sha ft • exhaust rocker arm shaft • intake rocker arm • exhaust rocker arm NOTE: _ Remove the rocker arm shafts with the slide hammer bolt 1 and[...]

5 - 19 ENG 2. Measure: • camshaft lobe dimensions a and b Out of specification → Replace the cam- shaft. 3. Measure: • camshaft runout Out of specification → Replace. Camshaft lobe dimensions Intake a 43.488 ~ 43.588 mm (1.7121 ~ 1.7161 in) <Limit>: 43.388 mm (1.7062 in) b 36.959 ~ 37.059 mm (1.4551 ~ 1.4590 in) <Limit>: 36.840 [...]

5 - 20 ENG ROCKER ARMS AND CAMSHAFT EAS00206 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure ap plies to both of the rocker arms and rocker arm shafts. 1. Chec k: • rocker arm Damage/wear → Replace. 2. Chec k: • rocker arm shaft Blue discoloration/excessive wear/pit ting/ scratches → Replace or check the lubrica- tion[...]

5 - 21 ENG ROCKER ARMS AND CAMSHAFT 5. Calculate: • rocker-arm-to-rocker-arm-shaft clearance NOTE: _ Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter. Above 0.081 mm (0.0032 in) → Replace the defective part(s). Rocker-arm-to-rocker-arm-shaft clearance 0.009 ~ 0.037 mm (0.0004 ~ 0.0[...]

5 - 22 ENG 3. Install: • decompressor lever pin 1 • decompressor lever 2 NOTE: _ Install the decompressor lever pin 1 and decompressor lever 2 in the camshaft 3 as shown in the illustration. 1 3 2 4. Install: • camshaft 1 NOTE: Install the camshaft on the slot a facing up. 5. Lubricate: • rocker arm shafts 6. Install: • exhaust rocker arm[...]

5 - 23 ENG VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS New M M New New M M M 7 6 5 5 4 4 3 2 1 6 7 7 6 3 2 3 2 1 2 3 6 7 Order Job/Part Q ’ ty Remarks Removing the valves and valve springs Remove the parts in the order listed . Cylinder head Refer to “ CYLINDER HEAD ” . Rocker arms/rocker arm shafts/cam- shaft Refer to “ ROCK[...]

5 - 24 ENG VALVES AND VALVE SPRINGS EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: _ Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1. Chec k: • valve sealing Leakage at the valve seat → Che[...]

5 - 25 ENG VALVES AND VALVE SPRINGS 3. Remov e: • valve spring retainer 1 • valve spring 2 • valve stem seal 3 • valve spring seat 4 • valve 5 NOTE: _ Identify the position of each part ver y carefully so that it can be reinstalled in its original place. EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all [...]

5 - 26 ENG VALVES AND VALVE SPRINGS 2. Replace: • valve g uide NOTE: _ To ease valve guide removal and installation, and to maintain the correct fit, he at the cylinder head to 100 ° C (212 ° F) in an oven . ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remov e the valv e gu[...]

5 - 27 ENG VALVES AND VALVE SPRINGS 6. Measure: • valve stem runout Out of specification → Replace the valve. NOTE: _ • When installing a new valve, always replace the valve guid e. • If the valve is removed or replaced, always replace the valve stem seal. EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valve[...]

5 - 28 ENG VALVES AND VALVE SPRINGS 4. Lap: • valve face • valve seat NOTE: _ After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply a coarse lapping compou[...]

5 - 29 ENG VALVES AND VALVE SPRINGS EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: • valve spring free length a Out of specification → Re place the valve spring. Valve spring free length Intake 40.38 mm (1.59 in) <Limit>: 38.36 mm (1.51 in) Exhaust 40.38 mm (1.59 in) <Limit&[...]

5 - 30 ENG VALVES AND VALVE SPRINGS EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Debu rr : • valve stem end (with an oil stone) 2. Lubricate: • valve stem 1 • valve stem seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3. Install: • valve[...]

5 - 31 ENG VALVES AND VALVE SPRINGS 4. Install: • valve cotters NOTE: _ Install the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attach- ment 2 . 5. T o secure the v alv e cotter s onto the v alv e stem, lightly tap the v alv e tip with a soft-f ace hammer . CAUTION: _ Hitting th[...]

5 - 32 ENG CYLINDER AND PISTON EAS00251 CYLINDER AND PISTON UP 1 E E E New New New New New New New New LS E T R . . 1st 15 Nm (1.5 m • kg, 11 ft • lb) 2nd 50 Nm (5.0 m • kg, 36 ft • lb) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) 2 3 4 5 7 7 9 8 6 6 10 11 12 Order Job/Part Q ’ ty Remarks Removin[...]

5 - 33 ENG UP 1 E E E New New New New New New New New LS E T R . . 1st 15 Nm (1.5 m • kg, 11 ft • lb) 2nd 50 Nm (5.0 m • kg, 36 ft • lb) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) 2 3 4 5 7 7 9 8 6 6 10 11 12 Order Job/Part Q ’ ty Remarks 11 2nd ring 1 Refer to “ REMOVING THE CYLINDER AND PIS[...]

5 - 34 ENG CYLINDER AND PISTON EAS00253 REMOVING THE CYLINDER AND PISTON 1. Remov e: • piston pin clips 1 • piston pin 2 • piston 3 CAUTION: _ Do not use a hammer to drive the piston pin out. NOTE: _ • Before removing the piston pin clip, cover the crankcase opening with a clean rag to pre- vent the piston pin clip from falling into the cra[...]

5 - 35 ENG CYLINDER AND PISTON 2. Measure: • piston-to-cylinder clearance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Measure cylinder bore “ C ” with the cylinder bore gauge . NOTE: _ Measure cylinder bore “ C ” by taking side-to- side and front-to-back measurements[...]

5 - 36 ENG CYLINDER AND PISTON EAS00263 CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance Out of specifica tion → Replace the piston and piston rings as a set. NOTE: _ Before measuring the piston ring side clear- ance, eliminate any carbon deposits from the piston ring grooves and piston rings. 2. Install: • piston ring (into[...]

5 - 37 ENG CYLINDER AND PISTON EAS00265 CHECKING THE PISTON PIN 1. Chec k: • piston pin Blue discoloration/grooves → Replace the piston pin, and then check the lubrication system. 2. Measure: • piston pin outside diameter a Out of specifica tion → Replace the piston pin. Piston pin outside diameter 22.991 ~ 23.000 mm (0.9052 ~ 0.9055 in) &l[...]

5 - 38 ENG CYLINDER AND PISTON EAS00267 INSTALLING THE PISTON AND CYLINDER 1. Install: • top ring 1 • 2nd ring 2 • oil ring expander 3 • lower oil ring rail 4 • upper oil ring rail 5 NOTE: _ Be sure to install the piston rings so that the manufacturer ’ s marks or numbers face up. 2. Install: • piston 1 • piston pin 2 • piston pin[...]

5 - 39 ENG CYLINDER AND PISTON 5. Offset: • piston ring end gaps a Top ring b Upper oil ring rail c Oil ring expander d Lower oil ring rail e 2nd ring f 20 mm (0.79 in ) È Exhaust side e a ff d c b 120˚ 120˚ 120˚ È 6. Install: • cylinder 1 • timing chain guide (exhau st) NOTE: _ • While compressing the piston rings with one hand, insta[...]

5 - 40 ENG CLUTCH EAS00273 CLUTCH CLUTCH COVER T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) New 1 2 3 4 5 5 (7) Order Job/Part Q ’ ty Remarks Removing the clutch cover Remove the parts in the order listed. Engine oil Drain . Refer to “ CHANGING THE ENGINE OIL ” in chapter 3. 1 Clutch cable 1 2 Clutch[...]

5 - 41 ENG PULL LEVER SHAFT New New New E 2 3 4 5 7 8 8 6 3 1 E Order Job/Part Q ’ ty Remarks Removing the pull lever sh aft Remove the parts in the order listed. 1 Circlip 1 2 Circlip 1 3 Washer 2 4P u l l l e v e r 1 5 Pull lever spring 1 6 Pull lever shaft 1 7 Oil seal 1 8 Bearing 2 For installation, rever se the removal pro- cedure. CLUTCH[...]

5 - 42 ENG CLUTCH EAS00274 CLUTCH E E New E M E T R . . 90 Nm (9.0 m • kg, 65 ft • Ib) T R . . 9 Nm (0.9 m • kg, 6.5 ft • Ib) 1 2 3 4 6 4 7 4 4 6 5 5 5 5 5 5 8 9 10 11 12 13 14 (5) (5) E E Order Job/Part Q ’ ty Remarks Removing the clutch Remove t he parts in the order listed. 1 Clutch spring 5 Refer to “ INSTALLING THE CLUTCH ” . 2 P[...]

5 - 43 ENG E E New E M E T R . . 90 Nm (9.0 m • kg, 65 ft • Ib) T R . . 9 Nm (0.9 m • kg, 6.5 ft • Ib) 1 2 3 4 6 4 7 4 4 6 5 5 5 5 5 5 8 9 10 11 12 13 14 (5) (5) E E Order Job/Part Q ’ ty Remarks 10 Clutch boss nut 1 Refer to “ REMOVING THE CLUTCH ” and “ INSTALLING THE CLUTCH ” . 11 Lock washer 1 12 Clutch boss 1 13 Thrust washer[...]

