2004 XT660R(S) XT660X(S) 5VK1-AE1 SERVICE MANUAL
EAS00000 XT660R(S)/XT660X(S) 2004 SERVICE MANUAL ©2003 by MBK Industrie First edition, December 2003 All rights reserved. Any reproduction or unauthorized use without the written permission of MBK Industrie is expressly prohibited.
EAS00002 NOTICE This manual was produced by MBK Industrie primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”. 2 Each chapter is divided into sections.
1 EAS00008 2 GEN INFO SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. SPEC 3 4 CHK ADJ 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Fuel injection system 8 Electrical system 9 Troubleshooting CHAS 5 6 ENG COOL 7 8 FI – ELEC 9 Symbols 0 to G indicate the following.
EAS00010 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL INJECTION SYSTEM GEN INFO 1 SPEC 2 CHK ADJ 3 CHAS 4 ENG 5 COOL 6 FI 7 – ELECTRICAL SYSTEM TROUBLESHOOTING + ELEC 8 TRBL SHTG 9
GEN INFO 1
GEN INFO CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION..................................................................1-1 VEHICLE IDENTIFICATION NUMBER .....................................................1-1 MODEL LABEL.......................................................................................... 1-1 FEATURES...................................................................................................... 1-2 OUTLINE ..............................................................
GEN INFO
MOTORCYCLE IDENTIFICATION GEN INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. EAS00018 MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.
FEATURES GEN INFO EAS00019 FEATURES EAS00896 OUTLINE The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In a conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective chamber.
FEATURES GEN INFO EAS00897 FI SYSTEM The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the injector at 324 kPa (3.24 kg/cm2, 46.1 psi) higher than the intake manifold pressure. Accordingly, when the energizing signal from the ECU energizes the injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
IMPORTANT INFORMATION GEN INFO EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to “SPECIAL TOOLS”. 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4.
IMPORTANT INFORMATION GEN INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease.
CHECKING THE CONNECTIONS GEN INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains → Connect and disconnect several times. 3. Check: • all connections Loose connection → Connect properly. NOTE: If the pin 1 on the terminal is flattened, bend it up. _ 4.
SPECIAL TOOLS GEN INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. Tool No.
SPECIAL TOOLS Tool No. T-handle 90890-01326 Holder 90890-01460 Tool name/Function GEN INFO Illustration T-handle Damper rod holder These tools are used to hold the damper rod holder when removing or installing the damper rod. Radiator cap tester adaptor 90890-01352 This tool is used to check the cooling system. Flywheel puller 150 90890-01362 80 60 M8 × 60 mm M8 × 80 mm M8 × 150 mm M8 M8 This tool is used to remove the A.C. magneto rotor.
SPECIAL TOOLS Tool No. Tool name/Function Thickness gauge 90890-03079 This tool is used to measure the valve clearance. Compression gauge 90890-03081 These tools are used to measure the engine compression. Pocket tester 90890-03112 This tool is used to check the electrical system. Timing light 90890-03141 This tool is used to check the ignition timing. Pressure gauge 90890-03153 This tool is needed to measure fuel pressure. Digital circuit tester 90890-03174 This tool is used to check electrical system.
SPECIAL TOOLS Tool No. Tool name/Function Valve guide remover (ø 6) 90890-04064 This tool is needed to remove and install the valve guides. Valve guide installer (ø 6) 90890-04065 This tool is needed to install the valve guides. Valve guide reamer (ø 6) 90890-04066 This tool is needed to rebore the new valve guides. Adaptor (Compression gauge) 90890-04082 This tool is needed to measure engine compression.
SPECIAL TOOLS Tool No. Tool name/Function Yamaha bond No. 1215 90890-85505 This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces).
SPEC 2
SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ........................................................................ 2-1 ENGINE SPECIFICATIONS ............................................................................2-2 CHASSIS SPECIFICATIONS ........................................................................2-11 ELECTRICAL SPECIFICATIONS .................................................................2-16 CONVERSION TABLE ...................................................................
SPEC
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Model code Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Weight Wet (with oil and a full fuel tank) Maximum load (total of cargo, rider, passenger, and accessories) Standard Limit XT660R: 5VK1 (Europe) 5VK2 (AUS) 5VK3 (GB) XT660X: 1D21 (Europe) 1D22 (AUS) 1D23 (GB) ------------------- 2,240 mm (88.2 in) (XT660R) 2,150 mm (84.6 in) (XT660X) 845 mm (33.
ENGINE SPECIFICATIONS SPEC ENGINE SPECIFICATIONS Item Engine Engine type Displacement Cylinder arrangement Bore × stroke Compression ratio Engine idling speed Water temperature Oil temperature Standard compression pressure (at sea level) Fuel Recommended fuel Fuel tank capacity Total (including reserve) Reserve only Engine oil Lubrication system Recommended oil -20 -10 0 10 20 30 40 50 ˚C Standard Limit Liquid-cooled, 4-stroke, SOHC 660 cm3 (40.27 cu · in) Forward-inclined single cylinder 100.0 × 84.
ENGINE SPECIFICATIONS Item Oil pump Oil pump type Inner-rotor-to-outer-rotor-tip clearance Outer-rotor-to-oil-pump-housing clearance Oil-pump-housing-to-inner-rotor-andouter-rotor clearance Cooling system Radiator capacity Radiator cap opening pressure Radiator core Width Height Depth Coolant reservoir Capacity Water pump Water pump type Reduction ratio Maximum impeller shaft tilt Starting system type Fuel injector Model/manufacturer Quantity Spark plug Model/manufacturer × quantity
ENGINE SPECIFICATIONS Item Standard Camshaft Drive system Intake camshaft lobe dimensions Chain drive (left) SPEC Limit ---- A B Measurement A 43.488 ~ 43.588 mm (1.7121 ~ 1.7161 in) 43.338 mm (1.7062 in) 36.959 ~ 37.059 mm (1.4551 ~ 1.4590 in) 36.840 mm (1.4504 in) Measurement B Exhaust camshaft lobe dimensions A B Measurement A Measurement B Valve timing Intake - open (B.T.D.C.) Intake - closed (A.B.D.C.) Exhaust - open (B.B.D.C.) Exhaust - closed (A.T.D.C.
SPEC ENGINE SPECIFICATIONS Item Standard Rocker arm/rocker arm shaft Rocker arm inside diameter Limit 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) 12.036 mm (0.4739 in) 11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in) 11.955 mm (0.4707 in) 0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.081 mm (0.0032 in) Shaft outside diameter Arm-to-shaft clearance Valves, valve seats, valve guides Valve clearance (cold) Intake Exhaust Valve dimensions 0.09 ~ 0.13 mm (0.0035 ~ 0.0051 in) 0.16 ~ 0.20 mm (0.0063 ~ 0.
ENGINE SPECIFICATIONS Item Valve-stem-to-valve-guide clearance Intake Exhaust Standard 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) Valve stem runout ---- Valve seat width Intake 1.00 ~ 1.20 mm (0.0394 ~ 0.0472 in) Exhaust 1.00 ~ 1.20 mm (0.0394 ~ 0.0472 in) Valve springs Free length Intake 40.38 mm (1.59 in) Exhaust 40.38 mm (1.59 in) Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust SPEC Limit 0.08 mm (0.
ENGINE SPECIFICATIONS Item SPEC Standard Cylinder Cylinder arrangement Bore × stroke Compression ratio Bore Forward-inclined single cylinder 100.0 × 84.0 mm (3.94 × 3.31 in) 10 : 1 100.000 ~ 100.010 (3.9370 ~ 3.9374 in) Maximum taper ---- Maximum out-of-round ---- Piston Piston-to-cylinder clearance Limit ---------100.080 mm (3.9402 in) 0.05 mm (0.002 in) 0.05 mm (0.002 in) 0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in) 0.13 mm (0.0051 in) 99.955 ~ 99.970 mm (3.9352 ~ 3.
ENGINE SPECIFICATIONS Item SPEC Standard Limit 2nd ring B T Ring type Dimensions (B × T) End gap (installed) Taper 1.20 × 4.00 mm (0.047 × 0.157 in) 0.35 ~ 0.50 mm (0.0138 ~ 0.0197 in) Ring side clearance 0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in) ------0.85 mm (0.0335 in) 0.11 mm (0.0043 in) Oil ring B T Dimensions (B × T) End gap (installed) Ring side clearance Crankshaft 2.50 × 3.40 mm (0.098 × 0.134 in) 0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in) 0.060 ~ 0.150 mm (0.0024 ~ 0.
ENGINE SPECIFICATIONS Item Clutch Clutch type Clutch release method Operation Clutch cable free play (at the end of the clutch lever) Friction plates 1 (inside dia.: 120 mm) Thickness Standard Wet, multiple disc Outer pull, rack and pinion pull Left-hand operation 10.0 ~ 15.0 mm (0.39 ~ 0.59 in) 2.90 ~ 3.10 mm (0.114 ~ 0.122 in) Plate quantity Friction plates 2 Thickness 4 Plate quantity Friction plates 3 (inside dia.
ENGINE SPECIFICATIONS Item Standard Maximum main axle runout ---- Maximum drive axle runout ---- Shifting mechanism Shift mechanism type Decompression device Device type Air filter type Fuel pump Pump type Model/manufacturer Consumption amperage Output pressure Throttle body Model/manufacturer × quantity Intake vacuum pressure Throttle cable free play (at the flange of the throttle grip) ID mark Throttle valve size SPEC Limit 0.08 mm (0.0031 in) 0.08 mm (0.
CHASSIS SPECIFICATIONS SPEC CHASSIS SPECIFICATIONS Item Frame Frame type Caster angle Trail Front wheel Wheel type Rim Size Material Wheel travel Standard Diamond 27.25° (XT660R) 26° (XT660X) 107 mm (4.21 in) (XT660R) 94 mm (3.70 in) (XT660X) ---------------- Spoke wheel ---- 21 × 1.85 (XT660R) 17M/C × MT3.50 (XT660X) Aluminum 225 mm (8.86 in) (XT660R) 200 mm (7.
CHASSIS SPECIFICATIONS Item Front tire Tire type Size Model/manufacturer Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 90 (198 lb) ~ Maximum load* Off-road riding Minimum tire tread depth Rear tire Tire type Size Model/manufacturer Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 90 (198 lb) ~ Maximum load* Off-road riding Minimum tire tread depth SPEC Standard Limit With tube 90/90-21M/C 54S, 90/90-21M/C 54T (XT660R) 120/70R 17M/C 58 H (XT660X) TOURANCE FRONT/METZELER, SIRAC/MICHELIN (XT660R) DRAGON/PIR
CHASSIS SPECIFICATIONS Item Standard Front brakes Brake type Operation Recommended fluid Brake discs Diameter × thickness SPEC Limit Single-disc brake Right-hand operation DOT 4 ------------- Minimum thickness 298.0 × 4.5 mm (11.73 × 0.18 in) (XT660R) 320.0 × 4.5 mm (12.60 × 0.18 in) (XT660X) ---- Maximum deflection ---- Pad thickness inner 4.1 mm (0.16 in) (XT660R) 5.2 mm (0.20 in) (XT660X) Pad thickness outer 4.1 mm (0.16 in) (XT660R) 5.2 mm (0.
CHASSIS SPECIFICATIONS Item Steering Steering bearing type Lock to lock angle (left) Lock to lock angle (right) Front suspension Suspension type Front fork type Front fork travel Spring Free length SPEC Standard Taper roller bearing 44.0° 44.0° ---------- Telescopic fork Coil spring/oil damper 225.0 mm (8.86 in) (XT660R) 200.0 mm (7.87 in) (XT660X) ------------- 633.0 mm (24.92 in) (XT660R) 593.0 mm (23.
CHASSIS SPECIFICATIONS Item Rear suspension Suspension type Rear shock absorber assembly type Rear shock absorber assembly travel Spring Free length Standard Swingarm (monocross) Coil spring/gas-oil damper 65.0 mm (2.56 in) 216.0 mm (8.50 in) SPEC Limit ---------- 205 mm (8.07 in) Installed length 206.0 mm (8.11 in) ---Spring rate (K1) 125.00 N/mm (12.75 kg/mm, 713.75 lb/in) ---Spring stroke (K1) 0 ~ 65.0 mm (0 ~ 2.
ELECTRICAL SPECIFICATIONS SPEC ELECTRICAL SPECIFICATIONS Item System voltage Ignition system Ignition system type Ignition timing Advancer type Crankshaft position senor resistance/ color Transistorized coil ignition unit model/manufacturer Ignition coil Model/manufacturer Minimum ignition spark gap Primary coil resistance Secondary coil resistance Spark plug cap Material Resistance Charging system System type Model/manufacturer Nominal output Stator coil resistance/color Rectifier/regulator Regulator typ
ELECTRICAL SPECIFICATIONS Item Bulbs (voltage/wattage × quantity) Headlight Auxiliary light Tail/brake light Front turn signal light Rear turn signal light Meter lighting Electric starting system System type Starter motor Model/manufacturer Power output Armature coil resistance Brushes Overall length Spring force Commutator diameter Mica undercut Starter relay Model /manufacturer Amperage Coil resistance Horn Horn type Model/manufacturer × quantity Maximum amperage Performance Coil resistance Turn signal/ha
ELECTRICAL SPECIFICATIONS Item Headlight relay Model/manufacturer Radiator fan Model/manufacturer Fan motor relay Model/manufacturer Intake air pressure sensor Thermostat type/manufacturer Output voltage Intake air temperature sensor Model/manufacturer Resistance Coolant temperature sensor Model/manufacturer Resistance Fuses (amperage × quantity) Main fuse Signaling system fuse Headlight fuse Ignition fuse Fuel injection system fuse Radiator fan motor fuse Parking lighting fuse Backup fuse (immobilizer uni
CONVERSION TABLE/ GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC MULTIPLIER IMPERIAL ** mm × 0.03937 = ** in 2 mm × 0.03937 = 0.
TIGHTENING TORQUE SPEC TIGHTENING TORQUE ENGINE TIGHTENING TORQUE Part to be tightened Cylinder head (exhaust pipe) Cylinder head (left side) = 145 mm (5.71 in) Cylinder head (right side) = 135 mm (5.31 in) Cylinder head (center lower side) Cylinder head Spark plug Cylinder (left side) = 116 mm (4.57 in) 1st 2nd Cylinder (right side) = 109 mm (4.
TIGHTENING TORQUE Part to be tightened Oil strainer Oil pump Oil baffle plate 2 Oil pump assembly Engine oil drain bolt (crankcase) Oil filter element cover Oil filter drain bolt Engine oil drain bolt (oil tank) Bleed bolt (oil filter element) Oil delivery pipe 1 Oil delivery pipe 2 Oil delivery hose 1 Oil delivery hose 2 Throttle body joint clamp screw Air filter case joint clamp screw Air filter case Exhaust pipe and exhaust pipe bracket Exhaust pipe bracket and frame Exhaust pipe and muffler Exhaust pipe
TIGHTENING TORQUE Part to be tightened Part name Thread Q’ty size SPEC Tightening torque Nm m · kg ft · lb Starter clutch Stator coil Crankshaft position sensor Starter motor and crankcase Starter motor lead Brush holder and starter motor yoke Starter motor assembly Drive axle oil seal retainer Bolt Bolt Bolt Bolt Nut Nut Bolt Nut M8 M6 M5 M6 M6 M6 M5 M6 3 3 2 2 1 1 2 2 30 10 7 10 5 11 5 10 3.0 1.0 0.7 1.0 0.5 1.1 0.5 1.0 22 7.2 5.1 7.2 3.6 8 3.6 7.2 Drive sprocket Nut M18 1 120 12.
TIGHTENING TORQUE SPEC CHASSIS TIGHTENING TORQUES Thread size Part to be tightened Engine mounting: Engine upper bracket and frame Engine upper bracket and engine Engine front bracket and frame Engine front bracket and engine Engine and frame Radiator cap retainer Coolant reservoir Chain tensioner (upper and lower) Pivot shaft and nut Rear shock absorber and frame Relay arm and frame Relay arm and connecting arm Swingarm and connecting arm Relay arm and rear shock absorber Chain cover and swingarm Stabil
TIGHTENING TORQUE Thread size Part to be tightened Fuel tank and frame Fuel pump and fuel tank Rectifier/regulator and air filter case ECU and air filter case Horn bracket and frame Side panels (left and right) and frame Grab bar, rear cover and frame Rear mud guard and frame Tail/brake light and rear mud guard Rear mud guard and rear fender Rear fender and frame Front fender and frame Front fork protector and front cowling assembly Front brake disc and wheel Front wheel axle Front wheel axle pinch bolt Fr
LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point Symbol Oil seal lips LS O-rings LS Bearings E Cylinder head tightening bolts E Cylinder tightening bolts E Crankshaft pin E Timing chain sprocket inner surface M Connecting rod big end thrust surface E Piston pin E Piston and ring groove E Balancer weight tightening nut E A.C.
LUBRICATION POINTS AND LUBRICANT TYPES Lubrication Point SPEC Symbol Crankcase mating surface Yamaha bond No.1215 A.C. magnet lead grommet (A.C. magneto cover) Yamaha bond No.1215 Oil seal holder tightening bolt Yamaha bond No.1215 Oil delivery hose 2 tightening bolt Yamaha bond No.
LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00032 CHASSIS Lubrication Point Symbol Front wheel oil seal lips (left and right) LS Rear wheel oil seal lips (left and right) LS Rear wheel drive hub contact surface LS Rear arm pivot shaft outer surface and bush outer surface and oil seal lip LS Dust cover thrust surface LS Relay arm and rear shock absorber mounting bolt outer surface LS Relay arm and rear shock absorber oil seal lips LS Relay arm and swingarm mounting bolt outer surface L
SPEC COOLING SYSTEM DIAGRAMS EAS00033 COOLING SYSTEM DIAGRAMS 1 Water jacket joint 2 Water pump outlet hose 3 Water pump outlet pipe 4 Water pump È From the radiator É To the cylinder 1 2 1 A 3 5VK È 2 5VK00 3 A 4 É È 4 2 - 28
COOLING SYSTEM DIAGRAMS 1 Fast idle plunger outlet hose 2 Coolant reservoir breather hose 3 Coolant reservoir hose 4 Radiator cap 5 Radiator 6 Coolant reservoir cap 7 Coolant reservoir 8 Radiator outlet hose 9 Water pump 0 Radiator fan A Radiator inlet hose 1 2 3 SPEC È From the fast idle plunger É To the cylinder Ê From the thermostat 4 5 È 6 7 8 É Ê 5 A 9 0 2 - 29
LUBRICATION CHART SPEC LUBRICATION CHART : Pressure feed : Splashed scavenge Camshaft Cylinder head Drive axle Oil tank Oil filter Crankshaft Main axle Check ball Connecting rod Oil pump rotor 1 Oil pump rotor 2 Oil strainer Oil pan 2 - 30
LUBRICATION DIAGRAMS SPEC EAS00034 LUBRICATION DIAGRAMS 1 Oil delivery hose 2 2 Oil strainer 3 Oil delivery hose 1 A-A 1 A A 3 2 2 - 31 2
LUBRICATION DIAGRAMS SPEC 1 Oil delivery pipe 2 2 Oil delivery pipe 1 3 Oil filter 4 Oil pump 3 A-A 1 2 A 3 A 4 2 - 32
LUBRICATION DIAGRAMS 1 Oil delivery hose 2 2 Oil delivery pipe 2 3 Oil filter 4 Oil pump rotor 1 5 Oil pump rotor 2 6 Main axle 7 Oil delivery pipe 3 SPEC È To oil tank È 2 3 1 7 6 5 2 - 33 4
LUBRICATION DIAGRAMS SPEC 1 Camshaft 2 Oil delivery pipe 1 3 Oil filter 4 Main axle 5 Drive axle 6 Crankshaft 2 1 6 3 5 4 2 - 34
CABLE ROUTING EAS00035 CABLE ROUTING 1 Left handlebar switch lead 2 Clutch switch lead 3 Clutch cable 4 Front brake light switch lead 5 Right handlebar switch lead 6 Throttle cable 7 Headlight lead 8 Meter assembly lead 9 Main switch lead 0 Immobilizer unit lead 2 - 35 SPEC
CABLE ROUTING È When fastening the front brake light switch lead, leave some slack in the lead at the area shown. É Fasten the right handlebar switch lead, front brake light switch lead, and throttle cables with a plastic band. Face the end of the plastic band forward. Ê Fasten the clutch cable with a cable holder. Ë Fasten the left handlebar switch lead and clutch switch lead with a plastic band. Face the end of the plastic band forward.
CABLE ROUTING 1 Front turn signal light lead (right) 2 Meter assembly lead 3 Auxiliary light lead 4 Front turn signal light lead (left) 5 Headlight lead 6 Sub-wire harness SPEC È Fasten the sub-wire harness and meter assembly lead with a plastic band. Fasten the sub-wire harness at the white tape. Face the end of the plastic band forward. É Make sure that there is no slack in the meter assembly lead between the meter assembly and the plastic band.
CABLE ROUTING Ë Fasten the left and right front turn signal light leads to the headlight stay with a plastic locking tie. Ì Pass the left and right front turn signal light leads in front of the headlight stay. Í Only the left side is shown in this illustration. Route the right front turn signal light lead in the same way. Î Pass the left and right front turn signal light leads between the headlight stay and front fork protector. SPEC Ï 0 ~ 5 mm (0 ~ 0.
CABLE ROUTING 1 Ignition coil lead 2 Main switch coupler 3 Immobilizer unit coupler 4 Air induction system lead 5 Horn lead 6 Horn 7 Ignition coil 8 Spark plug lead 9 Clutch cable 0 Oil delivery pipe 1 A Wire harness SPEC B Fast idle plunger outlet hose È Fasten the fast idle plunger outlet hose and ignition coil leads with a hose holder. Install the hose holder with its fastener facing down. É Fasten the wire harness, main switch lead, and immobilizer unit lead to the frame with a plastic band.
CABLE ROUTING SPEC Ì Fasten the clutch cable to the horn bracket with a cable holder. Í Install the cable holder as high as possible. Î Fasten the clutch cable and oil delivery pipe 1 with a cable holder. Ï Route the fast idle plunger outlet hose to the inside of the line shown in the illustration so that it is not pinched between the frame and right side panel. Ê Fasten the main switch lead, immobilizer unit lead, and horn switch lead with a plastic locking tie.
SPEC CABLE ROUTING 1 Rear brake light switch lead 2 Negative battery lead 3 Lean angle cut-off switch lead 4 Throttle position sensor lead 5 Coolant temperature sensor lead 6 Turn signal/hazard relay 7 Headlight relay 8 Radiator fan motor relay 9 Relay unit È Fasten the wire harness, negative battery lead, and rear brake light switch lead to the frame with a plastic locking tie. É Fasten the rear brake light switch lead to the frame with a plastic locking tie.
