BT1100

2005
BT1100
5JN4-AE1
SUPPLEMENTARY SERVICE MANUAL
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the Yamaha BT1100 (2005). For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manuals.
BT1100 SERVICE MANUAL: 5JN1-AE1
BT1100 2005 SUPPLEMENTARY SERVICE MANUAL 2004 by Yamaha Motor Italia S.p.A. First edition, September 2004 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Italia S.p.A. is expressly prohibited. Printed in Italy
NOTICE
This manual was produced by the Yamaha Motor Italia S.p.A. 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, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha motorcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair. Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and unfit for use. Yamaha Motor Italia S.p.A. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.
NOTE: Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or clearer.
CAUTION:
NOTE:
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. The current section title is shown at the top of each page, except in Chapter 3 ("PERIODIC CHECKS AND ADJUSTMENTS"), where the sub-section title(s) appears. 3 Sub-section titles appear in smaller print than the section title. 4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step. 6 Symbols indicate parts to be lubricated or replaced. Refer to "SYMBOLS". 7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 8 Jobs requiring more information (such as special tools and technical data) are described sequentially.
ILLUSTRATED SYMBOLS
The following symbols are not relevant to every vehicle. Illustrated symbols 1 to 8 are printed on the top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic inspections and adjustments 4 Engine 5 Carburetor 6 Chassis 7 Electrical system 8 Troubleshooting
GEN INFO
3
SPEC
4
INSP ADJ
5
ENG
6
CARB
7
CHAS
8
ELEC
9
TRBL SHTG
0
Illustrated symbols 9 to y are used to identify the specifications appearing in the text. 9 Can be serviced with engine mounted 0 Filling fluid q Lubricant w Special tool e Torque r Wear limit, clearance t Engine speed y Electrical data
Illustrated symbols u to s in the exploded diagrams indicate the types of lubricants and lubrication points. u Apply engine oil i Apply gear oil o Apply molybdenum disulfide oil p Apply wheel bearing grease a Apply lightweight lithium-soap base grease s Apply molybdenum disulfide grease Illustrated symbols d to f in the exploded diagrams indicate the following: d Apply locking agent (LOCTITE) f Replace the part
New
CONTENTS
SPECIFICATIONS GENERAL SPECIFICATIONS.................................................................................... MAINTENANCE SPECIFICATIONS ENGINE ........................................................ LUBRICATION CHART .............................................................................................. TIGHTENING TORQUES ENGINE ........................................................................ MAINTENANCE SPECIFICATIONS CHASSIS ...................................................... TIGHTENING TORQUES CHASSIS ...................................................................... MAINTENANCE SPECIFICATIONS ELECTRICAL ................................................ GENERAL TORQUE SPECIFICATIONS .................................................................. CONVERSION TABLE .............................................................................................. LUBRICATION POINTS AND LUBRICANT TYPES .................................................. LUBRICATION DIAGRAMS ...................................................................................... CABLE ROUTING ...................................................................................................... PERIODIC INSPECTIONS AND ADJUSTMENTS PERIODIC MAINTENANCE/LUBRICATION INTERVALS ........................................ CHASSIS ADJUSTING THE FRONT BRAKE ........................................................ CHECKING THE FUSES .......................................................................................... ENGINE ENGINE REMOVAL .................................................................................................. CARBURETION CARBURETOR .......................................................................................................... CHASSIS FRONT BRAKE MASTER CYLINDER ...................................................................... FRONT BRAKE CALIPERS ...................................................................................... HANDLEBAR.............................................................................................................. STEERING HEAD LOWER BRACKET ..................................................................
1 4 10 11 14 16 18 20 20 21 23 26
29 31 32
34
36
37 39 41 45
ELECTRICAL ELECTRICAL COMPONENTS .................................................................................. 47 SWITCHES ................................................................................................................ 49 CHECKING THE BULBS AND BULB SOCKETS ...................................................... 52 IMMOBILIZER SYSTEM ............................................................................................ 55 SELF-DIAGNOSIS DEVICE ...................................................................................... 63 IGNITION SYSTEM.................................................................................................... 68 ELECTRIC STARTING SYSTEM .............................................................................. 73 CHARGING SYSTEM ................................................................................................ 83 LIGHTING SYSTEM .................................................................................................. 86 SIGNALING SYSTEM ................................................................................................ 91 FUEL PUMP SYSTEM .............................................................................................. 99 CARBURETOR HEATER SYSTEM .......................................................................... 104 TROUBLESHOOTING STARTING FAILURE/HARD STARTING.................................................................... 107 WIRING DIAGRAM
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
Item Model code: Dimensions: Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius Weight: Dry (without oil and fuel) Wet (with oil and a full fuel tank) Bias weight (dry) front Bias weight (dry) rear Bias weight (wet) front Bias weight (wet) rear Maximum load-except motorcycle: Engine: Engine type Cylinder arrangement Displacement Bore stroke Compression ratio Compression pressure (STD) Starting system Lubrication system: Engine oil: Type BT1100: 5JN4 2,200 mm 800 mm 1,140 mm 812 mm 1,530 mm 168 mm 2,980 mm 233 kg 254 kg 109.5 kg 123.5 kg 122 kg 132 kg 200 kg Air cooled 4-stroke, SOHC V-type 2-cylinder 1,063 L 95 75 mm 8.3 : 1 1,000 kPa (10 kg/cm2, 10 bar) at 400 r/min Electric starter Wet sump SAE20W40SE or SAE10W30SE Recommended engine oil classification: API Service SE, SF, SG or higher Standard
Temp.
Final gear oil: Oil quantity: Engine oil Periodic oil change With oil filter replacement Total amount Final gear case oil Total amount
Hypoid gear oil SAE 80 (API GL4)
3.0 L 3.1 L 3.6 L 0.2 L
Item Air filter: Fuel: Type Fuel tank capacity Fuel reserve amount Carburetor: Type/quantity Manufacturer Spark plug: Type Manufacturer Spark plug gap Clutch type: Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio Dry type element Regular unleaded gasoline 20 L 5.8 L BSR37/2 MIKUNI BPR7ES/W22EPR-U NGK/DENSO 0.7 0.8 mm Wet, multiple-disc Standard
SPEC
1st 2nd 3rd 4th 5th
Spur gear 78/47 (1.660) Shaft drive 44/47 19/18 32/11 (2.875) Constant mesh 5-speed Left foot operation 40/17 (2.353) 40/24 (1.667) 36/28 (1.286) 32/31 (1.032) 29/34 (0.853) Twin tube Backbone 25 106 mm Tubeless 120/70-ZR17 (58W) 170/60-ZR17 (72W) DUNLOP / METZELER DUNLOP / METZELER D205F TL / MEZ3F TL D205 TL / MEZ3 TL 230 kPa (2.30 kg/cm2) (2.30 bar) 250 kPa (2.50 kg/cm2) (2.50 bar) 250 kPa (2.50 kg/cm2) (2.50 bar) 270 kPa (2.70 kg/cm2) (2.70 bar) * Load is the total weight of the cargo, rider, passenger and accessories. 200 kg (total weight of rider, passenger, cargo and accessories)
Chassis: Frame type Caster angle Trail Tire: Type Size Manufacturer Type Tire pressure (cold tire): 0 ~ 90 kg load *
front rear front rear front rear
front rear 90 kg (198 lb) ~ Maximum load * front rear
Maximum load:
Item Brake: Front brake Rear brake Suspension: Front suspension Rear suspension Shock absorber: Front shock absorber Rear shock absorber Wheel travel: Front wheel travel Rear wheel travel Electrical system: Ignition system Generator system Battery type Battery capacity Headlight type: Bulb voltage, wattage x quantity: Headlight Auxiliary light Tail/brake light License plate light Front turn signal indicator light Rear turn signal indicator light Meter lighting Neutral indicator light Turn signal light Oil level warning light High beam indicator light Fuel level warning light Immobilizer system light type operation type operation Standard Dual disc brake Right hand operation Single disc brake Right foot operation Telescopic fork Swingarm (link suspension)
SPEC
Coil spring/Oil damper Coil spring/Gas-oil damper/Spring preload adjustable 130 mm 113 mm T.C.I. (digital) A.C. magneto GT14B-4 12V 12Ah Quartz bulb (halogen) 12 V 60 W/55 W x 1 12 V 5 W x 1 12 V 5 W / 21 W x 1 12 V 5 W x 1 12 V 10 W x 2 12 V 10 W x 2 LED x 12 LED x 1 LED x 1 LED x 1 LED x 1 LED x 1 LED x 1
MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS

ENGINE
Item Cylinder head: Volume Warp limit 57.0 58.4 cm3 Standard
SPEC
Limit 0.03 mm
Cylinder: Bore size Measuring point Max. out of round
95.00 95.01 mm 40 mm
95.1 mm 0.01 mm
Camshaft: Drive method Cam cap inside diameter Camshaft outside diameter Shaft-to-cap clearance Cam dimensions:
Chain drive (left & right) 25.000 25.021 mm 24.96 24.98 mm 0.020 0.061 mm
Intake
A B C A B C
Exhaust
Camshaft runout limit
39.112 39.212 mm #1: 32.093 32.193 mm #2: 32,127 32.227 mm 7.162 mm 39.145 39.245 mm 32.200 32.300 mm 7.195 mm
39.012 mm #1: 31.993 mm #2: 32.027 mm 7.012 mm 39.045 mm 32.100 mm 7.045 mm 0.03 mm
MAINTENANCE SPECIFICATIONS
Item Timing chain: Timing chain type/No. of links Timing chain adjustment method Rocker arm/rocker arm shaft: Bearing inside diameter Shaft outside diameter Arm-to-shaft clearance Valve, valve seat, valve guide: Valve clearance (cold) IN EX Valve dimensions: SILENT 98L Automatic 14.000 mm 14.018 mm 13.985 mm 13.991 mm 0.009 mm 0.033 mm 0.07 0.12 mm 0.12 0.17 mm Standard
SPEC
Limit 14.036 mm 13.95 mm 0.086 mm
Head Diameter A head diameter B face width C seat width D margin thickness Stem outside diameter Guide inside diameter Stem-to-guide clearance
Face Width IN EX IN EX IN EX IN EX IN EX IN EX IN EX
Seat Width 47.0 47.2 mm 39.0 39.2 mm 2.1 mm 2.1 mm 1.2 1.4 mm 1.2 1.4 mm 1.1 1.5 mm 1.1 1.5 mm 7.975 7.990 mm 7.960 7.975 mm 8.000 8.012 mm 8.000 8.012 mm 0.010 0.037 mm 0.025 0.052 mm
Margin Thickness 1.8 mm 1.8 mm 0.8 mm 0.8 mm 7.955 mm 7.935 mm 8.042 mm 8.042 mm 0.08 mm 0.10 mm
Item Stem runout limit Standard
SPEC
Limit 0.03 mm
Valve seat width Valve spring: Free length Set length (valve closed) Compressed pressure (installed) Spring rate (K1) Spring rate (K2) Tilt limit
IN EX IN EX IN EX IN EX IN EX IN EX IN EX
1.2 1.4 mm 1.2 1.4 mm 44.6 mm 44.6 mm 40 mm 40 mm 160.7 N (16.4 kg) 160.7 N (16.4 kg) 35.28 N/mm (3.6 kgf/mm) 35.28 N/mm (3.6 kgf/mm) 45.37 N/mm (4.63 kgf/mm) 45.37 N/mm (4.63 kgf/mm)
2.0 mm 2.0 mm 43.5 mm 43.5 mm 2.5/1.9 mm 2.5/1.9 mm
Direction of winding (top view) Piston: Piston to cylinder clearance Piston size D
IN EX
Clockwise Clockwise 0.025 0.050 mm 94.960 94.975 mm
0.15 mm
Measuring point H Piston off-set Piston pin bore inside diameter Piston pin outside diameter
5 mm 0 mm 22.004 22.015 mm 21.991 22.000 mm
22.045 21.975
Item Piston rings: Top ring: Standard
SPEC
Limit
Type Dimensions (B x T) End gap (installed) Side clearance (installed) 2nd ring:
Plain 1.5 3.8 mm 0.3 0.5 mm 0.04 0.08 mm
0.8 mm 0.1 mm
Type Dimensions (B x T) End gap (installed) Side clearance Oil ring:
Taper 1.2 3.8 mm 0.30 0.45 mm 0.03 0.07 mm
0.8 mm 0.1 mm
Dimensions (B x T) End gap (installed) Connecting rod: Oil clearance Color code (corresponding size) Crankshaft:
2.5 3.4 mm 0.2 0.7 mm 0.044 0.073 mm 1 Blue 2 Black 3 Brown 4 Green 5 Yellow
Crank width A Runout limit C Big end side clearance D
101.95 102.00 mm 0.320 0.474 mm
0.02 mm
Item Clutch: Friction plate thickness Quantity Clutch plate thickness Quantity Clutch plate thickness Quantity Clutch spring free length Quantity Clutch housing thrust clearance Clutch housing radial clearance Clutch release method Push rod bending limit Transmission: Main axle deflection limit Drive axle deflection limit Shifter: Shifter type Shift fork thickness Carburetor: I. D. mark Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Pilot screw Valve seat size Starter jet Starter jet Throttle valve size Float height Engine idle speed CO% Intake vacuum Engine oil temperature Fuel pump: Type Model/manufacturer Consumption amperage Output pressure Standard 2.9 3.1 mm 8 2.5 2.7 mm 1 1.9 2.1 mm 7 7.2 mm 1 0.05 0.40 mm 0.010 0.044 mm Inner push, screw push Guide bar 5.76 5.89 mm 5JN4 10 #1: #128.8 - #2: #127.5 #55 5DL49-3 P-0M (826) #63.8 #142.5 1.0 #17.5 0.8 0.8 0.8 3.0 1.2 #45 0,9 #125 11 12 mm 950 1.050 r/min 4 5% 32.2 33.6 kPa (-242 -252 mmHg) 75 85 C Electrical type UC-Z61B/MITSUBISHI 0.8 A 12 kPa (0.12 kf/cm2)
SPEC
Limit 2.8 0.1 0.1 6.5 0.5 mm mm mm mm
mm
0.08 mm 0.08 mm
(M.J) (M.A.J) (J.N) (N.J) (P.A.J.1) (P.A.J.2) (P.O) (P.J) (B.P.1) (B.P.2) (B.P.3) (P.S) (V.S) (G.S.1) (G.S.2) (TH.V) (F.H)
<max>
Item Lubrication system: Oil filter type Oil pump type Tip clearance A or B Side clearance Bypass valve opening pressure Relief valve operating pressure Shaft drive: Middle gear backlash Final gear backlash Standard Paper type Trochoid type 0.03 0.09 mm 0.03 0.08 mm 80 120 kPa (0.8 ~ 1.2 kgf/cm2) 450 550 kPa (4.5 5.5 kgf/cm2) 0.1 0.2 mm 0.1 0.2 mm
SPEC
Limit 0.15 mm 0.15 mm
Item Lubrication chart: Standard
SPEC
Needle bearing (starter)
Connecting rod big end
Main axle
Crankshaft Pressure feed
Drive axle
Pinin drive Splashed Orifice Middle driveshaft
Rocker arm (EX)
Camshaft (EX)
Rocker arm (EX)
Rocker arm (IN)
Camshaft (IN)
Rocker arm (IN)
Oil filter
Relief valve
Oil pump
Oil pan
10
Cylinder head tightening sequence:
SPEC
Crankcase tightening sequence:
Left crankcase
Right crankcase
11
Tightening torques
Part name Nut Nut Bolt Screw Stud bolt Union bolt Bolt Bolt Bolt Bolt Bolt Bolt Screw Nut Nut Nut Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Union bolt Union bolt Screw Screw Screw Screw Screw Nut Screw Screw Screw Screw Screw Thread size M12 M10 M8 M6 M8 M16 M6 M6 M16 M8 M14 M6 M6 M6 M9 M16 M8 M10 M6 M6 M6 M6 M6 M6 M6 M6 M16 M10 M14 M5 M5 M6 M6 M5 M8 M8 M8 M8 M10 M6
SPEC
Part to be tightened Cylinder head Cylinder head Plate Cylinder head cover Cylinder head (exhaust pipe) Rocker arm shaft Camshaft sprocket cover Tappet cover Rocker arm shaft (oil passage) Stopper plate (camshaft) Spark plug Cylinder Lower cylinder head cover Upper cylinder head cover Connecting rod Rotor Valve adjusting locknut Camshaft sprocket Timing chain tensioner Timing chain tentioner cap Timing chain guide Oil pump Oil strainer cover Oil filter cover Oil pump gear Oil pump cap Oil delivery pipe (cylinder head) (crankcase) Oil drain bolt Air filter: Air filter cover fastener Carburetor cover fastener A.I.S. system: A.I.S. system fastener (pump and piping) A.I.S. system pipe fastener to engine starter A.I.S. pump fastener to A.I.S. bracket Exhaust system: Cylinder head and exhaust pipe joint Exhaust pipe bracket Exhaust pipe/exhaust pipe guard fastener (rear) Exhaust pipe strap Silencer fastener to passenger board support Exhaust pipe guard fastener
Qty 8 2 2 4 4 2 4 8 4 4 2 2 6 8 4 1 4 2 4 2 4 3 3 5 1 1 2 1 1 2 4 4 1 2 4 2 2 3 2 2
Tightening torque Nm 50 35 20 4 12.5 37.5 10 10 38 20 20 10 10 5 48 175 27 55 10 8 10 10 10 10 12 10 20 20 43 2 4.5 10 10 8 20 25 20 18 47 7 mkg 5.0 3.5 2.0 0.4 1.25 3.75 1.0 1.0 3.8 2.0 2.0 1.0 1.0 0.5 4.8 17.5 2.7 5.5 1.0 0.8 1.0 1.0 1.0 1.0 1.2 1.0 2.0 2.0 4.3 0.2 0.45 1.0 1.0 0.8 2.0 2.5 2.0 1.8 4.7 0.7
Remarks
Use lock washer
12
Part name Stud bolt Stud bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Nut Bolt Nut Nut Screw Nut Nut Nut Bolt Bolt Thread size M12 M10 M10 M6 M8 M6 M6 M6 M6 M20 M6 M8 M20 M8 M44 M88 M14 M8 M8
SPEC
Remarks
Part to be tightened Crankcase (cylinder) Crankcase (cylinder) Crankcase Crankcase Bearing retainer (middle drive pinion gear) Crankcase cover (left) Crankcase cover (right) Clamp One-way clutch Primary drive gear Clutch spring Clutch adjuster Clutch boss Push lever axle Middle drive pinion gear Bearing retainer (middle driven shaft) Yoke (middle driven shaft) Bearing housing (middle drive shaft) Shift lever stopper
Qty 8 2 3 10 3 13 11 1 8 1 6 1 1 1 1 1 1 4 1
Tightening torque Nm 24 20 38.5 10 25 10 10 10 12 110 8 12 70 12 110 110 25 22 mkg 2.4 2.0 3.85 1.0 2.5 1.0 1.0 1.0 1.2 11.0 0.8 1.2 7.0 1.2 11.0 11.0 2.5 2.2
Use lock washer
Use lock washer Stake Stake Stake
Use lock washer Guide bar stopper Shift dram segment Shift arm Shift pedal adjuster Screw Screw Bolt Nut M6 M5 M6 M6 2 1 1 2 7 4 10 10 0.7 0.4 1.0 1.0
1 of 2 has LH thread
Stator coil Pickup coil Starter motor Neutral switch Ignition coil Speed sensor Engine bracket: Rear fastener Front fastener Engine bracket fastener (front) Engine bracket fastener (front)
Screw Screw Bolt Screw Bolt Screw Screw Special screw Nut
M6 M5 M6 M10 M5 M6 M10 M12 M22 M12
3 2 2 1 4 1 1 1 1 1
10 7 10 20 2.5 7 65 110 18 85
1.0 0.7 1.0 2.0 0.25 0.7 6.5 11.0 1.8 8.5
13
MAINTENANCE SPECIFICATIONS CHASSIS