5 - 44 ENG CLUTCH EAS00275 REMOVING THE CLUTCH 1. Remov e: • clutch cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosen ed, remove them. 1 2. Straighten the loc k w asher tab . 3. Loosen: • clutch boss nut 1 NOTE: _ While hol ding the cl utch boss 2 with the uni-[...]

5 - 45 ENG CLUTCH 2. Measure: • friction plate 1 thickness • friction plate 2 thickness • friction plate 3 thickness Out of specification → Replace the friction plates as a set. NOTE: _ Measure the friction plate a t four places. Friction plate 1 thickness 2.90 ~ 3.10 mm (0.114 ~ 0.122 in) <Limit>: 2.80 mm (0.110 in) Friction plate 2 [...]

5 - 46 ENG CLUTCH 2. Measure: • clutch spring free len gth a Out of specification → Replace the clutch springs as a set. Clutch spring free length 55.6 mm (2.19 in) <Limit>: 52.82 mm (2.08 in) EAS00284 CHECKING THE CLUTCH HOUSING 1. Chec k: • clutch housing dogs Damage/pitting/wear → Deburr the clutch housing dogs or replace the clutc[...]

5 - 47 ENG CLUTCH 2. Chec k: • pull rod bearing Damage/wear → Replace. EAS00292 CHECKING THE PRIMARY DRIVEN GEAR 1. Chec k: • primary driven gear Damage/wear → Replace the primary drive gear and clutch housing as a set. Excessive noise during operation → Replace the primar y drive gear and clutch housing as a set . EAS00299 INSTALLING THE[...]

5 - 48 ENG CLUTCH 4. Lubricate: • friction plates • clutch plates (with the recommended lubricant) 5. Install: • clutch damper spring seat 1 • clutch damper spring 2 • friction plate 3 3 • clutch plates 4 • friction plates 1 5 , 7 • friction plates 2 6 NOTE: _ • Install the clutch damper spring 2 with the “ OUTSIDE ” mark faci[...]

5 - 49 ENG CLUTCH NOTE: _ • To install the clut ch cover, position the pull rod so that the teeth face towards that rear of the motorcycle. • Tighten the clutch cover bo lts in stages and in a crisscross pattern. 8. Install: • pull lever spring 1 • pull lever 2 • washer • circlip NOTE: _ • Install the pull lever with the “ UP ” ma[...]

5 - 50 ENG OIL PUMP OIL PUMP New New New New New New LT LS LS New New New LS New New T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 4 Nm (0.4 m • kg, 2.9 ft • Ib) T R . . 18 Nm (1.8 m • kg, 13 ft • Ib) T R . . 20 Nm (2.0 m • kg, 14 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) 4 3 [...]

5 - 51 ENG New New New New New New LT LS LS New New New LS New New T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 4 Nm (0.4 m • kg, 2.9 ft • Ib) T R . . 18 Nm (1.8 m • kg, 13 ft • Ib) T R . . 20 Nm (2.0 m • kg, 14 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) 4 3 5 7 7 6 8 10 9 11 [...]

5 - 52 ENG OIL PUMP EAS00360 Order Job/Part Q ’ ty Remarks Disassembling the oil pump Remove the parts in the ord er listed. 1 Oil pump housing 1/oil seal 1/1 2 Oil pump outer rotor 1 1 3 Dowel pin 1 4 Oil pump inner rotor 1 1 5 Oil pump housing cover/oil seal 1/1 6 Dowel pin 2 7 Oil pump shaft 1 8 Dowel pin 1 9 Oil pump inner rotor 2 1 Refer to [...]

5 - 53 ENG OIL PUMP EAS00364 CHECKING THE OIL PUMP 1. Chec k: • oil pump driven gear 1 • oil pump housing 1 2 • oil pump housing cover 3 • oil pump housing 2 4 Cracks/damage/wear → Replace th e defec- tive part(s). 2. Measure: • inner-rotor-to-outer-rotor-tip clearance a • outer-rotor-to-oil-pump-housing clearance b • oil-pump-housi[...]

5 - 54 ENG OIL PUMP EAS00367 CHECKING THE OIL DELIVERY PIPES AND HOSES The following procedure applie s to all of the oil delivery pipes and hoses. 1. Chec k: • oil delivery pipe • oil delivery hose Damage → Replace. Obstruction → Wash and blow out with compressed air. EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: • oil pump inner rotor [...]

5 - 55 ENG EAS00376 INSTALLING THE OIL PUMP 1. Install: • oil pump gasket • oil pump • oil baffle plate 2 • oil pump driven gear 1 • oil pump driven gear circlip • oil baffle plate 1 CAUTION: _ After tightening the bolts, make sure the oil pump turns smoothly. NOTE: _ • Install the oil pump driven gear 1 in the direction shown. • In[...]

5 - 56 ENG BALANCER DRIVEN GEAR BALANCER DRIVEN GEAR T R . . 70 Nm (7.0 m • kg, 50 ft • Ib) T R . . 80 Nm (8.0 m • kg, 58 ft • lb) E New New M 10 9 8 7 6 5 4 2 12 11 3 1 M Order Job/Part Q ’ ty Remarks Removing the balancer driven gear Remove the parts in the ord er listed. Water pump assembly Refer to “ WATER PUMP ” in chapter 6. Clu[...]

5 - 57 ENG BALANCER DRIVEN GEAR T R . . 70 Nm (7.0 m • kg, 50 ft • Ib) T R . . 80 Nm (8.0 m • kg, 58 ft • lb) E New New M 10 9 8 7 6 5 4 2 12 11 3 1 M Order Job/Part Q ’ ty Remarks 6 Water pump drive gear 1 7 Primary drive gear 1 8 Balancer drive gear 1 Refer to “ INSTALLING THE BALANCER DRIVEN GEAR AND BALANCER DRIVE GEAR ” . 9 Strai[...]

5 - 58 ENG BALANCER DRIVEN GEAR REMOVING THE BALANCER DRIVEN GEAR AND BALANCER DRIVE GEAR 1. Straighten the loc k w asher tab . 2. Loosen: • balancer driven gear nut 1 • primary drive gear nut 2 NOTE: Place an aluminum plate a between the teeth of the balancer drive n gear 3 and balancer drive gear 4 . 3. Remov e: • balancer driven gear • w[...]

5 - 59 ENG BALANCER DRIVEN GEAR INSTALLING THE BALANCER DRIVEN GEAR AND BALANCER DRIVE GEAR 1. Install: • washer • balancer drive gear 1 • straight key 2 • balancer driven gear 3 • straight key • primary drive gear • water pump drive gear NOTE: • Align the punch mark a on the balancer drive gear wi th the punch m ark b on the bal- a[...]

5 - 60 ENG SHIFT SHAFT EAS00327 SHIFT SHAFT SHIFT SHAFT AND STOPPER LEVER New New LS E E E LT LT T R . . 22 Nm (2.2 m • kg, 16 ft • Ib) T R . . 16 Nm (1.6 m • kg, 11 ft • Ib) 6 12 8 7 13 11 10 13 5 9 14 5 4 3 2 1 14 Order Job/Part Q ’ ty Remarks Removing the shift shaft and stop- per lever Remove the parts in the order listed . Water pump[...]

5 - 61 ENG SHIFT SHAFT New New LS E E E LT LT T R . . 22 Nm (2.2 m • kg, 16 ft • Ib) T R . . 16 Nm (1.6 m • kg, 11 ft • Ib) 6 12 8 7 13 11 10 13 5 9 14 5 4 3 2 1 14 Order Job/Part Q ’ ty Remarks 9 Stopper lever spring 1 Refer to “ INSTALLING THE SHIFT SHAFT ” . 10 Circlip 1 11 Stopper lever 1 Refer to “ INSTALLING THE SHIFT SHAFT ?[...]

5 - 62 ENG SHIFT SHAFT EAS00329 CHECKING THE SHIFT SHAFT 1. Chec k: • shift shaft 1 • shift shaft pawl 2 Bends/damage/wear → Replace. • shift shaft spring 3 Damage/wear → Replace. 3 1 2 EAS00330 CHECKING THE STOPPER LEVER 1. Chec k: • stopper lever 1 Bends/damage → Replace. Roller turns roughly → Replace the stopper lever. • stopp[...]

5 - 63 ENG STARTER CLUTCH AND A.C. MAGNETO EAS00341 STARTER CLUTCH AND A.C. MAGNETO (3) (3) (6) T R . . 30 Nm (3.0 m • kg, 22 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 80 Nm (8.0 m • kg, 58 ft ?[...]

5 - 64 ENG STARTER CLUTCH AND A.C. MAGNETO (3) (3) (6) T R . . 30 Nm (3.0 m • kg, 22 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 80 Nm (8.0 m • kg, 58 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 f[...]

5 - 65 ENG STARTER CLUTCH AND A.C. MAGNETO EAS00346 REMOVING THE A.C. MAGNETO ROTOR 1. Remov e: • torque limiter cover CAUTION: Do not remove the bearing 1 . 1 2. Remov e: • A.C. magneto cover NOTE: _ Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosen ed, remove them. 3. Remo[...]