CABLE ROUTING 1 Neutral switch connector 2 Crankshaft position sensor coupler 3 A.C. magneto coupler 4 Speed sensor lead 5 Intake air temperature sensor lead 6 ECU lead 7 Starter motor lead 8 Sidestand switch lead 9 Speed sensor 0 A.C.
CABLE ROUTING É Fasten the left handlebar switch lead, right handlebar switch lead, headlight lead, meter assembly lead, front brake light switch lead, clutch switch lead, radiator fan motor lead, and throttle cables with a plastic locking tie. To fasten the leads and cables, connect the couplers, and then turn the handlebar completely to the right. Ê Route the oil tank breather hose on the outside of the throttle cables.
CABLE ROUTING Ï Fasten the neutral switch lead, crankshaft position sensor lead, sidestand switch lead, speed sensor lead, starter motor lead, and A.C. magneto lead with a plastic band. Ð Fasten the neutral switch lead, crankshaft position sensor lead, sidestand switch lead, speed sensor lead, and starter motor lead with a plastic band. Ñ Fasten the air-filter-to-air-cut-off-valve hose, oil tank breather hose, and oil delivery hose 2 with a plastic clamp.
CABLE ROUTING SPEC Ò Fasten the wire harness, air-filter-to-air-cut-offvalve hose, and oil delivery hose 2 with a plastic clamp. Ó Fasten the left handlebar switch lead, right handlebar switch lead, headlight lead, meter assembly lead, front brake light switch lead, and clutch switch lead with a plastic band.
CABLE ROUTING 1 Starter motor lead 2 Fuse box 1 lead 3 Fuse box 2 lead 4 Tail/brake light lead 5 Rear turn signal light lead 6 Seat lock cable 7 Positive battery lead 8 Starter relay lead 9 Rectifier/regulator lead SPEC È Fasten the wire harness and starter motor lead to the frame with a plastic locking tie. É 45° Ê Fasten the wire harness to the frame with a plastic band.
SPEC CABLE ROUTING 1 Immobilizer unit coupler 2 Intake air temperature sensor 3 Fuel injector lead 4 Fuel pump lead 5 Fuel sender lead 6 Oil tank breather hose È 0 ~ 10 mm (0 ~ 0.39 in) É 30 ~ 40 mm (1.18 ~ 1.57 in) Ê 5 ~ 15 mm (0.20 ~ 0.59 in) Ë Fasten the wire harness to the frame with a plastic locking tie. Ì To the fuel tank Í 0 ~ 5 mm (0 ~ 0.
CABLE ROUTING 1 Battery 2 Negative battery lead 3 Tail/brake light coupler 4 Rear turn signal light connector 5 Seat lock cable 6 Anti-theft alarm coupler 7 Fuse box 2 8 Positive battery lead 9 Fuse box 1 0 Rear fender A Rear fender cover SPEC È Fasten the tail/brake light lead with two plastic locking ties so that the coupler is positioned to the inside of where the relays (turn signal/hazard relay, headlight relay, radiator fan motor relay, and relay unit) branch off from the wire harness.
CABLE ROUTING SPEC Ë Connect the couplers so that they are not pinched between the rear fender and rear fender cover. Ì Fasten the wire harness to the frame with a plastic locking tie. Í 0 ~ 5 mm (0 ~ 0.20 in) Î 0 ~ 10 mm (0 ~ 0.39 in) Ï The tail/brake light coupler and the rear turn signal light lead should not be lower than the line shown in the illustration.
CABLE ROUTING 1 Front brake hose 2 Front brake master cylinder 3 Front mud guard 4 Front brake caliper 5 Front fork boss SPEC È To install the brake hose holders, align the edge of each holder with the upper edge of the recess in the brake hose. É Route the front brake hose so that its alignment mark is facing toward the rear of the motorcycle. Ê 30 ~ 50° Ë Fasten the front brake hose with the brake hose holders.
CABLE ROUTING Ì Route the front brake hose between the front fork and front mud guard and between the bosses on the front fork. Í When installing the brake hose onto the brake caliper, make sure that the brake pipe touches the brake caliper as shown. Î When installing the brake hose onto the brake caliper, make sure that the brake pipe touches the projection on the brake caliper.
CABLE ROUTING 1 Brake fluid reservoir 2 Brake fluid reservoir hose 3 Rear brake light switch 4 Rear brake master cylinder 5 Rear brake hose 6 Rear brake caliper SPEC È When installing the brake hose onto the brake master cylinder, make sure that the brake pipe touches the brake master cylinder as shown. É Fasten the rear brake hose with the brake hose holder. Ê When installing the brake hose onto the brake caliper, make sure that the brake pipe touches the brake caliper as shown.
CHK ADJ 3
CHK ADJ CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION.............................................................................................. 3-1 PERIODIC MAINTENANCE AND LUBRICATION CHART ............................ 3-1 COWLING AND COVER ................................................................................. 3-3 COVER...................................................................................................... 3-3 COWLING ...................................................
CHK ADJ CHASSIS ....................................................................................................... 3-36 ADJUSTING THE REAR BRAKE PEDAL ............................................... 3-36 CHECKING THE BRAKE FLUID LEVEL................................................. 3-37 CHECKING THE FRONT AND REAR BRAKE PADS AND BRAKE PAD PINS .........................................................................3-38 ADJUSTING THE REAR BRAKE LIGHT SWITCH .................................
INTRODUCTION/PERIODIC MAINTENANCE AND LUBRICATION CHART CHK ADJ EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
PERIODIC MAINTENANCE AND LUBRICATION CHART CHK ADJ ODOMETER READING (× 1,000 km) 10 20 30 40 ANNUAL CHECK • Make sure that all nuts, bolts and screws are properly tightened. √ √ √ √ √ Sidestand (See page 3-53) • Check operation. • Lubricate. √ √ √ √ √ 17 * Sidestand switch (See page 8-5) • Check operation. √ √ √ √ √ 18 * Front fork (See page 3-46) • Check operation and for oil leakage. √ √ √ √ • Check operation and shock absorber for oil leakage.
COWLING AND COVER CHK ADJ COWLING AND COVER COVER T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 3 4 5 4 T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) 2 T. R. Order 1 2 3 4 5 Job/Part Removing the cover Seat Left side panel Right side panel Grab bar Rear cover Q’ty 7 Nm (0.7 m • kg, 5.1 ft • Ib) Remarks Remove the parts in the order listed. 1 1 1 2 1 For installation, reverse the removal procedure.
COWLING AND COVER CHK ADJ COWLING 5 3 4 2 1 R. R. 1 2 3 4 5 T . T. Order 8 Nm (0.8 m • kg, 5.8 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) Job/Part Removing the cowling Seat/side panels (left and right) Fuel tank Front fender Front fork protector Meter assembly coupler Sub-wire harness coupler Front cowling assembly Q’ty 1 1 2 1 1 Remarks Remove the parts in the order listed. Refer to “COWLING AND COVER”. Refer to “FUEL TANK”. Disconnect. Disconnect.
FUEL TANK CHK ADJ EAS00040 FUEL TANK T. 9 R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 4 5 3 10 8 2 6 7 1 Order 1 2 3 4 5 6 7 8 Job/Part Removing the fuel tank Seat/side panels (left and right) Fuel Fuel tank left side cover Fuel tank right side cover Intake air guide Fuel tank plate Damper 1 Fuel pump coupler Fuel sender coupler Fuel hose 9 10 Fuel tank Damper 2 Q’ty 1 1 1 1 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “COWLING AND COVER”. Drain. Disconnect. Disconnect.
FUEL TANK CHK ADJ REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank filler tube with a pump. 2. Remove: • fuel hose CAUTION: Although the fuel has been removed from the fuel tank be careful when removing the fuel hose, since there may be fuel remaining in it. a NOTE: • To remove the fuel hose from the fuel injection pipe, slide the cover a on the end of the hose in the direction of the arrow shown and then remove the hose.
FUEL TANK CHK ADJ T. INSTALLING THE FUEL PUMP 1. Install: 4 Nm (0.4 m · kg, 2.9 ft · lb) • fuel pump R. NOTE: • Do not damage the installation surfaces of the fuel tank when installing the fuel pump. • Always use a new fuel pump gasket. • Align the projection a on the fuel pump with the slot in the fuel pump bracket. • Tighten the bolts to the specified torque in the proper tightening sequence as shown. • Install the fuel pump in the direction shown in the illustration. INSTALLING THE FUEL HOSE 1.
CHK ADJ AIR FILTER CASE AIR FILTER CASE REAR MUD GUARD AND REAR FENDER T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 7 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 2 2 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 3 4 8 5 6 T. R. Order 1 2 Job/Part Removing the rear mud guard and rear fender Seat/side panels (left and right)/rear cover Fuel tank Muffler Battery cover Battery lead 7 Nm (0.7 m • kg, 5.1 ft • Ib) Q’ty Remarks Remove the parts in the order listed. Refer to “COWLING AND COVER”.
CHK ADJ AIR FILTER CASE T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 7 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 2 2 T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. 3 4 8 5 6 T. R. Order 6 7 8 Job/Part Fuse box 2 Rear mud guard Rear fender 7 Nm (0.7 m • kg, 5.1 ft • Ib) Q’ty 1 1 1 Remarks For installation, reverse the removal procedure.
AIR FILTER CASE CHK ADJ EAS00043 AIR FILTER CASE T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 6 8 4 15 (4) 7 2 16 14 5 T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) 12 11 10 1 9 17 3 T. R. T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 13 T. R.
AIR FILTER CASE T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 6 CHK ADJ 8 4 15 (4) 7 2 16 14 5 T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) 12 11 10 1 9 17 3 T. R. T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 13 T. R. Order 12 13 14 15 16 Job/Part Air-filter-to-crankcase-breather-chamber hose Drive chain tensioner Air filter case joint clamp screw Air filter case Air filter case joint clamp 17 Check hose 10 Nm (1.0 m • kg, 7.2 ft • Ib) LS 23 Nm (2.3 m • kg, 17 ft • Ib) Q’ty 1 Disconnect.
AIR FILTER CASE CHK ADJ INSTALLING THE AIR FILTER CASE JOINT CLAMP 1. Install: • air filter case joint clamp 1 b 1 a NOTE: To install the air filter case joint clamp, align its slot a with the projection b on the air filter case.
ADJUSTING THE VALVE CLEARANCE CHK ADJ EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. _ 1 2 1. Remove: • seat • side panels (left and right) Refer to “COWLING AND COVER”. • fuel tank Refer to “FUEL TANK”.
ADJUSTING THE VALVE CLEARANCE b CHK ADJ 6. Measure: • valve clearance Out of specification → Adjust. a Valve clearance (cold) Intake valve 0.09 ~ 0.13 mm (0.0035 ~ 0.0051 in) Exhaust valve 0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ d a. Turn the crankshaft counterclockwise. b. When the piston is at the top dead center (TDC) on the compression stroke, align the “I” mark a on the A.C. magneto rotor with the stationary pointer b on the A.C. magneto cover.
ADJUSTING THE VALVE CLEARANCE CHK ADJ d. Hold the adjusting screw to prevent it from moving and tighten the locknut to the specified torque. T. Locknut 14 Nm (1.4 m · kg, 10 ft · lb) R. e. Measure the valve clearance again. f. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ T. 8. Install: • timing mark accessing screw • crankshaft end accessing screw 9.
ADJUSTING THE EXHAUST GAS VOLUME CHK ADJ EAS00869 ADJUSTING THE EXHAUST GAS VOLUME NOTE: Be sure to set the CO density level to standard, and then adjust the exhaust gas volume. _ 1. Turn the main switch to “OFF” and set the engine stop switch to “ ”. 2. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more. NOTE: “dIAG” appears on the odometer/fuel reserve tripmeter/tripmeter 2 LCD. _ 3.
ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ EAS00054 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air filter element should be cleaned, and the engine should have adequate compression. _ 1. Start the engine and let it warm up for several minutes. 2. Check: • engine idling speed Out of specification → Adjust. Engine idling speed 1,300 ~ 1,500 r/min 3. Adjust: • engine idling speed ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ 1. Check: • throttle cable free play a Out of specification → Adjust. Throttle cable free play (at the flange of the throttle grip) 3.0 ~ 5.0 mm (0.12 ~ 0.20 in) 2. Adjust: • throttle cable free play 1 2 3 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ NOTE: When the throttle is opened, the accelerator cable 1 is pulled. _ a b Throttle body end a. Loosen the locknut 2 on the accelerator cable. b.
ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUG CHK ADJ c. Tighten the locknut. WARNING _ After adjusting the throttle cable free play, start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS00060 CHECKING THE SPARK PLUG 1. Disconnect: • spark plug cap 2.
CHECKING THE SPARK PLUG/ CHECKING THE IGNITION TIMING T. 7. Install: • spark plug CHK ADJ R. 13 Nm (1.3 m · kg, 9.4 ft · lb) NOTE: Before installing the spark plug, clean the spark plug and gasket surface. _ 8. Connect: • spark plug cap EAS00064 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure all connections are tight and free of corrosion. _ 1 1. • 2.
CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE 4. • 5. • CHK ADJ Detach: timing light Install: timing mark accessing screw EAS00067 MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance. _ 1. Measure: • valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEARANCE”. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Disconnect: • spark plug cap 4.
MEASURING THE COMPRESSION PRESSURE CHK ADJ 6. Measure: • compression pressure Out of specification → Refer to steps (c) and (d). Compression pressure (at sea level) Minimum 600 kPa (6.0 kg/cm2, 85.3 psi) Standard 650 kPa (6.5 kg/cm2, 92.4 psi) Maximum 700 kPa (7.0 kg/cm2, 99.6 psi) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the main switch to “ON” and the engine stop switch to “ ”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes.
MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL R. Install: spark plug Connect: spark plug cap T. 7. • 8. • CHK ADJ 13 Nm (1.3 m · kg, 9.4 ft · lb) EAS00069 CHECKING THE ENGINE OIL LEVEL 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. • Make sure the motorcycle is upright. _ 2. Start the engine, warm it up for 10 ~ 15 minutes, and then turn it off. 3.
CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL CHK ADJ 4. Start the engine, warm it up for several minutes, and then turn it off. 5. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. _ EAS00076 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine. 3. Remove: • engine oil filler cap 1 • camshaft sprocket cover 2 4.
CHANGING THE ENGINE OIL CHK ADJ 9. If the oil filter element is also to be replaced, perform the following procedure. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the oil filter element cover 1 and oil filter element 2. b. Check the O-rings 3 and replace them if they are cracked or damaged. c. Install the new oil filter element and the oil filter element cover. T. Oil filter element cover bolt 10 Nm (1.0 m · kg, 7.2 ft · lb) R. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 10.
CHANGING THE ENGINE OIL CHK ADJ 13.Install: • engine oil filler cap • camshaft sprocket cover T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) 14.Start the engine, warm it up for several minutes, and then turn it off. 15.Check: • engine (for engine oil leaks) 16.Check: • engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”. 17.Check: • engine oil pressure ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Slightly loosen the bleed bolt 1. b.
ADJUSTING THE CLUTCH CABLE FREE PLAY CHK ADJ EAS00078 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: • clutch cable free play a Out of specification → Adjust. Clutch cable free play (at the end of the clutch lever) 10.0 ~ 15.0 mm (0.39 ~ 0.59 in) 2. Adjust: • clutch cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Handlebar end a. Slide back the rubber cover 1. b. Loosen the locknut 2. c. Turn the adjusting bolt 3 in direction b or c until the specified clutch cable free play is obtained.
CHECKING THE AIR FILTER ELEMENT CHK ADJ EAS00086 CHECKING THE AIR FILTER ELEMENT NOTE: There is a check hose 1 at the bottom of the air filter case. If dust and/or water collects in this hose, clean the air filter element and air filter case. 1. Remove: • seat • right side panel Refer to “COWLING AND COVER”. 2. Remove: • air filter case cover (right) 1 3. • 4. • Remove: air filter element 1 Check: air filter element Damage → Replace. 5.
CHECKING THE AIR FILTER ELEMENT/ CHECKING THE THROTTLE BODY JOINT/ CHECKING THE FUEL HOSE CHK ADJ 6. Install: • right side panel • seat Refer to “COWLING AND COVER”. EAS00094 1 CHECKING THE THROTTLE BODY JOINT 1. Check: • throttle body joint 1 Cracks/damage → Replace. Refer to “FUEL INJECTION SYSTEM” in chapter 7. EAS00096 CHECKING THE FUEL HOSE 1. Remove: • seat • side panels (left and right) Refer to “COWLING AND COVER”. • fuel tank Refer to “FUEL TANK”. 1 2.
CHECKING THE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM CHK ADJ EAS00098 CHECKING THE BREATHER HOSE 1. Check: • crankcase-to-crankcase-breather-chamber hose 1 • air-filter-to-crankcase-breather-chamber hose 2 Cracks/damage → Replace. Loose connection → Connect properly. 2 1 CAUTION: _ Make sure the breather hoses are routed correctly. EAS00099 6 2 6 2 3 3 5 4 3 3 9 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets. 1.
CHECKING THE COOLANT LEVEL/ CHECKING THE COOLING SYSTEM CHK ADJ EAS00102 CHECKING THE COOLANT LEVEL 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. • Make sure the motorcycle is upright. _ 2. Check: • coolant level The coolant level should be between the maximum level mark a and minimum level mark b. Below the minimum level mark → Add the recommended coolant to the proper level.
CHECKING THE COOLING SYSTEM/ CHANGING THE COOLANT 2. • • • • • • 3 3 3. • 1 • • CHK ADJ Check: radiator 1 radiator outlet hose 2 radiator inlet hose 3 water pump assembly 4 water pump outlet pipe 5 water pump outlet hose 6 Cracks/damage → Replace. Refer to “COOLING SYSTEM” in chapter 6. Install: fuel tank Refer to “FUEL TANK”. side panels (left and right) seat Refer to “COWLING AND COVER”. 2 6 4 5 (3) EAS00105 CHANGING THE COOLANT 1.
CHANGING THE COOLANT CHK ADJ 2. Remove: • radiator cap retainer 1 • radiator cap 2 WARNING _ A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape.
CHANGING THE COOLANT CHK ADJ 10.Fill: • cooling system (with the specified amount of the recommended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity Total amount 1.00 L (0.88 Imp qt, 1.06 US qt) Coolant reservoir capacity 0.25 L (0.22 Imp qt, 0.26 US qt) From minimum to maximum level mark 0.15 L (0.13 Imp qt, 0.
CHANGING THE COOLANT CHK ADJ 11.Install: • radiator cap • radiator cap retainer T. R. a 7 Nm (0.7 m · kg, 5.1 ft · lb) 12.Fill: • coolant reservoir (with the recommended coolant to the maximum level mark a) 13.Install: • coolant reservoir cap 14.Start the engine, warm it up for several minutes, and then turn it off. 15.Check: • coolant level Refer to “CHECKING THE COOLANT LEVEL”. NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled. _ 16.
ADJUSTING THE REAR BRAKE PEDAL CHK ADJ EAS00110 CHASSIS ADJUSTING THE REAR BRAKE PEDAL 1. Check: • brake pedal position (distance a from the top of the rider footrest to the top of the brake pedal) Out of specification → Adjust. Brake pedal position (below the top of the rider footrest) 12.0 mm (0.47 in) 2. Adjust: • brake pedal position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut 1. b. Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained.
ADJUSTING THE REAR BRAKE PEDAL/ CHECKING THE BRAKE FLUID LEVEL CHK ADJ 3. Adjust: • rear brake light switch Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”. EAS00115 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. • Make sure the motorcycle is upright. _ È 2. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level.
CHECKING THE FRONT AND REAR BRAKE PADS AND BRAKE PAD PINS/ADJUSTING THE REAR BRAKE LIGHT SWITCH CHK ADJ EAS00118 È CHECKING THE FRONT AND REAR BRAKE PADS AND BRAKE PAD PINS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • front brake pads XT660R Wear indicator grooves 1 have almost disappeared → Replace the brake pads as a set. XT660X Wear limit 2 reached → Replace the brake pads as a set. Refer to “REPLACING THE FRONT BRAKE PADS” in chapter 4. 3.
ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE FRONT AND REAR BRAKE HOSES CHK ADJ 1. Check: • rear brake light operation timing Incorrect → Adjust. 2. Adjust: • rear brake light operation timing ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time. Direction a Brake light comes on sooner. Direction b Brake light comes on later.
BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ EAS00134 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING _ Bleed the hydraulic brake system whenever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. • brake operation is faulty. NOTE: • Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow.
BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SHIFT PEDAL CHK ADJ g. Loosen the bleed screw. NOTE: Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. _ h. Tighten the bleed screw, and then release the brake lever or brake pedal. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose. j. Tighten the bleed screw to the specified torque. T.
ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK CHK ADJ 2. Adjust: • shift pedal position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. b. c. d. 2 1 Remove the bolt 1. Remove the shift pedal 2. Install the shift pedal at the correct position. Install the bolt, and then tighten it to the specified torque. T. Shift pedal bolt 16 Nm (1.6 m · kg, 11 ft · lb) R.
ADJUSTING THE DRIVE CHAIN SLACK CHK ADJ 3. Check: • drive chain slack a Out of specification → Adjust. Drive chain slack 40.0 ~ 55.0 mm (1.57 ~ 2.17 in) 4. Adjust: • drive chain slack ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the wheel axle nut 1. b. Loosen both locknuts 2. c. Turn both adjusting nuts 3 in direction a or b until the specified drive chain slack is obtained. Direction a Drive chain is tightened. Direction b Drive chain is loosened.
LUBRICATING THE DRIVE CHAIN/ CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ EAS00142 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained properly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the motorcycle is used in dusty areas. This motorcycle has a drive chain with small rubber O-rings between each side plate.
CHECKING AND ADJUSTING THE STEERING HEAD 1 1 2 1 2 3 CHK ADJ 3. • • • • • Remove: handlebar protector cover (XT660X) handlebar protector (XT660X) handlebar holder caps upper handlebar holders 1 handlebar 2 4. • 5. • • • Loosen: upper bracket pinch bolts 1 Remove: steering stem nut 2 washer upper bracket 3 6. Adjust: • steering head ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the lock washer 1, the upper ring nut 2, and the rubber washer 3. b.
CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK CHK ADJ d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings. Refer to “STEERING HEAD” in chapter 4. e. Install the rubber washer 2. f. Install the upper ring nut 3. g. Finger tighten the upper ring nut 3, and then align the slots of both ring nuts.
CHECKING THE FRONT FORK/ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY CHK ADJ 3. Hold the motorcycle upright and apply the front brake. 4. Check: • front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement → Repair. Refer to “FRONT FORK” in chapter 4. EAS00156 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING _ Securely support the motorcycle so that there is no danger of it falling over.
CHECKING THE TIRES CHK ADJ EAS00166 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: • tire pressure Out of specification → Regulate. WARNING _ • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. • The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed.