Item Steering system: Steering bearing type Front suspension: Front fork travel Fork spring free length Fitting length Collar length Spring rate Stroke Optional spring Oil capacity Oil level Oil grade Rear suspension: Shock absorber travel Spring free length Fitting length Spring rate Stroke Optional spring Swingarm: Free play limit Front wheel: Rim size Dimensioni cerchio Rim material Rim runout limit Rear wheel: Type Rim size Rim material Rim runout limit Standard Angular bearing 130 mm 364.8 mm 339.8 mm 150 mm 7.5 N/mm (0.75 kg/mm) 12 N/mm (1.2 kg/mm) 83 mm 47 mm No 0.537 L 117 mm Fork oil 10W or equivalent 60 mm 175 mm 162 mm 120 N/mm (12.23 kg/mm) 0 60 mm No Cast wheel 17 MT3.50 Aluminium Cast wheel 17 MT5.50 Aluminium
SPEC
Limit 0 mm 1.0 mm 0.5 mm 1.0 mm 0.5 mm
(K1) (K2) (K1) (K2)
(K1) (K1)
End
radial lateral
radial lateral
14
Item Front brake: Type Disc outside diameter thickness Disc deflection limit Pad thickness inner outer Dual disc 298 5 mm 4.5 mm 4.5 mm Standard
SPEC
Limit 4.5 0.1 0.5 0.5
mm mm mm mm
Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Rear brake: Type Disc outside diameter thickeness Disc deflection limit Pad thickness inner outer Master cylinder inside diameter Caliper cylinder inside dimeter Brake fluid type Brake pedal position Clutch lever free play (at lever end) Throttle grip free play
15 mm 30.2 mm 27 mm DOT 4 Single disc 267 5 mm 5.5 mm 5.5 mm 13 mm 42.85 mm DOT 4 43 mm 5 10 mm 3 5 mm
4.5 mm 0.15 mm 0.5 mm 0.5 mm
15
MAINTENANCE SPECIFICATIONS Tightening torques

Thread size Tightening torque Nm 10 7 10 4 10 25 25 110 18 10 32 23 4.5 11 25 7 42 25 75 25 25 35 110 22 4 92 22 42 50 50 50 50 19 4.5 7 8 7 16 28 10 2 10 10 mkg 1.0 0.7 1.0 0.4 1.0 2.5 2.5 11.0 1.8 1.0 3.2 2.3 0.45 1.1 2.5 0.7 4.2 2.5 7.5 2.5 2.5 3.5 11.0 2.2 0.4 9.2 2.2 4.2 5.0 5.0 5.0 5.0 1.9 0.45 0.7 0.8 0.7 1.6 2.8 1.0 0.2 1.0 1.0
SPEC
Part to be tightened Headlight assembly/Cowling: Lower headlight support Upper headlight support (right and left) Headlight bracket (right and left) Plastic cover Front flasher lights (right and left) Handlebar/Front fork assembly: Upper bracket and inner tube Lower bracket and inner tube Front fork cap nut and steering shaft Ring nut (steering shaft) Meter bracket and upper bracket Handlebar holder (lower) and upper bracket Handlebar holder (lower) and handlebar (upper) Throttle cable Clutch lever assembly Handlebar weight (right and left) Front fender fastening screw Front wheel: Front brake caliper (right and left) Front brake disc (right and left) Front wheel axle Front wheel axle pinch bolt Rear wheel: Rear brake disc Rear brake caliper Rear wheel axle nut Rear wheel axle pinch bolt Dust cover fastening screw Swingarm assembly: Pivot shaft Swingarm pinch bolt Shock absorber fastener (upper) Shock absorber fastener (lower) Connecting arm Relay arm Final gear case fastening cap nut Sidestand/Shift pedal: Sidestand Sidestand switch Shift rod Ball-and-joint socket Shift boss Shift pedal Front brake: Brake hose union bolt Front master cylinder Front master cylinder cover Front brake joint fastening screw Brake hose holder fastening screw
Remarks
M6 M6 M6 M5 M12 M8 M8 M22 M6 M10 M8 M5 M6 M8 M6 M10 M8 M18 M8 M8 M10 M16 M8 M5 M16 M8 M10 M10 M12 M10 M10 M8 M5 M6 M6 M6 M8 M10 M6 M6 M6
See Note
16
Thread size Tightening torque Nm 25 10 16 10 7 28 25 5.5 55 23 4 7 23 7 7 7 7 7 23 7 10 7 10 10 7 6 4 7 7 mkg 2.5 1.0 1.6 1.0 0.7 2.8 2.5 0.55 5.5 2.3 0.4 0.7 2.3 0.7 0.7 0.7 0.7 0.7 2.3 0.7 1.0 0.7 1.0 1.0 0.7 0.6 0.4 0.7 0.7
SPEC
Remarks
Part to be tightened Rear brake/Footrests: Brake caliper torque rod Rear brake adjuster Rear brake pedal fastening screw (special) Rear master cylinder fastening screw Rear brake fluid reservoir fastening screw Special screw for fastening rear brake hose to brake caliper Special screw for fastening rear brake hose to master cylinder Brake caliper bleed screw Front footrest bracket fastening screw (aluminium) Front footrest bracket fastening screw (steel) Footrest damper fastening screw Rear footrest fastening screw Rear footrest bracket fastening screw Rear lights/Rear fender/Panel assembly: Side panel fastening screw Battery receptacle fastening screws Battery receptacle cover fastening screws Plastic rear fender fastening screws Plastic license bracket fastening screws Rear fender cover fastening screw (aluminium) Seat lock fastening screw Rear flasher lights (right and left) Tail light fastening screw Fuel tank: Fastening screw (front) Fastening screw (rear) Bracket fastening screw (rear) Tank cap fastening screw Tank cover fastening screw (aluminium) Fuel cock fastening screw Fuel sender fastening screw
M8 M6 M8 M6 M6 M10 M10 M6 M10 M8 M5 M6 M8 M6 M6 M6 M6 M6 M8 M6 M12 M6 M6 M6 M6 M5 M5 M6 M6
NOTE: 1. First, tighten the ring nut approximately 52 Nm (5.2 mkg) by using the torque wrench, then loosen the ring nut completely. 2. Retighten the ring nut to specification.
17
MAINTENANCE SPECIFICATIONS ELECTRICAL

Item Voltage: Ignition system: Ignition timing (B.T.D.C.) Advancer type T.C.I.: Pickup coil resistance/color T.C.I. unit model/manufacturer Ignition coil: Model/manufacturer Primary winding resistance Secondary winding resistance Spark plug cap: Type Resistance Charging system: Type Model/manufacturer Nominal output Stator coil resistance/color Voltage regulator: Type Model/manufacturer No load regulated voltage Rectifier: Model/manufacturer Capacity Withstand voltage Battery: Specific gravity Electric starter system: Type Starter motor: Model/manufacturer Output Armature coil resistance Brush overall length Brush spring pressure Commutator diameter Mica undercut Starter relay: Model/manufacturer Amperage rating Resistance 12 V 10 at 1,000 r/min Digital type 189 231 at 20 C / GrayBlack J4T157/MITSUBISHI F6T552/MITSUBISHI 3.57 4.83 at 20 C 10.7 14.5 k at 20 C Resin type 10 k A.C. magneto F4T654/MITSUBISHI 14V 350W at 5,000 r/min 0.36 0.44 at 20 C / WhiteWhite Semi-conductor, short-circuit type SH650D-11/SHINDENGEN 14.1 14.9 V SH650D-11/SHINDENGEN 18 A 200 V 1.320 Constant mesh type SM-13/MITSUBA 0.6 kW 0.026 0.034 at 20 C 10 mm 7.65 10,01 N (780 1021 g) 28 mm 0.7 mm MS5F-421/JIDECO 180 A 4.18 4.62 at 20 C Standard
SPEC
Limit 5 mm 27 mm
18
Item Horn: Type Quantity Model/manufacturer Maximum amperage Flasher relay: Type Model/manufacturer Self cancelling device Hazard flasher device Flasher frequency Wattage Oil level gauge: Model/manufacturer Starting circuit cut-off relay: Model/manufacturer Coil resistance Throttle position sensor: Resistance Fuel pump relay: Model/manufacturer Coil resistance Thermostat switch: Model/manufacturer Circuit breaker: Circuit breaker type Amperage for fuses: Main fuse Headlight fuse Signaling system fuse Ignition fuse Parking lighting fuse Odometer fuse (backup) Igniter fuse Carburetor heater fuse Reserve fuse Reserve fuse Reserve fuse Reserve fuse Plane type 1 K80 L-12V/LEB 3A Full transistor FE218BH/DENSO No Yes 75 95 cycle/min 10 W 2 + 3.4 W 5JN/DENSO G8R-30Y-U0/OMRON 162 198 at 20 C 4.0 6.0 k at 20 C / Blue-Black G8R-30Y-U0/OMRON 162 ~ 198 at 20 C 5FU/NIPPON THERMOSTAT Fuse 30 A 15 A 10 A 10 A 10 A 10 A 5A 15 A 30 A 15 A 10 A 5A Standard
SPEC
Limit
19
GENERAL TORQUE SPECIFICATIONS/ CONVERSION TABLE GENERAL TORQUE SPECIFICATIONS

This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until the specified torque is reached. Unless otherwise specified, torque specifications require clean, dry threads. Components should be at room temperature.
SPEC
CONVERSION TABLE
All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC ** mm 2 mm MULTIPLIER 0.03937 0.03937 = = IMP ** in 0.08 in
CONVERSION TABLE
METRIC TO IMP Known mkg mkg cmkg cmkg kg g km/hr km m m cm mm cc (cm3) cc (cm3) lt (liter) lt (liter) Multiplier 7.233 86.794 0.0723 0.8679 2.205 0.03527 0.6214 0.6214 3.281 1.094 0.3937 0.03937 0.03527 0.06102 0.8799 0.2199 ftlb inlb ftlb inlb lb oz mph mi ft yd in in oz (IMP liq.) cuin qt (IMP liq.) gal (IMP liq.) Result
Torque
Weight
A: Distance between flats B: Outside thread diameter A (nut) 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm B (Bolt) 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm General torque specifications Nm 6 15 30 55 85 130 mkg 0.6 1.5 3.0 5.5 8.5 13.0
Distance
Volume/ Capacity
Miscellaneous
kg/mm 55.997 lb/in 14.2234 psi (lb/in2) kg/cm2 Centigrade 9/5 (C) + 32 Fahrenheit (F)
20
LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication point Oil seal lips O-ring Bearing Connecting rod bolt/nut Connecting rod small end and big end Crankshaft pin Crankshaft journal/big end Piston surface Piston pin Camshaft cam lobe/journal Rocker arm shaft Valve stem (IN, EX) Valve stem end (IN, EX) Timing chain drive gear shafts/sprokets Oil pump rotor (inner/outer), housing Idle gear surface Starter idle gear Starter idle gear shaft Starter oneway cam Middle drive gear Primary driven gear Push rod 1, 2 Transmission gear (wheel/pinion) Shift cam Shift fork/guide bar Shift shaft assembly Push rod ball Push lever assembly
SPEC
Symbol
21
LUBRICATION POINTS AND LUBRICANT TYPES