5 - 66 ENG STARTER CLUTCH AND A.C. MAGNETO CHECKING THE STATOR COIL AND CRANKSHAFT POSITION SENSOR 1. Chec k: • stator coil • crankshaft position sensor Damage → Replace the crankshaft position sensor/stator assembly. EAS00351 CHECKING THE STARTER CLUTCH 1. Chec k: • starter clutch rollers 1 Damage/wear → Replace. 1 2. Chec k: • starter[...]

5 - 67 ENG STARTER CLUTCH AND A.C. MAGNETO CHECKING THE TORQUE LIMITER 1. Chec k: • torque limiter Damage/wear → Replace. EAS00354 INSTALLING THE A.C. MAGNETO ROTOR 1. Install: • stator coil 1 • crankshaft position sensor NOTE: _ Align the projection a on the stator coil with the slot b in the A.C. magneto cover. 2. Apply: • Yamaha bond N[...]

5 - 68 ENG STARTER CLUTCH AND A.C. MAGNETO 5. Tighten: • A.C. magneto rotor nut 1 NOTE: _ • While holding th e A.C. magneto rotor 2 with the sheave holder 3 , tight en the A.C. mag- neto rotor nut. • Do not allow the sheave holder to touch the projection a on the A.C. magneto rotor. 6. Install: • gasket • A.C. magneto cover NOTE: Tighten [...]

5 - 69 ENG CRANKCASE CRANKCASE New T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 8 Nm (0.8 m • kg, 5.8 ft • Ib) T R . . 4 Nm (0.4 m • kg, 2.9 ft • Ib) New New New T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) LT LS New LS New LT LS LS 1 2 3 4 8 9 9 1[...]

5 - 70 ENG CRANKCASE New T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 8 Nm (0.8 m • kg, 5.8 ft • Ib) T R . . 4 Nm (0.4 m • kg, 2.9 ft • Ib) New New New T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) LT LS New LS New LT LS LS 1 2 3 4 8 9 9 10 6 7 5 5 [...]

5 - 71 ENG CRANKCASE CRANKCASE BEARINGS 2 2 2 T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) E E E LS ∗ 1 3 4 4 4 4 LT * Apply sealant Yamaha bond No . 1215 90890-85505 Order Job/Part Q ’ ty Remarks Removing the crankcase bearings Remo ve the parts in the order listed. Crankshaft/balancer Refer to “ CR[...]

5 - 72 ENG CRANKCASE SEPARATING THE CRANKCASE 1. Separate: • right crankca se 1 • left crankcase 2 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remov e the crankcase bolts. NOTE: _ • Loosen each bolt 1/ 4 of a turn at a time and after all the bolts are loosened, remove th[...]

5 - 73 ENG CRANKCASE 2. Chec k: • oil delivery pipe 3 Cracks/damage → Replace. • oil delivery pipe holes 1 Clogged → Blow out with compressed air. 1 EAS00207 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDES 1. Chec k: • timing chain Damage/stiffness → Replace the timing chain and camshaft sprocket as a set. 2. Chec k: • timing chain [...]

5 - 74 ENG CRANKCASE EAS00418 ASSEMBLING THE CRANKCASE 1. Lubricate: • bearings • oil seals 2. Install: • bearings • bearing retainer 1 (to the right crankcase) • bearing retainer bolt s NOTE: Install the bearing retainer with the “ OUT ” mark a facing up. 3. Thoroughly clean all the gask et mating sur- f aces and cran kcase mating su[...]

5 - 75 ENG CRANKCASE 6. Fit the right crankcase onto the left cr ank- case. T ap lightly on the case with a soft hammer . CAUTION: _ Before installing and torquing the crank- case bolts, be sure to che ck whether the transmission is functioning properly by manually rotating the sh ift drum in both directions. 7. Install: • lead holder 1 • crank[...]

5 - 76 ENG CRANKSHAFT EAS00381 CRANKSHAFT CRANKSHAFT AND BALANCER 1 2 Order Job/Part Q ’ ty Remarks Removing the crankshaft and bal- ancer Remove the parts in the order listed . Crankcase Separate. Refer to “ CRANKCASE ” . 1B a l a n c e r 1 2 Crankshaft 1 Refer to “ REMOVING THE CRANK- SHAFT ASSEMBLY ” and “ INSTALLING THE CRANKSHAFT ?[...]

5 - 77 ENG CRANKSHAFT EAS00388 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remov e: • crankshaft 1 NOTE: _ • Remove the crankshaft with the cra nkcase separating tool 2 . • Make sure the crankcase separating tool is centered over the crankshaft. Crankcase separating tool 90890-01135 1 2 EAS00394 CHECKING THE CRANKSHAFT 1. Measure: • big end side cl[...]

5 - 78 ENG CRANKSHAFT ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. The crankshaft 1 and the cr ankshaft pin 2 oil passages must be properly intercon- nected with a toler ance of less than 1 mm (0.04 in). ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ?[...]

5 - 79 ENG TRANSMISSION EAS00419 TRANSMISSION E E E E E E 1 2 3 4 5 6 7 Order Job/Part Q ’ ty Remarks Removing the transmission, shift drum, and shift forks Remove the parts in the order listed . Crankcase Separate. Refer to “ CRANKCASE ” . 1 Shift fork “ C ” 1 Refer to “ INSTALLING THE TRANSMIS- SION ” . 2 Shift fork “ R ” 1 3 Sh[...]

5 - 80 ENG TRANSMISSION MAIN AXLE M M M New New New M 1 2 3 4 5 6 7 7 8 8 9 0 A Order Job/Part Q ’ ty Remarks Disassembling the main axle Remove the parts in the order listed . 1 Circlip 1 2 2nd pinion gear 1 3 Toothed lock washer 1 4 Toothed washer retainer 1 5 5th pinion gear 1 6 Toothed spacer 1 7 Toothed washer 2 Refer to “ ASSEMBLING THE M[...]

5 - 81 ENG TRANSMISSION DRIVE AXLE M M M New New New New LS 1 5 5 2 6 6 3 4 7 8 9 0 A Order Job/Part Q ’ ty Remarks Disassembling the drive axle Remove the parts in the order listed. 1 Circlip 1 Refer to “ ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ” . 2 Washer 1 3 1st wheel gear 1 4 4th wheel gear 1 5 Circlip 2 6 Toothed washer 2 7 3rd wheel ge[...]

5 - 82 ENG TRANSMISSION EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Chec k: • shift fork cam follower 1 • shift fork pawl 2 Bends/damage/scoring/wear → Replace the shift fork. 2. Chec k: • shift fork movement Rough movement → Replace the shift forks. EAS00422 CHECKING THE SHIFT DRUM ASSE[...]

5 - 83 ENG TRANSMISSION 2. Measure: • drive axle runout (with a centering device and dial g auge 1 ) Out of specification → Replace the drive axle. Drive axle runout limit 0.08 mm (0.0031 in) 3. Chec k: • transmission gears Blue discoloration/pitting/wear → Replace the defective gear(s). • transmission gear dogs Cracks/damage/rounded edge[...]

5 - 84 ENG TRANSMISSION INSTALLING THE TRANSMISSION 1. Install: • shift fork “ L ” 1 (to drive axle) • shift fork “ C ” 2 (to main axle) • shift fork “ R ” 3 (to drive axle) • shift drum 4 • transmission assembly NOTE: _ • The embossed marks on the shift forks should face towards the right side of the engine and be in the fo[...]

COOL 6[...]

COOL CHAPTER 6 COOLING SYSTEM RADIATOR ............................................. ........................................... .............. 6-1 CHECKING THE RADIATOR ................................ .................................... 6-3 INSTALLING THE RADIATOR .............................. .................................... 6-4 THERMOSTAT[...]

COOL[...]

6 - 1 COOL EAS00454 COOLING SYSTEM RADIATOR 6 T R . . 5 Nm (0.5 m • kg, 3.6 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) New New New New 1 2 3 3 5 12 9 8 10 11 7 4 Order Job/Part Q ’ ty Remarks Removing the radiator Remove the parts in the ord er listed. Seat/side panels (left and right) Refer to “ COWLING AND COVER ” in chapter 3.[...]

6 - 2 COOL RADIATOR 6 T R . . 5 Nm (0.5 m • kg, 3.6 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) New New New New 1 2 3 3 5 12 9 8 10 11 7 4 Order Job/Part Q ’ ty Remarks 7 Radiator outlet hose 1 Refer to “ INSTALLING THE RADIA- TOR ” . 8 Radiator inlet hose 1 9 Radiator fan motor coupler 1 Disconnect. 10 Radiator guard 1 11 Radiato[...]

6 - 3 COOL RADIATOR EAS00455 CHECKING THE RADIATOR 1. Chec k: • radiator fins Obstruction → Clea n. Apply compressed air to the rear of the radi- ator. Damage → Repair or repla ce. NOTE: _ Straighten any flattened fins with a thin, flat- head screwdriver. 2. Chec k: • radiator hoses Cracks/damage → Replace. 3. Measure: • radiator cap op[...]