CHECKING THE TIRES CHK ADJ XT660X Basic weight (with oil and a full fuel tank) 186.0 kg (410 lb) Maximum load* 186.0 kg (410 lb) Cold tire pressure Front Rear Up to 90 kg load* 210 kPa 210 kPa (2.10 kgf/cm2, (2.10 kgf/cm2, 30 psi) 30 psi) 90 kg ~ maximum load* 230 kPa 220 kPa (2.20 kgf/cm2, (2.30 kgf/cm2, 31 psi) 33 psi) * Total weight of rider, passenger, cargo and accessories WARNING _ It is dangerous to ride with a worn-out tire.
CHECKING THE TIRES È É CHK ADJ • Patching a punctured tube is not recommended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement. È Tire É Wheel Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire • After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design.
CHECKING THE TIRES/ CHECKING AND TIGHTENING THE SPOKES CHK ADJ WARNING _ New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. NOTE: For tires with a direction of rotation mark 1: • Install the tire with the mark pointing in the direction of wheel rotation. • Align the mark 2 with the valve installation point.
CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS AND BRAKE PEDAL/ LUBRICATING THE SIDESTAND CHK ADJ EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables. WARNING _ Damaged outer cable may cause the cable to corrode and interfere with its movement. Replace damaged outer cable and inner cables as soon as possible. 1. Check: • outer cable Damage → Replace. 2. Check: • cable operation Rough movement → Lubricate.
CHECKING AND CHARGING THE BATTERY CHK ADJ EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING _ Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries. • Charge batteries in a well-ventilated area. • Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).
CHECKING AND CHARGING THE BATTERY CHK ADJ NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. _ 1. Remove: • seat Refer to “COWLING AND COVER”. • battery cover Refer to “AIR FILTER CASE”. 2.
CHECKING AND CHARGING THE BATTERY Ambient temperature Open-circuit voltage (V) Charging CHK ADJ 5. Charge: • battery (refer to the appropriate charging method illustration) WARNING _ Do not quick charge a battery. Time (minutes) Check the open-circuit voltage. CAUTION: _ Open-circuit voltage (V) Ambient temperature Charging condition of the battery (%) • Never remove the MF battery sealing caps.
CHK ADJ CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger Charger Ammeter Measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. YES Is the amperage higher than the standard charging amperage written on the battery? NOTE: Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. NOTE: Set the charging voltage to 16 ~ 17 V.
CHECKING AND CHARGING THE BATTERY CHK ADJ Charging method using a constant voltage charger NOTE: Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. YES Is the amperage higher than the standard charging amperage written on the battery? Charge the battery until the charging voltage reaches 15 V.
CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. • 7. • 2 1 CHK ADJ Install: battery Connect: battery leads (to the battery terminals) CAUTION: _ First, connect the positive battery lead 1, then the negative battery lead 2. 8. Check: • battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. 9. Lubricate: • battery terminals Recommended lubricant Dielectric grease 10.Install: • battery cover Refer to “AIR FILTER CASE”. • seat Refer to “COWLING AND COVER”.
CHECKING THE FUSES 3 2 2. • • • CHK ADJ Check: fuse 1 fuse box 1 2 fuse box 2 3 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester to the fuse and check the continuity. 1 NOTE: Set the pocket tester selector to “Ω × 1”. _ Pocket tester 90890-03112 b. If the pocket tester indicates “∞”, replace the fuse. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Replace: • blown fuse ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the main switch to “OFF”. b. Install a new fuse of the correct amperage rating. c.
CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULB CHK ADJ WARNING _ Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Install: • left side panel • seat Refer to “COWLING AND COVER”. EAS00182 REPLACING THE HEADLIGHT BULB 1.
REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM 5. • • • CHK ADJ Install: headlight bulb New headlight bulb holder headlight bulb holder cover CAUTION: _ Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 6. • 7.
SETTING THE DIGITAL CLOCK CHK ADJ EAS00187 SETTING THE DIGITAL CLOCK 1. Set: • digital clock 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the main switch to “ON”. b. Push the “SELECT” button 2 and “RESET” button 3 together for at least two seconds. c. When the hour digits start flashing, push the “RESET” button to set the hours. d. Push the “SELECT” button and the minute digits will start flashing. e. Push the “RESET” button to set the minutes. f. Push the “SELECT” button to start the clock.
CHAS 4
CHAS CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISC............................................................... 4-1 FRONT WHEEL ........................................................................................4-2 REMOVING THE FRONT WHEEL............................................................ 4-3 CHECKING THE FRONT WHEEL ............................................................ 4-3 CHECKING THE FRONT BRAKE DISC ...................................................
CHAS FRONT FORK................................................................................................4-51 REMOVING THE FRONT FORK LEGS.................................................. 4-55 DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-55 CHECKING THE FRONT FORK LEGS .................................................. 4-57 ASSEMBLING THE FRONT FORK LEGS .............................................. 4-58 INSTALLING THE FRONT FORK LEGS .................................
FRONT WHEEL AND BRAKE DISC CHAS EAS00512 CHASSIS FRONT WHEEL AND BRAKE DISC T. R. 18 Nm (1.8 m • kg, 13 ft • Ib) T. R. 59 Nm (5.9 m • kg, 43 ft • Ib) 3 1 2 6 T. R. 40 Nm (4.0 m • kg, 29 ft • Ib) 7 5 4 (6) LT T. R. Order Job/Part Removing the front wheel and brake disc Q’ty 23 Nm (2.3 m • kg, 17 ft • Ib) Remarks Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
FRONT WHEEL AND BRAKE DISC CHAS EAS00518 FRONT WHEEL LS New 1 2 3 2 1 New LS Order 1 2 3 Job/Part Disassembling the front wheel Oil seal Bearing Spacer Q’ty Remarks Remove the parts in the order listed. 2 2 1 For assembly, reverse the disassembly procedure.
FRONT WHEEL AND BRAKE DISC CHAS EAS00519 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. WARNING _ Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. _ 2. Remove: • brake caliper NOTE: Do not apply the brake lever when removing the brake caliper. _ 3. Elevate: • front wheel NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
FRONT WHEEL AND BRAKE DISC CHAS 3. Check: • spokes Bends/damage → Replace. Loose → Tighten. Tap the spokes with a screwdriver. NOTE: A tight spoke will emit a clear, ringing tone, a loose spoke will sound flat. _ 4. Tighten: • spokes 1 (with a spoke wrench 2) T. R. 3 Nm (0.3 m · kg, 2.2 ft · lb) NOTE: After tightening the spokes, measure the front wheel runout. _ 5. Measure: • radial wheel runout 1 • lateral wheel runout 2 Over the specified limits → Replace. radial wheel runout limit 2.0 mm (0.
FRONT WHEEL AND BRAKE DISC CHAS 7. Check: • wheel bearings Front wheel turns roughly or is loose → Replace the wheel bearings. • oil seals Damage/wear → Replace. 8. Replace: • oil seals New • wheel bearings 2 1 New ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside of the front wheel hub. b. Remove the oil seals 1 with a flat-head screwdriver. NOTE: To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel surface. _ c.
FRONT WHEEL AND BRAKE DISC CHAS EAS00527 CHECKING THE FRONT BRAKE DISC 1. Check: • brake disc Damage/galling → Replace. 2. Measure: • brake disc deflection Out of specification → Correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maximum) 0.15 mm (0.006 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Place the motorcycle on a suitable stand so that the front wheel is elevated. b.
FRONT WHEEL AND BRAKE DISC CHAS 4. Adjust: • brake disc deflection ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. _ T. R. Brake disc bolt 23 Nm (2.3 m · kg, 17 ft · lb) LOCTITE® d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. f.
FRONT WHEEL AND BRAKE DISC CHAS T. 2. Tighten: • wheel axle 1 59 Nm (5.9 m · kg, 43 ft · lb) • wheel axle pinch bolts 2 R. T. R. 18 Nm (1.8 m · kg, 13 ft · lb) CAUTION: _ Before tightening the wheel axle nut, push down hard on the handlebar several times and check if the front fork rebounds smoothly. NOTE: To tighten the wheel axle pinch bolt, tighten the outer and inner bolts to the specified torque, and then tighten the outer bolt to the specified torque again. 3. Install: • brake caliper bolts T.
FRONT WHEEL AND BRAKE DISC CHAS 2. Find: • front wheel’s heavy spot NOTE: Place the front wheel on a suitable balancing stand. _ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Spin the front wheel. b. When the front wheel stops, put an “X1” mark at the bottom of the wheel. c. Turn the front wheel 90° so that the “X1” mark is positioned as shown. d. Release the front wheel. e. When the wheel stops, put an “X2” mark at the bottom of the wheel. f.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET CHAS EAS00550 REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET REAR WHEEL T. R. T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 105 Nm (10.5 m • kg, 75 ft • lb) 13 T. R. 3 16 Nm (1.6 m • kg, 11 ft • Ib) 6 8 7 9 LS 14 5 14 4 4 5 12 T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. 1 11 10 R. T. R. Order T. 2 16 Nm (1.6 m • kg, 11 ft • Ib) 7 Nm (0.7 m • kg, 5.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET T. R. T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) CHAS 105 Nm (10.5 m • kg, 75 ft • lb) 13 T. R. 3 16 Nm (1.6 m • kg, 11 ft • Ib) 6 8 7 9 LS 14 5 14 4 4 5 12 T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. 1 11 10 R. T. R. Order 10 T. 2 16 Nm (1.6 m • kg, 11 ft • Ib) 7 Nm (0.7 m • kg, 5.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET CHAS BRAKE DISC AND REAR WHEEL SPROCKET T. R. 13 Nm (1.3 m • kg, 9.4 ft • Ib) 7 LT (6) 6 4 5 LS 3 New 1 2 6 LS (6) T. R. Order 1 2 3 4 5 6 7 69 Nm (6.9 m • kg, 50 ft • Ib) Job/Part Removing the brake disc and rear wheel sprocket Oil seal Rear wheel sprocket Bearing Rear wheel drive hub Spacer Rear wheel drive hub damper Rear brake disc Q’ty Remarks Remove the parts in the order listed.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET Order 1 2 3 Job/Part Disassembling the rear wheel Bearing Oil seal Spacer Q’ty CHAS Remarks Remove the parts in the order listed. 2 1 1 For assembly, reverse the disassembly procedure.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET CHAS EAS00561 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. WARNING _ Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. _ 2. • • 3.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET CHAS 2. Check: • tire • rear wheel Damage/wear → Replace. Refer to “CHECKING THE TIRES” in chapter 3. 3. Check: • spokes Refer to “CHECKING THE FRONT WHEEL”. 4. Measure: • radial wheel runout • lateral wheel runout Refer to “CHECKING THE FRONT WHEEL”. EAS00527 CHECKING THE REAR BRAKE DISC 1. Check: • brake disc Damage/galling → Replace. 2. Measure: • brake disc deflection Out of specification → Correct the brake disc deflection or replace the brake disc.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET CHAS 3. Measure: • brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification → Replace. Brake disc thickness limit (minimum) 4.5 mm (0.18 in) 4. Adjust: • brake disc deflection ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. _ T. R.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET CHAS EAS00568 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Check: • rear wheel sprocket More than 1/4 tooth a wear → Replace the rear wheel sprocket. Bent teeth → Replace the rear wheel sprocket. b Correct 1 Drive chain roller 2 Rear wheel sprocket 2. Replace: • rear wheel sprocket ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the self-locking nuts and the rear wheel sprocket. b.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET 2. • • • • • CHAS Install: rear wheel washer (O) rear axle washer (N) rear axle nut NOTE: Install the washer with the “N” mark on the right-hand side of the vehicle and the washer with the “O” mark on the left-hand side of the vehicle. Be sure to install both washers with the marks facing outward. 3. Adjust: • drive chain slack Drive chain slack 40.0 ~ 55.0 mm (1.57 ~ 2.17 in) Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. 4.
CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS (XT660R) T. R. 14 Nm (1.4 m • kg, 10 ft • Ib) 5 4 6 3 1 5 2 1 T. R. Order 1 2 3 4 5 6 40 Nm (4.0 m • kg, 29 ft • Ib) Job/Part Removing the front brake pads Brake caliper bolt Brake pad clip Brake pad pin Brake pad Brake pad spring Bleed screw Q’ty 2 1 1 2 2 1 Remarks Remove the parts in the order listed. Refer to “REPLACING THE FRONT BRAKE PADS”. For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS FRONT BRAKE PADS (XT660X) T. R. 14 Nm (1.4 m • kg, 10 ft • Ib) 6 4 1 1 5 T. R. 40 Nm (4.0 m • kg, 29 ft • Ib) 2 2 3 Order 1 2 3 4 5 6 Job/Part Removing the front brake pads Brake caliper bolt Brake pad clip Brake pad pin Brake pad spring Brake pad Bleed screw Q’ty 2 2 2 1 2 1 Remarks Remove the parts in the order listed. Refer to “REPLACING THE FRONT BRAKE PADS”. For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EAS00578 REAR BRAKE PADS T. R. 14 Nm (1.4 m • kg, 10 ft • Ib) 1 2 5 4 3 4 Order 1 2 3 4 5 Job/Part Removing the rear brake pads Rear wheel Brake pad pin Retaining bolt Brake pad Brake pad spring Bleed screw Q’ty 1 1 2 2 1 Remarks Remove the parts in the order listed. Refer to “REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET”. Refer to “REPLACING THE REAR BRAKE PADS”. For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EAS00579 CAUTION: _ Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. • Never use solvents on internal brake components. • Use only clean or new brake fluid for cleaning brake components.
FRONT AND REAR BRAKES CHAS 2. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. È Brake pad wear limit 1.0 mm (0.04 in) È XT660R É XT660X 3. Check: • brake pad pin(s) Damage/wear → Replace. É È 2 1 4. Install: • brake pad springs • brake pads NOTE: Always replace the brake pads and brake pad springs as a set. _ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ É a. Connect a clear plastic hose 1 tightly to the bleed screw 2.
FRONT AND REAR BRAKES CHAS d. Install new brake pads and new brake pad springs. È NOTE: The arrow a on the brake pad spring must point in the direction of rotation. _ a È XT660R É XT660X ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ É R. Install: brake pad pin brake pad clip brake caliper T. 5. • • • 40 Nm (4.0 m · kg, 29 ft · lb) a 6. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 7.
FRONT AND REAR BRAKES a CHAS 3. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 1.0 mm (0.04 in) 4. Install: • brake pad springs • brake pads 1 2 NOTE: Always replace the brake pads and brake pad springs as a set. _ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a clear plastic hose 1 securely to the bleed screw 2. Put the other end of the hose into an open container. b.
CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER 1 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 2 11 3 4 12 8 T. R. 6 Nm (0.6 m • kg, 4.3 ft • Ib) LS 10 6 New 7 9 5 T. R. Order 1 2 3 4 Job/Part Removing the front brake master cylinder Brake fluid Rearview mirror (right) Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm Q’ty Remarks Remove the parts in the order listed. Drain. 1 1 1 1 4 - 26 30 Nm (3.
CHAS FRONT AND REAR BRAKES 1 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 2 11 3 4 12 8 T. R. 6 Nm (0.6 m • kg, 4.3 ft • Ib) LS 10 6 New 7 9 5 T. R. Order 5 6 7 8 9 10 11 12 Job/Part Front brake light switch Union bolt Copper washer Brake hose Brake lever Spring Brake master cylinder holder Brake master cylinder Q’ty 1 Disconnect. 1 2 1 Disconnect. 30 Nm (3.
FRONT AND REAR BRAKES CHAS EAS00585 Order 1 2 3 4 Job/Part Disassembling the front brake master cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder Q’ty Remarks Remove the parts in the order listed. 1 1 1 1 For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EAS00586 REAR BRAKE MASTER CYLINDER 1 2 T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) 3 4 6 7 New 5 8 9 10 New 13 11 12 LS T. R. 18 Nm (1.8 m • kg, 13 ft • Ib) T. R. Order 1 2 3 4 5 6 7 8 9 23 Nm (2.3 m • kg, 17 ft • Ib) Job/Part Q’ty Remarks Removing the rear brake master cylRemove the parts in the order listed. inder Brake fluid Drain.
FRONT AND REAR BRAKES CHAS 1 2 T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) 3 4 6 7 New 5 8 9 10 New 13 11 12 LS T. R. 18 Nm (1.8 m • kg, 13 ft • Ib) T. R. Order 10 11 12 13 23 Nm (2.3 m • kg, 17 ft • Ib) Job/Part Cotter pin Washer Pin Master cylinder Q’ty 1 1 1 1 Remarks Refer to “INSTALLING THE REAR BRAKE MASTER CYLINDER”. For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EAS00587 Order 1 2 3 Job/Part Disassembling the rear brake master cylinder Hose joint Brake master cylinder kit Brake master cylinder Q’ty 1 1 1 4 - 31 Remarks Remove the parts in the order listed. Refer to “ASSEMBLING THE REAR BRAKE MASTER CYLINDER”. For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. _ 1. Disconnect: • front brake light switch 1 NOTE: Push the fastener to remove the front brake light switch from the brake master cylinder. 2.
FRONT AND REAR BRAKES CHAS EAS00592 È CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to both of the brake master cylinders. 1. Check: • brake master cylinder 1 Damage/scratches/wear → Replace. • brake fluid delivery passages (brake master cylinder body) Obstruction → Blow out with compressed air. É È Front É Rear 1 È 2. Check: • brake master cylinder kit Damage/scratches/wear → Replace as a set. É È Front É Rear 1 3 2 1 2 3 3.
FRONT AND REAR BRAKES CHAS 5. Check: • brake hoses Cracks/damage/wear → Replace. EAS00598 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING _ • Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components. Recommended brake fluid DOT 4 1. Install: • brake master cylinder 1 • brake master cylinder holder 1 T. R. 7 Nm (0.7 m · kg, 5.
FRONT AND REAR BRAKES CHAS 3. Fill: • brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 WARNING _ • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
FRONT AND REAR BRAKES CHAS EAS00608 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING _ • All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid DOT 4 • Whenever a master cylinder is disassembled, replace the piston seals and dust seals. 1. Install: • brake master cylinder kit • joint 1 NOTE: Turn the adjusting bolt 2 until the clearance a is within the specified limits when install the joint 1. _ Clearance 2.1 mm (0.
FRONT AND REAR BRAKES 2 CHAS 2. Install: • right side heel plate T. R. 23 Nm (2.3 m · kg, 17 ft · lb) • copper washers New • brake hose 1 • union bolt 2 30 Nm (3.0 m · kg, 22 ft · lb) 1 T. R. WARNING a _ Proper brake hose routing is essential to insure safe motorcycle operation. Refer to “CABLE ROUTING” in chapter 2. CAUTION: _ When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection a as shown. 3.
FRONT AND REAR BRAKES CHAS 4. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 5. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 6. Adjust: • brake pedal position a Refer to “ADJUSTING THE REAR BRAKE PEDAL” in chapter 3. Brake pedal position (below the top of the rider footrest) 12.0 mm (0.47 in) 7.
FRONT AND REAR BRAKES CHAS EAS00612 FRONT BRAKE CALIPER (XT660R) T. R. 40 Nm (4.0 m • kg, 29 ft • Ib) 4 3 2 New 1 5 T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) New 2 Order 1 2 3 4 5 Job/Part Removing the front brake caliper Brake fluid Union bolt Copper washer Brake hose Front brake caliper bolt Brake caliper Q’ty 1 2 1 2 1 Remarks Remove the parts in the order listed. Drain. Disconnect. Refer to “INSTALLING THE FRONT BRAKE CALIPER”. For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EAS00614 LS 4 LS 3 4 2 1 5 T. R. Order 1 2 3 4 5 Job/Part Disassembling the front brake caliper Brake pad clip Brake pad pin Brake pad Brake pad spring Bleed screw 14 Nm (1.4 m • kg, 10 ft • Ib) Q’ty 1 1 2 2 1 Remarks Remove the parts in the order listed. Refer to “INSTALLING THE FRONT BRAKE CALIPER”. For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS FRONT BRAKE CALIPER (XT660X) T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) 3 1 2 New 4 5 T. R. 40 Nm (4.0 m • kg, 29 ft • Ib) Order 1 2 3 4 5 Job/Part Removing the front brake caliper Brake fluid Union bolt Copper washer Brake hose Front brake caliper bolt Brake caliper Q’ty 1 2 1 2 1 Remarks Remove the parts in the order listed. Drain. Disconnect. Refer to “INSTALLING THE FRONT BRAKE CALIPER”. For installation, reverse the removal procedure.
FRONT AND REAR BRAKES T. R. 14 Nm (1.4 m • kg, 10 ft • Ib) CHAS 5 3 1 2 1 4 Order 1 2 3 4 5 Job/Part Disassembling the front brake caliper Brake pad clip Brake pad pin Brake pad spring Brake pad Bleed screw Q’ty 2 2 1 2 1 Remarks Remove the parts in the order listed. Refer to “INSTALLING THE FRONT BRAKE CALIPER”. For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EAS00616 REAR BRAKE CALIPER T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) 2 New 3 T. 4 R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 5 1 T. R. Order 1 2 3 4 5 Job/Part Removing the rear brake caliper Brake fluid Rear wheel Brake caliper protector Union bolt Copper washer Brake hose Brake caliper Q’ty 1 1 2 1 1 4 Nm (0.4 m • kg, 2.9 ft • Ib) Remarks Remove the parts in the order listed. Drain. Refer to “REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET”. Disconnect.
FRONT AND REAR BRAKES CHAS EAS00617 2 T. R. 3 14 Nm (1.4 m • kg, 10 ft • Ib) 6 5 4 5 1 LS Order 1 2 3 4 5 6 Job/Part Disassembling the rear brake caliper Brake caliper bracket Brake pad clip Brake pad pin Brake pad Brake pad spring Bleed screw Q’ty 1 1 1 2 2 1 Remarks Remove the parts in the order listed. Refer to “INSTALLING THE REAR BRAKE CALIPER”. For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EAS00619 È REMOVING THE FRONT BRAKE CALIPER 4 NOTE: Before removing the brake caliper, drain the brake fluid from the entire brake system. _ 3 1 2 É 3 1. • • • • Remove: union bolt 1 copper washers 2 brake hose 3 brake caliper 4 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.
CHAS FRONT AND REAR BRAKES EAS00633 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule È Brake pads If necessary Brake hoses Every four years Brake fluid Every two years and whenever the brake is disassembled 1. Check: • brake caliper pistons 1 Rust/scratches/wear → Replace the brake caliper. • brake caliper body 2 Cracks/damage → Replace the brake caliper. • brake caliper Brake fluid leakage → Replace the brake caliper.