CHASSIS
SPEC
Lubrication point Steering head pipe (upper/lower), bearing Steering head pipe, bearing cover lip Steering head pipe, oil seal lip Front wheel oil seal lip (right/left) Rear wheel oil seal lip Clutch hub fitting area Rear brake pedal shaft Shift pedal shaft Sidestand bolt, sidestand sliding surface Tube guide (throttle grip) inner surface Brake lever pivot bolt, contact surface Clutch lever pivot bolt, contact surface Rear shock absorber (lower) oil seal lip Swingarm pivot bearing inner surface Swingarm pivot oil seal lip Relay arm bearing, collar and oil seal Drive shaft spline Drive shaft dust cover Drive shaft coupling gear oil seal
Symbol
22
LUBRICATION DIAGRAMS
EB205000
SPEC
1 Rocker arm shaft (intake) 2 Rocker arm shaft (exhaust) 3 Oil filter 4 Oil pump 5 Drive axle 6 Middle drive shaft
23
1 Oil pump 2 Releaf valve 3 Oil filter 4 Middle drive shaft
SPEC
24
1 Camshaft 2 Crankshaft 3 Main axle 4 Middle drive shaft 5 Drive axle 6 Connecting rod big end
SPEC
25
CABLE ROUTING CABLE ROUTING

1 2 3 4 5 6 7 8
Relays group Flasher relay Speed sensor Sidestand switch Fuel drain hose Engine earth Neutral switch Carburetor heater
SPEC
9 0 q w e r t y
Filler tank cap fuel drain pipe Filler tank cap fuel drain pipe Fuel hose (carburetor-3 way) Handlebar switch leads (left) Rectifier/regulator Spark plug cap (front cilinder) Throttle cables Wireharness
u i o p
Clutch cable Front brake cable (left) Carburetor pipe vent Pipe drain
Fix the wires of the left swicth assy to the handlebar by means of no. 2 plastic clamps. Fix the headlight leads to the clamp.
q 0
o y w e
26
CABLE ROUTING
a Rubber cap for front wiring s d f g h j k l
connections Horn Front brake hose (right) A.I.S. pipe to the front cylinder Starter motor Starter motor lead Oil level gauge Rear brake hose Brake fluid reservoir hose
SPEC
; z x c v b n m ,
Ignition coil (rear cylinder) Starter relay assy Depression fuel cock Spark plug cap (rear cylinder) A.I.S. pipe to the rear cylinder A.I.S. system Throttle position sensor (TPS) Ignition coil (front cylinder) Handlebar switch leads (right)
. Throttle cables / Brake cable

(front master cylinder) ! Thermo swicth Check that the wires of the ignition coil do not remain tensioned. Fix the wires of the right switch assy to the handlebar by means of no. 1 plastic clamp.
/ ; z x c , m !
a s l v n b
f k
27
CABLE ROUTING
@ # $ % ^ & *
Carburetor pipe vent Depression fuel cock Battery Fuel hose Spark plug lead (rear) Battery positive (+) terminal Fuse box
SPEC
( ) Q W E R T
Battery negative (-) terminal Igniter unit Fuel filter Fuel pump Fuel sender Air intake pipe (A.I.S. system) Anti-theft alarm connectors
Y Rubber cap for front wiring

connections
U Spark plug lead (front) I Throttle cable

Position the spark plug wire of the rear cylinder below the fuel hose.
U R
@ I
E # W % Q ) ( & ^ * $
28
INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS
INSP ADJ
PERIODIC INSPECTIONS AND ADJUSTMENTS

INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS

ODOMETER READING (x 1,000 km) N0. 1 2 3 * * Fuel line Fuel filter Spark plugs ITEM CHECK OR MAINTENANCE JOB Check fuel hoses and vacuum hose for cracks or damage. Check condition. Check condition. Clean and regap. Replace. 4 5 6 * Valves Air filter element Clutch Check valve clearance. Adjust. Clean. Replace. Check operation. Adjust. Check operation, fluid level and vehicle for fluid leakage. Replace brake pads. 8 * Rear brake Check operation, fluid level and vehicle for fluid leakage. Replace brake pads. 9 10 * * Brake hoses Wheels Check for cracks or damage. Replace. Check runout and for damage. Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. 1 10 20 30 40 Annual check
Front brake
Whenever worm to the limit
Whenever worm to the limit
Every 4 years
11
Tires
12 13
* *
Wheel bearings Swingarm Steering bearings Chassis fasteners Sidestand
Check bearing for looseness or damage. Check operation and for excessive play. Lubrificate with lithium-soap-based grease. Check bearing play and steering for roughness. Lubrificate with lithium-soap-based grease. Make sure that all nuts, bolts and screws are properly tightened. Check operation. Lubricate. Check operation and for oil leakage. Check operation and for oil leakage. Check operation and shock absorber for oil leakage.

Every 50,000 km
14 15 16 17 18 19
* *
Every 20,000 km
* * *
Sidestand Switch Front fork Rear shock absorber assembly
29
INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS

N0. ITEM Rear suspension relay arm and connecting arm pivoting points Carburators CHECK OR MAINTENANCE JOB
INSP ADJ
30 40 Annual check
ODOMETER READING (x 1,000 km) 1 10 20
Check operation.
20
Lubricate with lithium-soap-based grease. Check starter (choke) operation. Adjust engine idling speed and synchronization. Change. Check oil level and vehicle for oil leakage. Replace. Check oil level and vehicle for oil leakage. Change. Check operation.

21
22
Engine oil Engine oil filter element Final gear oil Front and rear brake switch Moving parts and cables * Throttle grip housing and cable Air induction system Muffler and exhaust pipe Lights, signals and switches

23 24

25 * 26
Lubricate. Check operation and free play. Adjust the throttle cable free play if necessary. Lubricate the throttle grip housing and cable. Check the air cut valve, reed valve and hose for damage. Replace the entire air induction system if necessary. Check the screw clamp for looseness. Check operation. Adjust headlight beam.
27
28

29 30
* *
* Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. NOTE: The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. From 50,000 km, repeat the maintenance intervals starting from 10,000 km. The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake system: Check the brake fluid level regularly and fill as required. Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years. Replace the brake hoses every four years or if cracked or damaged.
30
ADJUSTING THE FRONT BRAKE

EB304001
INSP ADJ
CHASSIS
ADJUSTING THE FRONT BRAKE 1. Adjust: brake lever position (distance a between the brake lever and the handlebar grip)
MMMMMMMMMMMMMMMMMMMMMMMMMMMMM
a. Turn the adjusting dial 1 while holding the lever pushed away from the handlebar grip NOTE: Align the setting on the adjusting dial with the arrow mark 2 Position n. 1 Position n. 5 Maximum a distance Minimum a distance
WARNING After adjusting the brake lever position, make sure the pin on the brake lever holder is firmly inserted in the hole in the adjusting dial.
LLLLLLLLLLLLLLLLLLLLLLLLLLLLL
WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system. Air in the brake system will considerably reduce braking performance and could result in loss of control and possibly an accident. Therefore, inspect and, if necessary, bleed the brake system. After adjusting the brake lever free play, make sure that there is no brake drag.
31
CHECKING THE FUSES

EAS00181
INSP ADJ
CHECKING THE FUSES The following procedure applies to all of the fuses. CAUTION: To avoid a short circuit, always turn the main switch to "OFF" when checking or replacing a fuse. 1. Remove: seat storage compartment 1 2. Check: fuse
a. Connect the pocket tester to the fuse and check it for continuity. NOTE: Set the pocket tester selector to 1. Pocket tester 90890-03112 b. If the pocket tester indicates "", replace the fuse.
3. Replace: blown fuse

a. Turn off the ignition. b. Install a new fuse of the correct amperage rating. c. Turn on the switches to verify if the electrical circuit is operational. d. If the fuse immediately blows again, check the electrical circuit.
32
CHECKING THE FUSES
INSP ADJ
Amperage rating 30 A 15 A 15 A 10 A 10 A 10 A 10 A 5A 30 A 15 A 10 A 5A Quantity 1 1 1 1 1 1 1 1 1 1 1 1
Fuses 1 Main fuse 2 Carburetor heater fuse 3 Headlight fuse 4 Signaling system fuse 5 Ignition fuse 6 Odometer fuse (backup) 7 Parking lighting fuse 8 Igniter fuse 9 Reserve fuse 0 Reserve fuse q Reserve fuse w Reserve fuse
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: storage compartment seat
33
ENGINE REMOVAL
ENG
ENGINE
ENGINE REMOVAL
SEAT, STORAGE COMPARTMENT, SIDE COVERS, FUEL TANK, AIR FILTER CASE ASSEMBLY, CARBURETOR ASSEMBLY AND EXHAUST SYSTEM
Order
Job name/Part name
Qty
Remarks Remove the parts in the order listed. Stand the motorcycle on a level surface.
Removing the seat, storage compartment, side covers, fuel tank, air filter case assembly, carburetor assembly and exhaust system
WARNING Securely support the motorcycle so there is no danger of it falling over. 1 Seat Storage compartment 1
34
ENGINE REMOVAL
ENG
Order 2
Job name/Part name
Qty 2 Disconnect
Remarks NOTE: First, disconnect the negative lead, then disconnect the positive lead.
Battery leads
Side covers Fuel tank Air filter case assembly Carburetor assembly 3 4 5 6 A.I.S. system cover A.I.S. system Muffler assembly Exhaust pipes 1 1 2 2
Refer to "SEAT, SIDE COVERS AND FUEL TANK" in Chapter 3. Refer to "CARBURETOR" in Chapter 5.
For installation, reverse the removal procedure.
35
CARBURETOR
CARB
CARBURETION
CARBURETOR
Order
Job name/Part name Removing the carburetors Seat Fuel tank Air filter case assembly Air ducts Cylinder head breather hose Cover Throttle position sensor lead Carburetor heater lead Fuel hoses Carburetor assembly Starter cable Throttle cables
Qty
Remarks Remove the parts in the order listed. Refer to "SEAT, SIDE COVERS AND FUEL TANK" in Chapter 3.
1 2 3 4 5 6 7 8 9 10
1 2 1 1 1 1 2 1 1 2
Disconnect Disconnect Disconnect Disconnect NOTE: After removing the carburetor assembly, remove the starter cable and throttle cables. For installation, reverse the removal procedure.
36
FRONT BRAKE
CHAS
CHASSIS
FRONT BRAKE MASTER CYLINDER
Order
Job name/Part name Removing the front brake master cylinder Drain the brake fluid Brake lever Front brake switch lead Front brake switch Union bolt Copper washers/brake hose Master cylinder bracket Master cylinder
Qty
Remarks Remove the parts in the order listed.
1 2 3 4 5 6 7
1 2 1 1 2/1 1 1
Refer to REMOVING/INSTALLING THE FRONT BRAKE MASTER CYLINDER. For installation, reverse the removal procedure.
37
FRONT BRAKE
CHAS
Order
Job name/Part name Disassembling the front brake master cylinder Dust boot Circlip Master cylinder cup Spring
Qty
1 2 3 4
1 1 1 1 For assembly, reverse the disassembly procedure.
38
FRONT BRAKE
FRONT BRAKE CALIPERS
CHAS
Order
Job name/Part name Removing the front brake calipers Drain the brake fluid Union bolt Copper washers Brake hose Brake caliper assembly
Qty
1 2 3 4
1 2 1 1
Refer to REMOVING/INSTALLING THE FRONT BRAKE CALIPERS.
39
FRONT BRAKE
CHAS
Order
Job name/Part name Disassembling the front brake calipers Pad pin clips Pad pin Pad spring Brake pads Bleed screw Brake caliper pistons Dust seals Caliper piston seals
Qty
1 2 3 4 5 6 7 8
2 1 1 2 1 4 4 4
Refer to REPLACING THE FRONT BRAKE PADS.
Refer to DISASSEMBLING THE FRONT BRAKE CALIPER. For assembly, reverse the disassembly procedure.
40
HANDLEBAR
CHAS
HANDLEBAR
Order
Job name/Part name Removing the handlebar
Qty
Remarks Remove the parts in the order listed. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over.
1 2 3 4 5 6 7 8 9
Plastic locking ties Clutch cable Handlebar switch (left) Grip (left) Clutch lever assembly/rear view mirror Master cylinder bracket Master cylinder assembly/rear view mirror Handlebar switch (right) Throttle cables 41
2/2 1 1 1 1/1 1 1/1 1 2
Refer to INSTALLING THE HANDLEBAR. Refer to REMOVING THE HANDLEBAR.
Refer to INSTALLING THE HANDLEBAR.
HANDLEBAR
CHAS
Order 10 11 12 13
Job name/Part name Throttle grip assembly Handlebar holders (upper) Handlebar Handlebar holders (lower)
Qty 1 2 1 2
Remarks Refer to INSTALLING THE HANDLEBAR.
42
HANDLEBAR
EASB0025
CHAS
INSTALLING 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. Install: handlebar upper handlebar holders 23 Nm (2.3 mkg) CAUTION: First, tighten the bolts on the front side of the handlebar holder, then 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. NOTE: Align the match marks on the handlebar with the upper surface of the lower handlebar holders.
3. Install: throttle grip 1 throttle cable WARNING Make sure that the pin a on the throttle cable housing is aligned with the hole b in the handlebar.
4. Install: master cylinder 1 Refer to FRONT AND REAR BRAKES. NOTE: Align the slit in the brake lever holder with the punch mark a in the handlebar.
43
HANDLEBAR
CHAS
5. Install: master cylinder holder 2 10 Nm (1.0 mkg) NOTE: Install the master cylinder holder 2 with the mark "UP" facing up.
6. Install: clutch lever holder 1 NOTE: Align the slit in the clutch lever a holder with the punch mark in the handlebar. 7. Install: left handlebar switch 2 NOTE: Aligh the matching surface on the handlebar switches with the punch mark a on the handlebar. 8. Install: clutch cable 9. Connect: clutch switch coupler NOTE: Apply a thin coat of lithium soap base grease onto the end of the clutch cable. 10. 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) 5 10 mm 11. 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 5 mm
44
STEERING HEAD
CHAS
STEERING HEAD
LOWER BRACKET
Order
Job name/Part name Removing the lower bracket Front wheel Front fork legs Handlebar Crown nut/washer plate Upper bracket Special washer Upper ring nut Rubber seal Lower ring nut Lower bracket Rubber washer Bearing cover Bearing
Qty
Remarks Remove the parts in the order listed. Refer to FRONT WHEEL AND BRAKE DISCS. Refer to FRONT FORK. Refer to HANDLEBAR.
1 2 3 4 5 6 7 8 9 10
1/1 1 1 1 1 1 1 1 1 1
Refer to INSTALLING THE STEERING HEAD. Refer to REMOVING THE LOWER BRACKET/INSTALLING THE STEERING HEAD.
45
STEERING HEAD
CHAS
Order 11 12 13
Job name/Part name Bearing Dust seal Lower handlebar holder
Qty 1 1 2
Remarks
46
ELECTRICAL COMPONENTS
ELEC
ELECTRICAL
1 2 3 4 5 Main switch Igniter unit Ignition coil (rear cylinder) Ignition coil (front cylinder) Horn 6 7 8 9 0 Oil level gauge assembly Neutral switch Sidestand switch Speed sensor Immobilizer control unit
47
q w e r t Fuel meter senser unit Battery Starter relay Relay assembly Flasher relay y u i o Relay assembly Fuse assembly Rectifier/regulator Thermo switch
ELEC
48
SWITCHES
EAS0010
ELEC
SWITCHES
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. Pocket tester 90890-03112 NOTE: Before checking for continuity, set the pocket tester to 0 and to the x 1 range. When checking for continuity, switch back and forth between the switch positions a few times. The terminal connections for switches (e.g., main switch, engine stop switch) are shown in an illustration similar to the one on the left. The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration. NOTA: The symbol indicates a continuity of electricity between switch terminals (i.e., a closed circuit at the respective switch position). The example illustration on the left shows that: There is continuity between Brown/Red and Red when the switch is set to F. There is continuity between Brown/Red and Red, between Brown/Blue and Red, and between Brown/Blue and Brown/Red when the switch is set to ON.
49
CHECKING THE SWITCHES