6 - 4 COOL RADIATOR EAS00456 INSTALLING THE RADIATOR 1. Install: • radiator inlet hose 1 • radiator outlet hose 2 • hose clamps 3 NOTE: _ Install the radiator inlet hose and radiator out- let hose so that each hose contacts the respective projection a . 2. Fill: • cooling syste m (with the specified amount of the recom- mended coolant) Refe[...]

6 - 5 COOL THERMOSTAT EAS00460 THERMOSTAT LS T R . . 18 Nm (1.8 m • kg, 13 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) New New 6 5 4 2 8 7 1 3 New Order Job/Part Q ’ ty Remarks Removing the thermostat Remove the parts in the order listed. Coolant Drain. Refer to “ CHANGING THE COOLANT ” in chapter 3. 1 Coolant temperature sensor [...]

6 - 6 COOL THERMOSTAT EAS00462 CHECKING THE THERMOSTAT 1. Chec k: • thermostat 1 Does not open at 71 ~ 85 ° C (159.8 ~ 185 ° F) → Replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Suspend the thermostat in a container filled with wa ter . b . Slowly heat the w ater . [...]

6 - 7 COOL THERMOSTAT 2. Install: • radiator inlet hose 1 • hose clamp 2 NOTE: Install the radiator inlet hose 1 so that it con- tacts the projection on the thermostat cover a . 3. Install: • copper washer • coolant temperature sensor CAUTION: _ Use extreme care when handling the cool- ant temperature sensor. Replace the sen- sor if it is d[...]

6 - 8 COOL WATER PUMP EAS00468 WATER PUMP New New LS New New New LS New T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) 2 5 2 1 4 3 6 8 7 (3) 1 Order Job/Part Q ’ ty Remarks Removing the water pump Remove the parts in the order listed. NOTE: It is not necessary to[...]

6 - 9 COOL New New LS New New New LS New T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) 2 5 2 1 4 3 6 8 7 (3) 1 Order Job/Part Q ’ ty Remarks 5 Water pump assembly 1 Refer to “ INSTALLING THE WATER PUMP ” . 6 Water pump outlet pipe 1 7 O-ring 1 8 Water pump o[...]

6 - 10 COOL WATER PUMP New New New New LS E LS 5 7 2 1 0 9 6 8 4 3 Order Job/Part Q ’ ty Remarks Disassembling the water pump Remove the parts in the order listed. 1 Circlip 1 Refer to “ ASSEMBLING THE WATER PUMP ” . 2 Impeller shaft gear 1 3 Pin 1 4 Washer 1 5 Impeller shaft assembly 1 Refer to “ DISASSEMBLIN G THE WATER PUMP ” and “ A[...]

6 - 11 COOL WATER PUMP EAS00470 DISASSEMBLING THE WATER PUMP 1. Remov e: • water pump seal 1 NOTE: _ Tap out the water pump seal from water pump housing in the direction of the arrow shown. 2 Water pump housing 2. Remov e: • bearing 1 • oil seal 2 NOTE: _ Tap out the bearing and oil seal from water pump housing in the directio n of the arrow [...]

6 - 12 COOL WATER PUMP 5. Chec k: • water pump outlet pipe • radiator outlet hose • water jacket inlet housing Cracks/damage/wear → Replace. EAS00475 ASSEMBLING THE WATER PUMP 1. Install: • oil seal 1 (into the water pump housing 2 ) • bearing 3 NOTE: _ • Before installing the oil seal, apply tap water or coolant onto its outer surfac[...]

6 - 13 COOL WATER PUMP 3. Install: • rubber damper 1 • rubber damper holder 2 NOTE: _ Before installing the rubber damper, apply tap water or coolant onto its outer surface. New New 4. Measure: • impeller shaft tilt Out of specification → Repeat steps (3) and (4). CAUTION: _ Make sure the rubber damper and rubber damper holder are flush wit[...]

6 - 14 COOL WATER PUMP EAS00478 INSTALLING THE WATER PUMP 1. Install: • water pump outlet hose 1 • O-rings • water pump outlet pipe (to the water pump assembly) • hose clamps 2 W ARNING _ Always use new O-rings. NOTE: _ • Install the water pump outlet hose so that it contacts the projection a on the water jacket joint. • Before installi[...]

FI 7[...]

FI CHAPTER 7 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM ............................................................................ 7-1 WIRING DIAGRAM .......................................................... ......................... 7-2 ECU SELF-DIAGNOSTIC FUNCTION ........................................ .............. 7-3 ALTERNATE OPERATION[...]

FI[...]

7 - 1 FI EAS00894 FUEL INJECTION SYSTEM EAS00895 FUEL INJECTION SYSTEM 1 Air cut-off valv e 2 Air induction system solenoid 3 Engine trouble warning light 4 Fuel tank 5 Fuel pump (inclu de fuel pres- sure reg ulator) 6 Fuel hose 7 Fuel injector 8 Throttle position sensor 9 Intake air temper ature sensor 0 Air filter case A Fuel injection system rel[...]

7 - 2 FI FUEL INJECTION SYSTEM EAS00898 WIRING DIAGRAM ON OFF P - - - - (BLACK) (BLACK) (DARK BLUE) (GRAY) - R / W RR L / W B B SUB-WIRE HARNESS MAIN HARNESS A G Ch Lg YB Dg Y B L / R Ch G L / R G B Y Y Br B L / R B B ( BLUE ) ( DARK GREEN ) ( BLUE ) B L / G B B B / Y L / Y B B L / R B ( BLACK ) ( BLACK ) Y Br B B B Y L / R Y BL R / BL / BR / L Br [...]

7 - 3 FI FUEL INJECTION SYSTEM EAS00899 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function to ensure the normal operation of the fuel injec- tion system. If a malfunction is detected in the fuel injection system, the self-diagnostic function immediately operates the engine with alterna te operating instructions and the[...]

7 - 4 FI FUEL INJECTION SYSTEM EAS00901 Checking for a defective engine trouble warning lig ht bulb The engine trouble warning light comes on for 1.4 seconds after the main switch is turne d to “ ON ” or when the start switch is pushed. If the warning light does not come on under these conditions, the warning light bulb may be defective. EAS009[...]

7 - 5 FI FUEL INJECTION SYSTEM Communication error with the meter 30 Lean angle cut-off switch (latch up detected) The motorcycle has over- turned. — No No 33 Faulty ignition Open circuit is detected in the primary lead of the ignition coil. — No No 41 Lean angle cut-off switch (open or short circuit) Open or short circuit is detected. — No N[...]

7 - 6 FI FUEL INJECTION SYSTEM EAS00904 TROUBLESHOOTING CHART Engine operation is not normal or the engine trouble warning light is on. The engine trouble warning light may not come on even if the engine op eration is not normal. The engine trouble warn ing light comes on. Check the fault code numbe r displayed on the mete r. Identify the system wi[...]

7 - 7 FI FUEL INJECTION SYSTEM EAS00905 DIAGNOSTIC MODE Setting the diagnostic mode 1. Set the main s witch to “ OFF ” and set the engine stop s witch to “” . 2. Disconnect the wire har ness coupler from the fuel pump . 3. Simultaneously press and hold the “ SELECT ” and “ RESET ” b uttons, tur n the main s witch to “ ON ” , and[...]

7 - 8 FI 8. V erify the operation of the sen sor or actua- tor . • Sensor operation The data representing the operating condi- tions of the sensor appears on the odome- ter/fuel reserve tripmeter/tripmeter 2 LCD. • Actuator operation Set the engine stop switch to “” to oper- ate the actuator. NOTE: _ If the engine stop switch is set to “?[...]

7 - 9 FI FUEL INJECTION SYSTEM EAS00906 Diagnostic monitoring code table Fault code No. Symptom Probable cause of malfunction Diagnostic code 12 No normal signals are received from the crankshaft position sensor. • Open or short circuit in wire harness • Defective crankshaft position sensor • Disconnected crankshaft position sensor coupler ?[...]

7 - 10 FI FUEL INJECTION SYSTEM EAS00907 Diagnostic mode table Switch the meter display from the regular mode to the diag nostic mode. To switch the display, refer to “ DIAGNOSTIC MODE ” . NOTE: _ • Check the intake air temperature and coolant temperature as close as possible to the in take air temperature sensor and the coolant temperat ure [...]

7 - 11 FI FUEL INJECTION SYSTEM 08 Lean angle cut-off switch Displays the lean angle cut-off switch values. Upright: 0.4 ~ 1.4 V Overturned: 3.7 ~ 4.4 V 09 Fuel system voltage (bat- tery voltage) Displays the fuel system voltage (battery voltage). Set the engine stop switch to “” . Approximately 12.0 V 20 Sidestand switch Displays that the swit[...]

7 - 12 FI FUEL INJECTION SYSTEM EAS00908 TROUBLESHOOTING DETAILS This section describes the countermeasu res per fault code number displayed on the meter. Check and service the items or compone nts that are the probable cause o f the malfunction following the order in the “ TROU BLESHOOTING CHART ” . After the checking and servicing the malfunc[...]