FRONT AND REAR BRAKES CHAS EAS00634 INSTALLING THE FRONT BRAKE CALIPER 1. Install: • brake pad springs • brake pads • brake pad pin(s) • brake pad clip(s) Refer to “FRONT BRAKE PADS”. 2. Install: • brake caliper 1 • brake caliper bolts 2 È 2 T. R. 3 40 Nm (4.0 m · kg, 29 ft · lb) • copper washers New • brake hose 3 • union bolt 4 30 Nm (3.0 m · kg, 22 ft · lb) 4 T. R. 1 WARNING _ É Proper brake hose routing is essential to insure safe motorcycle operation.
FRONT AND REAR BRAKES CHAS 3. Fill: • brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 WARNING _ • Use only the designated brake fluid. Other brake fluids may cause the piston seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
FRONT AND REAR BRAKES CHAS EAS00642 INSTALLING THE REAR BRAKE CALIPER 1. Install: • brake caliper springs • brake pads • brake pad pin • brake pad clip Refer to “REAR BRAKE PADS”. 3 2 b 1 T. a 2. Install: • brake caliper • rear wheel Refer to “REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET”. • copper washers New • brake hose 1 • union bolt 2 30 Nm (3.0 m · kg, 22 ft · lb) R. WARNING _ Proper brake hose routing is essential to insure safe motorcycle operation. Refer to “CABLE ROUTING” in chapter 2.
FRONT AND REAR BRAKES CHAS WARNING _ • Use only the designated brake fluid. Other brake fluids may cause the piston seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. • When refilling, be careful that water does not enter the brake fluid reservoir.
FRONT FORK CHAS EAS00646 FRONT FORK T. R. 18 Nm (1.8 m • kg, 13 ft • Ib) 7 6 T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) 8 5 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 2 2 10 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 9 R. T. R. 3 T. (4) 16 Nm (1.6 m • kg, 11 ft • Ib) 7 Nm (0.7 m • kg, 5.
FRONT FORK CHAS T. R. 18 Nm (1.8 m • kg, 13 ft • Ib) 7 6 T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) 8 5 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 2 2 10 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 9 R. T. R. 3 T. (4) 16 Nm (1.6 m • kg, 11 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 4 Order 6 7 8 9 10 Job/Part Upper bracket pinch bolt Cap bolt Lower bracket pinch bolt Front fork leg Front fork leg Q’ty 2 Loosen. 1 Loosen. 2 Loosen.
FRONT FORK CHAS EAS00648 T. R. 18 Nm (1.8 m • kg, 13 ft • Ib) 1 New 2 LS 3 5 New 6 A New 0 B 4 F C New 8 New E New 9 D R. Job/Part Disassembling the front fork legs 7 LT T. Order G Q’ty 30 Nm (3.0 m • kg, 22 ft • Ib) Remarks Remove the parts in the order listed. NOTE: The following the procedure applies to both of the front fork legs.
FRONT FORK CHAS T. R. 18 Nm (1.8 m • kg, 13 ft • Ib) 1 New 2 LS 3 5 New 6 A New 0 B 4 F C New 8 New E New 9 D R. Job/Part Oil seal Washer Outer tube bushing Oil flow stopper Inner tube bushing Outer tube Outer tube 7 LT T. Order A B C D E F G G 30 Nm (3.0 m • kg, 22 ft • Ib) Q’ty Remarks 1 1 Refer to “ASSEMBLING THE FRONT 1 FORK LEGS”. 1 1 1 XT660R 1 XT660X For assembly, reverse the disassembly procedure.
FRONT FORK CHAS EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. WARNING _ Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. _ 2. Remove: • brake hose holders 1 1 2 1 3.
FRONT FORK CHAS 2. Drain: • fork oil NOTE: Stroke the outer tube several times while draining the fork oil. 3. Remove: • dust seal 1 • oil seal clip 2 (with a flat-head screwdriver) CAUTION: _ Do not scratch the inner tube. 4. Remove: • damper rod bolt 1 • copper washer NOTE: While holding the damper rod assembly with the damper rod holder 2 and T-handle 3, loosen the damper rod bolt 1. _ Damper rod holder 90890-01460 T-handle 90890-01326 5. Remove: • inner tube ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
FRONT FORK CHAS • Avoid bottoming the inner tube into the outer tube during the above procedure, as the oil flow stopper will be damaged. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS00657 È 1 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: • inner tube 1 • outer tube 2 Bends/damage/scratches → Replace. 2 WARNING _ Do not attempt to straighten a bent inner tube as this may dangerously weaken it. É 1 È XT660R É XT660X 2 2.
FRONT FORK CHAS 3. Check: • damper rod 1 Damage/wear → Replace. Obstruction → Blow out all of the oil passages with compressed air. • oil flow stopper 2 Damage → Replace. 1 2 CAUTION: _ • The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particularly sensitive to foreign material. • When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork.
FRONT FORK CHAS 2. Lubricate: • inner tube’s outer surface Recommended lubricant Fork oil 10 W or equivalent 3. Tighten: • damper rod bolt 1 New T. 1 R. Damper rod bolt 30 Nm (3.0 m · kg, 22 ft · lb) LOCTITE® NOTE: While holding the damper rod with the damper rod holder 2 and T-handle 3, tighten the damper rod bolt. _ LT Damper rod holder 90890-01460 T-handle 90890-01326 4.
FRONT FORK CHAS 5. Install: • oil seal 1 New (with the fork seal driver weight 2 and fork seal driver attachment 3) CAUTION: _ Make sure the numbered side of the oil seal faces up. NOTE: • Before installing the oil seal, lubricate its lips with lithium-soap-based grease. • Lubricate the outer surface of the inner tube with fork oil. • Before installing the oil seal, cover the top of the front fork leg with a plastic bag 4 to protect the oil seal during installation. _ 6.
FRONT FORK CHAS 8. Fill: • front fork leg (with the specified amount of the recommended fork oil) Quantity (each front fork leg) XT660R 640.0 cm3 (22.53 Imp oz, 21.64 US oz) XT660X 600.0 cm3 (21.12 Imp oz, 20.29 US oz) Recommended oil Fork oil 10 W or equivalent 9. Measure: • front fork leg oil level a Out of specification → Correct. Front fork leg oil level (from the top of the inner tube, with the inner tube fully compressed and without the fork spring) 125.0 mm (4.
FRONT FORK CHAS EAS00662 b a INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: • front fork leg Temporarily tighten the lower bracket pinch bolts. NOTE: To install the front fork leg, align the inner tube a with the lower edge b of the bevel on the upper bracket as shown. _ 2. Tighten: • lower bracket pinch bolts 1 T. R. 23 Nm (2.3 m · kg, 17 ft · lb) T. 18 Nm (1.8 m · kg, 13 ft · lb) • cap bolt 2 • upper bracket pinch bolts 3 R. T. R.
HANDLEBAR CHAS EAS00664 HANDLEBAR T. R. 1 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) 13 1 5 3 16 14 11 8 16 9 LS 6 2 17 12 4 2 10 6 15 LS 7 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. 7 Nm (0.7 m • kg, 5.
HANDLEBAR T. R. 1 CHAS 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) 13 1 5 3 16 14 11 8 16 9 LS 6 2 17 12 2 4 10 6 15 LS 7 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order 13 14 15 Job/Part Clutch lever Left handlebar switch Handlebar grip 16 17 Upper handlebar holder Handlebar Q’ty Remarks 1 Refer to “INSTALLING THE HANDLEBAR”. 1 1 Refer to “REMOVING THE HANDLEBAR” and “INSTALLING THE HANDLEBAR”.
HANDLEBAR CHAS EAS00666 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING _ Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • front brake light switch 1 • clutch switch NOTE: • Push the fastener to remove the front brake light switch from the brake master cylinder. • Push the fastener to remove the clutch switch from the clutch lever. 3.
HANDLEBAR a 2. Install: • handlebar 1 • upper handlebar holders 2 2 2 T. R. 23 Nm (2.3 m · kg, 17 ft · lb) • handlebar protector (XT660X) • handlebar protector cover (XT660X) 1 b CHAS CAUTION: _ • First, tighten the bolts on the front side of the upper handlebar holder, then the bolts on the rear side. • Turn the handlebar all the way to the left and right. If there is any contact with the fuel tank, adjust the handlebar position.
HANDLEBAR 1 CHAS 4. Install: • left handlebar switch 1 b NOTE: Align the projection a on the left handlebar switch with the hole b in the handlebar. _ a 5. Install: • clutch lever • clutch lever holder 1 1 T. a R. 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: Align the mating surfaces of the clutch lever holder with the punch mark a on the handlebar. _ 1 Install: throttle grip 1 throttle cables 2 right handlebar switch 3 7 Nm (0.7 m · kg, 5.1 ft · lb) grip end T. R. 2 6.
HANDLEBAR CHAS 8. Install: • brake master cylinder • brake master cylinder holder Refer to “FRONT AND REAR BRAKES”. 9. Adjust: • clutch cable free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PLAY” in chapter 3. Clutch cable free play (at the end of the clutch lever) 10.0 ~ 15.0 mm (0.39 ~ 0.59 in) 10.Adjust: • throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3. Throttle cable free play (at the flange of the throttle grip) 3.0 ~ 5.0 mm (0.12 ~ 0.
CHAS STEERING HEAD EAS00675 STEERING HEAD LOWER BRACKET T. T. R. 32 Nm (3.2 m • kg, 23 ft • Ib) R. . T . R 23 Nm (2.3 m • kg, 17 ft • Ib) 130 Nm (13.0 m • kg, 94 ft • lb) 1 4 1 T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) 15 LS 13 5 16 2 6 10 3 32 Nm (3.2 m • kg, 23 ft • Ib) T. R. . R. T. R. Order 1 2 3 4 5 6 7 8 9 10 R T. LS 14 . T 7 8 9 11 23 Nm (2.3 m • kg, 17 ft • Ib) 1st 43 Nm (4.3 m • kg, 31 ft • lb) 2nd 7 Nm (0.7 m • kg, 5.1 ft • lb) 12 23 Nm (2.
CHAS STEERING HEAD T. T. R. 32 Nm (3.2 m • kg, 23 ft • Ib) R. . T . R 23 Nm (2.3 m • kg, 17 ft • Ib) 130 Nm (13.0 m • kg, 94 ft • lb) 1 4 1 T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) 15 LS 13 5 16 2 6 10 3 32 Nm (3.2 m • kg, 23 ft • Ib) T. R. . R. T. R. Order 11 12 13 14 15 16 R T. LS 14 . T 7 8 9 11 23 Nm (2.3 m • kg, 17 ft • Ib) 1st 43 Nm (4.3 m • kg, 31 ft • lb) 2nd 7 Nm (0.7 m • kg, 5.1 ft • lb) 12 23 Nm (2.
STEERING HEAD CHAS EAS00679 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. WARNING _ Securely support the motorcycle so that there is no danger of it falling over. 3 4 2. • • • • Remove: upper ring nut 1 rubber washer lower ring nut 2 lower bracket NOTE: Hold the lower ring nut with the steering nut wrench 3, and then remove the upper ring nut with the ring nut wrench 4.
STEERING HEAD CHAS 3. Replace: • bearings • bearing races ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. c. Install a new dust seal and new bearing races. CAUTION: _ If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: • Always replace the bearings and bearing races as a set.
STEERING HEAD CHAS 3. Install: • upper bracket • steering stem nut NOTE: Temporarily tighten the steering stem nut. _ 4. Install: • front fork legs Refer to “INSTALLING THE FRONT FORK LEGS”. NOTE: Temporarily tighten the lower bracket pinch bolts. _ 5. Tighten: • steering stem nut T. R. 130 Nm (13.0 m · kg, 94 ft · lb) 6. Install: • lower handlebar holders • lower handlebar holder nuts NOTE: Temporarily tighten the lower handlebar nuts. 7.
CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY T. R. 59 Nm (5.9 m • kg, 43 ft • Ib) T. R. 7 59 Nm (5.9 m • kg, 43 ft • Ib) T. R. 42 Nm (4.2 m • kg, 30 ft • Ib) T. R. 8 59 Nm (5.
CHAS REAR SHOCK ABSORBER ASSEMBLY T. R. 59 Nm (5.9 m • kg, 43 ft • Ib) T. R. 7 59 Nm (5.9 m • kg, 43 ft • Ib) T. R. 42 Nm (4.2 m • kg, 30 ft • Ib) T. R. 8 59 Nm (5.
REAR SHOCK ABSORBER ASSEMBLY CHAS EAS00686 HANDLING THE REAR SHOCK ABSORBER WARNING _ This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber. • Do not tamper or attempt to open the rear shock absorber.
REAR SHOCK ABSORBER ASSEMBLY CHAS EAS00690 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the motorcycle on a level surface. WARNING _ Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. _ 2. Remove: • connecting arm bolt 1 • rear shock absorber assembly lower bolt 2 NOTE: While removing the rear shock absorber assembly lower bolt, hold the swingarm so that it does not drop down. 2 1 3.
REAR SHOCK ABSORBER ASSEMBLY CHAS EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: • rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly. • rear shock absorber Gas leaks/oil leaks → Replace the rear shock absorber assembly. • spring Damage/wear → Replace the rear shock absorber assembly. • bolts Bends/damage/wear → Replace. CHECKING THE CONNECTING ARMS AND RELAY ARM 1. Check: • connecting arms 1 • relay arm 2 Damage/wear → Replace. 2.
REAR SHOCK ABSORBER ASSEMBLY CHAS EAS00697 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: • bearings • bolts Recommended lubricant Lithium-soap-based grease 2. Install: • rear shock absorber assembly NOTE: When installing the rear shock absorber assembly, lift up the swingarm. _ 3. Tighten: • rear shock absorber assembly upper nut T. R. 59 Nm (5.9 m · kg, 43 ft · lb) • rear shock absorber assembly lower nut T. R. 42 Nm (4.2 m · kg, 30 ft · lb) • relay-arm-to-frame nut T. R. 59 Nm (5.
CHAS SWINGARM AND DRIVE CHAIN EAS00700 SWINGARM AND DRIVE CHAIN R. R. T. T. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 3 59 Nm (5.9 m • kg, 43 ft • Ib) T. R. T. R. 120 Nm (12.0 m • kg, 85 ft • lb) 2 23 Nm (2.3 m • kg, 17 ft • Ib) T. R. 92Nm (9.2 m • kg, 66 ft • Ib) LS 1 New LS 11 T. R. 48 Nm (4.8 m • kg, 35 ft • Ib) 23 Nm (2.3 m • kg, 17 ft • Ib) T. R. 6 9 7 LS 8 New 17 18 11 10 15 14 18 14 10 4 15 16 LS LS 5 19 12 13 LS LS T. R. T. R. T. R. T. R. 10 Nm (1.
CHAS SWINGARM AND DRIVE CHAIN R. R. T. T. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 3 59 Nm (5.9 m • kg, 43 ft • Ib) T. R. T. R. 120 Nm (12.0 m • kg, 85 ft • lb) 2 23 Nm (2.3 m • kg, 17 ft • Ib) T. R. 92Nm (9.2 m • kg, 66 ft • Ib) LS 1 New LS 11 T. R. 48 Nm (4.8 m • kg, 35 ft • Ib) 23 Nm (2.3 m • kg, 17 ft • Ib) T. R. 6 9 7 LS 8 New 17 18 11 10 15 14 18 14 10 4 15 16 LS LS 5 19 12 13 LS LS T. R. T. R. 23 Nm (2.
SWINGARM AND DRIVE CHAIN CHAS EAS00703 REMOVING THE SWINGARM 1. Stand the motorcycle on a level surface. WARNING _ Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. _ 2. Measure: • swingarm side play • swingarm vertical movement ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure the tightening torque of the pivot shaft nut. T. Pivot shaft nut 92 Nm (9.2 m · kg, 66 ft · lb) R. b.
SWINGARM AND DRIVE CHAIN CHAS REMOVING THE DRIVE SPROCKET NOTE: Loosen the drive sprocket nut before removing the rear wheel. 2 1 3 1. • • 2. 3. • • • Remove: drive sprocket cover chain guard Straighten the lock washer tab a Remove: drive sprocket nut 1 lock washer 2 drive sprocket 3 a EAS00704 REMOVING THE DRIVE CHAIN 1. Stand the motorcycle on a level surface. WARNING _ Securely support the motorcycle so that there is no danger of it falling over.
SWINGARM AND DRIVE CHAIN CHAS 2. Check: • pivot shaft Roll the pivot shaft on a flat surface. Bends → Replace. WARNING _ Do not attempt to straighten a bent pivot shaft. 3. • • • • • Wash: pivot shaft dust covers spacer bushing bearings Recommended cleaning solvent Kerosene 4. • • • Check: dust covers spacers oil seals Damage/wear → Replace. • bearings • bushings Damage/pitting → Replace. EAS00709 CHECKING THE DRIVE CHAIN 1.
SWINGARM AND DRIVE CHAIN CHAS 2. Check: • drive chain Stiffness → Clean and lubricate or replace. 3. Clean: • drive chain ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wipe the drive chain with a clean cloth. b. Put the drive chain in kerosene and remove any remaining dirt. c. Remove the drive chain from the kerosene and completely dry it. CAUTION: _ • This motorcycle has a drive chain with small rubber O-rings 1 between the drive chain side plates.
SWINGARM AND DRIVE CHAIN CHAS 5. Lubricate: • drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 6. Check: • drive sprocket • rear wheel sprocket More than 1/4 tooth a wear → Replace the drive chain sprockets as a set. Bent teeth → Replace the drive chain sprockets as a set. b Correct 1 Drive chain roller 2 Drive chain sprocket EAS00711 INSTALLING THE SWINGARM 1.
SWINGARM AND DRIVE CHAIN 3. • • • Install: swingarm pivot shaft pivot shaft nut T. R. 4. • • • R. 3 1 1 59 Nm (5.9 m · kg, 43 ft · lb) • rear wheel Refer to “INSTALLING WHEEL”. 5. Install: • drive sprocket 1 • lock washer 2 New • drive sprocket nut 3 T. R. a 92 Nm (9.2 m · kg, 66 ft · lb) Install: connecting arm bolt washer connecting arm nut T. New 2 3 CHAS THE REAR 120 Nm (12.0 m · kg, 85 ft · lb) NOTE: • Install the drive sprocket 1 and drive sprocket nut 3 in the direction shown.
ENG 5
ENG CHAPTER 5 ENGINE ENGINE REMOVAL ........................................................................................5-1 EXHAUST PIPES AND MUFFLERS .........................................................5-1 LEADS, CABLES, HOSES, AND IGNITION COIL ....................................5-2 ENGINE..................................................................................................... 5-5 INSTALLING THE ENGINE.......................................................................
ENG CLUTCH ........................................................................................................5-40 CLUTCH COVER ....................................................................................5-40 PULL LEVER SHAFT .............................................................................. 5-41 CLUTCH .................................................................................................. 5-42 REMOVING THE CLUTCH ..........................................................
ENG CRANKCASE ................................................................................................5-69 CRANKCASE BEARINGS....................................................................... 5-71 SEPARATING THE CRANKCASE.......................................................... 5-72 CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE 3 ............. 5-72 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDES ..........5-73 CHECKING THE BEARINGS AND OIL SEALS......................................
ENG
ENGINE REMOVAL ENG EAS00188 ENGINE ENGINE REMOVAL EXHAUST PIPES AND MUFFLERS R. R. 27 Nm (2.7 m • kg, 19 ft • Ib) T. T. 27 Nm (2.7 m • kg, 19 ft • Ib) 1 1 LS LS T. R. 20 Nm (2.0 m • kg, 14 ft • Ib) 3 New 3 New New 3 New 3 LT LT 4 2 T. R. T. R. T. R. 27 Nm (2.7 m • kg, 19 ft • Ib) LT T. R. R. R. Job/Part Removing the exhaust pipes and mufflers Muffler (left and right) Exhaust pipe (left and right) Gasket Exhaust pipe bracket T. T. 1 2 3 4 20 Nm (2.
ENG ENGINE REMOVAL LEADS, CABLES, HOSES, AND IGNITION COIL * Apply sealant T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) Yamaha bond No. 1215 90890-85505 5 New LS 2 LT 8 9 7 6 13 11 ∗ 8 7 New 1 6 12 4 R. LS T. 3 10 7 Nm (0.7 m • kg, 5.1 ft • Ib) 14 T. R. 16 Nm (1.
ENG ENGINE REMOVAL * Apply sealant T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) Yamaha bond No. 1215 90890-85505 5 New LS 2 LT 8 9 7 6 13 11 ∗ 8 7 New 1 6 12 4 R. LS T. 3 10 7 Nm (0.7 m • kg, 5.1 ft • Ib) 14 T. R. 16 Nm (1.
ENG ENGINE REMOVAL * Apply sealant T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) Yamaha bond No. 1215 90890-85505 5 New LS 2 LT 8 9 7 6 13 11 ∗ 8 7 New 1 6 12 4 R. LS T. 3 10 7 Nm (0.7 m • kg, 5.1 ft • Ib) 14 T. R. 16 Nm (1.6 m • kg, 11 ft • Ib) Order 3 4 5 6 7 8 9 10 11 12 13 14 Job/Part Oil delivery hose 2 Oil tank breather hose Crankcase-to-crankcase-breatherchamber hose A.C.
ENG ENGINE REMOVAL EAS00191 ENGINE T. R. 5 6 73 Nm (7.3 m • kg, 53 ft • lb) 5 5 7 8 6 4 2 5 4 1 2 T. R. 55 Nm (5.5m • kg, 40 ft • Ib) T. R. 73 Nm (7.3 m • kg, 53 ft • lb) 1 3 9 1 T. R. Order 1 Job/Part Removing the engine Q’ty 73 Nm (7.3 m • kg, 53 ft • lb) Remarks Remove the parts in the order listed. NOTE: Place a suitable stand under the frame and engine. _ CAUTION: Install all of the nuts and bolt, and then tighten them to specified torques.
ENG ENGINE REMOVAL T. R. 5 6 73 Nm (7.3 m • kg, 53 ft • lb) 5 5 7 8 6 4 2 5 4 1 2 T. R. 55 Nm (5.5m • kg, 40 ft • Ib) T. R. 73 Nm (7.3 m • kg, 53 ft • lb) 1 3 9 1 T. R. Order 7 8 9 Job/Part Engine upper bracket (right) Engine upper bracket (left) Engine 1 73 Nm (7.3 m • kg, 53 ft • lb) Q’ty Remarks 1 1 1 NOTE: Remove the Refer to “INSTALLengine from the ING THE ENGINE”. right side of the motorcycle. For installation, reverse the removal procedure.
ENGINE REMOVAL ENG EAS00192 INSTALLING THE ENGINE 1. Install: • engine front bracket 1 • engine front bracket bolt/nut 2 • engine front mounting bolt/nut 3 • engine rear mounting bolt/nut 4 • engine front bracket bolt/nut 5 • engine front mounting bolt/nut 6 • engine upper bracket (left) 7 • engine upper bracket (right) 8 • engine upper bracket bolts/nuts 9 • engine upper mounting bolt/nut 0 9 0 98 7 4 0 9 2 5 9 4 2 3 5 NOTE: Do not fully tighten the bolts. 3 6 1 6 2.