EAS00731
ELEC

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 the switch. Improperly connected Properly connect. Incorrect continuity reading Replace the switch.
50

1 2 3 4 5 6 7 Clutch switch Pass switch Horn switch Dimmer switch Turn switch Main switch Front brake switch 8 9 0 q w e r Hazard switch Engine stop switch Start switch Fuses Rear brake switch Sidestand switch Neutral switch
ELEC
51
CHECKING THE BULBS AND BULB SOCKETS

EAS00732
ELEC

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. Incorrect continuity reading Repair or replace the bulb, bulb socket or both.
TYPES OF BULBS Le lampadine utilizzate su questo motociclo sono illustrate nella figura a sinistra. The bulbs used on this motorcycle are shown in the illustration on the left. Bulbs A and B are used for headlights and usually use a bulb holder which must be detached before removing the bulb. The majority of these bulbs can be removed from their respective socket by turning them counterclockwise. Bulb C is used for turn signal and tail/brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise. Bulbs D and E are used for meter and indicator lights and can be removed from their respective socket by turn D and pulling E them out.
CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: bulb
52

WARNING
ELEC
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. 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.
2. Check: bult (for continuity) (with the pocket tester) No continuity Replace. Pocket tester 90890-03112 NOTE: Before checking for continuity, set the pocket tester to 0 and to the x 1 range.
a. Connect the tester positive probe to terminal 1 and the tester negative probe to terminal 2, and check the continuity. b. Connect the tester positive probe to terminal 1 and the tester negative probe to terminal 3, and check the continuity. c. If either of the readings indicate no continuity, replace the bulb.
53
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. Connect the pocket tester probes to the respective leads of the bulb socket. c. Check the bulb socket for continuity. If any of the readings indicate no continuity, replace the bulb socket.
54
EB805000
B B2 RG
YL GL RW
RG B2 B RW GL YL
50
B2
1
B W
R R
RG GL RW YL
R W
CIRCUIT DIAGRAM
Gy BL
SbW
B Gy RB R L B R RB Or Or RB L LB Sb LY BY LG LR RW YL RW R L RW LG LY Sb BY LW
Gy1
(BLACK)
4
SbW RB
BL L LB LR
5
B B Lg LR YB Y L Gy1 LY RB RW B Br Or WB YL Sb W RL BL G Gy2
W W
W W
W W W
W W W
2
B LW B
11
BrR BrR B B B LB LB B (BLACK) Gy1 LR PUMP Gy2 Gy2 (BLACK) B BW RB R BrL R BrL
7 9 10 12
PU Y L L Y BL LY WB RL
SP RPM GND
8
LB
IMMOBILIZER SYSTEM
ON OFF P
43
BrL L B SL2 SS HD +B G W YB B Br Sb Br G L Y B VCC NS TPS S.GND SL1 Y BL 10A RW
B2 B1
40
B1 B2
15 6 40 48
RW RB LW
B2 B1
3 13
LG B G Y LR
BB3 BB4
G B LR Y
BB2 BB1
MAIN HARNESS
HEAD LIGHT
21
RB GY RW Br HAZARD OFF ON OFF RUN PUSH B B B LG B (BLUE) (BLUE) LW B Dg BrW Ch Ch
BrW Dg
GY RB Br RW E/G STOP FREE START
17 14 49
G Br
B B B B R B LW 10A
BrB
BrB
BB3 BB2
BB4 BB1
16
Gy Br Dg BrW Ch B B
MAIN HARNESS
CARB.HEATER
RY
Br
42
RY RY LB Br WB P BrG (BLACK) BrW LB WB
BrW
R RL B B GY
5A
45
RY
BrG
25
L W BL BrW
GY Br
RY
47
Dg BrW Ch HORN OFF ON N R LY BY (BLACK) Y B G Ch
Dg LB
L W BL W L B
Ch
BrW
Dg DIMMER HI LO PASSING OFF ON TURN L
BY
LY
24
P
BrY
BrB
LR
B B B
BrB B BrB
LR A
44
LR Y G LR GY 12V5W LR B B LR LR Y G B 12V21/5W
BrB
BrB
Ch
Dg
Ch
Dg
Ch
Dg
Ch
12V10W
12V10W
Dg
12V10W
12V5W
12V60/55W
LR B GY
29
GY B LR B B G Y B A B B
Ch B B
Dg B B
Ch B B
Dg B B B
12V10W
Sb
35 36 37 39
Ch B
Dg
Ch B B
Dg Sb
Sb
55
18
BrL 15A RY B GW BrL 10A Br GW B
19
38
41
BrR
10A BrG
46 20 51
B B RY B P G Y BY LY LB G P B RY LB LY BY Y
BrL BrY
15A
23
34
BrBBrY
26
Y HI BEAM B
22
IMMOBILIZER SYSTEM
3 5 0 t a h # % )
30
IMOBILIZER GL
31
32
33
ELEC
RG Br B GW W YB
Dg Ch GL Y BW SbW
27 28
Main switch Battery Igniter unit Ignition fuse Backup fuse Multi-function display Anti-theft alarm (option) Igniter fuse Immobilizer control unit
IMMOBILIZER SYSTEM GENERAL INFORMATION
ELEC
This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: a code re-registering key (with a red bow) two standard keys (with a black bow) that can be re-registered with new codes a transponder (which is installed in each key bow) an immobilizer unit the igniter unit an immobilizer system indicator light The key with the red bow is used to register codes in each standard key. Do not use the key with the red bow for driving. It should only be used for re-registering new codes in the standard keys. The immobilizer system cannot be operated with a new key until the key registered with a code. If you lose the code reregistering key, the igniter unit and main switch (included with an immobilizer unit) needs to be re-placed. Therefore, always use a standard key for driving. (See caution below.)
NOTE: Each standard key is registered during production, therefore re-registering at purchase is not necessary.
CAUTION:
DO NOT LOSE THE CODE RE-REGISTERING KEY! If the code re-registering key is lost, registering new codes in the standard keys is impossible. The standard keys can still be used to start the vehicle, however if code re-registering is required (i.e., if a new standard key is made or all keys are lost) the entire immobilizer system must be replaced. Therefore, it is highly recommended to use either standard key after any code re-registering and keep the code re-registering key in a safe place. Do not submerse either of the keys in water. Do not expose the keys to excessively high temperatures. Do not place either of the keys close to magnets (this includes, but not limited to, products such as speakers, etc.). Do not place heavy items on either key. Do not grind either key or alter their shape. Do not disassemble the plastic part of either key. Keep other immobilizer keys away for this units code re-registering key and main switch.
56
IMMOBILIZER SYSTEM KEY CODES REGISTRATION METHOD
ELEC
In the course of use, you may encounter the following case where replace these parts and registration of code re-registering/ standard key is required.
NOTE: Each standard key is registered during production, therefore re-registering at purchase is not neces-sary.
Replacement parts on troubles

Replacement parts Main switch *1 Standard key Igniter unit Accessory lock*2 and key Required key registration
Immobilizer unit
Standard key is missing and replace it is required All keys have been lost (Including code re-registering key) Igniter unit is defective Immobilizer unit is defective Main switch is defective Accessory lock*2 is defective
Standard key Code re-registering key and standard keys Code re-registering key Code re-registering key and standard keys Code re-registering key and standard keys No required
*1 Replaced as a set with the immobilizer unit. (Because attended to replace the code re-registering key) *2 Accessory locks mean the seat lock, fuel tank cap or the helmet holder. Code re-registering key registration: When the immobilizer unit or igniter unit is replaced, the unit cannot be used until the key code is registered because it is not registered to the unit. After replacement of the immobilizer unit or igniter unit: 1. Turn ON the main switch with the code re-registering key. Make sure the immobilizer system indicator light goes on for about one second and then off. This shows that the code re-registering key registration is finished. 2. Check that the engine can be started. 3. Consequently, carry out the standard key registration, according the section below. Standard key registration: When you lose a standard key and need a new one. Or when the code re-registering key is re-registered after the immobilizer unit or igniter unit, are replaced.
NOTE: It is prohibited to start the engine with the standard key that is not registered. If the main switch is turned ON with the standard key that is not registered, the immobilizer system indicator light blinks and indicates the error code 52. (Refer to SELF-DIAGNOSIS ERROR CODE INDICATION).
57
IMMOBILIZER SYSTEM
ELEC
1. Check that the immobilizer system indicator light is flashing. It indicates the standby mode. To initiate the standby mode, turn OFF the main switch and then it will be the standby mode when it passes 30 seconds. After 24 hours have passed, the indicator light stop flashing and the standby mode ends.
2. After the main switch is turned ON with the code re-registering key, before 5 seconds elapses, turn OFF the main switch and then turn ON the main switch with the standard key (the first new key) that you want to register. 3. It enters the key registration mode and the two standard key codes that have been stored in the memory are erased and the first new standard key code will be registered. At this time, the indicator light rapidly blinks (OFF for 0.5 sec. and ON for 0.5 sec.). 4. In the condition as mentioned above (while the indicator light continues rapid flashing), after the main switch is turned ON with the first new standard key, turn OFF the main switch before 5 seconds elapses, and then turn ON the main switch with the standard key that you want to register (which is the second new key or the standard key remained in hand). 5. When the registration is finished, the indicator light goes off. 6. Check that the engine can be started with the two registered standard keys.
NOTE: The flashing stops when 5 seconds elapses and the registration mode is finished. In this case, the seccond standard key cannot be registered and only the first standard key is registered.
Voiding the standard key code: If you lose one standard key that you used and you want to make the lost standard key unable to be used anymore, re-register another standard key. To re-register, refer to Standard key registration. This re-registration disables the lost standard key because its key code has been changed.
58
IMMOBILIZER SYSTEM
EAS00781 EAS00739
ELEC
TROUBLESHOOTING The immobilizer system fail to operate. (The immobilizer system indicator light starts to blinking the self-diagnosis code sequence.) Check: 1. Main, ignition and backup fuses 2. Battery 3. Main switch 4. Wiring (of the entire immobilizer system) NOTE: Before troubleshooting, remove the following part(-s). 1) Seat 2) Side covers 3) Fuel tank (lift) 4) Cowling (lift forward) 5) Storage compartment/battery cover Troubleshoot with the following special tool(-s).
2. Battery Check the condition of the battery. Refer to CHECKING AND CHARGING THE BATTERY in chapter 3. Open-circuit voltage 12.8 V or more at 20 C Is the battery OK? YES NO Clean the battery terminals. Recharge or replace the battery.
EAS00749
3. Main switch Check the main switch for continuity. Refer to CHECKING THE SWITCHES. Is the main switch OK? YES NO Replace the main switch.
Pocket tester 90890-03112