7 - 13 FI FUEL INJECTION SYSTEM Fault code No . 13 Symptom Op en or short circuit is detected from the intake air pressure sensor. Used diagnostic code No. 03 (intake air pressure se nsor) Order Item/components Check or maintenan ce job Restore method 1 Coupler connections Intake air pressure sensor coupler ECU coupler Sub-wire harness coup ler Che[...]

7 - 14 FI FUEL INJECTION SYSTEM Fault code No . 14 Symptom Inta ke air pressure sensor hose is disconnected or clogged. Used diagnostic code No. 03 (intake air pressure se nsor) Order Item/components Check or maintenan ce job Restore method 1 Disconnected, clogged, kinke d, or pinched intake air pressure sensor hose Repair or replace the hose. Rein[...]

7 - 15 FI FUEL INJECTION SYSTEM Fault code No . 16 Symptom Th e throttle position sensor is detected stuck. Used diagnostic code No. 01 (throttle position sensor) Order Item/components Check or maintenan ce job Restore method 1 Defective throttle position sensor Replace the sens or if it is defective. Refer to “ THROTTLE BODY ASSEMBLY ” . Reins[...]

7 - 16 FI FUEL INJECTION SYSTEM Fault code No . 22 Symptom Op en or short circuit is detected from the intake air temp erature sensor. Used diagnostic code No. 05 (intake air temperature sensor) Order Item/components Check or maintenan ce job Restore method 1 Intake air temperature sensor installation Check the sensor looseness or pinching. Reinsta[...]

7 - 17 FI FUEL INJECTION SYSTEM Fault code No . 30 Symptom The motorcycle has overturned. Used diagnostic code No. 08 (lean angle cut-o ff switch) Order Item/components Check or maintenan ce job Restore method 1 The motorcycle has overturned. Raise the motorcycle upright. Reinstated by set- ting the main switch to “ ON ” (the engine cannot be s[...]

7 - 18 FI FUEL INJECTION SYSTEM Fault code No . 42 Symptom A. No normal signals are received from the speed sensor. B. Open or short circuit is detected in the neutral switch. Used diagnostic code No. 07 (speed sensor) → A1 ~ A4 / No. 21 (neutral switch) → B1 ~ B4 Order Item/components Check or maintenan ce job Restore method A-1 Coupler connec[...]

7 - 19 FI FUEL INJECTION SYSTEM B-1 Coupler connections Neutral switch connector Wiring harness ECU coupler Check the couplers for any pins that may have pulled out. Check that the couplers are securely locked. If necessary, repair the coupler or securely con- nect it. Reinstated by starting the engine, and input- ting the vehicle speed signals by [...]

7 - 20 FI FUEL INJECTION SYSTEM Fault code No . 43 Symptom Th e ECU is unabl e to monitor the battery voltage. Used diagnostic code No. 09, 50 (fuel system voltage) Order Item/components Check or maintenan ce job Restore method 1 Coupler connections Fuel injection system relay cou- pler Wiring harness ECU coupler Check the couplers for any pins tha[...]

7 - 21 FI FUEL INJECTION SYSTEM Fault code No . 44 Symptom Error i s detected while reading or writing on EEPROM (CO adjustment value). Used diagnostic code No. 60 (EEPROM improper cylinder indication) Order Item/components Check or maintenan ce job Restore method 1 Malfunction in ECU Execute the diagnosti c mode. (Code No. 60) • Check the faulty[...]

7 - 22 FI FUEL INJECTION SYSTEM Fault code No . Er-1 Symptom No signals are received from the ECU. Used diagnostic code No. – – Order Item/components Check or maintenan ce job Restore method 1 Coupler connections ECU coupler Meter couplers Check the couplers for any pins that may have pulled out. Check that the couplers are securely locked. If [...]

7 - 23 FI THROTTLE BODY ASSEMBLY EAS00909 THROTTLE BODY ASSEMBLY 8 8 11 10 10 4 T R . . 6 Nm (0.6 m • kg, 4.3 ft • Ib) 3 1 2 6 5 7 9 Order Job/Part Q ’ ty Remarks Removing the throttle body assem- bly Remove the parts in the order listed . Seat Refer to “ COWLING AND COVER ” in chapter 3. Fuel tank Refer to “ FUEL TANK ” in chapter 3.[...]

7 - 24 FI 8 8 11 10 10 4 T R . . 6 Nm (0.6 m • kg, 4.3 ft • Ib) 3 1 2 6 5 7 9 Order Job/Part Q ’ ty Remarks 5 Fast idle plunger outlet hose 1 Disconnect. 6 Fast idle plunger inlet hose 1 7 Pilot air hose 1 8 Throttle body joint clamp screw 2 Loosen. 9 Throttle body assembly 1 Refer to “ INSTALLING THE THROT- TLE BODY ASSEMBLY ” . 10 Throt[...]

7 - 25 FI THROTTLE BODY ASSEMBLY 1 4 3 2 New New Order Job/Part Q ’ ty Remarks Disassembling the throttle body assembly Remove the parts in the order listed . 1 Throttle position sensor 1 2 Fuel injection pipe 1 3 Fuel injector 1 4 Throttle body 1 CAUTION: Do not disassemble the throttle body. For assembly, reverse the disassembly procedure.[...]

7 - 26 FI THROTTLE BODY ASSEMBLY EAS00912 CHECKING THE FUEL INJECTOR 1. Chec k: • fuel injector Damage → Replace. 2. Chec k: • fuel injector resista nce ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the injection wire har ness cou- pler from the fuel injector . [...]

7 - 27 FI THROTTLE BODY ASSEMBLY INSTALLING THE THROTTLE BODY ASSEMBLY 1. Install: • throttle body joint cla mps NOTE: Align the projection a on the throttle body joint with the slot b in the throttle body joint clamp. b a b a 2. Install: • throttle body joint NOTE: Align the projection a on the cylinder head with the slot b in the throttle bod[...]

7 - 28 FI EAS00819 CHECKING THE FUEL PUMP W ARNING _ Gasoline is extremely flammable a nd under certain circumstances there can b e a dan- ger of an explosion or fire. Be extremely careful and note the followin g points: • Stop the engine before refueling. • Do not smoke, and keep away from open flames, sparks, or any other source of fire. • [...]

7 - 29 FI 2. Chec k: • fuel pressure ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remov e the fuel tank. Refer to “ FUEL TANK ” in chapter 3. b . Connect the pressure gauge 1 to the adapter 2 . c. Connect the fuel pressure adapter to the fuel pump and fuel hose 3 . d. Con[...]

7 - 30 FI 1. Chec k: • throttle position sensor (removed from the throttle body) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the throttle position sensor cou- pler from the throttle position sensor . b . Remov e the t hrottle position sensor from the throttle body[...]

7 - 31 FI ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ Throttle position sens or resis- tance 0 ~ 5 ± 1.0 k Ω at 20 ° C (68 ° F) (yellow — black/blue) 2. Adjust: • throttle position sensor angle ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼?[...]

7 - 32 FI AIR INDUCTION SYSTEM EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned exhaust gases by injecting fresh air (second- ary air) into the exhaust port, reducin g the emission of hydrocarbons. When there is negative pressure a t the exhaust port, the reed valve opens, allowing secondary air to flow into the e[...]

7 - 33 FI AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Air filter case 2 Reed valve 3 Air cut-off valv e 4 Exhaust port 1 2 4 3 4[...]

7 - 34 FI AIR INDUCTION SYSTEM AIR CUT-OFF VALVE ASSEMBLY 1 4 3 2 Order Job/Part Q ’ ty Remarks Removing the air cut-off val ve assembly Remove the parts in the order listed . Right side panel Refer to “ COWLING AND COVER ” in chapter 3. Fuel tank right side cover Refer to “ FUEL TANK ” in chapter 3. 1 Air induction system solenoid couple[...]

7 - 35 FI AIR INDUCTION SYSTEM 1 2 3 LT LT Order Job/Part Q ’ ty Remarks Disassembling the air cut-off valve assembly Remove the parts in the order listed . 1 Air cut-off valve cover 1 2 Reed valve assembly 1 3 Air cut-off valve 1 For assembly, reverse the disassembly procedure.[...]

7 - 36 FI AIR INDUCTION SYSTEM EAS00918 CHECKING THE AIR INDUCTION SYSTEM 1. Chec k: • hoses Loose connections → Connect prope rly. Cracks/damage → Replace. • pipe Cracks/damage → Replace. Refer to “ CYLINDER HEAD ” in chapter 5. 2. Chec k: • reed valve • reed valve stopper • reed valve seat Cracks/damage → Replace the reed va[...]

ELEC 8 –+[...]

– + ELEC CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ............................................... ......................... 8-1 CHECKING SWITCH CONTINUITY ....................................... ......................... 8-3 CHECKING THE SWITCHES ...................................... .................................... 8-5 CHECKING THE[...]

– + ELEC IMMOBILIZER SYSTEM ......................................................... ....................... 8-52 CIRCUIT DIAGRAM .................................................................... ............ 8-52 GENERAL INFORMATION ..................................................................... 8-53 KEY CODE REGISTRATION .............[...]