ENG CYLINDER HEAD EAS00221 CYLINDER HEAD T. 20 Nm (2.0 m • kg, 14 ft • Ib) R. T. R. 13 Nm (1.3 m • kg, 9.4 ft • Ib) T. R. 50 Nm (5.0 m • kg, 36 ft • Ib) 20 Nm (2.0 m • kg, 14 ft • Ib) T. R. E T. 1 R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) New New 3 (4) 7 LS New 8 New New New 12 3 E New 3 6 10 11 (4) 3 9 LS 2 New 4 New 5 New New T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) E LS T. R. T. T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 20 Nm (2.0 m • kg, 14 ft • Ib) R.
ENG CYLINDER HEAD T. 20 Nm (2.0 m • kg, 14 ft • Ib) R. T. R. 13 Nm (1.3 m • kg, 9.4 ft • Ib) T. R. 50 Nm (5.0 m • kg, 36 ft • Ib) 20 Nm (2.0 m • kg, 14 ft • Ib) T. R. E T. 1 R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) New New 3 (4) 7 LS New 8 New New New 12 3 E New 3 6 10 11 (4) 3 9 LS 2 New 4 New 5 New New T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) E LS T. R. T. T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 20 Nm (2.0 m • kg, 14 ft • Ib) R.
CYLINDER HEAD ENG EAS00225 b a REMOVING THE CYLINDER HEAD 1. Align: • “I” mark a on the A.C. magneto rotor (with the stationary pointer b on the A.C. magneto cover) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise. b. When the piston is at top dead center (TDC) on the compression stroke, align the “I” mark c on the camshaft sprocket with the stationary pointer d on the cylinder head. d ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ c 2.
CYLINDER HEAD ENG EAS00229 CHECKING THE CYLINDER HEAD 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damaging or scratching: • spark plug bore threads • valve seats _ 2. Check: • cylinder head Damage/scratches → Replace. • cylinder head water jacket Mineral deposits/rust → Eliminate. 3. Measure: • cylinder head warpage Out of specification → Resurface the cylinder head. Maximum cylinder head warpage 0.03 mm (0.
CYLINDER HEAD ENG EAS00212 2 1 3 3 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER 1. Check: • tappet covers 1 • camshaft sprocket cover 2 • O-rings 3 Damage/wear → Replace the defective part(s). EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • timing chain tensioner Cracks/damage → Replace. 2. Check: • one-way cam operation Rough movement → Replace the timing chain tensioner housing. 3.
CYLINDER HEAD 2. • • • ENG Install: cylinder head washers New cylinder head bolts NOTE: • Lubricate the cylinder head bolt threads and muting surface with engine oil. • Install the washers with their blunt surface facing the bolt seat. 3. Tighten: • cylinder head bolts 1 4 T. 3 R. 2 • cylinder head bolts 2 1 T. R. 2 = 145 mm (5.71 in) 50 Nm (5.0 m · kg, 36 ft · lb) • cylinder head bolts 3 1 4 T. R. 4 = 135 mm (5.31 in) 50 Nm (5.0 m · kg, 36 ft · lb) 45 Nm (4.
CYLINDER HEAD e 3 d 1 2 ENG c. Install the timing chain 1 onto the camshaft sprocket 2, then the camshaft sprocket onto the camshaft, and then finger tighten the camshaft sprocket bolts. NOTE: To install the camshaft sprocket sprocket, install the projection 3 on the camshaft sprocket into the slot a in the decompression lever. d. Make sure the “I” mark d on the camshaft sprocket with the stationary pointer e on the cylinder head.
CYLINDER HEAD ENG d. Install the spring and timing chain tensioner cap bolt. T. Timing chain tensioner cap bolt 20 Nm (2.0 m · kg, 14 ft · lb) R. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b a 6. Turn: • crankshaft (several turns counterclockwise) 7. Check: • “I” mark a NOTE: Check that the “I” mark on the A.C. magneto rotor is aligned with the stationary pointer b on the A.C. magneto cover.
ROCKER ARMS AND CAMSHAFT ENG ROCKER ARMS AND CAMSHAFT T. R. 14 Nm (1.4 m • kg, 10 ft • Ib) 4 4 3 T. R. 4 14 Nm (1.4 m • kg, 10 ft • Ib) 2 4 3 E 8 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 7 M 5 E 1 M 2 E M Order 1 2 3 4 5 6 6 LT Job/Part Q’ty Remarks Removing the rocker arms and camRemove the parts in the order listed. shaft Cylinder head Refer to “CYLINDER HEAD”.
ROCKER ARMS AND CAMSHAFT ENG T. R. 14 Nm (1.4 m • kg, 10 ft • Ib) 4 4 3 T. R. 4 14 Nm (1.4 m • kg, 10 ft • Ib) 2 4 3 E 8 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 7 M 5 E 1 M 2 E M Order 7 8 Job/Part Decompressor lever pin Bearing Q’ty 1 1 5 - 17 6 LT Remarks Refer to “REMOVING THE ROCKER ARMS AND CAMSHAFT” and “INSTALLING THE CAMSHAFT AND ROCKER ARMS”. For installation, reverse the removal procedure.
ROCKER ARMS AND CAMSHAFT ENG EAS00202 1 2 1 REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Loosen: • locknuts • adjusting screws 2. Remove: • camshaft retainer 1 3. • • • • Remove: intake rocker arm shaft exhaust rocker arm shaft intake rocker arm exhaust rocker arm NOTE: Remove the rocker arm shafts with the slide hammer bolt 1 and weight 2. _ Slide hammer bolt 90890-01083 Weight 90890-01084 4. Remove: • camshaft EAS00205 CHECKING THE CAMSHAFT 1.
ROCKER ARMS AND CAMSHAFT ENG 2. Measure: • camshaft lobe dimensions a and b Out of specification → Replace the camshaft. Camshaft lobe dimensions Intake a 43.488 ~ 43.588 mm (1.7121 ~ 1.7161 in) : 43.388 mm (1.7062 in) b 36.959 ~ 37.059 mm (1.4551 ~ 1.4590 in) : 36.840 mm (1.4504 in) Exhaust a 43.129 ~ 43.229 mm (1.6980 ~ 1.7019 in) : 42.983 mm (1.6922 in) b 37.007 ~ 37.107 mm (1.4570 ~ 1.4609 in) : 36.886 mm (1.4522 in) 3.
ROCKER ARMS AND CAMSHAFT ENG EAS00206 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to both of the rocker arms and rocker arm shafts. 1. Check: • rocker arm Damage/wear → Replace. 2. Check: • rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches → Replace or check the lubrication system. 3. Measure: • rocker arm inside diameter Out of specification → Replace. Rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) : 12.036 mm (0.
ROCKER ARMS AND CAMSHAFT ENG 5. Calculate: • rocker-arm-to-rocker-arm-shaft clearance NOTE: Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter. _ Above 0.081 mm (0.0032 in) → Replace the defective part(s). Rocker-arm-to-rocker-arm-shaft clearance 0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) : 0.081 mm (0.0032 in) EAS00220 1 a b INSTALLING THE CAMSHAFT AND ROCKER ARMS 1.
ROCKER ARMS AND CAMSHAFT ENG 3. Install: • decompressor lever pin 1 • decompressor lever 2 1 2 NOTE: Install the decompressor lever pin 1 and decompressor lever 2 in the camshaft 3 as shown in the illustration. _ 3 a 4. Install: • camshaft 1 NOTE: Install the camshaft on the slot a facing up. 5. Lubricate: • rocker arm shafts 1 Recommended lubricant Engine oil 1 2 3 6.
ENG VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS 1 3 3 2 1 2 2 2 6 3 M 6 M 7 6 7 New 7 M 7 3 6 New M New 5 4 4 5 M Order 1 2 3 4 5 6 7 Job/Part Removing the valves and valve springs Cylinder head Rocker arms/rocker arm shafts/camshaft Valve cotter Valve spring retainer Valve spring Exhaust valve Intake valve Valve stem seal Valve spring seat Q’ty Remarks Remove the parts in the order listed. Refer to “CYLINDER HEAD”. Refer to “ROCKER ARMS AND CAMSHAFT”.
VALVES AND VALVE SPRINGS ENG EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. _ 1. Check: • valve sealing Leakage at the valve seat → Check the valve face, valve seat, and valve seat width. Refer to “CHECKING THE VALVE SEATS”. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
VALVES AND VALVE SPRINGS 3. • • • • • ENG Remove: valve spring retainer 1 valve spring 2 valve stem seal 3 valve spring seat 4 valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. _ EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1.
VALVES AND VALVE SPRINGS ENG 2. Replace: • valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. _ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve guide with the valve guide remover 1. b. Install the new valve guide with the valve guide installer 2 and valve guide remover 1. c.
VALVES AND VALVE SPRINGS ENG 6. Measure: • valve stem runout Out of specification → Replace the valve. NOTE: • When installing a new valve, always replace the valve guide. • If the valve is removed or replaced, always replace the valve stem seal. _ Valve stem runout 0.010 mm (0.0004 in) EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. 1. Eliminate: • carbon deposits (from the valve face and valve seat) 2.
VALVES AND VALVE SPRINGS ENG 4. Lap: • valve face • valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. _ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a coarse lapping compound a to the valve face. CAUTION: _ Do not let the lapping compound enter the gap between the valve stem and the valve guide. b. Apply molybdenum disulfide oil onto the valve stem. c. Install the valve into the cylinder head. d.
VALVES AND VALVE SPRINGS ENG EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: • valve spring free length a Out of specification → Replace the valve spring. Valve spring free length Intake 40.38 mm (1.59 in) : 38.36 mm (1.51 in) Exhaust 40.38 mm (1.59 in) : 38.36 mm (1.51 in) 2. Measure: • compressed valve spring force a Out of specification → Replace the valve spring.
VALVES AND VALVE SPRINGS ENG EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: • valve stem end (with an oil stone) 2. Lubricate: • valve stem 1 • valve stem seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3.
VALVES AND VALVE SPRINGS ENG 4. Install: • valve cotters NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2. _ Valve spring compressor 98090-04019 Valve spring compressor attachment 90890-01243 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. CAUTION: _ Hitting the valve tip with excessive force can damage the valve.
ENG CYLINDER AND PISTON EAS00251 CYLINDER AND PISTON New R. E T. 1 1st 15 Nm (1.5 m • kg, 11 ft • lb) 2nd 50 Nm (5.0 m • kg, 36 ft • lb) New T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) New E New LS 3 New 4 10 11 12 E 9 5 New 2 UP 6 New 7 6 8 T. R. 10 Nm (1.0 m • kg, 7.
ENG CYLINDER AND PISTON New R. E T. 1 1st 15 Nm (1.5 m • kg, 11 ft • lb) 2nd 50 Nm (5.0 m • kg, 36 ft • lb) New T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) New E New LS 3 New 4 10 11 12 E 9 5 New 2 UP 6 New 7 6 8 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) E Order 11 12 Job/Part 2nd ring Oil ring 7 New Q’ty 1 1 5 - 33 Remarks Refer to “REMOVING THE CYLINDER AND PISTON” and “INSTALLING THE PISTON AND CYLINDER”. For installation, reverse the removal procedure.
CYLINDER AND PISTON ENG EAS00253 2 1 REMOVING THE CYLINDER AND PISTON 1. Remove: • piston pin clips 1 • piston pin 2 • piston 3 CAUTION: _ 3 Do not use a hammer to drive the piston pin out. NOTE: • Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. • Before removing the piston pin, deburr the piston pin clip’s groove and the piston’s pin bore area.
CYLINDER AND PISTON ENG 2. Measure: • piston-to-cylinder clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure cylinder bore “C” with the cylinder bore gauge. NOTE: Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the cylinder. Then, find the average of the measurements. _ Cylinder bore “C” 100.000 ~ 100.010 mm (3.9370 ~ 3.9374 in) Taper limit “T” 0.05 mm (0.002 in) Out-of-round “R” 0.05 mm (0.
CYLINDER AND PISTON ENG EAS00263 CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance Out of specification → Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. _ Piston ring side clearance Top ring 0.030 ~ 0.080 mm (0.0012 ~ 0.0031 in) : 0.13 mm (0.0051 in) 2nd ring 0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in) : 0.11 mm (0.0043 in) 2.
CYLINDER AND PISTON ENG EAS00265 CHECKING THE PISTON PIN 1. Check: • piston pin Blue discoloration/grooves → Replace the piston pin, and then check the lubrication system. 2. Measure: • piston pin outside diameter a Out of specification → Replace the piston pin. Piston pin outside diameter 22.991 ~ 23.000 mm (0.9052 ~ 0.9055 in) : 22.971 mm (0.9044 in) 3. Measure: • piston pin bore inside diameter b Out of specification → Replace the piston. Piston pin bore inside diameter 23.004 ~ 23.015 mm (0.
CYLINDER AND PISTON ENG EAS00267 INSTALLING THE PISTON AND CYLINDER 1. Install: • top ring 1 • 2nd ring 2 • oil ring expander 3 • lower oil ring rail 4 • upper oil ring rail 5 NOTE: Be sure to install the piston rings so that the manufacturer’s marks or numbers face up. _ 2. • • • 1 a Install: piston 1 piston pin 2 piston pin clips 3 New NOTE: • Apply engine oil to the piston pin. • Make sure the punch mark a on the piston points towards the exhaust side of the cylinder.
CYLINDER AND PISTON 120˚ e 120˚ 5. Offset: • piston ring end gaps a a Top ring b Upper oil ring rail c Oil ring expander d Lower oil ring rail e 2nd ring f 20 mm (0.79 in) È Exhaust side 120˚ f f d c È ENG b 6. Install: • cylinder 1 • timing chain guide (exhaust) 1 NOTE: • While compressing the piston rings with one hand, install the cylinder with the other hand. • Pass the timing chain and timing chain guide (exhaust side) through the timing chain cavity. _ 7.
CLUTCH ENG EAS00273 CLUTCH CLUTCH COVER T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 2 1 5 5 4 New (7) 3 T. R. Order 10 Nm (1.0 m • kg, 7.2 ft • Ib) Job/Part Removing the clutch cover Engine oil Q’ty 1 2 3 Clutch cable Clutch cable holder Clutch cover 1 1 1 4 5 Gasket Dowel pin 1 2 Remarks Remove the parts in the order listed. Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Refer to “REMOVING THE CLUTCH” and “INSTALLING THE CLUTCH”. For installation, reverse the removal procedure.
ENG CLUTCH PULL LEVER SHAFT 1 New 3 E 7 New 8 8 6 E 5 Order 1 2 3 4 5 6 7 8 Job/Part Removing the pull lever shaft Circlip Circlip Washer Pull lever Pull lever spring Pull lever shaft Oil seal Bearing Q’ty 4 3 2 New Remarks Remove the parts in the order listed. 1 1 2 1 1 1 1 2 For installation, reverse the removal procedure.
CLUTCH ENG EAS00274 CLUTCH E 14 12 13 9 E 8 4 56 56 7 5 5 4 4 5 5 E 4 New 11 2 10 3 M E (5) T. R. R. Order 1 E E T. 90 Nm (9.0 m • kg, 65 ft • Ib) (5) 1 2 3 4 Job/Part Removing the clutch Clutch spring Pressure plate Pull rod Friction plate 1 Q’ty 5 6 Clutch plate Friction plate 2 6 2 7 Friction plate 3 1 8 9 Clutch damper spring Clutch damper spring seat 1 1 5 1 1 4 5 - 42 9 Nm (0.9 m • kg, 6.5 ft • Ib) Remarks Remove the parts in the order listed.
CLUTCH ENG E 14 12 13 9 E 8 4 56 56 7 5 5 4 4 5 5 E 4 New 11 2 10 3 M E (5) T. R. R. Order 10 11 12 13 14 Job/Part Clutch boss nut Lock washer Clutch boss Thrust washer Clutch housing 1 E E T. 90 Nm (9.0 m • kg, 65 ft • Ib) (5) Q’ty 1 1 1 1 1 9 Nm (0.9 m • kg, 6.5 ft • Ib) Remarks Refer to “REMOVING THE CLUTCH” and “INSTALLING THE CLUTCH”. For installation, reverse the removal procedure.
CLUTCH ENG EAS00275 1 REMOVING THE CLUTCH 1. Remove: • clutch cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Straighten the lock washer tab. 3. Loosen: • clutch boss nut 1 3 2 1 NOTE: While holding the clutch boss 2 with the universal clutch holder 3, loosen the clutch boss nut. _ Universal clutch holder 90890-04086 4.
CLUTCH 2. • • • ENG Measure: friction plate 1 thickness friction plate 2 thickness friction plate 3 thickness Out of specification → Replace the friction plates as a set. NOTE: Measure the friction plate at four places. _ Friction plate 1 thickness 2.90 ~ 3.10 mm (0.114 ~ 0.122 in) : 2.80 mm (0.110 in) Friction plate 2 thickness 2.92 ~ 3.08 mm (0.115 ~ 0.121 in) : 2.80 mm (0.110 in) Friction plate 3 thickness 2.90 ~ 3.10 mm (0.114 ~ 0.122 in) : 2.80 mm (0.
CLUTCH ENG 2. Measure: • clutch spring free length a Out of specification → Replace the clutch springs as a set. Clutch spring free length 55.6 mm (2.19 in) : 52.82 mm (2.08 in) EAS00284 CHECKING THE CLUTCH HOUSING 1. Check: • clutch housing dogs Damage/pitting/wear → Deburr the clutch housing dogs or replace the clutch housing. NOTE: Pitting on the clutch housing dogs will cause erratic clutch operation. _ EAS00285 CHECKING THE CLUTCH BOSS 1.
CLUTCH ENG 2. Check: • pull rod bearing Damage/wear → Replace. EAS00292 CHECKING THE PRIMARY DRIVEN GEAR 1. Check: • primary driven gear Damage/wear → Replace the primary drive gear and clutch housing as a set. Excessive noise during operation → Replace the primary drive gear and clutch housing as a set. EAS00299 3 2 1 INSTALLING THE CLUTCH 1. Install: • clutch boss • lock washer New • clutch boss nut 1 NOTE: Lubricate the crankshaft end threads with engine oil. 2. Tighten: • clutch boss nut T. R.
CLUTCH ENG 4. Lubricate: • friction plates • clutch plates (with the recommended lubricant) Recommended lubricant Engine oil 12 5. • • • • • • 4 Install: clutch damper spring seat 1 clutch damper spring 2 friction plate 3 3 clutch plates 4 friction plates 1 5, 7 friction plates 2 6 NOTE: • Install the clutch damper spring 2 with the “OUTSIDE” mark facing out. • First, install a friction plate and then alternate between a clutch plate and a friction plate.
CLUTCH ENG NOTE: • To install the clutch cover, position the pull rod so that the teeth face towards that rear of the motorcycle. • Tighten the clutch cover bolts in stages and in a crisscross pattern. _ 8. • • • • 1 2 b a b NOTE: • Install the pull lever with the “UP” mark facing up. • Align the punch mark a on the pull lever with the punch mark b on the clutch cover. • Install the pull lever spring 1 as shown. _ a 1 c Install: pull lever spring 1 pull lever 2 washer circlip New 9.
OIL PUMP ENG OIL PUMP T. R. 20 Nm (2.0 m • kg, 14 ft • Ib) T. R. 18 Nm (1.8 m • kg, 13 ft • Ib) 4 3 New T. R. 1 3 New 3 New 5 10 Nm (1.0 m • kg, 7.2 ft • Ib) New New 7 New 2 6 New New 7 LS LS (9) 12 13 New LS 11 14 New T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) New LT R. 10 T. 9 10 Nm (1.0 m • kg, 7.2 ft • Ib) 8 T. R. 4 Nm (0.4 m • kg, 2.
OIL PUMP T. R. 20 Nm (2.0 m • kg, 14 ft • Ib) T. R. 18 Nm (1.8 m • kg, 13 ft • Ib) 4 3 New T. R. 1 New New 7 3 New 3 New 5 10 Nm (1.0 m • kg, 7.2 ft • Ib) ENG New 2 6 New New 7 LS LS (9) 12 13 New LS 11 14 New T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) New LT R. 10 T. 9 10 Nm (1.0 m • kg, 7.2 ft • Ib) 8 T. R. 4 Nm (0.4 m • kg, 2.
OIL PUMP ENG EAS00360 Order 1 2 3 4 5 6 7 8 9 0 A Job/Part Disassembling the oil pump Oil pump housing 1/oil seal Oil pump outer rotor 1 Dowel pin Oil pump inner rotor 1 Oil pump housing cover/oil seal Dowel pin Oil pump shaft Dowel pin Oil pump inner rotor 2 Oil pump outer rotor 2 Oil pump housing 2 Q’ty 1/1 1 1 1 1/1 2 1 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “ASSEMBLING THE OIL PUMP”. For assembly, reverse the disassembly procedure.
OIL PUMP ENG EAS00364 CHECKING THE OIL PUMP 1. Check: • oil pump driven gear 1 • oil pump housing 1 2 • oil pump housing cover 3 • oil pump housing 2 4 Cracks/damage/wear → Replace the defective part(s). 2. Measure: • inner-rotor-to-outer-rotor-tip clearance a • outer-rotor-to-oil-pump-housing clearance b • oil-pump-housing-to-inner-rotor-and-outerrotor clearance c Out of specification → Replace the oil pump. 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner-rotor-to-outer-rotor-tip clearance 0.
OIL PUMP ENG EAS00367 CHECKING THE OIL DELIVERY PIPES AND HOSES The following procedure applies to all of the oil delivery pipes and hoses. 1. Check: • oil delivery pipe • oil delivery hose Damage → Replace. Obstruction → Wash and blow out with compressed air. EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: • oil pump inner rotor 1 • oil pump inner rotor 2 • oil pump outer rotor 1 • oil pump outer rotor 2 • oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2.
OIL PUMP ENG EAS00376 INSTALLING THE OIL PUMP 1. Install: • oil pump gasket New • oil pump • oil baffle plate 2 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) • oil pump driven gear 1 • oil pump driven gear circlip New • oil baffle plate 1 1 T. LT R. 4 Nm (0.4 m · kg, 2.9 ft · lb) CAUTION: _ After tightening the bolts, make sure the oil pump turns smoothly. NOTE: • Install the oil pump driven gear 1 in the direction shown. • Install the circlip with its blunt surface facing the engine.
BALANCER DRIVEN GEAR ENG BALANCER DRIVEN GEAR T. 70 Nm (7.0 m • kg, 50 ft • Ib) R. 11 12 New 3 1 E 5 New 4 6 9 10 M 2 8 7 M T. R. Order 80 Nm (8.0 m • kg, 58 ft • lb) 1 2 3 Job/Part Removing the balancer driven gear Water pump assembly Clutch housing Crankcase cover (right) Balancer driven gear nut Primary drive gear nut Lock washer Q’ty 4 Lock washer 1 5 Washer 1 1 1 1 5 - 56 Remarks Remove the parts in the order listed. Refer to “WATER PUMP” in chapter 6. Refer to “CLUTCH”.