EAS00738
1. Main, ignition and backup fuses Check the main, ignition and backup fuses for continuity. Refer to CHECKING THE FUSES in chapter 3. Are the main, ignition and backup fuses OK? YES NO Replace the fuse(-s).
EAS00787
4. Wiring Check the entire immobilizer systems wiring. Refer to CIRCUIT DIAGRAM. Is the immobilizer systems wiring properlyconnected and without defects? YES Check the condition of each of the immobilizer systems circuits. Refer to CHECKING THE IMMOBILIZER SYSTEM. NO Properly connect or repair the immobilizer systems wiring.
59
IMMOBILIZER SYSTEM
CHECKING THE IMMOBILIZER SYSTEM 1. Immobilizer system indicator light does not go on when the main switch is turned ON. 1. Voltage Connect the pocket tester (DC 20 V) to the multi-function display couplers as shown. Tester positive probe green/blue 1 Tester negative probe black 2 YES
ELEC
Set the main switch to ON. Measure the voltage (12 V) between red/ green and black on the immobilizer unit. Are the voltage within specification? NO The wiring circuit from the battery to the immobilizer unit is faulty and must be repaired.
RG Br B GW W YB
Dg Ch GL Y BW SbW
3. Voltage Connect the pocket tester (DC 20 V) to the immobilizer unit couplers as shown. Tester positive probe red/white 1 Tester negative probe black 2
Set the main switch to ON. Measure the voltage (12 V) between green/ blue and black on the multi-function display. Are the voltage within specification? YES Replace the multifunction display NO
B B2 RG YL GL RW
1
RG B2 B RW GL YL
2. Voltage Connect the pocket tester (DC 20 V) to the immobilizer unit couplers as shown. Tester positive probe red/ green 1 Tester negative probe black 2
Set the main switch to ON. Measure the voltage (12 V) between red/ white and black on the immobilizer unit. Are the voltage within specification? YES NO The wiring circuit from the main switch to the immobilizer unit is faulty and must be repaired.
B B2 RG YL GL RW
RG B2 B RW GL YL
60
IMMOBILIZER SYSTEM
4. Voltage Connect the pocket tester (DC 20 V) to the immobilizer unit couplers as shown. Tester positive probe green/blue 1 Tester negative probe black 2
ELEC
B B2 RG YL GL RW
1
RG B2 B RW GL YL
Set the main switch to ON. Measure the voltage (12 V) between green/ blue and black on the immobilizer unit. Are the voltage within specification? YES Replace the immobilizer unit. NO The wiring circuit from the immobilizer unit to the multi-function display is faulty and must be repaired.
61
IMMOBILIZER SYSTEM
SELF-DIAGNOSIS ERROR CODE INDICATION
ELEC
When the system failure occurred, the error code number is indicated in the immobilizer system indicator light blinks at the same time. The pattern of blinking also shows the error code.
Error code 51 Detection Symptoms Trouble Measures
IMMOBILIZER Cannot transmit code 1) Objects that may keep off radio 1) Keep clear of magnets, metals and other keys UNIT between the key and waves exist around the keys and from the surroundings of immobilizer unit. antennas. keys and antennas. 2) Immobilizer unit failure. 2) Replace the immobilizer 3) Key failure. unit. 3) Replace the key. IMMOBILIZER Codes do not match 1) Disturbed by other transponder. 1) Place the immobilizer UNIT between the key and Failed to verify continually for ten unit away more than 50 immobilizer unit. times. mm from the transpon2) Unregistered sub key was used. der of other vehicle. 2) Register the standard key. IMMOBILIZER Cannot transmit code be- Noise interference or disconnected 1) Check the wire harness UNIT and connector. tween the ignitor unit and lead/cable. immobilizer unit. 1) Obstruction due to radio wave 2) Replace the immobilizer unit. noise. 2) Error by disconnection of the 3) Replace the ignitor unit. communication harness. 3) Immobilizer unit failure. 4) Ignitor unit failure. IMMOBILIZER Codes do not match be- Noise interference or disconnected 1) Register the code reUNIT registering key ID. tween ignitor unit and im- lead/cable. mobilizer unit. 1) Obstruction due to radio wave 2) Replace the immobilizer unit. noise. 3) Replace the ignitor unit. 2) Immobilizer unit failure. 3) Ignitor unit failure (When the used parts from other vehicles are used, the code re-registering key ID is not registered to the ECU.) IMMOBILIZER Key code registration error. Same standard key was attempted Prepare the new standard UNIT key and register it. to continuously two times register. ECU IGNITER Underfinition code is re- Noise interference or disconnected UNIT ceived. lead/cable. 1) Check the wire harness and connector. 2) Replace the immobilizer unit. 3) Replace the ignitor unit.
52
53
54
55 56
Immobilizer system indicator light error code indication Digit of 10: Cycles of 1 sec. ON and 1.5 sec. OFF. Digit of 1: Cycles of 0.5 sec. ON and 0.5 sec. OFF. <Example> 52 Light ON
Light OFF
62
SELF-DIAGNOSIS DEVICE
ELEC
When the key is turned to "ON", the tachometer and speedometer needles should move to the maximum, then back to zero. In addition all the warning lights and the indicator lights should come on for a few seconds, then go off. If the tachometer or speedometer needle does not move as described or either of the warning lights or indicator lights do not come on, check their electrical circuits. This model is equipped with a self-diagnosis device for the following electrical circuits: speedometer tachometer throttle position sensor speed sensor ignition coil No. 1 ignition coil No. 2 fuel cut solenoid carburetor No. 1 fuel cut solenoid carburetor No. 2. If any of the above circuits are defective, the tachometer needle will repeatedly signal a two digit error code (e.g., 15, 16, 23, 24, 33, 34, 42). If the tachometer needle signal such an error code, note the circuit-specific number of r/min and check the operation of the system according to the following procedure. 0 / r/min (for 3 seconds)
Indication of the r/min corresponding to the first figure of error code (for 2.5 seconds)
0 / r/min (for 0.5 second)
Indication of the r/min corresponding to the second figure of error code (for 2.5 seconds)
Current engine speed (for 3 seconds)
Specific r/min
Faulty electrical circuit Throttle position sensor Throttle position sensor Fuel cut solenoid carburetor No. 1 Fuel cut solenoid carburetor No. 2. Ignition coil No. 1 Ignition coil No. 2 Speed sensor
Condition Disconnected Short-circuit Locked Disconnected Short-circuit Disconnected Short-circuit Open circuit the primary Open circuit the primary Disconnected Short-circuit
Fail-safe action Fixes the throttle position sensor to fully open. Fixes the throttle position sensor to fully open.
1 5 1 6 2 3 2 4 3 3 3 4 4 2
r/min r/min r/min r/min r/min r/min r/min
Fuel is cut off only to the cylinder in which a malfunction is detected. Fuel is cut off only to the cylinder in which a malfunction is detected.
63
EASB0044
ELEC
TROUBLESHOOTING The tachometer displays the throttle position sensor/speed sensor error code. Check: 1. Throttle position sensor 2. Speed sensor 3. Ignition coil N. 1 and 2 4. Fuel-cut solenoid N. 1 and 2 NOTE: Before troubleshooting, remove the following part(-s): 1) Seat 2) Side cover (left) 3) Fuel tank (lift) 4) Air filter case Troubleshoot with the following special tool(-s).
1. Wire harness Check the wire harness for continuity. Refer to "CIRCUIT DIAGRAM". Is the wire harness OK? YES NO Repair or replace the wire harness.
EB812401
2. Throttle position sensor Check the throttle position sensor for continuity. Refer to "CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR" in Chapter 5. Is the throttle position sensor OK? YES Replace the ignitor unit. NO Replace the throttle position sensor.
EAS00836
1. Throttle position sensor CIRCUIT DIAGRAM
YL
Lg LR YB Y L Gy1 LY RB RW B Br Or WB Sb W RL BL G Gy2
LR
LB
RW YL
RB
LB
Or
9
B LB (BLACK) LB B (BLACK) LR
10
PUMP PU
Gy2
Gy1
Y L
L B
13
BL
L Y B
L Y BL LY WB RL
NS S.GND SL1 SL2 SS HD +B

SP RPM GND
VCC TPS
Sb Br G
YB
0 Ignitor unit e Throttle position sensor
64
1. Speed sensor CIRCUIT DIAGRAM
ELEC
RB
SbW RB
LB LR
LG LY Sb BY LW RB Or Or
YL
LB
RW YL
RB
11 12
LG
LR LB
9
B LB (BLACK)
B
LB B (BLACK) LR
10
PUMP PU
RB Gy2 Gy2
Gy1
Y L
L B
13
LG
BL
L Y B
L Y BL LY WB RL
VCC NS TPS S.GND SL1 SL2 SS HD +B

SP RPM GND
Sb Br G
48
G Br
B G Y LR
G B LR Y
MAIN HARNESS
HEAD LIGHT
B B B (BLUE)
LG B (BLUE)
14
49
Br
BrB
BrB
MAIN HARNESS
B
CARB.HEATER
Set the main switch to ON. Turn the rear wheel slowly. Check the tester voltage (0 V ~ 5 V ~ 0 V). Is the speed sensor OK? YES Replace the ignitor unit. NO Replace the speed sensor.
YB
B GW
GW B
38
B
BrG
25
BrW
L W BL L W BL W L B
41
0 Ignitor unit ! Speed sensor 1. Wire harness Check the wire harness for continuity. Refer to "CIRCUIT DIAGRAM". Is the wire harness OK? YES NO Repair or replace the wire harness.
2. Speed sensor Place the motorcycle on a suitable stand so that the rear wheel is elevated. Connect the pocket tester (DC 20 V) to the speed sensor connector. Tester (+) lead White terminal 1 Tester () lead Body earth
BrW
65
3. Ignition coil N. 1 and 2 1. Wiring Check the entire ignition systems wiring. Refer to CIRCUIT DIAGRAM. Is the ignition systems wiring properly connected and without defects? YES NO Repair or replace the wire harness.
ELEC
Secondary coil resistance 10.7 14.5 k at 20C (68F) Is the ignition coil OK? YES NO Replace the ignition coil.
EAS00747
2. Ignition coil resistance The following procedure applies to all of the ignition coils. Disconnect the ignition coil connectors from the ignition coil terminals. Connect the pocket tester ( 1) to the ignition coil as shwon. Tester positive probe Red/Black Tester negative probe Orange (Gray)
Replace the ignitor unit.
Measure the primary coil resistance. Primary coil resistance 3.57 4.83 at 20C (68 F) Connect the pocket tester ( 1k) to the ignition coil as shown. Measure the secondary coil resistance. spark plug lead 1 Tester negative probe Orange (gray) lead 2 Tester positive probe
66
4. Fuel-cut solenoid (EUR) CIRCUIT DIAGRAM
L LB LR
ELEC
Sb BY LW RB Lg LR YB Y L Gy1 LY RB RW B Br Or WB L Sb W RL BL G Gy2
RW YL RB
Or Or
11
9
LB CK) LB B LR (BLACK)
10
Gy2 PUMP PU Gy1
RB Gy2
12
Y L BL
L B
L Y B
L Y BL LY WB RL

SP RPM GND
Sb Br G
48
G Br
YB
49
B UE)
Br
14
0 Igniter unit * Fuel-cut solenoid 1 ( Fuel-cut solenoid 2 1. Wire harness Check the wire harness for continuity. Refer to CIRCUIT DIAGRAM. Is the wire harness OK? YES Replace the fuel-cut solenoid 1 or 2. NO Repair or replace the wire harness.
67
B B2 RG
YL GL RW
RG B2 B RW GL YL
50
B2
1
B W R R (BLACK)
SbW
RG GL RW YL
CIRCUIT DIAGRAM
R W
Gy BL RB
B Gy
Gy1 R L
4
SbW RB
BL L LB LR
30A
5
R R RB Or Or RB L LB Sb LY LG BY LR RW YL RW L RW LG LY Sb BY LW B B Lg LR YB Y L Gy1 LY RB RW B Br Or WB YL Sb W RL BL G Gy2
W W B
W W
IGNITION SYSTEM
W W W
W W W
2
B LW B
11
BrR BrR B B B LB LB B (BLACK) Gy1 LR PUMP Gy2 Gy2 (BLACK) B BW RB R BrL R BrL
7 9 10 12
SP RPM GND
8
LB
ON OFF P
43
BrL L B SL2 SS HD +B G W YB B Sb Br G L Y B VCC NS TPS S.GND SL1 Y BL
B2 B1
40
B1 B2
15
10A RW
6 40 48
Br RW RB LW
B2 B1
3 13
LG
BB3 BB4
B G Y LR
G B LR Y
BB2 BB1
MAIN HARNESS
HEAD LIGHT
21
BrW Dg
17 14 49
G
B B B B R B LW 10A
Br
BrB
BrB
BB3 BB2
BB4 BB1
16
Gy Br Dg BrW Ch B B
MAIN HARNESS
CARB.HEATER
RY
Br
42
BrW
R RL B B GY
5A
45
RY GY Br
RY
BrG
25
L BrW W BL
47
Dg BrW Ch HORN OFF ON DIMMER HI LO PASSING OFF ON
LB
L W BL W L B
Ch
BrW
Dg
BY
LY
24
P
BrY
BrBBrY BrB
B B
IGNITION SYSTEM
22
G LR
Ch
Dg
B B B
BrB B BrB
LR A
44
LR GY 12V5W LR B B 12V21/5W
LR
Y G
BrB
BrB
Ch
Dg
Ch
Dg
Ch
Dg
Ch
LR
Y G
12V10W
12V10W
Dg
12V10W
12V5W
12V60/55W
LR B GY
29
ELEC
Ch B B
Dg B B
Ch B B
Dg B B B
12V10W
Sb
35 36 37
1 Pickup coil 3 Main switch 4 Starter relay 5 Battery 6 Wire minus lead 8 Starting circuit cut-off relay 0 Igniter unit qw Ignition coil r Sidestand switch t Ignition fuse y Right handlebar switch j Neutral switch lead k Neutral switch # Alarm system (Option) ) Immobilizer control unit
BrL 10A Br BrR 10A BrG
Sb
39
Ch
Dg
Ch
Dg
Sb
68
18
BrL 15A RY B GW GW B
19
38
46 20 51
RY B P G Y BY LY LB G P B RY LB LY BY Y
41
BrL BrY
15A
23
LY BY (BLACK)
TURN L N R
34
26
Y HI BEAM B
IMOBILIZER GL
30
B LR
31
32
33
RG Br B GW W YB
Dg Ch GL Y BW SbW
27 28
IGNITION SYSTEM
EASB0030 EAS00739
ELEC
TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). Check: 1. Main and ignition fuses 2. Battery 3. Spark plugs 4. Ignition spark gap 5. Spark plug cap resistance 6. Ignition coil resistance 7. Pickup coil resistance 8. Main switch 9. Engine stop switch 10. Neutral switch 11. Sidestand switch 12. Wiring (of the entire ignition system) NOTE: Before troubleshooting, remove the following part(-s): 1) Seat 2) Side covers 3) Fuel tank (lift) 4) Cowling (lift forward) 5) Storage compartment/battery cover 6) Cylinder head covers Troubleshoot with the following special tool(-s). Ignition checker 90890-06754 Pocket tester 90890-03112
EAS00738
2. Battery Check the condition of the battery. Refer to CHECKING AND CHARGING THE BATTERY in Chapter 3. Min. open-circuit voltage 12.8 V or more at 20 C (68 F) Is the battery OK? YES NO Clean the battery terminals. Recharge or replace the battery.
EAS00741
3. Spark plugs The following procedure applies to all of the spark plugs. Check the condition of the spark plug. Check the spark plug type. Measure the spark plug gap. Refer to CHECKING THE SPARK PLUGS in Chapter 3. Standard spark plug BPR7ES W22EPR-U Spark plug gap 0.7 0.8 mm Is the spark plug in good condition, is it of the correct type, and its gap within specification? YES NO Re-gap or replace the spark plug.
1. Main and ignition fuses Check the main and ignition fuses for continuity. Refer to CHECKING THE FUSES in Chapter 3. Are the main and ignition fuses OK?
YES
NO Replace the fuse(-s).
69
IGNITION SYSTEM
EAS00743
ELEC
4. Ignition spark gap The following procedure applies to all of the spark plugs. Disconnect the spark plug cap from the spark plug. Connect the ignition checker 1 as shown. Spark plug cap 2. 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.
Spark plug cap resistance 10 k at 20C (68 F) Is the spark plug cap OK? YES NO Replace the spark plug cap.
EAS00747
6. Ignition coil resistance The following procedure applies to all of the ignition coils. Disconnect the ignition coil connectors from the ignition coil terminals. Connect the pocket tester ( 1) to the ignition coil as shwon. Tester positive probe Red/Black Tester negative probe Orange (Gray) Min. ignition spark gap 6 mm Is there a spark and is the spark gap within specification ? NO YES The ignition system is OK.
EAS00745
Measure the primary coil resistance. Primary coil resistance 3.57 4.83 at 20C (68 F) Connect the pocket tester ( 1k) to the ignition coil as shown. Measure the secondary coil resistance. spark plug lead 1 Tester negative probe Orange (gray) lead 2 Tester positive probe
5. Spark plug cap resistance. The following procedure applies to all of the spark plug caps. Disconnect the spark plug cap from the spark plug. Connect the pocket tester ( 1k) to the spark plug cap as shown. Measure the spark plug cap resistance.
70
IGNITION SYSTEM
EAS00749
ELEC
EAS00750
Secondary coil resistance 10.7 14.5 k at 20C (68F) Is the ignition coil OK? YES NO Replace the ignition coil. 9. Engine stop switch
Check the engine stop switch for continuity. Refer to CHECKING THE SWITCHES. Is the engine stop switch OK? YES NO Replace the right handlebar switch.
EAS00748
7. Pickup coil resistance Disconnect the pickup coil coupler from the wire harness. Connect the pocket tester ( 100) to the pickup coil terminal. Tester positive probe Gray 1 Tester negative probe Black 2
EAS00751
10. Neutral switch Check the neutral switch for continuity. Refer to CHECKING THE SWITCHES. Is the neutral switch OK? YES NO Replace the neutral switch.
Measure the pickup coil resistance. Pickup coil resistance 189 231 at 20C (68F) (between Gray and Black) Is the pickup coil OK? YES NO
EAS00752
11. Sidestand switch Check the sidestand switch for continuity. Refer to CHECKING THE SWITCHES. Is the sidestand switch OK? YES NO Replace the sidestand switch.
Replace the pickup coil.
71
IGNITION SYSTEM
ELEC
EAS00754
14. Wiring Check the entire ignition systems wiring. Refer to CIRCUIT DIAGRAM. Is the ignition systems wiring properly connected and without defects? NO Properly connect or repair the ignition systems wiring. YES Replace the ignitor unit.
72
B B2 RG
YL GL RW
RG B2 B RW GL YL
50
B2
1
B W (BLACK)
SbW
RG GL RW YL
CIRCUIT DIAGRAM
R W R R
Gy BL RB
B Gy
Gy1 R L
4
SbW RB
BL L LB LR
30A
5
R R RB Or Or RB L LB YL Sb LY LG BY LR RW YL RW L RW LG LY Sb BY LW B B Lg LR YB Y L Gy1 LY RB RW B Br Or WB Sb W RL BL G Gy2
W W B
W W
W W W
W W W
2
B LW B
11
BrR BrR B RB Gy2 Gy2 B B LB LB B (BLACK) Gy1 LR PUMP (BLACK) B BW R BrL R BrL
7 9 10 12
SP RPM GND
8
LB
ON OFF P
43
BrL L B SL2 SS HD +B G W YB B Sb Br G L Y B VCC NS TPS S.GND SL1 Y BL
B2 B1
40
B1 B2
15
10A RW
6 40 48
Br RW RB LW LG
B2 B1
3 13
BB3 BB4
B G Y LR
G B LR Y
ELECTRIC STARTING SYSTEM
BB2 BB1
MAIN HARNESS
HEAD LIGHT
21
BrW Dg
17 14 49
G
B B B B R B LW 10A
Br
BrB
BrB
BB3 BB2
BB4 BB1
16
Gy Br Dg BrW Ch B B
MAIN HARNESS
CARB.HEATER
RY
Br
42
BrW
R RL B B GY
5A
45
RY GY Br
RY
BrG
25
L BrW W BL
47
LB
L W BL W L B
Ch
BrW
Dg
BY
LY
24
P
BrY
BrBBrY BrB
B B
22
LR
Ch
Dg
B B B
BrB B BrB
LR A
44
LR GY 12V5W LR B B 12V21/5W B LR
LR
Y G
BrB
BrB
Ch
Dg
Ch
Dg
Ch
Dg
Ch
LR
Y G
12V10W
12V10W
Dg
12V10W
12V5W
12V60/55W
LR B GY
ELEC
29
Ch B B
Dg B B
Ch B B
Dg B B B
12V10W
Sb
35 36 37
3 4 5 6 7 8 r t y d j k # )
BrR 10A BrG
Main switch Starter relay Battery Wire minus lead Starter motor Starting circuit cut-off relay Sidestand switch Ignition fuse Right handlebar switch Clutch switch Neutral switch lead Neutral switch Alarm system (Option) Immobilizer control unit
46 20 51
RY B P G Y BY LY LB G P B RY LB LY BY Y BrL BrY 15A
Sb
39
Ch
Dg
Ch
Dg
Sb
73
18
BrL 15A RY B GW BrL Br 10A GW B
19
38
41
TURN L N R
23
LY BY (BLACK)
34
26
Y HI BEAM B
IMOBILIZER GL
30
31
32
33
RG Br B GW W YB
Dg Ch GL Y BW SbW
27 28