8 - 1 – + ELEC EAS00729 ELECTRICAL SYSTEM ELECTRICAL COM PONENTS 1 Spark plug 2 Spark plug cap 3 Ignition coil 4 Intake air pressure sensor 5 Front brake light switch 6 Right handlebar switch 7 Immobilizer unit 8 Main switch 9 Fuel pump 0 Clutch switch A Left handlebar switch B Throttle position sensor C Coolant tem perature sensor D Fuel injecto[...]

8 - 2 – + ELEC ELECTRICAL COMPONENTS L Fuse box 2 M Starter relay N Main fuse O Rectifier/regulator P ECU Q Intake air temper ature sensor R Sidestand switch S Neutral switch T Crankshaft po sition sensor U Stator coil V Rear brake lig ht switch W Speed sensor X Starter moto r Y Radiator fan mo tor Z Horn [ Air induction system solenoid 8 7 3 2 1[...]

8 - 3 – + ELEC CHECKING SWITCH CONTINUITY EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch. CAUTION: _ Never insert the tester probes into the cou- pler terminal slots 1 . Always insert the prob[...]

8 - 4 – + ELEC CHECKING SWITCH CONTINUITY[...]

8 - 5 – + ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for dama ge or wear, proper connections, and also for continuity between the ter- minals. Refer to “ CHECKING SWITCH CONTINUITY ” . Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading → Replace the swi[...]

8 - 6 – + ELEC CHECKING THE SWITCHES 1 Main switch 2 Horn switch 3 Pass switch 4 Dimmer switch 5 Turn signal switch 6 Hazard switch 7 Clutch switch 8 Engine stop switch 9 Start switch 0 Front brake light switch A Sidestand switch B Neutral switch C Rear brake lig ht switch D Fuses[...]

8 - 7 – + ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socke t for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both. Improperly connected → Properly connect. No continuity → Repa[...]

8 - 8 – + ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remov e: • bulb W ARNING _ Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: _ • Be sure to hold the socket firml[...]

8 - 9 – + ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Chec k: • bulb socket (for continuity) (with the pocket tester) No continuity → Replace. NOTE: _ Check each bulb socket for continuity in the same manner as described in the bulb section;[...]

8 - 10 – + ELEC b . Connect two jumper lead s 1 from the bat- ter y ter minals to the respectiv e coupler ter- minal as shown. Immobilizer system indicator LED Connect the pocket tester (k Ω × 1 ) t o t h e meter coupler. Turn signal indicator light (left) Positive ba ttery ter- minal → chocolate Negative ba ttery ter- minal → black/whit e[...]

8 - 11 – + ELEC W ARNING _ • A wire that is used as a jumper lead must have at least the same capacity of the bat- tery lead, otherwise the jum per lead may burn. • This check is likely to produce sparks, therefore, make sure no flammable gas or fluid is in the vicinity. CAUTION: Do not connect the jumper lead (battery voltage) to the termina[...]

8 - 12 – + ELEC IGNITION SYSTEM EAS00734 IGNITION SYSTEM CIRCUIT DIAGRAM ON OFF P - - - - (BLACK) (BLACK) (DARK BLUE) (GRAY) - R / W RR L / W B B SUB-WIRE HARNESS MAIN HARNESS A G Ch Lg YB Dg Y B L / R Ch G L / R G B Y Y Br B L / R B B ( BLUE ) ( DARK GREEN ) ( BLUE ) B L / G B B B / Y L / Y B B L / R B ( BLACK ) ( BLACK ) Y Br B B B Y L / R Y BL[...]

8 - 13 – + ELEC IGNITION SYSTEM EAS00736 TROUBLESHOOTING Check: 1. main and ignition fuses 2. batter y 3. spark plug 4. ignition spark gap 5. spark plug cap resistance 6. ignition coil resistance 7. crankshaft position sen sor resistance 8. main s witch 9. engine stop s wit ch 10.lean angle cut-off s witch 11.wiring connections (of the entire ign[...]

8 - 14 – + ELEC IGNITION SYSTEM EAS00742 YES NO EAS00744 YES NO 4. Ignition spar k gap • Disconnect the spark plug cap 1 from the spark plug. • Connect the ignition checker 2 as shown. • Set the main switch to “ ON ” . • Measure the ignition spark gap a . • Crank the engine by pushing the start switch and gradually increase th e spa[...]

8 - 15 – + ELEC IGNITION SYSTEM EAS00746 YES NO EAS00748 YES NO EAS00749 YES NO 6. Ignition c oil resistance • Disconnect the ignition coil connectors from the ignition coil terminals. • Connect the pocket tester ( Ω × 1) to the ignition coil as shown. Positive tester probe → red/black Negative tester probe → orange • Measure the pri[...]

8 - 16 – + ELEC IGNITION SYSTEM EAS00750 YES NO YES NO EAS00754 YES NO 9. Engine stop s witch • Check the engine stop swit ch for continu- ity. Refer to “ CHECKING THE SWITCHES ” . • Is the engine stop switch OK? Replace the right handlebar switch. 10.Lean angle cut-off s witch • Connect the pocket tester (DC 20 V) to the lean angle cut[...]

8 - 17 – + ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM ON OFF P - - - - - R / W RR L / W B B SUB-WIRE HARNESS MAIN HARNESS A G Ch Lg YB Dg Y B L / R Ch G L / R ( BLUE ) ( DARK GREEN ) ( BLUE ) B L / G B B B / Y L / Y B B ( BLACK ) ( BLACK ) Y Br B B R / BL / BR / L Br L / W L / WL / RR / WL / GL / YS b B / YL g[...]

8 - 18 – + ELEC ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “” and the main switch is set to “ ON ” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: • The transmission is in neutral (the neutral switch is[...]

8 - 19 – + ELEC ELECTRIC STARTING SYSTEM EAS00757 TROUBLESHOOTING Check: 1. main and ignition fuses 2. batter y 3. star te r motor 4. rela y unit (star ting circuit cut-off relay) 5. rela y unit (diode) 6. star ter rela y 7. main s witch 8. engine stop s wit ch 9. neutral s witch 10.sidestand s witch 11.clutc h s witch 12.star t s witch 13.wiring[...]

8 - 20 – + ELEC ELECTRIC STARTING SYSTEM EAS00759 YES NO EAS00760 YES NO 4. Rela y unit (star ting circuit cut-off rela y) • Disconnect the relay unit from the wire harness. • Connect the pocket tester ( Ω × 1) and bat- tery (12 V) to the relay unit terminals as shown. Positive battery terminal → red/bla ck 1 Negative battery terminal ?[...]

8 - 21 – + ELEC ELECTRIC STARTING SYSTEM EAS00761 YES NO EAS00749 YES NO EAS00750 YES NO EAS00751 YES NO EAS00752 YES NO EAS00763 YES NO 6. Star ter rela y • Disconnect the starter relay coupler from the coupler. • Connect the pocket tester ( Ω × 1) and bat- tery (12 V) to the starter relay coupler as shown. Positive battery terminal → r[...]

8 - 22 – + ELEC ELECTRIC STARTING SYSTEM EAS00764 YES NO EAS00766 YES NO 12.Star t s witch • Check the start switch for continuity. Refer to “ CHECKING THE SWITCHES ” . • Is the start switch OK? Replace the right handlebar switch. 13. Wiring • Check the entire starting system ’ s wiring. Refer to “ CIRCUIT DIAGRAM ” . • Is the s[...]

8 - 23 – + ELEC STARTER MOTOR EAS00767 STARTER MOTOR T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 5 Nm (0.5 m • kg, 3.6 ft • Ib) 4 6 7 1 2 5 3 Order Job/Part Q ’ ty Remarks Removing the starter motor Remove the parts in the order listed. 1 Crankcase-to-crankcase-breather- chamber hose 1 Disconnect. 2 Air-filter-to-crankcase-breather-[...]

8 - 24 – + ELEC Order Job/Part Q ’ ty Remarks Disassembling the starter motor Remove the parts in the order listed . 1 Circlip 1 2 Starter motor gear 1 3 O-ring 1 4 Front bracket 1 5 Shims 6 Lock washer 1 7 Rear bracket 1 8 Shims 9 Brush holder assembly 1 0 Brush 1 A Armature coil 1 B O-ring 2 C Starter motor yoke 1 For assembly, reverse the di[...]

8 - 25 – + ELEC STARTER MOTOR EAS00770 CHECKING THE STARTER MOTOR 1. Chec k: • commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 27 mm (1.06 in) 3. Measure: • mica undercut a Out of specification → Scrape the mica to the proper m[...]

8 - 26 – + ELEC STARTER MOTOR b . If any resist ance is out of specifica tion, replace the star ter motor . ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ Pocket tester 90890-03112 Armature coil Commutator resistance 1 0.025 ~ 0.035 Ω at 20 ° C (68 ° F) Insulation resistance 2[...]

8 - 27 – + ELEC STARTER MOTOR EAS00772 ASSEMBLING THE STARTER MOTOR 1. Install: • brush seat 1 NOTE: _ Align the tab a on the brush seat with the slot b in the starter motor yoke. 2. Install: • lock washer NOTE: Align the tabs a on the lock washer with the groves in the front bracket. a 3. Install: • rear bracket NOTE: Align the slot a in t[...]