BALANCER DRIVEN GEAR ENG T. R. 70 Nm (7.0 m • kg, 50 ft • Ib) 11 12 New 3 1 E New 4 5 6 9 10 M 2 8 7 M T. R. Order 6 7 8 80 Nm (8.0 m • kg, 58 ft • lb) Job/Part Water pump drive gear Primary drive gear Balancer drive gear 9 10 11 Straight key Washer Balancer driven gear 12 Straight key Q’ty Remarks 1 1 1 Refer to “INSTALLING THE BALANCER DRIVEN GEAR AND BALANCER DRIVE GEAR”. 1 1 1 Refer to “INSTALLING THE BALANCER DRIVEN GEAR AND BALANCER DRIVE GEAR”.
BALANCER DRIVEN GEAR 3 1 4 REMOVING THE BALANCER DRIVEN GEAR AND BALANCER DRIVE GEAR 1. Straighten the lock washer tab. 2. Loosen: • balancer driven gear nut 1 • primary drive gear nut 2 NOTE: Place an aluminum plate a between the teeth of the balancer driven gear 3 and balancer drive gear 4. a 3 ENG a 4 3.
BALANCER DRIVEN GEAR 3 1 b a 2 ENG INSTALLING THE BALANCER DRIVEN GEAR AND BALANCER DRIVE GEAR 1. Install: • washer • balancer drive gear 1 • straight key 2 • balancer driven gear 3 • straight key • primary drive gear • water pump drive gear NOTE: • Align the punch mark a on the balancer drive gear with the punch mark b on the balancer driven gear. • Install the key with its blunt surface facing c the crankshaft. 2 c 2. Install: • lock washer 1 New • primary drive gear nut 2 T. 1 R.
ENG SHIFT SHAFT EAS00327 SHIFT SHAFT SHIFT SHAFT AND STOPPER LEVER 2 New 4 1 3 5 LS E 14 T. R. 16 Nm (1.6 m • kg, 11 ft • Ib) LT LT T. E R. 22 Nm (2.2 m • kg, 16 ft • Ib) 14 1113 8 7 12 5 13 6 10 New 9 E Order 1 2 3 4 5 6 Job/Part Removing the shift shaft and stopper lever Water pump assembly Clutch housing Crankcase cover (right) Shift pedal Circlip Washer Oil seal Bearing Shift shaft 7 8 Shift shaft spring Spacer Q’ty Remarks Remove the parts in the order listed.
ENG SHIFT SHAFT 2 New 4 1 3 5 LS E 14 T. R. 16 Nm (1.6 m • kg, 11 ft • Ib) LT LT T. E R. 22 Nm (2.2 m • kg, 16 ft • Ib) 14 1113 8 7 12 5 13 6 10 New 9 E Order 9 Job/Part Stopper lever spring 10 11 Circlip Stopper lever 12 13 14 Spacer Washer Shift shaft spring stopper Q’ty Remarks 1 Refer to “INSTALLING THE SHIFT SHAFT”. 1 1 Refer to “INSTALLING THE SHIFT SHAFT”. 1 2 1 For installation, reverse the removal procedure.
SHIFT SHAFT ENG EAS00329 1 CHECKING THE SHIFT SHAFT 1. Check: • shift shaft 1 • shift shaft pawl 2 Bends/damage/wear → Replace. • shift shaft spring 3 Damage/wear → Replace. 3 2 EAS00330 CHECKING THE STOPPER LEVER 1. Check: • stopper lever 1 Bends/damage → Replace. Roller turns roughly → Replace the stopper lever. • stopper lever spring 2 Damage/wear → Replace. 2 1 EAS00331 4 INSTALLING THE SHIFT SHAFT 1. Install: • shift shaft spring stopper LT T. R. 1 5 3 2 2. • • • 22 Nm (2.
ENG STARTER CLUTCH AND A.C. MAGNETO EAS00341 STARTER CLUTCH AND A.C. MAGNETO * Apply sealant Yamaha bond No. 1215 90890-85505 7 11 14 E E 10 7 R. 2 T. E 80 Nm (8.0 m • kg, 58 ft • Ib) T. 15 R. 30 Nm (3.0 m • kg, 22 ft • Ib) 7 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) E LT 7 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 17 16 ∗ 8 LT (3) 9 2 1 5 13 LT E LT 3 12 4 4 New (3) New T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) New Job/Part Removing the starter clutch and A.C.
ENG STARTER CLUTCH AND A.C. MAGNETO * Apply sealant Yamaha bond No. 1215 90890-85505 7 11 14 E E 10 7 R. 2 T. E 80 Nm (8.0 m • kg, 58 ft • Ib) T. 15 R. 30 Nm (3.0 m • kg, 22 ft • Ib) 7 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) E LT 7 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 17 16 ∗ 8 LT (3) 9 2 1 5 13 LT E LT 3 12 4 4 New (3) New T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) New Job/Part Torque limiter/washer Dowel pin A.C.
STARTER CLUTCH AND A.C. MAGNETO ENG EAS00346 REMOVING THE A.C. MAGNETO ROTOR 1. Remove: • torque limiter cover 1 CAUTION: Do not remove the bearing 1. 2. Remove: • A.C. magneto cover NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. _ 3. Remove: • A.C. magneto rotor nut 1 • washer 3 a 1 2 NOTE: • While holding the A.C. magneto rotor 2 with the sheave holder 3, loosen the A.C. magneto rotor nut.
STARTER CLUTCH AND A.C. MAGNETO ENG CHECKING THE STATOR COIL AND CRANKSHAFT POSITION SENSOR 1. Check: • stator coil • crankshaft position sensor Damage → Replace the crankshaft position sensor/stator assembly. EAS00351 CHECKING THE STARTER CLUTCH 1. Check: • starter clutch rollers 1 Damage/wear → Replace. 1 1 2 a È 2. Check: • starter clutch idle gear 1 • starter clutch gear 2 Burrs/chips/roughness/wear → Replace the defective part(s). 3.
STARTER CLUTCH AND A.C. MAGNETO ENG CHECKING THE TORQUE LIMITER 1. Check: • torque limiter Damage/wear → Replace. EAS00354 1 a b INSTALLING THE A.C. MAGNETO ROTOR 1. Install: • stator coil 1 LT T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) • crankshaft position sensor LT T. R. 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: Align the projection a on the stator coil with the slot b in the A.C. magneto cover. _ 1 2. Apply: • Yamaha bond No. 1215 1 (into the slits) Yamaha bond No. 1215 90890-85505 3.
STARTER CLUTCH AND A.C. MAGNETO ENG 5. Tighten: • A.C. magneto rotor nut 1 3 T. R. a 1 2 80 Nm (8.0 m · kg, 58 ft · lb) NOTE: • While holding the A.C. magneto rotor 2 with the sheave holder 3, tighten the A.C. magneto rotor nut. • Do not allow the sheave holder to touch the projection a on the A.C. magneto rotor. _ Sheave holder 90890-01701 6. Install: • gasket New • A.C. magneto cover T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Tighten the A.C.
ENG CRANKCASE CRANKCASE T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) New LS New 6 R. 9 T. 11 10 Nm (1.0 m • kg, 7.2 ft • Ib) 12 12 4 5 LS 8 New 2 LS 5 9 New New 3 LS 1 7 (3) 10 New T. R. LT LT 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. Order 1 2 3 4 Job/Part Separating the crankcase Engine Cylinder head Cylinder/piston A.C.
ENG CRANKCASE T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) New LS New 6 R. 9 T. 11 10 Nm (1.0 m • kg, 7.2 ft • Ib) 12 12 4 5 LS 8 New 2 LS 5 9 New New 3 LS 1 7 (3) 10 New T. R. LT LT 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. Order 5 6 7 8 9 10 11 12 Job/Part Lead holder Crankcase (right) Crankcase (left) Dowel pin/O-ring Dowel pin Oil strainer Oil delivery pipe 3 O-ring Q’ty 2 1 1 1/1 2 1 1 2 8 Nm (0.
ENG CRANKCASE CRANKCASE BEARINGS T. * Apply sealant R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) Yamaha bond No. 1215 90890-85505 ∗ LS 2 1 2 4 E 4 4 3 E LT T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 2 E 4 Order 1 2 3 4 Job/Part Removing the crankcase bearings Crankshaft/balancer Transmission Oil seal holder Oil seal Bearing retainer Bearing Q’ty Remarks Remove the parts in the order listed. Refer to “CRANKSHAFT”. Refer to “TRANSMISSION”. 1 3 1 7 For installation, reverse the removal procedure.
CRANKCASE ENG SEPARATING THE CRANKCASE 1. Separate: • right crankcase 1 • left crankcase 2 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the crankcase bolts. NOTE: • Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them. • Loosen the bolts in stages, using a crisscross pattern. _ 2 b. Remove the right crankcase. NOTE: Insert a screwdriver or pry bar into the pry points in the crankcase and then carefully pry apart the crankcase halves.
CRANKCASE ENG 2. Check: • oil delivery pipe 3 Cracks/damage → Replace. • oil delivery pipe holes 1 Clogged → Blow out with compressed air. 1 EAS00207 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDES 1. Check: • timing chain Damage/stiffness → Replace the timing chain and camshaft sprocket as a set. 2. Check: • timing chain guide (intake side) Damage/wear → Replace. EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1.
CRANKCASE ENG EAS00418 ASSEMBLING THE CRANKCASE 1. Lubricate: • bearings • oil seals Recommended lubricant Bearing Engine oil Oil seal Lithium-soap-based grease a 1 2. Install: • bearings New • bearing retainer 1 (to the right crankcase) • bearing retainer bolts T. LT R. 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Install the bearing retainer with the “OUT” mark a facing up. 3. Thoroughly clean all the gasket mating surfaces and crankcase mating surfaces. 1 4. Apply: • Yamaha bond No.
CRANKCASE ENG 6. Fit the right crankcase onto the left crankcase. Tap lightly on the case with a soft hammer. CAUTION: _ Before installing and torquing the crankcase bolts, be sure to check whether the transmission is functioning properly by manually rotating the shift drum in both directions. È 1 7. Install: • lead holder 1 • crankcase bolts È Left crankcase É Right crankcase 8. Tighten: • crankcase bolts (follow the proper tightening sequence) T. R. É 10 Nm (1.0 m · kg, 7.
CRANKSHAFT ENG EAS00381 CRANKSHAFT CRANKSHAFT AND BALANCER 1 2 Order 1 2 Job/Part Removing the crankshaft and balancer Crankcase Balancer Crankshaft Q’ty Remarks Remove the parts in the order listed. Separate. Refer to “CRANKCASE”. 1 1 5 - 76 Refer to “REMOVING THE CRANKSHAFT ASSEMBLY” and “INSTALLING THE CRANKSHAFT”. For installation, reverse the removal procedure.
CRANKSHAFT ENG EAS00388 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: • crankshaft 1 1 NOTE: • Remove the crankshaft with the crankcase separating tool 2. • Make sure the crankcase separating tool is centered over the crankshaft. _ 2 Crankcase separating tool 90890-01135 EAS00394 CHECKING THE CRANKSHAFT 1. Measure: • big end side clearance D Out of specification → Replace the big end bearing, crankshaft pin, or connecting rod. D C Big end side clearance 0.350 ~ 0.650 mm (0.0138 ~ 0.0256 in) C 2.
CRANKSHAFT ENG ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. The crankshaft 1 and the crankshaft pin 2 oil passages must be properly interconnected with a tolerance of less than 1 mm (0.04 in). 1 2 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • crankshaft sprocket Damage/wear → Replace the crankshaft. • bearing Cracks/damage/wear → Replace the crankshaft. 5. Check: • crankshaft journal Scratches/wear → Replace the crankshaft. • crankshaft journal oil passage Obstruction → Blow out with compressed air.
TRANSMISSION ENG EAS00419 TRANSMISSION 7 6 3 E E 2 1 5 E 4 E E E Order 1 2 3 4 5 6 7 Job/Part Removing the transmission, shift drum, and shift forks Crankcase Shift fork “C” Shift fork “R” Shift fork “L” Shift drum Main axle assembly Spacer Drive axle assembly Q’ty Remarks Remove the parts in the order listed. Separate. Refer to “CRANKCASE”. 1 1 1 1 1 1 1 Refer to “INSTALLING THE TRANSMISSION”. For installation, reverse the removal procedure.
ENG TRANSMISSION MAIN AXLE 7 8 9 8 7 0 A New M New 1 2 M 3 4 5 New 6 M M Order 1 2 3 4 5 6 7 8 9 0 A Job/Part Disassembling the main axle Circlip 2nd pinion gear Toothed lock washer Toothed washer retainer 5th pinion gear Toothed spacer Toothed washer Circlip 3rd pinion gear 4th pinion gear Main axle/1st pinion gear Q’ty 1 1 1 1 1 1 2 2 1 1 1 Remarks Remove the parts in the order listed. Refer to “ASSEMBLING THE MAIN AXLE AND DRIVE AXLE”. For assembly, reverse the disassembly procedure.
TRANSMISSION ENG DRIVE AXLE 8 M 6 5 4 7 M New A New 1 LS 2 0 3 9 New 6 5 M New Order 1 2 3 4 5 6 7 8 9 0 A Job/Part Disassembling the drive axle Circlip Washer 1st wheel gear 4th wheel gear Circlip Toothed washer 3rd wheel gear 5th wheel gear 2nd wheel gear Drive axle O-ring Q’ty 1 1 1 1 2 2 1 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “ASSEMBLING THE MAIN AXLE AND DRIVE AXLE”. For assembly, reverse the disassembly procedure.
TRANSMISSION ENG EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: • shift fork cam follower 1 • shift fork pawl 2 Bends/damage/scoring/wear → Replace the shift fork. 2. Check: • shift fork movement Rough movement → Replace the shift forks. EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: • shift drum grooves Damage/scratches/wear → Replace the shift drum assembly. • shift drum segment 1 Damage/wear → Replace the shift drum assembly.
TRANSMISSION ENG 2. Measure: • drive axle runout (with a centering device and dial gauge 1) Out of specification → Replace the drive axle. Drive axle runout limit 0.08 mm (0.0031 in) 3. Check: • transmission gears Blue discoloration/pitting/wear → Replace the defective gear(s). • transmission gear dogs Cracks/damage/rounded edges → Replace the defective gear(s). 4.
TRANSMISSION ENG INSTALLING THE TRANSMISSION 1. Install: • shift fork “L” 1 (to drive axle) • shift fork “C” 2 (to main axle) • shift fork “R” 3 (to drive axle) • shift drum 4 • transmission assembly 3 1 4 2 NOTE: • The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence: “R”, “C”, and “L”. • Make sure that the shift fork cam follower is properly seated in the shift drum groove. _ 2. Check: • shift operation Unsmooth operation → Repair.
COOL 6
COOL CHAPTER 6 COOLING SYSTEM RADIATOR ...................................................................................................... 6-1 CHECKING THE RADIATOR.................................................................... 6-3 INSTALLING THE RADIATOR..................................................................6-4 THERMOSTAT ................................................................................................6-5 CHECKING THE THERMOSTAT.............................................
COOL
RADIATOR COOL EAS00454 COOLING SYSTEM RADIATOR 8 New New T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 9 12 2 5 3 3 4 11 6 10 New 7 New T. R. Order 5 Nm (0.5 m • kg, 3.
RADIATOR COOL 8 New New T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 9 12 2 5 3 3 4 11 6 10 New 7 New T. R. Order 7 8 9 10 11 12 5 Nm (0.5 m • kg, 3.6 ft • Ib) Job/Part Radiator outlet hose Radiator inlet hose Radiator fan motor coupler Radiator guard Radiator Radiator fan Q’ty Remarks 1 Refer to “INSTALLING THE RADIATOR”. 1 1 Disconnect. 1 1 1 For installation, reverse the removal procedure.
RADIATOR COOL EAS00455 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flathead screwdriver. _ 2. Check: • radiator hoses Cracks/damage → Replace. 3. Measure: • radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Radiator cap opening pressure 110.0 ~ 140.0 kPa (1.10 ~ 1.40 kg/cm2, 16.0 ~ 20.
RADIATOR COOL EAS00456 2 1 INSTALLING THE RADIATOR 1. Install: • radiator inlet hose 1 • radiator outlet hose 2 • hose clamps 3 New New 3 a a 3 New NOTE: Install the radiator inlet hose and radiator outlet hose so that each hose contacts the respective projection a. _ 2. Fill: • cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 3. Check: • cooling system Leaks → Repair or replace any faulty part.
THERMOSTAT COOL EAS00460 THERMOSTAT 3 8 New 1 2 New 7 T. R. 18 Nm (1.8 m • kg, 13 ft • Ib) 4 6 5 New LS T. R. Order 1 2 3 4 5 6 7 8 10 Nm (1.0 m • kg, 7.2 ft • Ib) Job/Part Removing the thermostat Coolant Coolant temperature sensor coupler Hose clamp Radiator inlet hose Thermostat cover O-ring Thermostat Coolant temperature sensor Copper washer Q’ty 1 1 1 1 1 1 1 1 Remarks Remove the parts in the order listed. Drain. Refer to “CHANGING THE COOLANT” in chapter 3. Disconnect.
THERMOSTAT COOL EAS00462 CHECKING THE THERMOSTAT 1. Check: • thermostat 1 Does not open at 71 ~ 85 °C (159.8 ~ 185 °F) → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d. While stirring the water, observe the thermostat and thermometer’s indicated temperature.
THERMOSTAT New 2 COOL 2. Install: • radiator inlet hose 1 • hose clamp 2 New 1 a NOTE: Install the radiator inlet hose 1 so that it contacts the projection on the thermostat cover a. 3. Install: • copper washer New • coolant temperature sensor T. R. 18 Nm (1.8 m · kg, 13 ft · lb) CAUTION: _ Use extreme care when handling the coolant temperature sensor. Replace the sensor if it is dropped or subjected to a strong impact. 4.
WATER PUMP COOL EAS00468 WATER PUMP New 1 LS 8 2 T. 10 Nm (1.0 m • kg, 7.2 ft • Ib) R. New 7 5 New 4 6 T. 3 R. New 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 New LS New (3) T. R. Order 10 Nm (1.0 m • kg, 7.2 ft • Ib) Job/Part Removing the water pump Q’ty Remarks Remove the parts in the order listed. NOTE: It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil.
WATER PUMP COOL New 1 LS 8 2 T. 10 Nm (1.0 m • kg, 7.2 ft • Ib) R. New 7 5 New 4 6 T. 3 R. New 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 New LS New (3) T. R. Order 5 6 7 8 10 Nm (1.0 m • kg, 7.2 ft • Ib) Job/Part Water pump assembly Water pump outlet pipe O-ring Water pump outlet hose Q’ty 1 1 1 1 Remarks Refer to “INSTALLING THE WATER PUMP”. For installation, reverse the removal procedure.
WATER PUMP COOL 9 New LS 0 New 7 5 New 6 LS 3 1 New 4 2 8 E Order 1 2 3 4 5 6 7 8 9 0 Job/Part Disassembling the water pump Circlip Impeller shaft gear Pin Washer Impeller shaft assembly Water pump seal Oil seal Bearing O-ring Water pump housing Q’ty 1 1 1 1 1 1 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “ASSEMBLING THE WATER PUMP”. Refer to “DISASSEMBLING THE WATER PUMP” and “ASSEMBLING THE WATER PUMP”. For assembly, reverse the disassembly procedure.
WATER PUMP COOL EAS00470 DISASSEMBLING THE WATER PUMP 1. Remove: • water pump seal 1 NOTE: Tap out the water pump seal from water pump housing in the direction of the arrow shown. _ 2 Water pump housing 2. Remove: • bearing 1 • oil seal 2 NOTE: Tap out the bearing and oil seal from water pump housing in the direction of the arrow shown. _ 3 Water pump housing 3.
WATER PUMP 5. • • • COOL Check: water pump outlet pipe radiator outlet hose water jacket inlet housing Cracks/damage/wear → Replace. EAS00475 ASSEMBLING THE WATER PUMP 1. Install: • oil seal 1 New (into the water pump housing 2) • bearing 3 NOTE: • Before installing the oil seal, apply tap water or coolant onto its outer surface. • Install the oil seal with a socket that matches its outside diameter. _ 2.
WATER PUMP COOL 3. Install: • rubber damper 1 New • rubber damper holder 2 New NOTE: Before installing the rubber damper, apply tap water or coolant onto its outer surface. _ 4. Measure: • impeller shaft tilt Out of specification → Repeat steps (3) and (4). CAUTION: _ Make sure the rubber damper and rubber damper holder are flush with the impeller. Impeller shaft tilt limit 0.15 mm (0.006 in) 1 Straightedge 2 Impeller 5.
WATER PUMP COOL EAS00478 New 2 a INSTALLING THE WATER PUMP 1. Install: • water pump outlet hose 1 • O-rings New • water pump outlet pipe (to the water pump assembly) T. 1 R. 10 Nm (1.0 m · kg, 7.2 ft · lb) • hose clamps 2 New WARNING _ Always use new O-rings. NOTE: • Install the water pump outlet hose so that it contacts the projection a on the water jacket joint. • Before installing the water pump outlet pipe, lubricate the O-rings with a thin coat of lithium-soap-based grease. _ 2.
FI 7
FI CHAPTER 7 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM............................................................................7-1 WIRING DIAGRAM ................................................................................... 7-2 ECU SELF-DIAGNOSTIC FUNCTION......................................................7-3 ALTERNATE OPERATION CONTROL (FAIL-SAFE ACTION) ................ 7-4 FAIL-SAFE ACTION TABLE .....................................................................
FI
FI FUEL INJECTION SYSTEM EAS00894 FUEL INJECTION SYSTEM EAS00895 FUEL INJECTION SYSTEM 1 Air cut-off valve 2 Air induction system solenoid 3 Engine trouble warning light 4 Fuel tank 5 Fuel pump (include fuel pressure regulator) 6 Fuel hose 7 Fuel injector 8 Throttle position sensor 1 2 9 Intake air temperature sensor 0 Air filter case A Fuel injection system relay B Battery C Catalytic converter D ECU E Lean angle cut-off switch F Fast idle plunger G Crankshaft position sensor 3 4 5 6 7 H Coolant
W G/W L/Y W Gy G/W ON OFF P 4 W W W W 3 Br/L Br/R R L 2 B BB R/G W W W B1 BB B B B R 5 7-2 BB4 BB1 BB B1 BB3 BB4 BB2 BB1 R/G G/L R/W BB Y/L B W W W BB3 BB2 B B { B2 B1 È z R/W Lg Y/L R/G B2 B Y/L G/L R/W Br/L Br/R Br/L Sb R W W W R Br/R 1 Gy G/W B R Br/R Br/L Br/L Br/L y x w v R R R Br R/L Br R B A 0 Br R/G Br B L/R B 6 B R B B B R R B B L G/Y R/W Br B L q 9 L R R 7 8 R R R L Br L/W R/W R/W R L/R Y G/Y R/W L/
FI FUEL INJECTION SYSTEM EAS00899 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function to ensure the normal operation of the fuel injection system. If a malfunction is detected in the fuel injection system, the self-diagnostic function immediately operates the engine with alternate operating instructions and the engine trouble warning light comes on to alert the rider of the malfunction.