EB803010
ELEC
STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, and the starting circuit cut-off relay. If the engine stop switch is on RUN and the main switch is on ON (both switches are closed), the starter motor can operate only if: The transmission is in neutral (the neutral switch is closed). or if The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the sidestand switch is closed). The starting circuit cut-off relay prevents the starter from operating when neither of these conditions have been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the starter motor. When at least one of the above conditions have been met however, the starting circuit cut-off relay is closed, and the engine can be started by pressing the starter switch. WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED IN 1 2 3 4 5 6 7 8 9 0 q w Battery Main fuse Main switch Ignition fuse Engine stop switch Starting circuit cut-off relay Starter motor Clutch switch Sidestand switch Neutral switch Start switch Starter relay
74

EASB0031 EAS00739
ELEC
TROUBLESHOOTING The starter motor fails to turn. Check: 1. Main and ignition fuses 2. Battery 3. Starter motor 4. Starting circuit cut-off relay 5. Starter relay 6. Main switch 7. Engine stop switch 8. Neutral switch 9. Sidestand switch 10. Clutch switch 11. Start switch 12. Wiring (of the entire starting system) NOTE: Before troubleshooting, remove the following part(-s): 1) Seat 2) Side covers 3) Fuel tank (lift) 4) Cowling (lift forward) 5) Storage compartment/battery cover Troubleshoot with the following special tool(-s).
2. Battery Check the condition of the battery. Refer to CHECKING AND CHARGING THE BATTERY in Chapter 3. Min. open-circuit voltage: 12.8 V or more at 20 C (68 F) Is the battery OK? YES NO Clean the battery terminals. Recharge or replace the battery.
EAS00758
3. Starter motor Connect the battery positive terminal 1 and starter motor lead 2 with a jumper lead 3.

EAS00738
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 that no flammable gas or fluid is in the vicinity. Does the starter motor turn? Replace the fuse(-s). YES NO Repair or replace the starter motor.
1. Main and ignition fuses Check the main and ignition fuses for continuity. Refer to CHECKING THE FUSES in Chapter 3 Are the main and ignition fuses OK? YES NO
75

EAS00739 EAS00761
ELEC
4. Starting circuit cut-off relay Disconnect the relay unit from the coupler. Connect the pocket tester ( 1) and battery (12V) to the relay unit terminals as shown. Battery positive terminal Red/Black 1 Battery negative terminal Black/Yellow 2 Tester positive probe Blue 3 Tester negative probe Blue/White 4
5. Starter relay Disconnect the starter relay from the coupler. Connect the pocket tester ( 1) and battery (12V) to the starter relay coupler as shown. Battery positive terminal Red/White 1 Battery negative terminal Blue 2 Tester positive probe Red 3 Tester negative probe Black 4
Does the starting circuit cut-off relay have continuity between Black and Blue/White? YES NO Replace the relay unit.
Does the starter relay have continuity between Red and Black? YES NO Replace the starter relay.
EAS00749
76

EAS00750 EAS00764
ELEC
7. Engine stop switch Check the engine stop switch for continuity. Refer to CHECKING THE SWITCHES. Is the engine stop switch OK? YES NO Replace the right handlebar switch.
11. 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.
EAS00751
EAS00766
8. Neutral switch Check the neutral switch for continuity. Refer to CHECKING THE SWITCHES. Is the neutral switch OK? YES NO
12. Wiring Check the entire starting systems wiring. Refer to CIRCUIT DIAGRAM. Is the starting systems wiring properly connected and without defects? NO Replace the neutral switch. Properly connect or repair the starting systems wiring. YES The starting system circuit is OK.
EAS00752
9. Sidestand switch Check the sidestand switch for continuity. Refer to CHECKING THE SWITCHES. Is the sidestand switch OK? YES Replace the stand switch. NO side-
EAS00763
10. Clutch switch Check the clutch switch for continuity. Refer to CHECKING THE SWITCHES. Is the clutch switch OK? YES NO Replace the clutch switch.
77
ELEC
STARTER MOTOR
Order 1 2
Job name/Part name Removing the starter motor Starter motor lead Starter motor assembly
Qty 1 1
For installation, reverse the removal procedure. 1 2 3 4 5 Disassembling the starter motor Circlip Starter motor drive gear Starter motor rear cover Washer set Starter motor front cover Disassembly the pats in the order listed. 1 1 1 1 1
Refer to Assembling the starter motor. Refer to Assembling the starter motor.
78
ELEC
Order 6 7 8 9 0 q
Job name/Part name Washer set End bracket Planetary gears Armature assembly Brush holder/brush Starter motor yoke
Qty 1 1 2 1 1/1 1
Remarks Refer to Assembling the starter motor.
Refer to Assembling the starter motor. For assembly, reverse the disassembly procedure.
79