8 - 28 – + ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM ON OFF P R / W RR L / W B B WW W WW W G / WL / Y Gy G / W L / B R B R / B R / W Lg Y / L R / G B2 B Y / LG / L R / W BB B R / G WW W BR Br / R Br / R R Br / L R Br / L 5 2 1 3 4 z 0 A B 6 7 8 9 Gy L R Br / L Br / R G / W R R R R R B B B B B R W R / G R R R Br R / G Br R / W [...]

8 - 29 – + ELEC CHARGING SYSTEM EAS00774 TROUBLESHOOTING Check: 1. main fuse 2. batter y 3. charging v oltage 4. stator coil resistance 5. wiring connections (of the entire charging system) NOTE: _ • Before troubleshooting, remove the following part(s): 1. seat 2. batter y cov er 3. left side panel • Troubleshoot with the following special to[...]

8 - 30 – + ELEC CHARGING SYSTEM EAS00775 NO YES EAS00776 YES NO EAS00779 YES NO 3. Charging v oltage • Connect the pocket tester (DC 20 V) to the battery as shown. Positive tester probe → positive battery terminal Negative tester probe → negative battery terminal • Start the engine and let it run at approxi- mately 5,000 r/min. • Measur[...]

8 - 31 – + ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM ON OFF P - - - - (BLACK) (BLACK) (DARK BLUE) (GRAY) - R / W RR L / W B B SUB-WIRE HARNESS MAIN HARNESS A G Ch Lg YB Dg Y B L / R Ch G L / R G B Y Y Br B L / R B B ( BLUE ) ( DARK GREEN ) ( BLUE ) B L / G B B B / Y L / Y B B L / R B ( BLACK ) ( BLACK ) Y Br B B B Y L / R Y BL[...]

8 - 32 – + ELEC LIGHTING SYSTEM EAS00781 TROUBLESHOOTING Check: 1. main, headlight, and parking lighting fuses 2. batter y 3. main s witch 4. dimmer s witch 5. pass s wit ch 6. headlight rela y 7. wiring connections (of the entire lighting system) NOTE: _ • Before troubleshooting, remove the following part(s): 1. seat 2. batter y cov er 3. side[...]

8 - 33 – + ELEC LIGHTING SYSTEM EAS00784 YES NO EAS00786 YES NO YES NO EAS00787 YES NO 4. Dimmer s witch • Check the dimmer switch for continuity. Refer to “ CHECKING THE SWITCHES ” . • Is the dimmer switch OK? The dimmer switch is faulty. Replace the left handlebar switch. 5. P ass swi tch • Check the pass switch for continuity. Refer [...]

8 - 34 –+ ELEC LIGHTING SYSTEM EAS00788 CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light f ail to come on. YES NO YES NO YES NO 1. Headlight b ulb and soc k et • Check the headlight bulb a nd socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. • Are the headlight bulb and socket OK? Replac[...]

8 - 35 –+ ELEC LIGHTING SYSTEM EAS00790 2. The tail/brak e light f ails to come on. YES NO YES NO EAS00791 3. The auxiliar y light f ails to come on. YES NO YES NO 1. T ail/brak e light b ulb and soc k et • Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. • Are the tail/brake light[...]

8 - 36 – + ELEC LIGHTING SYSTEM[...]

8 - 37 – + ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM ON OFF P - - - - (BLACK) (BLACK) (DARK BLUE) (GRAY) - R / W RR L / W B B SUB-WIRE HARNESS MAIN HARNESS A G Ch Lg YB Dg Y B L / R Ch G L / R G B Y Y Br B L / R B B ( BLUE ) ( DARK GREEN ) ( BLUE ) B L / G B B B / Y L / Y B B L / R B ( BLACK ) ( BLACK ) Y Br B B B Y L / R Y [...]

8 - 38 – + ELEC SIGNALING SYSTEM 3 Neutral switch 4 Main switch 6 Battery 7 Main fuse A Backup fuse ( immobilizer u nit, meter ass embly) F Front brake light switch G Relay unit K Fuel pump L ECU R Coolant tem perature sensor S Speed sensor X Neutral indicator light Y Multifunction meter Z Coolant temperat ure warning light [ Engine trouble warni[...]

8 - 39 – + ELEC SIGNALING SYSTEM EAS00794 TROUBLESHOOTING Check: 1. main, ignition, signaling system, parking lighting, and bac kup fuses 2. batter y 3. main s witch 4. wiring connections (of the entire signaling system) NOTE: _ • Before troubleshooting, remove the following part(s): 1. seat 2. batter y cov er 3. side panels (left and right) 4.[...]

8 - 40 – + ELEC SIGNALING SYSTEM EAS00796 CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. YES NO YES NO YES NO 1. Hor n switch • Check the horn switch for continuity. Refer to “ CHECKING THE SWITCHES ” . • Is the horn switch OK? Replace the left han- dlebar switch. 2. V ol tage • Connect the pocket tester (DC 20 V) to the horn[...]

8 - 41 –+ ELEC SIGNALING SYSTEM EAS00797 2. The tail/brak e light f ails to come on. YES NO YES NO YES NO 1. T ail/brak e light b ulb and soc k et • Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. • Are the tail/brake light bulb and socket OK? Replace the tail/ brake light bulb, s[...]

8 - 42 –+ ELEC SIGNALING SYSTEM EAS00799 3. The tur n signal light, tur n signal indicator light or both f ail to b lin k. YES NO YES NO YES NO YES NO YES NO 1. T ur n signal indicator light b ulb and soc k et • Check the turn signal light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. • Are the turn signa[...]

8 - 43 – + ELEC SIGNALING SYSTEM YES NO YES NO 6. V ol tage • Connect the pocket tester (DC 20 V) to the turn signal/hazard rela y coupler (wire har- ness end) as shown. Positive tester probe → brown/white 1 Negative tester probe → ground • Set the main switch to “ ON ” . • Set the turn signal switch to “” or “” . • Measur[...]

8 - 44 – + ELEC SIGNALING SYSTEM EAS00800 4. The neutral indicator light f ails to come on. YES NO YES NO EAS00753 YES NO 1. Neutral indicator light LED • Check the LED of the neutral indicator light. Refer to “ CHECKING THE BULBS AND BULB SOCKETS ” . • Is the neutral indicator light LED OK? Replace the meter assembly. 2. Neutral s witch [...]

8 - 45 – + ELEC SIGNALING SYSTEM YES NO EAS00803 5. The fuel le v el w arning light fa ils to come on. YES NO YES NO 4. V ol tage • Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness end) as shown. Positive tester probe → light green 1 Negative tester probe → ground • Set the main switch to “ ON ” . • Sh[...]

8 - 46 – + ELEC SIGNALING SYSTEM YES NO 6. The speedometer f ails to come on. YES NO 3. V ol tage • Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness end) as shown. Positive tester probe → green/white 1 Negative tester probe → black/white 2 • Set the main switch to “ ON ” . • Measure the voltage (DC 12 [...]

8 - 47 – + ELEC SIGNALING SYSTEM YES NO 7. The coolant temper ature wa r ning light f ails to come on. YES NO YES NO 2. Speed sensor • Connect the pocket tester (DC 20 V) to the speed sensor coupler as shown. Positive tester probe → pink 1 Negative tester probe → black/white 2 • Set the main switch to “ ON ” . • Elevate the rear whe[...]

8 - 48 – + ELEC SIGNALING SYSTEM EAS00812 YES NO EAS00813 YES NO 3. Coolant temperature sensor • Remove the coolant temperature senso r from the engine. • Connect the pocket tester ( Ω × 10) to the coolant temperature sensor 1 as sh own. • Immerse the coolant temperature sensor in a container filled with coolan t 2 . NOTE: _ Make sure th[...]

8 - 49 – + ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM ON OFF P - - - - (BLACK) (BLACK) (DARK BLU E (GRAY) - R / W RR L / W B B SUB-WIRE HARNESS MAIN HARNESS A G Ch Lg YB Dg Y B L / R Ch G L / R G B Y Y Br B B ( BLUE ) ( DARK GREEN ) ( BLUE ) B L / G B B B / Y L / Y B B ( BLACK ) ( BLACK ) Y Br B B B Y L / R R / BL / BR / L Br L /[...]

8 - 50 – + ELEC COOLING SYSTEM EAS00808 TROUBLESHOOTING Check: 1. main, radiat or f an motor , and ignition fuses 2. batter y 3. main s witch 4. radiator fan motor 5. radiator fan motor rela y 6. wiring connections (the entire cooling system) NOTE: _ • Before troubleshooting, remove the following part(s): 1. seat 2. batter y cov er 3. side pane[...]

8 - 51 – + ELEC COOLING SYSTEM EAS00809 YES NO YES NO EAS00813 YES NO 4. Radiator f an motor • Disconnect the radiator fan motor couple r from the wire harness. • Connect the battery (DC 12 V) as sh own. Positive battery lead → red 1 Negative battery lead → black 2 • Does the radiator fan motor turn? The radiator fan motor is faulty and[...]