FI FUEL INJECTION SYSTEM EAS00901 Checking for a defective engine trouble warning light bulb The engine trouble warning light comes on for 1.4 seconds after the main switch is turned to “ON” or when the start switch is pushed. If the warning light does not come on under these conditions, the warning light bulb may be defective. Main switch Main switch on off Engine trouble warning light Light off Light on for 1.
FI FUEL INJECTION SYSTEM Fault code No. 30 Item Lean angle cut-off switch (latch up detected) The motorcycle has overturned. Faulty ignition Open circuit is detected in the primary lead of the ignition coil. 33 41 44 46 50 Fail-safe action Startability Driveability — No No — No No — No No Yes Yes Yes Yes Lean angle cut-off switch (open or short circuit) Open or short circuit is detected.
FI FUEL INJECTION SYSTEM EAS00904 TROUBLESHOOTING CHART Engine operation is not normal or the engine trouble warning light is on. The engine trouble warning light may not come on even if the engine operation is not normal. The engine trouble warning light comes on. The engine trouble warning light does not come on. Check the fault code number displayed on the meter. Check the operation of the following sensors and actuators in the diagnostic mode. Refer to “Diagnostic mode table”.
FUEL INJECTION SYSTEM FI EAS00905 DIAGNOSTIC MODE Setting the diagnostic mode 1. Set the main switch to “OFF” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more. NOTE: All displays on the meter disappear “dIAG” appears on the odometer/fuel reserve tripmeter/tripmeter 2 LCD. _ 4.
FUEL INJECTION SYSTEM FI 8. Verify the operation of the sensor or actuator. • Sensor operation The data representing the operating conditions of the sensor appears on the odometer/fuel reserve tripmeter/tripmeter 2 LCD. • Actuator operation Set the engine stop switch to “ ” to operate the actuator. NOTE: If the engine stop switch is set to “ “ ”, and then set it to “ ” again. _ ”, set it to 9. Set the main switch to “OFF” to cancel the diagnostic mode.
FUEL INJECTION SYSTEM FI EAS00906 Diagnostic monitoring code table Fault code No. Symptom No normal signals are received from the crankshaft position sensor. 14 Open or short circuit in wire harness Defective crankshaft position sensor Disconnected crankshaft position sensor coupler Malfunction in A.C. magneto rotor Malfunction in ECU Improperly installed crankshaft position sensor — Open or short circuit is detected in the intake air pressure sensor.
FUEL INJECTION SYSTEM Fault code No. 44 46 50 Er-1 Er-2 Er-3 Er-4 Symptom Probable cause of malfunction FI Diagnostic code An error is detected while reading or writing on EEPROM. • Malfunction in ECU (The CO adjustment value is not properly written on or read from the internal memory.) 60 Power supply to the fuel injection system relay is not normal. • Open circuit in wire harness • Malfunction in rectifier/regulator • Malfunction in A.C. magneto rotor Refer to “CHARGING SYSTEM” in chapter 8.
FUEL INJECTION SYSTEM Diagnostic code 08 09 20 21 Item Displays the lean angle cut-off switch values. Upright: 0.4 ~ 1.4 V Overturned: 3.7 ~ 4.4 V Fuel system voltage (battery voltage) Displays the fuel system voltage (battery voltage). Set the engine stop switch to “ ”. Approximately 12.0 V Sidestand switch Displays that the switch is on or off. (When the gear is in a position other than neutral.) Stand retracted: On Stand extended: Off Neutral switch Displays that the switch is on or off.
FUEL INJECTION SYSTEM FI EAS00908 TROUBLESHOOTING DETAILS This section describes the countermeasures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order in the “TROUBLESHOOTING CHART”. After the checking and servicing the malfunctioning part, reset the meter display. Refer to “Restore method”. Fault code No.: Fault code number displayed on the meter when the engine failed to work normally.
FUEL INJECTION SYSTEM Fault code No. 13 Symptom FI Open or short circuit is detected from the intake air pressure sensor. Used diagnostic code No. 03 (intake air pressure sensor) Order 1 Item/components Check or maintenance job Restore method Coupler connections Intake air pressure sensor coupler ECU coupler Sub-wire harness coupler Check the couplers for any pins that may have pulled out. Check that the couplers are securely locked. Reinstated by cranking the engine.
FI FUEL INJECTION SYSTEM Fault code No. 14 Symptom Intake air pressure sensor hose is disconnected or clogged. Used diagnostic code No. 03 (intake air pressure sensor) Order 1 Item/components Check or maintenance job Restore method Disconnected, clogged, kinked, or pinched intake air pressure sensor hose Repair or replace the hose. Reinstated by starting the engine and operating it at idle. Intake air pressure sensor malfunc- Check and repair the connection.
FUEL INJECTION SYSTEM Fault code No. 16 Symptom FI The throttle position sensor is detected stuck. Used diagnostic code No. 01 (throttle position sensor) Order Item/components Check or maintenance job Restore method 1 Defective throttle position sensor Replace the sensor if it is defective. Refer to “THROTTLE BODY ASSEMBLY”. 2 Throttle position sensor installation Execute the diagnostic mode. (Code No. 01) Check the sensor for looseness or pinching.
FUEL INJECTION SYSTEM Fault code No. 22 Symptom FI Open or short circuit is detected from the intake air temperature sensor. Used diagnostic code No. 05 (intake air temperature sensor) Order Item/components Check or maintenance job Restore method 1 Intake air temperature sensor installation Check the sensor looseness or pinching. 2 Coupler connections Check the couplers for any pins that may have Intake air temperature sensor cou- pulled out. pler Check that the couplers are securely locked.
FI FUEL INJECTION SYSTEM Fault code No. 30 Symptom The motorcycle has overturned. Used diagnostic code No. 08 (lean angle cut-off switch) Order Item/components Check or maintenance job Restore method 1 The motorcycle has overturned. Raise the motorcycle upright. 2 Lean angle cut-off switch installation Check the switch for looseness or pinching. 3 Coupler connections Lean angle cut-off switch coupler ECU coupler Check the coupler for any pins that may have pulled out.
FUEL INJECTION SYSTEM Fault code No. 42 Symptom FI A. No normal signals are received from the speed sensor. B. Open or short circuit is detected in the neutral switch. Used diagnostic code No. 07 (speed sensor) → A1 ~ A4 / No. 21 (neutral switch) → B1 ~ B4 Order A-1 Item/components Check or maintenance job Restore method Coupler connections Speed sensor coupler ECU coupler Check the couplers for any pins that may have pulled out. Check that the couplers are securely locked.
FUEL INJECTION SYSTEM Fault code No. 42 Symptom FI A. No normal signals are received from the speed sensor. B. Open or short circuit is detected in the neutral switch. Used diagnostic code No. 07 (speed sensor) → A1 ~ A4 / No. 21 (neutral switch) → B1 ~ B4 Order B-1 Item/components Check or maintenance job Restore method Coupler connections Neutral switch connector Wiring harness ECU coupler Check the couplers for any pins that may have pulled out. Check that the couplers are securely locked.
FUEL INJECTION SYSTEM Fault code No. 43 Symptom FI The ECU is unable to monitor the battery voltage. Used diagnostic code No. 09, 50 (fuel system voltage) Order 1 Item/components Check or maintenance job Restore method Coupler connections Fuel injection system relay coupler Wiring harness ECU coupler Check the couplers for any pins that may have pulled out. Check that the couplers are securely locked. Reinstated by starting the engine and operating it at idle.
FUEL INJECTION SYSTEM Fault code No. 44 Symptom FI Error is detected while reading or writing on EEPROM (CO adjustment value). Used diagnostic code No. 60 (EEPROM improper cylinder indication) Order 1 Item/components Check or maintenance job Restore method Malfunction in ECU Execute the diagnostic mode. (Code No. 60) • Check the faulty cylinder. • Readjust the CO of the displayed cylinder. Refer to “ADJUSTING THE EXHAUST GAS VOLUME” in chapter 3. Replace the ECU if it is defective.
FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom FI No signals are received from the ECU. Used diagnostic code No. – – Order 1 Item/components Check or maintenance job Restore method Coupler connections ECU coupler Meter couplers Check the couplers for any pins that may have pulled out. Check that the couplers are securely locked. Reinstated automatically when it receives a normal signal. If there is a malfunction, repair it and connect it securely.
THROTTLE BODY ASSEMBLY FI EAS00909 THROTTLE BODY ASSEMBLY 3 1 5 4 2 6 9 8 11 10 10 8 R. Order T. 7 Job/Part Removing the throttle body assembly Seat 6 Nm (0.6 m • kg, 4.3 ft • Ib) Q’ty Fuel tank Air filter case Coolant 1 2 3 Fuel injector coupler Throttle position sensor coupler Throttle cable 1 1 2 4 Vacuum hose 1 7 - 23 Remarks Remove the parts in the order listed. Refer to “COWLING AND COVER” in chapter 3. Refer to “FUEL TANK” in chapter 3. Refer to “AIR FILTER CASE” in chapter 3.
THROTTLE BODY ASSEMBLY FI 3 1 5 4 2 6 9 8 11 10 10 8 Job/Part Fast idle plunger outlet hose Fast idle plunger inlet hose Pilot air hose Throttle body joint clamp screw Throttle body assembly Throttle body joint clamp Throttle body joint R. Order 5 6 7 8 9 10 11 T. 7 6 Nm (0.6 m • kg, 4.3 ft • Ib) Q’ty Remarks 1 Disconnect. 1 1 2 Loosen. 1 Refer to “INSTALLING THE THROT2 TLE BODY ASSEMBLY”. 1 For installation, reverse the removal procedure.
FI THROTTLE BODY ASSEMBLY New 3 New 4 2 1 Order 1 2 3 4 Job/Part Disassembling the throttle body assembly Throttle position sensor Fuel injection pipe Fuel injector Throttle body Q’ty 1 1 1 1 Remarks Remove the parts in the order listed. CAUTION: Do not disassemble the throttle body. For assembly, reverse the disassembly procedure.
THROTTLE BODY ASSEMBLY FI EAS00912 1 2 R/L R/B CHECKING THE FUEL INJECTOR 1. Check: • fuel injector Damage → Replace. 2. Check: • fuel injector resistance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the injection wire harness coupler from the fuel injector. b. Connect the pocket tester (Ω × 1) to the fuel injector terminal as shown. Positive tester probe → red/black 1 Negative tester probe → red/blue 2 c. Measure the fuel injector resistance. Out of specification → Replace the fuel injector.
THROTTLE BODY ASSEMBLY INSTALLING THE THROTTLE BODY ASSEMBLY 1. Install: • throttle body joint clamps b b NOTE: Align the projection a on the throttle body joint with the slot b in the throttle body joint clamp. a a 2. Install: • throttle body joint a NOTE: Align the projection a on the cylinder head with the slot b in the throttle body joint. b a FI b 3. Install: • throttle body assembly NOTE: Align the projection a on the throttle body assembly with the slot b throttle body joint. 4. • 5.
THROTTLE BODY ASSEMBLY FI EAS00819 CHECKING THE FUEL PUMP WARNING _ Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. Be extremely careful and note the following points: • Stop the engine before refueling. • Do not smoke, and keep away from open flames, sparks, or any other source of fire. • If you do accidentally spill gasoline, wipe it up immediately with dry rags. • If gasoline touches the engine when it is hot, a fire may occur.
THROTTLE BODY ASSEMBLY 1 4 2 3 FI 2. Check: • fuel pressure 5 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the fuel tank. Refer to “FUEL TANK” in chapter 3. b. Connect the pressure gauge 1 to the adapter 2. c. Connect the fuel pressure adapter to the fuel pump and fuel hose 3. Pressure gauge 90890-03153 Fuel pressure adapter 90890-03176 d. Connect the fuel pump coupler 4 and fuel sender coupler 5 to the fuel pump. Refer to “FUEL TANK” in chapter 3. e.
THROTTLE BODY ASSEMBLY 2 3 1 FI 1. Check: • throttle position sensor (removed from the throttle body) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ B/L Y L a. Disconnect the throttle position sensor coupler from the throttle position sensor. b. Remove the throttle position sensor from the throttle body. c. Connect the pocket tester (Ω × 1k) to the throttle position sensor. Positive tester probe → blue terminal 1 Negative tester probe → black/blue terminal 2 d. Measure the maximum throttle position sensor resistance.
THROTTLE BODY ASSEMBLY FI Throttle position sensor resistance 0 ~ 5 ± 1.0 kΩ at 20 °C (68 °F) (yellow — black/blue) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Adjust: • throttle position sensor angle ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1 2 B/L Y L a. Connecting the throttle position sensor coupler to the wire harness. b. Connect the digital circuit tester to the throttle position sensor. Positive tester probe → yellow terminal 1 Negative tester probe → black/blue terminal 2 Digital circuit tester 90890-03174 c.
AIR INDUCTION SYSTEM FI EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned exhaust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port. The required temperature for burning the unburned exhaust gases is approximately 600 to 700 °C (1,112 to 1,292 °F).
AIR INDUCTION SYSTEM FI EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Air filter case 2 Reed valve 3 Air cut-off valve 4 Exhaust port 1 4 3 2 4 7 - 33
FI AIR INDUCTION SYSTEM AIR CUT-OFF VALVE ASSEMBLY 4 1 3 2 Order 1 2 3 4 Job/Part Removing the air cut-off valve assembly Right side panel Q’ty Fuel tank right side cover Air induction system solenoid coupler Air cut-off valve outlet hose Air-filter-to-air-cut-off-valve hose Air cut-off valve assembly 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “COWLING AND COVER” in chapter 3. Refer to “FUEL TANK” in chapter 3. Disconnect. For installation, reverse the removal procedure.
AIR INDUCTION SYSTEM FI LT LT 3 2 1 Order 1 2 3 Job/Part Disassembling the air cut-off valve assembly Air cut-off valve cover Reed valve assembly Air cut-off valve Q’ty Remarks Remove the parts in the order listed. 1 1 1 For assembly, reverse the disassembly procedure.
AIR INDUCTION SYSTEM FI EAS00918 CHECKING THE AIR INDUCTION SYSTEM 1. Check: • hoses Loose connections → Connect properly. Cracks/damage → Replace. • pipe Cracks/damage → Replace. Refer to “CYLINDER HEAD” in chapter 5. 2. Check: • reed valve • reed valve stopper • reed valve seat Cracks/damage → Replace the reed valve assembly. 3. Check: • air cut-off valve Cracks/damage → Replace. 4. Check • Air induction system solenoid 2 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Br/R R/W a.
– ELEC + 8
ELEC CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS........................................................................ 8-1 CHECKING SWITCH CONTINUITY................................................................8-3 CHECKING THE SWITCHES..........................................................................8-5 CHECKING THE BULBS AND BULB SOCKETS .......................................... 8-7 TYPES OF BULBS ....................................................................................
ELEC IMMOBILIZER SYSTEM................................................................................ 8-52 CIRCUIT DIAGRAM ................................................................................ 8-52 GENERAL INFORMATION ..................................................................... 8-53 KEY CODE REGISTRATION .................................................................. 8-54 SELF-DIAGNOSIS MALFUNCTION CODES..........................................8-57 TROUBLESHOOTING .................
– ELEC ELECTRICAL COMPONENTS + EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1 Spark plug 2 Spark plug cap 3 Ignition coil 4 Intake air pressure sensor 5 Front brake light switch 6 Right handlebar switch 7 Immobilizer unit 8 Main switch 9 Fuel pump 0 Clutch switch A Left handlebar switch B Throttle position sensor C Coolant temperature sensor D Fuel injector 9 6 3 E Lean angle cut-off switch F Turn signal/hazard relay G Headlight relay H Radiator fan motor relay I Relay unit J Battery K Fuse box
L Fuse box 2 M Starter relay N Main fuse O Rectifier/regulator P ECU Q Intake air temperature sensor R Sidestand switch S Neutral switch T Crankshaft position sensor U Stator coil V Rear brake light switch 3 + W Speed sensor X Starter motor Y Radiator fan motor Z Horn [ Air induction system solenoid 9 6 – ELEC ELECTRICAL COMPONENTS 0 A B 8 7 D 4 C E 5 2 H G 1 I Z F [ J K L Y W M X N V O T U S 8-2 R Q P
CHECKING SWITCH CONTINUITY ELEC – + EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. CAUTION: _ Never insert the tester probes into the coupler terminal slots 1. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
CHECKING SWITCH CONTINUITY 8-4 ELEC – +
CHECKING THE SWITCHES ELEC – + EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading → Replace the switch.
CHECKING THE SWITCHES 1 Main switch 2 Horn switch 3 Pass switch 4 Dimmer switch 5 Turn signal switch 6 Hazard switch 7 Clutch switch 8 Engine stop switch 9 Start switch 0 Front brake light switch A Sidestand switch B Neutral switch C Rear brake light switch D Fuses 8-6 ELEC – +
CHECKING THE BULBS AND BULB SOCKETS ELEC – + EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both. Improperly connected → Properly connect. No continuity → Repair or replace the bulb, bulb socket or both. TYPES OF BULBS The bulbs used on this motorcycle are shown in the illustration on the left.
CHECKING THE BULBS AND BULB SOCKETS ELEC – + CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: • bulb WARNING _ Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: _ • Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler.
CHECKING THE BULBS AND BULB SOCKETS ELEC – + CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester 90890-03112 NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. _ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install a good bulb into the bulb socket. b.
CHECKING THE BULBS AND BULB SOCKETS ELEC – + b. Connect two jumper leads 1 from the battery terminals to the respective coupler terminal as shown.
CHECKING THE BULBS AND BULB SOCKETS ELEC – + WARNING _ • A wire that is used as a jumper lead must have at least the same capacity of the battery lead, otherwise the jumper lead may burn. • This check is likely to produce sparks, therefore, make sure no flammable gas or fluid is in the vicinity. CAUTION: Do not connect the jumper lead (battery voltage) to the terminals (green/blue and black/white) for the immobilizer system indicator light (LED). The LED could be damaged. c.
W G/W L/Y W Gy G/W 8 - 12 3 Br/L Br/R R L 2 B BB R/G W W W B1 BB B B B R 5 BB4 BB1 BB B1 BB3 BB4 BB2 BB1 R/G G/L R/W BB Y/L B W W W BB3 BB2 B B { B2 B1 È z R/W Lg Y/L R/G B2 B Y/L G/L R/W Br/L Br/R Br/L Sb R W W W R Br/R 1 B R 1 Crankshaft position sensor 4 Main switch 6 Battery 7 Main fuse D Engine stop switch L ECU M Ignition coil N Spark plug V Lean angle cut-off switch v Ignition fuse ON OFF P 4 W W W W Gy G/W Br/R Br/L Br/L Br/L y x w v R R R
IGNITION SYSTEM EAS00736 ELEC – + EAS00739 TROUBLESHOOTING 2. Battery The ignition system fails to operate (no spark or intermittent spark). • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main and ignition fuses 2. battery 3. spark plug 4. ignition spark gap 5. spark plug cap resistance 6. ignition coil resistance 7. crankshaft position sensor resistance 8. main switch 9. engine stop switch 10.lean angle cut-off switch 11.
IGNITION SYSTEM EAS00742 ELEC – + EAS00744 4. Ignition spark gap 5. Spark plug cap resistance • Disconnect the spark plug cap 1 from the spark plug. • Connect the ignition checker 2 as shown. • Set the main switch to “ON”. • Measure the ignition spark gap a. • Crank the engine by pushing the start switch and gradually increase the spark gap until a misfire occurs. • Remove the spark plug cap from the spark plug lead. • Connect the pocket tester (Ω × 1k) to the spark plug cap as shown.
IGNITION SYSTEM EAS00746 ELEC – + EAS00748 7. Crankshaft position sensor resistance 6. Ignition coil resistance • Disconnect the crankshaft position sensor coupler from the wire harness. • Connect the pocket tester (Ω × 100) to the crankshaft position sensor terminal as shown. • Disconnect the ignition coil connectors from the ignition coil terminals. • Connect the pocket tester (Ω × 1) to the ignition coil as shown.
IGNITION SYSTEM EAS00750 ELEC – + EAS00754 9. Engine stop switch 11.Wiring • Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the engine stop switch OK? • Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the ignition system’s wiring properly connected and without defects? NO YES YES Replace the right handlebar switch. Replace the ECU. 10.
8 - 17 3 Br/L Br/R R L 2 B BB R/G W W W B1 BB B B B R 5 BB4 BB1 BB B1 BB3 BB4 BB2 BB1 R/G G/L R/W BB Y/L B W W W BB3 BB2 B B { B2 B1 È z R/W Lg Y/L R/G B2 B Y/L G/L R/W Br/L Br/R Br/L Sb R W W W R Br/R 1 3 Neutral switch 4 Main switch 6 Battery 7 Main fuse 8 Starter relay 9 Starter motor D Engine stop switch ON OFF P 4 W G/W L/Y W W W Gy G/W W W Gy G/W B R y x w v Br R/L Br R B A 0 Br R/G Br B B R B B B R B B (BLACK) L G/Y R/W Br B R
ELECTRIC STARTING SYSTEM ELEC – + EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: • The transmission is in neutral (the neutral switch is closed). • The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the sidestand switch is closed).
ELECTRIC STARTING SYSTEM EAS00757 ELEC – + EAS00739 TROUBLESHOOTING 2. Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main and ignition fuses 2. battery 3. starter motor 4. relay unit (starting circuit cut-off relay) 5. relay unit (diode) 6. starter relay 7. main switch 8. engine stop switch 9. neutral switch 10.sidestand switch 11.clutch switch 12.start switch 13.
ELECTRIC STARTING SYSTEM EAS00759 4. Relay unit (starting circuit cut-off relay) • Disconnect the relay unit from the wire harness. • Connect the pocket tester (Ω × 1) and battery (12 V) to the relay unit terminals as shown.
ELECTRIC STARTING SYSTEM EAS00761 – ELEC + EAS00750 6. Starter relay 8. Engine stop switch • Disconnect the starter relay coupler from the coupler. • Connect the pocket tester (Ω × 1) and battery (12 V) to the starter relay coupler as shown. • Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the engine stop switch OK? YES Positive battery terminal → red/white 1 Negative battery terminal → blue/white 2 NO Replace the right handlebar switch.