EAS00769
ELEC
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. Min. commutator diameter 27 mm 3. Measure: mica undercut a Out of specification Scrape the mica to the proper measurement with a hacksaw blade which has been grounded to fit the commutator. Mica undercut 0.7 mm NOTE: The mica must be undercut to ensure proper operation of the commutator.
4. Measure: armature assembly resistances (commutator and insulation) Out of specification Replace the starter motor.
a. Measure the armature assembly resistances with the pocket tester. Pocket tester 90890-03112 Armature assembly Armature coil resistance 1 0.026 0.034 at 20C (68 F) Insulation resistance 2 Above 1 M at 20C (68 F) b. If any resistance is out of specification, replace the starter motor.
80
ELEC
5. Measure: brush length a Out of specification Replace the brushes as a set. Min. brush length 5 mm
6. Measure: brush spring force Out of specification Replace the brush springs as a set. Bruch spring force 7.65 10.01 N (780 1.020 g)
7. Check: gear teeth Damage/wear Replace the gear. 8. Check: oil seal Damage/wear Replace the defective part(-s).
EAS00772
Assembling the starter motor 1. Install: brush holder 1 NOTE: Align the tab a on the brush holder with the slot in the starter motor rear cover.
2. Install: starter motor yoke 1 end bracket 2 starter motor front cover 3 NOTE: Align the projection a on the front cover with the slot b on the end cover and starter motor yoke.
81
ELEC
3. Install: starter motor rear cover 1 NOTE: Align the match marks a on the rear cover with the match marks b on the front cover.
82
CIRCUIT DIAGRAM
1
B W
R R
R W
CHARGING SYSTEM
Gy BL R
30A
B Gy
Gy1
(BLACK)
4
L RW RW L
BL R R
5
B
W W B
W W
W W W
W W W
2
B B B
BrR BrR R BrL R BrL
B B
7 6
Gy
Br
Dg
Pickup coil Rectifier/regulator Starter relay Battery Wire minus lead
BrW Ch
83
ON OFF P
43 3
BrL 10A
B2 B1
B1 B2
15
RW
B2 B1
BB3 BB4
BB2 BB1
21
R 10A
CHARGING SYSTEM
RB GY RW Br
GY RB Br RW
17
HAZARD OFF ON LW B Dg BrW Ch Ch
BrW Dg
E/G STOP OFF RUN B LW
1 2 4 5 6
B B B B
BB3 BB2
ELEC
BB4 BB1
CHARGING SYSTEM
EAS00774 EAS00739
ELEC
TROUBLESHOOTING The battery is not being charged. Check: 1. Main fuse 2. Battery 3. Charging voltage 4. Startor coil assembly resistance 5. Wiring (of the entire charging system) NOTE: Before troubleshooting, remove the following part(-s): 1) Seat 2) Side covers 3) Storage compartment/battery cover Troubleshoot with the following special tool(-s). Engine tachometer 90890-03113 Pocket tester 90890-03112
EAS00775
3. Charging voltage Connect the engine tachometer to the spark plug lead of cylinder #1. Connect the pocket tester (DC 20 V) to the battery as shown. Tester positive probe battery positive terminal Tester negative probe battery negative terminal
EAS00738
1. Main fuse Check the main fuse for continuity. Refer to CHECKING THE FUSES in Chapter 3. Is the main fuse OK? YES NO Replace the fuse.
Start the engine and let it run at approximately 5,000 r/min. Measure the charging voltage. Charging voltage 14 V at 5,000 r/min
84
CHARGING SYSTEM
EAS00779
ELEC
NOTE: Make sure that the battery is fully charged. Is the charging voltage within specification? NO YES The charging circuit is OK.
5. Wiring Check the wiring connections of the entire charging system. Refer to CIRCUIT DIAGRAM. Is the charging systems wiring properly conected and without defects? NO Properly connect or repair the charging systems wiring. YES Replace the rectifier/ regulator.
EAS00776
4. Stator coil assembly resistances Remove the left side cover. Connect the pocket tester ( 1) to the stator coil assembly coupler as shown Tester positive probe White 1 Tester negative probe White 2 Tester positive probe White 1 Tester negative probe White 3
Measure the stator coil assembly resistances. Stator coil resistance 0.36 0.44 at 20C (68 F) Is the stator coil assembly OK? YES NO Replace the stator coil assembly.
85
B B2 RG
YL GL RW
RG B2 B RW GL YL
50
B2
1
B W
R R
RG GL RW YL
R W
Gy BL
SbW
B Gy RB L R B R RB Or Or RB L LB YL Sb LY BY LG LR RW YL RW R L RW LG LY Sb BY LW
Gy1
(BLACK)
4
SbW RB
CIRCUIT DIAGRAM
BL L LB LR
5
B B Lg LR YB Y L Gy1 LY RB RW B Br Or WB Sb W RL BL G Gy2
W W
W W
W W W
W W W
2
B B LW
11
LB
LIGHTING SYSTEM
BrR BrR B RB Gy2 Gy2 B B LB LB B (BLACK) Gy1 LR PUMP (BLACK) B BW R BrL R BrL
7 9 10 12
SP RPM GND
ON OFF P
43
BrL L B SL2 SS HD +B G W YB B Br Sb Br G L Y B VCC NS TPS S.GND SL1 Y BL
B2 B1
40
B1 B2
15
10A RW
6 40 48
RW RB LW
B2 B1
3 13
LG
BB3 BB4
B G Y LR
G B LR Y
BB2 BB1
MAIN HARNESS
HEAD LIGHT
21
BrW Dg
17 14 49
G Br
B B B B R B LW 10A
BrB
BrB
BB3 BB2
BB4 BB1
16
Gy Br Dg BrW Ch B B
MAIN HARNESS
CARB.HEATER
RY
Br
42
BrW
R RL B B GY
5A
45
RY
BrG
25
L W BL BrW
GY Br
47
RY
L W BL W L B
Ch
BrW
Dg
LB
BY
LY
24
P
BrY
BrBBrY BrB
B B
22
LR
Ch
Dg
B B B
LR
Y G
BrB B BrB
LR A
LR
BrB
GY
BrB
12V5W
Ch
Dg
Ch
Ch
Dg
Ch
LR
Y G
12V10W
12V21/5W
12V10W
Dg
LR B B LR
33
12V10W 12V5W 12V60/55W
Dg
LR B GY
29
Ch B B
Dg B B
Ch B B
Dg B B B
12V10W
Sb
ELEC
35 36 37 39
Ch B
Dg
Ch B B
Dg Sb
Sb
86
18
BrL 15A RY
19
BrL 10A Br
B GW
GW B
38
41
BrR
10A BrG
46 20 51
RY B P G Y BY LY LB G P B RY LB LY BY Y LY BY (BLACK)
BrL BrY
15A
23
TURN L N R
34
26
Y HI BEAM B
IMOBILIZER GL
LIGHTING SYSTEM
44
30
31
32
RG Br B GW W YB
Dg Ch GL Y BW SbW
27 28
3 4 5 6 0 y i s h l .
Main switch Starter relay Battery Wire minus lead Igniter unit Right handlebar switch Headlight fuse Left handlebar switch Speedometer Headligh Tail/brake light $ License plate light & Dimmer switch relay
LIGHTING SYSTEM
EASB0033 EAS00739
ELEC
TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, license plate light or meter light. Check: 1. Main and headlight fuses 2. Battery 3. Main switch 4. Dimmer switch 5. Pass switch 6. Dimmer switch relay 7. Igniter unit 8. Wiring (of the entire charging system) NOTE: Before troubleshooting, remove the following part(-s). 1) Seat 2) Side covers 3) Fuel tank (lift) 4) Cowling (lift forward) 5) Storage compartment/battery cover Troubleshoot with the following special tool(-s). Pocket tester 90890-03112
EAS00749
EAS00738
EAS00784
1. Main and headlight fuses Check the main and headlight fuses for continuity. Refer to CHECKING THE FUSES in Chapter 3. Are the main and headlight fuses OK? YES NO Replace the fuse(-s).
4. Dimmer switch 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 right handlebar switch.
87
LIGHTING SYSTEM
EAS00786
ELEC
5. Pass switch Check the pass switch for continuity. Refer to CHECKING THE SWITCHES. Is the pass switch OK? YES NO The pass switch is faulty. Replace the right handlebar switch.
7. Igniter unit Disconnect the igniter unit from the coupler and connect a new one. Is the lighting systems OK ? YES Replace the igniter unit. NO The igniter unit is OK.
EAS00787
8. Wiring 6. Dimmer switch relay Disconnect the dimmer switch relay from the coupler. Connect the pocket tester ( 1) and battery (12V) to the dimmer switch relay coupler. Battery positive terminal White/Black 1 Battery negative terminal Red/Yellow 2 Tester positive probe Blue/Black 3 Tester negative probe Red/Yellow 4 Check the entire lighting systems wiring. Refer to CIRCUIT DIAGRAM. Is the lighting systems wiring properly connected and without defects? YES Check the condition of each of the lighting systems circuits. Refer to CHECKING THE LIGHTING SYSTEM. NO Properly connect or repair the lighting systems wiring.
RY LB RY
2 3
WB
EAS00788
CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light fail to came on.
Does the dimmer switch relay have continuity between Blue/Black and Red/Yellow? YES NO Replace the dimmer switch relay.
1. Headlight bulb and socket Check the headlight bulb and socket for continuity. Refer to CHECKING THE BULBS AND BULB SOCKETS. Are the headlight bulb and socket OK? YES NO Replace the headlight bulb, socket or both.
88
LIGHTING SYSTEM
EAS00789
ELEC
2. Voltage Connect the pocket tester (DC 20 V) to the headlight and high beam indicator light couplers as shown. When the dimmer switch is set to 2 When the dimmer switch is set to 1 Headlight Tester positive probe Yellow 1 or Green 2 Tester negative probe Black 3 High beam indicator light Tester positive probe Yellow 4 Tester negative probe Black 5 Headlight coupler (wire harness side)
2. A meter light fails to come on. 1. Meter light bulb and socket. Check the meter light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS. Are the meter light bulb and socket OK? YES NO Replace the meter light bulb, socket or both.
2. Voltage Connect the pocket tester (20 V) to the meter assembly coupler (wire harness side) as shown. Tester positive probe Brown 1 Tester negative probe Black 2 Set the main switch to ON. Set the dimmer switch to 2 or 1.
Measure the voltage (12 V) of Yellow 1 or Green 2 on the headlight coupler (headlight side). Measure the voltage (12V) of Yellow 4 on the meter assembly coupler. Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the main switch to the headlight coupler is faulty and must be repaired.
Set the main switch to ON. Measure the voltage (12 V) of Brown 1 on the meter assembly coupler (wire harness side). Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the main switch to the meter assembly coupler is faulty and must be repaired.
89
LIGHTING SYSTEM
EAS00790 EASB0034
ELEC
3. A tail/brake light fails to come on. 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? YES NO Replace the tail/ brake light bulb, socket or both.
4. The license plate light fails to come on. 1. License plate light bulb and socket Check the license plate light bulb and socket for continuity. Refer to CHECKING THE BULBS AND BULB SOCKETS. Are the license plate light bulb and socket OK? YES NO Replace the license plate light bulb, socket or both.
2. Voltage Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown. Tester positive probe Blue/Red 1 Tester negative probe Black 2
2. Voltage Connect the pocket tester (DC 20 V) to the license plate light coupler (wire harness side) as shown. Tester positive probe Blue/Red 1 Tester negative probe Black 2
Set the main switch to ON. Measure the voltage (12 V) of Blue/Red 1 on the tail/brake light coupler (wire harness side). Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the main switch to the tail/brake light coupler is faulty and must be repaired.
Set the main switch to ON. Measure the voltage (12 V) of Blue/Red 1 on the license plate light coupler (wire harness side). Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the main switch to the license plate light coupler is faulty and must be repaired.
90
B B2 RG
YL GL RW
RG B2 B RW GL YL
50
B2
1
R R
RG GL RW YL
CIRCUIT DIAGRAM
R W
Gy BL
SbW
B Gy RB L
Gy1
(BLACK)
4
SbW RB
BL L LB LR
30A
R R R RB Or Or RB L LB Sb LY BY LG LR RW YL RW L RW LG LY Sb BY LW
5
B B Lg LR YB Y L Gy1 LY RB RW B Br Or WB YL Sb W RL BL G Gy2
W W
W W
W W W
W W W
2
B B LW
11
LB
SIGNALING SYSTEM
BrR B B B LB LB B (BLACK) Gy1 LR PUMP Gy2 Gy2 (BLACK) B BW RB
BrR
7 9 10 12
PU Y L L L Y BL LY WB RL MAIN HARNESS G W YB B Br
SP RPM GND
ON OFF P
BrL
BrL
43
BrL Y B SL2 SS HD +B Sb Br G B G Y LR G B LR Y L Y B VCC NS TPS S.GND SL1 10A RW
B2 B1
40
B1 B2
15 6 14 48
RW RB LW
B2 B1
3 13
LG BL HEAD LIGHT
BB3 BB4
BB2 BB1 GY RB Br RW HAZARD OFF ON OFF RUN PUSH B B B LG B (BLUE) (BLUE) LW B Dg BrW Ch Ch
BrW Dg
21 17
E/G STOP FREE START RB GY RW Br B LW
B B B B
10A
14
49
G Br
BrB
BrB
BB3 BB2
BB4 BB1
16
Gy Br Dg BrW Ch B B
MAIN HARNESS
CARB.HEATER
RY
R RL P BrG (BLACK) BrW LB WB B B GY
5A
BrW
45
Br RY LB Br WB RY
42
RY
BrG
25
L W BL BrW
GY Br
47
RY
Dg BrW Ch HORN OFF ON N R LY BY (BLACK) Y B G Ch TURN L DIMMER HI LO PASSING OFF ON
L W BL W L B
Ch
BrW
Dg
LB
BY
LY
24
P
BrY
BrBBrY BrB
B B
SIGNALING SYSTEM
22
LR
Dg
B B B
BrB B BrB
LR A
44
LR Y G LR GY 12V5W Ch
BrB
BrB
Dg
Ch
Ch
Dg
Ch
LR
Y G
12V10W
12V21/5W
12V10W
Dg
LR B B LR
33
12V10W
Dg
12V5W
12V60/55W
LR B GY
29
B B G Y B A B
GY B LR
Ch B B
Dg B B
Ch B B
Dg B B B
12V10W
Sb
35 39
36 37
Ch B
Dg B
Ch B B
Dg Sb
Sb
91
RY B GW Br GW B
18 38
BrL
15A
19
BrL
10A
41
BrR
10A BrG
46 20 51
RY B P G Y BY LY LB G P B RY LB LY BY Y
BrL BrY
15A
23
34
26
Y HI BEAM B
IMOBILIZER GL
ELEC
30
31
32
RG Br B GW W YB
Dg Ch GL Y BW SbW
27 28
SIGNALING SYSTEM
3 4 5 6 t y u o s f g h j k ; z x c . / @
Main switch Starter relay Battery Wire minus lead Ignition fuse Right handlebar switch Front brake switch Signal fuse Left handlebar switch Horn Flasher relay Multi-function display Neutral switch lead Neutral switch Front turn signal light (L) Front turn signal light (R) Rear turn signal light (L) Rear turn signal light (R) Tail/brake light Oil level gauge Rear brake switch
ELEC
92
SIGNALING SYSTEM
EASB0035 EAS00739
ELEC
TROUBLESHOOTING Any of the following fail to light: turn signal light, brake light or an indicator light. The horn fails to sound. Check: 1. Main and signaling system fuses 2. Battery 3. Main switch 4. Hazard switch 5. Wiring (of the entrire signaling system) NOTE: Before troubleshooting, remove the following part(-s): 1) Seat 2) Side covers 3) Fuel tank (lift) 4) Cowling (lift forward) 5) Storage compartment/battery cover Troubleshoot with the following special tool(-s). Pocket tester 90890-03112
EAS00749
EAS00738
1. Main, ignition and signaling system fuses Check the main, ignition and signaling system fuses for continuity. Refer to CHECKING THE FUSES in Chapter 3. Are the main, ignition and signaling system fuses OK? YES NO Replace the fuse(-s). Replace the hazard switch. 4. Hazard switch. Check the hazard switch for continuity. Refer to CHECKING THE SWITCHES. Is the hazard switch OK? YES NO
93
SIGNALING SYSTEM
EAS00795
ELEC
5. Wiring Check the entire signaling systems wiring. Refer to CIRCUIT DIAGRAM. Is the signaling systems wiring properly connected and without defects? YES Check the condition of each of the signaling systems circuits. Refer to "CHECKING THE SIGNALING SYSTEM". NO Properly connect or repair the signaling systems wiring.
2. Voltage Connect the pocket tester (DC 20 V) to the horn connector at the horn terminal as shown. Tester positive probe Brown 1 Tester negative probe Ground
EAS00796
CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. 1. Horn switch Check the horn switch for continuity. Refer to CHECKING THE SWITCHES. Is the horn switch OK? YES NO Replace the left handlebar switch.
Set the main switch to ON. Measure the voltage (12 V) of Brown at the horn terminal. Is the voltage within specification? YES NO The wiring circuit from the main switch to the horn connector is faulty and must be repaired.
3. Horn 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. Does the horn sound?
NO
YES The horn is OK.
94
SIGNALING SYSTEM
4. Voltage Connect the pocket tester (DC 20 V) to the horn connecter at the black terminal as shown. Tester positive probe Black 1 Tester negative probe Ground 2. Brake light switches
ELEC
Check the brake light switches for continuity. Refer to CHECKING THE SWITCHES. Is the brake light switch OK? YES NO Replace the brake light switch.
3. Voltage Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown. Set the main switch to ON. Measure the voltage (12 V) of Black 1 at the horn terminal. Is the voltage within specification? YES Repair or replace the horn. NO Replace the horn. Tester positive probe Green/Yellow 1 Tester negative probe Black 2
EAS00797
2. A tail/brake light fails to come on. 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? YES NO Replace the tail/ brake lightbulb, socket or both.
Set the main switch to ON. Pull in the brake lever or push down on the brake pedal. Measure the voltage (12 V) of Yellow at the tail/brake light coupler (wire harness side). Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the main switch to the tail/brake light coupler is faulty and must be repaired.
95
SIGNALING SYSTEM
EAS00799
ELEC
3. A turn signal light, turn signal indicator light or both fail to blink. 1. Turn signal 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? YES NO Replace the turn signal light bulb, socket or both.
3. Voltage Connect the pocket tester (DC 20 V) to the flasher relay coupler (wire harness side) as shown. Tester positive probe Brown/Green 1 Tester negative probe Ground
Set the main switch to ON. Measure the voltage (12 V) of Brown/Green 1 at the flasher relay coupler (wire harness side). Is the voltage within specification? YES NO The wiring circuit from the main switch to the flasher relay coupler (flasher relay side) is faulty and must be repaired.
2. Turn signal switch Check the turn signal for continuity. Refer to CHECKING THE SWITCHES. Is the turn signal switch OK? YES NO Replace the left handlebar switch. 4. Voltage
Connect the pocket tester (DC 20 V) to the flasher relay coupler (wire harness side) as shown.
96
SIGNALING SYSTEM
Tester positive probe Brown/White 1 Tester negative probe Ground
ELEC
Set the main switch to ON. Set the turn signal switch to or . Measure the voltage (12 V) of Chocolate 1 or Dark green 2 at the turn signal light connector (wire harness side). Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the turn signal switch to the turn signal light connector is faulty and must repaired.
Set the main switch to ON. Set the turn signal switch to or . Measure the voltage (12 V) of Brown/White at the flasher relay coupler (wire harness side). Is the voltage within specification? YES NO
EAS00800
The flasher relay is faulty and must be replaced.
4. The neutral indicator light fails to come on. 1. Neutral indicator light bulb and socket Check the neutral indicator light bulb and socket for continuity. Refer to CHECKING THE BULBS AND BULB SOCKETS. Are the neutral indicator light bulb and socket OK? YES NO Replace the neutral indicator light bulb, socket or both.
5. Voltage Connect the pocket tester (DC 20 V) to the turn signal light connectors or the meter assembly coupler (wire harness side) as shown. Turn signal light Turn signal indicator light Left turn signal light Tester positive probe Chocolate 1 Tester negative probe Ground Right turn signal light Tester positive probe Dark green 2 Tester negative probe Ground
2. Neutral switch Check the neutral switch for continuity. Refer to CHECKING THE SWITCHES. Is the neutral switch OK? YES NO Replace the neutral switch.
97
SIGNALING SYSTEM
3. Voltage Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown. Tester positive probe Brown 1 Tester negative probe Sky Blue/White 2 2. Oil level switch
ELEC
Drain the engine oil and remove the oil level switch from the oil pan. Check the oil level switch for continuity. Refer to CHECKING THE SWITCHES. Is the oil level switch OK? YES NO Replace the oil level switch.
3. Voltage Set the main switch to ON. Measure the voltage (12 V) of Brown 1 and Sky blue/White 2 at the meter assembly coupler. Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the main switch to the meter light bulb coupler is faulty and must be repaired. Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown. Tester positive probe Red/White 1 Tester negative probe Black/White 2
EASB0036
5. The oil level warning light fails to come on. 1. Oil level warning light bulb and socket Check the oil level warning light bulb and socket for continuity. Refer to CHECKING THE BULBS AND BULB SOCKETS Are the oil level warning light bulb and socket OK? YES NO Replace the oil level warning light bulb, socket or both.
Set the main switch to ON. Measure the voltage (12 V) of Brown 1 and Black/White 2 at the meter assembly coupler. Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the main switch to the meter assembly coupler is faulty and must be repaired.
98
W
R R
R W
(BLACK)
SbW
4
RB L
SbW RB
R R R RB Or Or RB L LB YL Sb LY LG BY LR RW YL RW L RW LG LY Sb BY LW
5
L LB LR B B Lg LR YB Y L Gy1 LY RB RW B Br Or WB Sb W RL BL G Gy2
CIRCUIT DIAGRAM
W W W
2
B B LW LB
FUEL PUMP SYSTEM
BrR B B B LB LB B (BLACK) LR PUMP (BLACK) B BW Gy2
BrR
7 9 10
PU Y L L Y BL LY WB RL L B L Y B Y Gy1 RB Gy2
ON OFF P
BrL
BrL
15 6
40
BrL
10A
RW
3 40
RW RB LW LG
13
BL