8 - 52 – + ELEC IMMOBILIZER SYSTEM EB805000 IMMOBILIZER SYSTEM CIRCUIT DIAGRAM ON OFF P - - - - (BLACK) (BLACK) (DARK BLUE ) (GRAY) - R / W RR L / W B B SUB-WIRE HARNESS MAIN HARNESS A G Ch Lg YB Dg Y B L / R Ch G L / R G B Y Y Br B B ( BLUE ) ( DARK GREEN ) ( BLUE ) B L / G B B B / Y L / Y B B ( BLACK ) ( BLACK ) Y Br B B B Y L / R R / BL / BR /[...]

8 - 53 – + ELEC IMMOBILIZER SYSTEM GENERAL INFORMATION This motorcycle is equipped with an immobilizer system to help prevent the ft by registering codes in standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) that ca n be re-registered with new codes • a t[...]

8 - 54 – + ELEC IMMOBILIZER SYSTEM KEY CODE REGISTRATION The replacement of parts or code registration of a code re-registering key or standard key may be required in the following con ditions. NOTE: Each standard key is registered d uring production, therefore, re gistering the keys at purchase is not necessary. Parts to replace: replacing a los[...]

8 - 55 – + ELEC IMMOBILIZER SYSTEM Standard key registration: A standard key should be registered or the other standard key should be re-reg istered when a reg- istered standard key has been lost. The stan dard keys must be re-registered when the immobilizer unit or ECU has been replaced and th e code re-registering key has been re-registered. NO[...]

8 - 56 – + ELEC IMMOBILIZER SYSTEM 6. Chec k that the engine can be star ted with the two registered standard k e ys . Voiding a standard key code: If a registered standard key has been lost and you want to disable its use, register a n ew standard key or re-register the other standard key. For registration of a standard key, refer to “ Standar[...]

8 - 57 – + ELEC IMMOBILIZER SYSTEM SELF-DIAGNOSIS MALFUNCTION CODES When a system malfunction occurs, the malfunction code number is displayed on the multifunction display and is indicated b y the immobilizer system indicator light flash patterns. Immobilizer system indicator light malfunction code indication Digits of 10: on for 1 second and off[...]

8 - 58 – + ELEC IMMOBILIZER SYSTEM EAS00781 TROUBLESHOOTING Check: 1. main, ignition, and bac kup fu ses 2. batter y 3. main s witch 4. wir ing (of the entire immobilizer system) NOTE: • Before troubleshooting, remove the following part(s). 1. seat 2. batter y cov er 3. side panels (left and right) 4. fuel tank side cov ers (left and r ight) 5.[...]

8 - 59 – + ELEC IMMOBILIZER SYSTEM CHECKING THE IMMOBILIZER SYSTEM 1. Immobil izer system indicato r light does not go on when the main s witch is set to “ ON ” . YES NO YES NO YES NO 1. Immobilizer system indicator light LED • Check the LED of the immobilizer system indicator light. Refer to “ CHECKING THE BULBS AND BULB SOCKETS ” . ?[...]

8 - 60 – + ELEC IMMOBILIZER SYSTEM YES NO YES NO 4. V oltag e • Connect the pocket tester (DC 20 V) to the immobilizer unit coupler as shown. Positive tester probe → red/white 1 Negative tester probe → black 2 • Set the main switch to “ ON ” . • Measure the voltage (12 V) betwe en red/ white and black on t he immobilizer unit couple[...]

8 - 61 – + ELEC IMMOBILIZER SYSTEM 2. The multifunction displa y is not indicated. YES NO 1. V oltag e • Connect the pocket tester (DC 20 V) to the meter assembly couple rs as shown. Positive tester probe → red/green 1 and red/ white 3 Negative tester probe → black/white 2 • Turn the main switch to “ ON ” . • Measure the voltage (DC[...]

8 - 62 – + ELEC IMMOBILIZER SYSTEM 3. When the main s witch is set to “ ON ” , the immobiliz er system indicator light flashes after 1 sec- ond. • Check if metal or other immobilizer system keys exists near the immobilizer unit. If found, remove the metal or keys, and then check the con dition again. Set the main switch to “ ON ” with a[...]

8 - 63 – + ELEC EAS00834 SELF-DIAGNOSIS The XT660R/XT660X features a self-diag nosing system for the following circuit: • Fuel sender (thermistor) If the circuit is defective, the condition code will be displayed on the fuel level warning light when the main switch is set to “ ON ” (irrespective of whether the engine is running or not). * 1[...]

8 - 64 – + ELEC SELF-DIAGNOSIS EAS00835 TROUBLESHOOTING Check: 1. fuel sender (thermistor) NOTE: _ • Before troubleshooting, remove the following part(s): 1. seat 2. side panels (left and right) 3. fuel tank side cov ers (left and r ight) 4. fuel tank • Troubleshoot with the following special tool(s). EAS00838 1. Fuel sender (thermistor) CIRC[...]

8 - 65 – + ELEC SELF-DIAGNOSIS EAS00842 YES NO 3. Fuel sender (thermistor) • Disconnect the fuel sender coupler from the wire harness. • Connect the pocket tester (k Ω × 1) to the fuel sender as shown. Positive tester probe → green/white 1 Negative tester probe → black 2 • Check the fuel sender for continuity. • Is the fuel sender [...]

[...]

TRBL SHTG 9[...]

TRBL SHTG CHAPTER 9 TROUBLESHOOTING STARTING FAILURES ...................................................................... .............. 9-1 ENGINE ....................... ..................................................... ......................... 9-1 FUEL SYSTEM ............................................ ..................................[...]

TRBL SHTG FAULTY LIGHTING OR SIGNALING SYSTEM .............................................. 9-6 HEADLIGHT DOES NOT COME ON .......................................... .............. 9-6 HEADLIGHT BULB BURNT OUT .............................................................. 9-6 TAIL/BRAKE LIGHT DOES NOT COME ON ......................................[...]

9 - 1 TRBL SHTG EAS00844 TROUBLESHOOTING NOTE: _ The following guide for troubleshootin g does not cover all the possible causes of trou ble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this man- ual for checks, adjustments, and replacement of parts. STARTING FAILURES ENGINE Cylinder and cy[...]

9 - 2 TRBL SHTG STARTING FAILURES/ INCORRECT ENGINE IDLING SPEED ELECTRICAL SYSTEMS Battery • Discharged battery • Faulty battery Fuse(s) • Blown, damaged or incorrect fuse • Improperly installed fuse Spark plug • Incorrect spark plug gap • Incorrect spark plug heat range • Fouled spark plug • Worn or damaged electrode • Worn or d[...]

9 - 3 TRBL SHTG POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ FAULTY GEAR SHIFTING/FAULTY CLUTCH EAS00848 POOR MEDIUM-AND-HIGH-SP EED PERFORMANCE Refer to “ STARTING FAILURES ” . ENGINE Air filter • Clogged air filter element FUEL SYSTEM Fuel pump • Faulty fuel pump EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT Refer to “ CLUTCH DRAGS ”[...]

9 - 4 TRBL SHTG OVERHEATING/OVERCOOLING/ POOR BRAKING PERFORMANCE EAS00855 OVERHEATING ENGINE Clogged coolant passages • Cylinder head and piston • Heavy carbon buildup Engine oil • Incorrect oil level • Incorrect oil visc osity • Inferior oil quality COOLING SYSTEM Coolant • Low coolant level Radiator • Damaged or leaking radiator ?[...]

9 - 5 TRBL SHTG FAULTY FRONT FORK LEGS/ UNSTABLE HANDLING EAS00861 FAULTY FRONT FORK LEGS LEAKING OIL • Bent, damaged or rusty inner tube • Cracked or damaged outer tube • Improperly installed oil seal • Damaged oil seal lip • Incorrect oil level (high) • Loose damper rod assembly bolt • Damaged damper rod assembly bolt copper washer [...]

9 - 6 TRBL SHTG FAULTY LIGHTING OR SIGNALING SYSTEM EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT COME ON • Wrong headlight bulb • Too many electrical accessories • Hard charging • Incorrect connection • Improperly grounded circuit • Poor contacts (main switch) • Burnt-out headlight bulb • Faulty headlight relay ?[...]

XT660R(S)/XT660X(S) 2004 WIRING DIAGRAM 1 Crankshaft po sition sensor 2 A.C. magneto 3 Neutral switch 4 Main switch 5 Rectifier/regulator 6 Battery 7 Main fuse 8 Starter relay 9 Starter mo tor 0 Fuel injection system fuse A Backup fuse ( immobilizer u nit, meter ass embly) B Radiator fan mo tor fuse C Right handlebar switch D Engine stop switch E S[...]

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XT660R(S)/XT660X(S) 2004 WIRING DIAGRAM ON OFF P - - - - (BLACK) (BLACK) (DARK BLUE) (GRAY) - R / W RR L / W B B SUB-WIRE HARNESS MAIN HARNESS A G Ch Lg YB Dg Y B L / R Ch G L / R G B Y Y Br B L / R B B ( BLUE ) ( DARK GREEN ) ( BLUE ) B L / G B B B / Y L / Y B B L / R B ( BLACK ) ( BLACK ) Y Br B B B Y L / R Y BL R / BL / BR / L Br L / W L / WL / [...]