ELECTRIC STARTING SYSTEM EAS00764 12.Start switch • Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the start switch OK? YES NO Replace the right handlebar switch. EAS00766 13. Wiring • Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the starting system’s wiring properly connected and without defects? YES The starting system circuit is OK. NO Replace the relay unit and properly connect or repair the starting system’s wiring.
STARTER MOTOR ELEC – + EAS00767 STARTER MOTOR 3 . T R. 5 Nm (0.5 m • kg, 3.6 ft • Ib) 2 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 5 1 4 6 7 Order 1 2 3 4 5 6 7 Job/Part Removing the starter motor Crankcase-to-crankcase-breatherchamber hose Air-filter-to-crankcase-breather-chamber hose Crankcase breather chamber Starter motor lead Negative battery lead Crankcase breather chamber bracket Starter motor Q’ty 1 Remarks Remove the parts in the order listed. Disconnect. 1 Disconnect.
STARTER MOTOR Order 1 2 3 4 5 6 7 8 9 0 A B C Job/Part Disassembling the starter motor Circlip Starter motor gear O-ring Front bracket Shims Lock washer Rear bracket Shims Brush holder assembly Brush Armature coil O-ring Starter motor yoke Q’ty ELEC – + Remarks Remove the parts in the order listed. 1 1 1 1 1 1 1 1 1 2 1 For assembly, reverse the disassembly procedure.
STARTER MOTOR ELEC – + EAS00770 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 27 mm (1.06 in) 3. Measure: • mica undercut a Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Mica undercut 0.70 mm (0.
STARTER MOTOR ELEC – + Pocket tester 90890-03112 Armature coil Commutator resistance 1 0.025 ~ 0.035 Ω at 20 °C (68 °F) Insulation resistance 2 Above 1 MΩ at 20 °C (68 °F) b. If any resistance is out of specification, replace the starter motor. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Measure: • brush length a. Out of specification → Replace the brushes as a set. Brush length wear limit 5.00 mm (0.20 in) 6. Measure: • brush spring force Out of specification → Replace the brush springs as a set.
STARTER MOTOR ELEC – + EAS00772 ASSEMBLING THE STARTER MOTOR 1. Install: • brush seat 1 NOTE: Align the tab a on the brush seat with the slot b in the starter motor yoke. _ 2. Install: • lock washer NOTE: Align the tabs a on the lock washer with the groves in the front bracket. a 3. Install: • rear bracket a NOTE: Align the slot a in the rear bracket with the tab b on the brush seat. b 2 1 3 b Install: starter motor yoke 1 front bracket 2 rear bracket 3 O-rings 4 New bolts 5 Nm (0.
W G/W L/Y W Gy G/W 8 - 28 ON OFF P 4 W W W W 3 Br/L Br/R R L 2 B BB R/G W W W R R/G G/L R/W BB Y/L B W W W B 5 B R R R R B A 0 Br R/G Br B B 6 B B B R R R R 9 B B R R L/W R/W R/W L/W 2 A.C.
CHARGING SYSTEM EAS00774 ELEC – + EAS00738 TROUBLESHOOTING 1. Main fuse The battery is not being charged. • Check the main fuse for continuity. Refer to “CHECKING THE FUSES” in chapter 3. • Are the main fuse OK? Check: 1. main fuse 2. battery 3. charging voltage 4. stator coil resistance 5. wiring connections (of the entire charging system) YES Replace the fuse. NOTE: • Before troubleshooting, remove the following part(s): 1. seat 2. battery cover 3.
CHARGING SYSTEM EAS00775 ELEC – + EAS00776 4. Stator coil resistance 3. Charging voltage • Disconnect the A.C. magneto coupler from the wire harness. • Connect the pocket tester (Ω × 1) to the charging coils as shown. • Connect the pocket tester (DC 20 V) to the battery as shown.
W G/W L/Y W Gy G/W ON OFF P 4 W W W W 3 Br/L Br/R R L 2 B BB R/G W W W B1 BB B B B R 5 BB4 BB1 BB B1 BB3 BB4 BB2 BB1 R/G G/L R/W BB Y/L B W W W BB3 BB2 B B { B2 B1 È z R/W Lg Y/L R/G B2 B Y/L G/L R/W R Br/R Br/L Sb R W W W Br/L Br/R 1 Gy G/W B R 8 - 31 Br/R Br/L Br/L Br/L y x w v R R R Br R/L Br R B A 0 Br R/G Br B L/R B t (BLACK) B R B B B B B L G/Y B r R R L Br L/W B L/R Y G/Y R/W L/W R/W R/W (BLACK) B L q B L/R
LIGHTING SYSTEM EAS00781 ELEC – + EAS00738 TROUBLESHOOTING 1. Main, headlight, and parking lighting fuses Any of the following fail to come on: headlight, high beam indicator light, tail/ brake light, on auxiliary light. • Check the main, headlight, and parking lighting fuses for continuity. Refer to “CHECKING THE FUSES” in chapter 3. • Are the main, headlight, and parking lighting fuses OK? Check: 1. main, headlight, and parking lighting fuses 2. battery 3. main switch 4. dimmer switch 5.
LIGHTING SYSTEM EAS00784 ELEC – + 6. Headlight relay 4. Dimmer switch • Disconnect the headlight relay from the wire harness. • Connect the pocket tester (Ω × 1) and battery (12 V) to the headlight relay terminal as shown. • Check the headlight relay for continuity. • Check the dimmer switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the dimmer switch OK? YES NO The dimmer switch is faulty. Replace the left handlebar switch.
ELEC LIGHTING SYSTEM EAS00788 CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light fail to come on. 1. Headlight bulb and socket • Check the headlight bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”.
ELEC LIGHTING SYSTEM EAS00790 EAS00791 2. The tail/brake light fails to come on. 3. The auxiliary light fails to come on. 1. Tail/brake light bulb and socket 1. Auxiliary light bulb and socket – + • Check the auxiliary light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. • Are the auxiliary light bulb and socket OK? • Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”.
LIGHTING SYSTEM 8 - 36 ELEC – +
W G/W L/Y W Gy G/W ON OFF P 4 W W W W 3 Br/L Br/R R L 2 B BB R/G W W W B1 BB B B B R 5 BB4 BB1 BB B1 BB3 BB4 BB2 BB1 R/G G/L R/W BB Y/L B W W W BB3 BB2 B B { B2 B1 È z R/W Lg Y/L R/G B2 B Y/L G/L R/W Br/L Br/R Br/L Sb R W W W R Br/R 1 Gy G/W B R 8 - 37 Br/R Br/L Br/L Br/L y x w v R R R Br R/L Br R B A 0 Br R/G Br B L/R B t (BLACK) B R B B B B B L G/Y B r R R L Br L/W B L/R Y G/Y R/W L/W R/W R/W (BLACK) B L q B L/R
SIGNALING SYSTEM 3 Neutral switch 4 Main switch 6 Battery 7 Main fuse A Backup fuse (immobilizer unit, meter assembly) F Front brake light switch G Relay unit K Fuel pump L ECU R Coolant temperature sensor S Speed sensor X Neutral indicator light Y Multifunction meter Z Coolant temperature warning light [ Engine trouble warning light \ Fuel level warning light _ Turn signal indicator light c Turn signal/hazard relay e Horn switch h Turn signal switch i Hazard switch k Horn m Rear turn signal light (left) n
SIGNALING SYSTEM EAS00794 ELEC – + EAS00739 TROUBLESHOOTING 2. Battery • Any of the following fail to come on: a turn signal light, an indicator light, a warning light, or the tail/brake light • The horn fails to sound. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Minimum open-circuit voltage 12.8 V or more at 20 °C (68 °F) Check: 1. main, ignition, signaling system, parking lighting, and backup fuses 2. battery 3. main switch 4.
SIGNALING SYSTEM EAS00796 • Disconnect the black connector at the horn terminal. • Connect a jumper lead 1 to the horn terminal and ground the jumper lead. • Set the main switch to “ON”. • Push the horn switch. • Does the horn sound? 1. Horn switch • Check the horn switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the horn switch OK? NO P Replace the left handlebar switch. 1 2. Voltage • Connect the pocket tester (DC 20 V) to the horn connector at the horn terminal as shown.
SIGNALING SYSTEM EAS00797 + • Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness end) as shown. 1. Tail/brake light bulb and socket • Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. • Are the tail/brake light bulb and socket OK? Positive tester probe → yellow 1 Negative tester probe → black 2 2 NO B L Y Replace the tail/ brake light bulb, socket or both. • Set the main switch to “ON”.
SIGNALING SYSTEM EAS00799 3. The turn signal light, turn signal indicator light or both fail to blink. – + 4. Hazard switch • Check the hazard switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the hazard switch OK? 1. Turn signal indicator light bulb and socket • Check the turn signal light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. • Are the turn signal light bulb and socket OK? NO YES Replace the left handlebar switch. 5.
SIGNALING SYSTEM È 6. Voltage • Connect the pocket tester (DC 20 V) to the turn signal/hazard relay coupler (wire harness end) as shown. ELEC – Ch G + É Ch Dg 1 2 1 3 Positive tester probe → brown/white 1 Negative tester probe → ground Ê 3 • Set the main switch to “ON”. • Set the turn signal switch to “ ” or “ ”. • Measure the voltage (DC 12 V) of brown/ white 1 at the turn signal/hazard relay coupler (wire harness end).
SIGNALING SYSTEM EAS00800 – ELEC + EAS00753 4. The neutral indicator light fails to come on. 3. Relay unit (diode) 1. Neutral indicator light LED • Check the LED of the neutral indicator light. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. • Is the neutral indicator light LED OK? YES NO Replace the meter assembly. 2. Neutral switch • Disconnect the relay unit from the wire harness. • Connect the pocket tester (Ω × 1) to the relay unit terminals as shown. • Check the diode for continuity.
SIGNALING SYSTEM ELEC – + EAS00803 4. Voltage 5. The fuel level warning light fails to come on. • Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness end) as shown. 1. Fuel level warning light LED • Check the LED of the fuel level warning light. Refer to “CHECKING THE BULBS AND BULB SOCKETS”.
ELEC SIGNALING SYSTEM – + 6. The speedometer fails to come on. 3. Voltage • Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness end) as shown. Positive tester probe → green/white 1 Negative tester probe → black/white 2 Ch R/G Y Dg G/L R/W 1. Voltage • Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness end) as shown.
ELEC SIGNALING SYSTEM 2. Speed sensor • Connect the pocket tester (DC 20 V) to the speed sensor coupler as shown. 1. Coolant temperature warning light LED • Check the LED of the coolant temperature warning light. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. • Is the coolant temperature warning light LED OK? 1 B/W L W Replace the meter assembly. • Set the main switch to “ON”. • Elevate the rear wheel and slowly rotate it. • Measure the voltage (DC 5 V) of pink and black/white.
ELEC SIGNALING SYSTEM – + EAS00812 3. Coolant temperature sensor • Remove the coolant temperature sensor from the engine. • Connect the pocket tester (Ω × 10) to the coolant temperature sensor 1 as shown. • Immerse the coolant temperature sensor in a container filled with coolant 2. 3 NOTE: Make sure that the coolant temperature sensor terminals do not get wet. _ 1 • Place a thermometer 3 in the coolant.
W G/W L/Y W Gy G/W 8 - 49 R L Br/L Br/R 3 2 B BB R/G W W W B1 BB B B B R 5 BB4 BB1 BB B1 BB3 BB4 BB2 BB1 R/G G/L R/W BB Y/L B W W W BB3 BB2 B B { B2 B1 È z R/W Lg Y/L R/G B2 B Y/L G/L R/W Br/L Br/R Br/L Sb R W W W R Br/R 1 B R 4 Main switch 6 Battery 7 Main fuse B Radiator fan motor fuse L ECU q Radiator fan motor relay r Radiator fan motor v Ignition fuse ON OFF P 4 W W W W Gy G/W Br/R Br/L Br/L Br/L y x w v R R R Br R/L Br R B A 0 Br R/G
COOLING SYSTEM EAS00808 ELEC – + EAS00739 TROUBLESHOOTING 2. Battery The radiator fan motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main, radiator fan motor, and ignition fuses 2. battery 3. main switch 4. radiator fan motor 5. radiator fan motor relay 6. wiring connections (the entire cooling system) Minimum open-circuit voltage 12.
COOLING SYSTEM EAS00809 ELEC – + 5. Radiator fan motor relay 4. Radiator fan motor • Disconnect the radiator fan motor coupler from the wire harness. • Connect the battery (DC 12 V) as shown. • Disconnect the radiator fan motor relay from the wire harness. • Connect the pocket tester (Ω × 1) and battery (DC 12 V) to the radiator fan motor terminal as shown. • Check the radiator fan motor for continuity.
W G/W L/Y W Gy G/W 8 - 52 3 Br/L Br/R R L 2 B BB R/G W W W B1 BB B B B R 5 BB4 BB1 BB B1 BB3 BB4 BB2 BB1 R/G G/L R/W BB Y/L B W W W BB3 BB2 B B { B2 B1 È z R/W Lg Y/L R/G B2 B Y/L G/L R/W Br/L Br/R Br/L Sb R W W W R Br/R 1 B R Br/R Br/L Br/L Br/L y x w v R R R Br R/L Br R B A 0 4 Main switch 6 Battery 7 Main fuse A Backup fuse (immobilizer unit, meter assembly) L ECU Y Multifunction meter a Immobilizer system indicator light v Ignition fuse z Immo
IMMOBILIZER SYSTEM ELEC – + GENERAL INFORMATION This motorcycle is equipped with an immobilizer system to help prevent theft by registering codes in standard keys.
IMMOBILIZER SYSTEM ELEC – + KEY CODE REGISTRATION The replacement of parts or code registration of a code re-registering key or standard key may be required in the following conditions. NOTE: Each standard key is registered during production, therefore, registering the keys at purchase is not necessary.
IMMOBILIZER SYSTEM ELEC – + Standard key registration: A standard key should be registered or the other standard key should be re-registered when a registered standard key has been lost. The standard keys must be re-registered when the immobilizer unit or ECU has been replaced and the code re-registering key has been re-registered. NOTE: Do not start the engine with a standard key that has not been registered.
IMMOBILIZER SYSTEM ELEC – + 6. Check that the engine can be started with the two registered standard keys. less than 5.0 s Standard key registration ON Main switch OFF On LED Off less than 5.0 s less than 5.0 s less than 5.0 s First standard key Registration mode Code re-registering key Registration of the second standard key is complete. Second standard key Immobilizer system indicator light stops flashing when the registration of the second standard key is complete.
IMMOBILIZER SYSTEM ELEC – + SELF-DIAGNOSIS MALFUNCTION CODES When a system malfunction occurs, the malfunction code number is displayed on the multifunction display and is indicated by the immobilizer system indicator light flash patterns. Malfunction code Part Symptom Cause Action Immobilizer unit Code cannot be transmitted between the key and immobilizer unit. 1) Objects that interrupt radio waves exist around the keys or antennas.
IMMOBILIZER SYSTEM ELEC – + EAS00739 EAS00781 TROUBLESHOOTING 2. Battery The immobilizer system fails to operate. (The immobilizer system indicator light starts to flash in the self-diagnosis code sequence.) • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Minimum open-circuit voltage 12.8 V or more at 20 °C Check: 1. main, ignition, and backup fuses 2. battery 3. main switch 4.
IMMOBILIZER SYSTEM ELEC – CHECKING THE IMMOBILIZER SYSTEM 1. Immobilizer system indicator light does not go on when the main switch is set to “ON”. 3. Voltage 1. Immobilizer system indicator light LED Positive tester probe → red/green 1 Negative tester probe → black 2 • Check the LED of the immobilizer system indicator light. Refer to “CHECKING THE BULBS AND BULB SOCKETS”.
IMMOBILIZER SYSTEM – + 5. Voltage 4. Voltage • Connect the pocket tester (DC 20 V) to the immobilizer unit coupler as shown. • Connect the pocket tester (DC 20 V) to the immobilizer unit coupler as shown. Positive tester probe → green/blue 1 Negative tester probe → black 2 Positive tester probe → red/white 1 Negative tester probe → black 2 2 B ELEC 2 BB R/G Y/L G/L R/W R/G B2 B B Y/L G/L R/W R/W Lg Y/L R/G B2 B R/W Lg Y/L 1 1 • Set the main switch to “ON”. • Measure the voltage (2.
IMMOBILIZER SYSTEM 2. The multifunction display is not indicated. 1. Voltage • Connect the pocket tester (DC 20 V) to the meter assembly couplers as shown. Ch R/G Y Dg G/L R/W 3 2 G/W Y/L B/W Lg G G/L R/W B/W Lg Ch R/G Y G/W Y/L 1 Positive tester probe → red/green 1 and red/white 3 Negative tester probe → black/white 2 • Turn the main switch to “ON”. • Measure the voltage (DC 12 V) meter assembly couplers (wire harness end). • Is the voltage within specification? YES Replace the meter assembly.
IMMOBILIZER SYSTEM ELEC – + 3. When the main switch is set to “ON”, the immobilizer system indicator light flashes after 1 second. • Check if metal or other immobilizer system keys exists near the immobilizer unit. If found, remove the metal or keys, and then check the condition again. Set the main switch to “ON” with another standard key and check the immobilizer system indicator. The indicator goes on for about 1 second, then goes off. Correct First standard key (transponder) is defective.
SELF-DIAGNOSIS ELEC – + EAS00834 SELF-DIAGNOSIS The XT660R/XT660X features a self-diagnosing system for the following circuit: • Fuel sender (thermistor) If the circuit is defective, the condition code will be displayed on the fuel level warning light when the main switch is set to “ON” (irrespective of whether the engine is running or not). Circuit Fuel pump thermistor Defect(-s) • Open circuit • Short circuit System response • The fuel warning light indicate the condition code.
SELF-DIAGNOSIS EAS00835 EAS00838 TROUBLESHOOTING 1. Fuel sender (thermistor) CIRCUIT DIAGRAM The fuel level warning light starts to indicates the self-diagnosis sequence. L/G (BLUE) G/W B J B B (BLUE) NOTE: • Before troubleshooting, remove the following part(s): 1. seat 2. side panels (left and right) 3. fuel tank side covers (left and right) 4. fuel tank • Troubleshoot with the following special tool(s). _ + R/L G/W L/G B Check: 1.
SELF-DIAGNOSIS EAS00842 3. Fuel sender (thermistor) • Disconnect the fuel sender coupler from the wire harness. • Connect the pocket tester (kΩ × 1) to the fuel sender as shown. Positive tester probe → green/white 1 Negative tester probe → black 2 • Check the fuel sender for continuity. • Is the fuel sender OK? YES Replace the meter assembly. NO Replace the fuel pump assembly.
TRBL SHTG 9
TRBL SHTG CHAPTER 9 TROUBLESHOOTING STARTING FAILURES.................................................................................... 9-1 ENGINE..................................................................................................... 9-1 FUEL SYSTEM.......................................................................................... 9-1 ELECTRICAL SYSTEMS ..........................................................................9-2 INCORRECT ENGINE IDLING SPEED..........................
TRBL SHTG FAULTY LIGHTING OR SIGNALING SYSTEM..............................................9-6 HEADLIGHT DOES NOT COME ON ........................................................9-6 HEADLIGHT BULB BURNT OUT.............................................................. 9-6 TAIL/BRAKE LIGHT DOES NOT COME ON ............................................9-6 TAIL/BRAKE LIGHT BULB BURNT OUT.................................................. 9-6 TURN SIGNAL DOES NOT COME ON ..........................................
STARTING FAILURES TRBL SHTG EAS00844 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
STARTING FAILURES/ INCORRECT ENGINE IDLING SPEED ELECTRICAL SYSTEMS Battery • Discharged battery • Faulty battery Fuse(s) • Blown, damaged or incorrect fuse • Improperly installed fuse Spark plug • Incorrect spark plug gap • Incorrect spark plug heat range • Fouled spark plug • Worn or damaged electrode • Worn or damaged insulator • Faulty spark plug cap Ignition coil • Cracked or broken ignition coil body • Broken or shorted primary or secondary coils • Faulty spark plug lead TRBL SHTG Ignition system •
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ FAULTY GEAR SHIFTING/FAULTY CLUTCH TRBL SHTG EAS00848 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING FAILURES”.
OVERHEATING/OVERCOOLING/ POOR BRAKING PERFORMANCE TRBL SHTG EAS00855 OVERHEATING FUEL SYSTEM Throttle body • Faulty throttle body • Damaged or loose throttle body joint Air filter • Clogged air filter element CHASSIS Brake(s) • Dragging brake ELECTRICAL SYSTEMS Spark plug • Incorrect spark plug gap • Incorrect spark plug heat range Ignition system • Faulty ECU ENGINE Clogged coolant passages • Cylinder head and piston • Heavy carbon buildup Engine oil • Incorrect oil level • Incorrect oil viscosity • In
FAULTY FRONT FORK LEGS/ UNSTABLE HANDLING TRBL SHTG EAS00861 FAULTY FRONT FORK LEGS MALFUNCTION • Bent or damaged inner tube • Bent or damaged outer tube • Damaged fork spring • Worn or damaged outer tube bushing • Bent or damaged damper rod • Incorrect oil viscosity • Incorrect oil level LEAKING OIL • Bent, damaged or rusty inner tube • Cracked or damaged outer tube • Improperly installed oil seal • Damaged oil seal lip • Incorrect oil level (high) • Loose damper rod assembly bolt • Damaged damper rod
FAULTY LIGHTING OR SIGNALING SYSTEM TRBL SHTG EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM TURN SIGNAL DOES NOT COME ON • Faulty turn signal switch • Faulty turn signal/hazard relay • Burnt-out turn signal bulb • Incorrect connection • Damaged or faulty wire harness • Improperly grounded circuit • Faulty battery • Blown, damaged or incorrect fuse TURN SIGNAL FLASHES SLOWLY • Faulty turn signal/hazard relay • Faulty main switch • Faulty turn signal switch • Incorrect turn signal bulb TURN SIGNAL REMAINS L
XT660R(S)/XT660X(S) 2004 WIRING DIAGRAM 1 Crankshaft position sensor 2 A.C.
XT660R(S)/XT660X(S) 2004 WIRING DIAGRAM A Ch Lg L/R G Y B L/R G Ch B Y Dg Gy G/W MAIN HARNESS SUB-WIRE HARNESS W W 1 W W W W Gy G/W G/W L/Y W W W 2 5 W W W R B Sb R R R R R R L B R B B B R 7 8 6 W W W 3 R/W R/B R Gy L/W R/L B R 4 B Br/R ON OFF P L/W R/B L/W Br 9 G Br/R R R Br/L Br/L O O R/B R/B O Lg I H Br L/W R/W B/Y R/LL/R L/B Br/L Br/R R B BB R/G R/B L/B R/L L/W L/R R/W L/G L/Y Sb B/Y Lg A Y/L G/L R/W R/G B2 B R/W Lg Y/L R B R/B D R/G R R