SP RPM GND
Sb Br G
RB GY RW Br HAZARD OFF ON OFF RUN PUSH B B B (BLUE) LG B (BLUE) FREE E/G STOP START
GY RB Br RW
17 16
Br Dg BrW Ch B B
YB
21 14
18
FUEL PUMP SYSTEM
BrL
15A
RY
19
RY Br
BrL
10A
Br
Gy
42
RY RY LB RY WB LB WB B B GY
ELEC
5A
RL
45
GY Br
Br P
BrW
BrG
47
RY
BrW
BY
LY
LB
BrW
24
99
BrG (BLACK)
10A
49
LW B Dg BrW Ch
B LW Ch BrW Dg
25
BrR
10A
BrG
46
3 4 5 6 8 9 0 t y
Main switch Starter relay Battery Wire minus lead Starting circuit cut-off relay Fuel pump Igniter unit Ignition fuse Right handlebar switch
FUEL PUMP SYSTEM

EB808010
ELEC
FUEL PUMP CIRCUIT OPERATION The fuel pump circuit consists of the fuel pump relay, fuel pump, engine stop switch and ignitor unit. The ignitor unit includes the control unit for the fuel pump. 1 2 3 4 5 6 7 8 Battery Main fuse Main switch Ignition fuse Engine stop switch Ignitor unit Fuel pump relay Fuel pump
100
FUEL PUMP SYSTEM

EASB0037 EAS00739
ELEC
TROUBLESHOOTING The fuel pump fails to operate. Check: 1. Main, and ignition fuses 2. Battery 3. Main switch 4. Engine stop switch 5. Starting circuit cutoff relay (fuel pump relay) 6. Fuel pump 7. Wiring (of the entire charging system) NOTE: Before troubleshooting, remove the following part(-s): 1) Seat 2) Side covers 3) Fuel tank (lift) 4) Storage compartment/battery cover Troubleshoot with the following special tool(-s). Pocket tester 90890-03112
2. Battery Check the condition of the battery. Refer to "CHECKING AND CHARGING THE BATTERY" in Chapter 3. Open-circuit voltage 12.8 V or more at 20 C (68 F) Is the battery OK? YES NO Clean the battery terminals. Recharge or replace the battery.
EAS00749
3. Main switch Check the main switch for continuity. Refer to "CHECKING THE SWITCHES". Is the main switch OK? YES NO Replace the main switch.
EAS00738
1. Main and ignition fuses Check the main and ignition fuses for continuity. Refer to "CHECKING THE FUSES" in Chapter 3. Are the main and ignition fuses OK? YES NO Replace the fuse(-s). YES NO Replace the right handlebar switch.
EAS00750
4. Engine stop switch Check the engine stop switch for continuity. Refer to "CHECKING THE SWITCHES". Is the engine stop switch OK?
101
FUEL PUMP SYSTEM

EB803023 EB808021
ELEC
5. Starting circuit cutoff relay (fuel pump relay) Remove the relay unit from the wire harness. Connect the pocket tester ( 1) and battery (12 V) to the relay unit terminals. Battery (+) terminal Red/Black terminal 1 Battery () terminal Blue/Red terminal 2 Tester (+) lead Red/Black terminal 1 Tester () lead Blue/Black terminal 3
6. Fuel pump resistance Disconnect the fuel pump coupler from the wire harness. Connect the pocket tester ( 1) to the fuel pump coupler terminals. Tester (+) lead Blue/Black terminal 1 Tester () lead Black terminal 2
Measure the fuel pump resistance. Fuel pump resistance: 1.6 ~ 2.2 at 20 C (68 F) Does the fuel pump relay have continuity between Red/Black and Blue/Black? YES NO Replace the starting circuit cutoff relay. Is the fuel pump OK? YES Replace pump. NO the fuel
7. Wiring Check the entire fuel pump systems wiring. Refer to "CIRCUIT DIAGRAM". Is the fuel pump systems wiring properly connected and without defects? NO Properly connect or repair the fuel pump systems wiring. YES Replace the ignitor unit.
102
FUEL PUMP SYSTEM

EASB0038
ELEC
FUEL PUMP TEST WARNING Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or combustion. Be extremely careful and note the following points: Stop the engine before refuelling. Do not smoke and keep away from open flames, sparks, or any other source of fire. Take care not to spill gasoline. If you do accidentally spill some, wipe it up immediately with dry rags. If gasoline touches the engine when the engine is still hot, there is a danger of combustion. Make sure that the engine is completely cool before performing the following test.
1. Check: Fuel pump operation

a. Fill up the fuel tank. b. Put the end of the fuel hose into an open container. c. Connect the battery (12 V) to the fuel pump coupler terminals. Battery (+) lead Blue/Black terminal 1 Battery () lead Black terminal 2 d. Operate the engine starter to open the vacuum fuel cock. e. If fuel flows out from the fuel hose, the fuel pump is good. If not, replace the fuel pump assembly.
103
3 4 5 6 p v b n m Q
1
R R
R W
Gy BL
SbW
B Gy RB L
Gy1
(BLACK)
4
SbW RB
BL L LB LR
30A
R R R RB L LB YL Or Or Sb LY LG BY LR RW YL RB RW L RW LG LY Sb BY LW
5
B B Lg LR YB Y L Gy1 LY RB RW B Br Or WB Sb W RL BL G Gy2
W W
W W
W W W
W W W
2
B B LW
11
CIRCUIT DIAGRAM
Main switch Starter relay Battery Wire minus lead Carburetor heater Thermo switch Carburetor heater Carburetor heater Carburetor heater Carburetor heater
BrR B B B LB LB B (BLACK) Gy1 LR PUMP Gy2 Gy2 (BLACK) B BW RB
BrR
7 9 10 12
8
LB
ON OFF P
BrL
BrL
fuse
earth 1 2 3/4
43
10A RW Y L L Y BL NS S.GND SL1 SL2 SS HD +B
SP RPM GND
B2 B1
40
B1 B2 PU L B Sb Br G L Y B VCC TPS LY WB RL Y
15 6
BL
B2 B1
3 40 48
G W YB B Br RW RB LW
BrL
BB3 BB4
13
LG
B G Y LR
G B LR Y
BB2 BB1 GY RB Br RW HAZARD OFF ON OFF RUN PUSH B B B LG B (BLUE) (BLUE) LW B Dg BrW Ch B LW Ch BrW Dg FREE E/G STOP START RB GY RW Br
MAIN HARNESS
HEAD LIGHT
21 17 14 49
G Br
B B B B
10A
BrB
BrB
BB3 BB2
BB4 BB1
16
Gy Br Dg BrW Ch B B
CARBURETOR HEATER SYSTEM
MAIN HARNESS
CARB.HEATER
RY
Br
42
BrW
R B B GY
5A
RL
45
RY
BrG
25
L W BL BrW
L W BL W L B
GY Br
47
RY
P Dg BrW Ch HORN OFF ON TURN L N R LY BY (BLACK) Y B G Ch DIMMER HI LO PASSING OFF ON
Ch
BrW
Dg
LB
BY
24
LY
BrR
10A
BrG
46 20 51
B B RY B P G Y BY LY LB G P B RY LB LY BY Y
BrL
15A
23
BrY
BrY
34 22
LR
26
Dg
Y HI BEAM B
BrBBrY
BrB
IMOBILIZER GL A A Y G LR
B B B
BrB B BrB
44
LR LR A Y G GY 12V5W LR B B LR LR Y G B 12V21/5W
BrB
BrB
Ch
Ch
31
Ch 12V10W 12V60/55W
Dg
33
Ch Dg 12V10W 12V10W
Dg
30
32
RG Br B GW W YB Dg
ELEC
Dg Ch GL Y BW SbW
12V5W
LR B GY
29
GY B LR B B G Y A B B
Ch B B
Dg B B
Ch B B
Dg B B B
12V10W
Sb
35 39
36 37
Ch B
Dg B
Ch B B
Dg Sb
Sb
27 28
104
18
B GW GW B
BrL
15A
RY
19
BrL
10A
Br

EASB0039 EAS00739
ELEC
TROUBLESHOOTING The carburetor heater fails to operate. Check: 1. Main and carburetor heater fuses 2. Battery 3. Main switch 4. Thermo 5. Carburetor heater 6. Wiring (of the entire charging system) NOTE: Before troubleshooting, remove the following part(-s): 1) Seat 2) Side covers 3) Fuel tank (lift) 4) Storage compartment/battery cover Troubleshoot with the following special tool(-s). Pocket tester 90890-03112
2. Battery Check the condition of the battery. Refer to "CHECKING AND CHARGING THE BATTERY" in Chapter 3. Open-circuit voltage 12.8 V or more at 20 C (68 F) Is the battery OK? YES NO Clean the battery terminals. Recharge or replace the battery.
EAS00749
3. Main switch Check the main switch for continuity. Refer to "CHECKING THE SWITCHES". Is the main switch OK? YES NO Replace the main switch.
EAS00738
1. Main and carburetor heater fuses Check the main and carburetor heater fuses for continuity. Refer to "CHECKING THE FUSES" in Chapter 3. Are the main, and carburetor heater fuses OK? YES NO Replace the fuse(-s).
EASB0040
4. Thermo switch Remove the thermo switch from the thermo switch plate. Connect the pocket tester to the thermo switch lead. Tester (+) lead Brown/Yellow terminal 1 Tester () lead Brown/Black 2
105

EASB0041
ELEC
5. Carburetor heater Remove the carburetor heater from the carburetor body. Connect the pocket tester to the carburetor heater. Tester (+) lead Heater terminal 1 Tester () lead Heater body 2
Immerse the thermo switch in the water 3. Check the thermo switch for continuity. Note the temperatures while heating the water with the temperature gauge 4. Test step 1 2 3 4 Water temperature Less than 23 3 C More than 23 3 C More than 12 4 C Less than 12 4 C Good condition O

Measure the heater resistance. Carburetor heater resistance: 12 V 30 W: 6 ~ 10 at 20 C (68 F) Is the carburetor heater OK? YES NO Replace the carburetor heater.
Test 1 & 2: Heat-up test Test 3 & 4: Cool-down test O : Continuity : No continuity OFF
EASB0042
6. Wiring Check the entire carburetor heater systems wiring. Refer to "CIRCUIT DIAGRAM". Is the carburetor heater systems wiring properly connected and without defects? Thermoswitch 23 3 C NO Properly connect or repair the carburetor heater systems wiring. YES The carburetor heater system circuit is OK.
ON Thermoswitch 12 4 C
Is the thermo switch OK? YES NO Replace the thermo switch.
106
STARTING FAILURE/HARD STARTING
TRBL SHTG
TROUBLESHOOTING
NOTE: The following guide for troubleshooting does not cover all the possible causes of problems. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts.
STARTING FAILURE/HARD STARTING

ELECTRICAL SYSTEM Immobilizer system Refer to TROUBLESHOOTING of immobilizer system in chapter ELECTRICAL of this manual. Spark plug Improper plug gap Worn electrodes Wire between terminals severed Improper heat range Faulty spark plug cap Ignition coil Broken or shorted primary/secondary Faulty spark plug lead Broken body Full-transistor system Faulty ignitor unit Faulty pickup coil
Switch and wiring Faulty main switch Faulty engine stop switch Broken or shorted wiring Faulty neutral switch Faulty start switch Faulty sidestand switch Faulty clutch switch Starter motor Faulty starter motor Faulty starter relay Faulty relay unit (starting circuit cut-off relay) Faulty starter clutch
107
YAMAHA MOTOR ITALIA S.P.A.
PRINTED IN ITALY
BT1100 WIRING DIAGRAM

B B2 RG YL GL RW RG B2 B RW GL YL RG GL RW YL B2
WIRING DIAGRAM 1 2 3 4 5 6 7 8 9 0 q w e r t y u i o p a s d f g h j k l ; z x c v b n m , . / ! @ # $ % ^ & * ( ) Q Pickup coil Rectifier/regulator Main switch Starter relay Battery Wire minus lead Starter motor Starting circuit cut-off relay Fuel pump Igniter unit Ignition coil 1 Ignition coil 2 Throttle position sensor Sidestand switch Ignition fuse Right handlebar switch Front brake switch Headlight fuse Signal fuse Carburetor heater fuse Backup fuse Left handlebar switch Clutch switch Horn Flasher relay Multi-function display Neutral switch lead Neutral switch Headlight Front turn signal light (left) Front turn signal light (right) Rear turn signal light (left) Rear turn signal light (right) Thermo switch Carburetor heater earth Carburetor heater 1 Carburetor heater 2 Fuel sender Tail/brake light Oil warning light Speed sensor Rear brake switch Anti-theft alarm (option) License plate light Igniter fuse Parking lighting fuse Dimmer switch relay Fuel cut solenoid carburetor No. 1 Fuel cut solenoid carburetor No. 2 Immobilizer control unit Carburetor heater 3/4
50
B
1
Gy BL B Gy Gy1 BL W W W W W W
B W (BLACK)
R W
R R
W W W
W W W
R B
5
R R B B L
4
SbW
RB
SbW RB
LB LR
L RW RW
LG LY Sb BY LW RB Or Or
YL
RW YL
RB
BrR
BrR R BrL
B B
7
BW
11 12
Sb
BY
LG
LW
LR LB
LY
LB
9
B LB (BLACK) LB B (BLACK) LR
43
ON OFF P
B2 B1 B1 B2
R BrL
10
PUMP PU
RB Gy2 Gy2
15
BrL 10A RW
40
Gy1
B2 B1 BB3 BB4
Y L
L B
40
RW RB LW
13
LG
BL
L Y B
L Y BL LY WB RL
NS S.GND SL1 SL2 SS HD +B

SP RPM GND
VCC TPS
Sb Br G
48
G Br
B G Y LR
G B LR Y
BB2 BB1
MAIN HARNESS
HEAD LIGHT
YB
21
R 10A
RB GY RW Br
GY RB Br RW
17
HAZARD OFF ON E/G STOP OFF RUN
START FREE PUSH B B B (BLUE) LG B (BLUE)
B B B B
BB3 BB2 BB4 BB1
LW B Dg BrW Ch
B LW Ch BrW Dg Dg BrW Ch
16
Gy Br B B
14
49
Br
BrB
BrB
MAIN HARNESS
CARB.HEATER
18
BrL 15A RY B GW BrL 10A Br GW B
19
38
B
5A
RL
45 46 20 51
B B BrB
Br
42
B B
RY
RY LB RY WB WB LB
RY
Br P
BrW
BrG
BrG (BLACK) BrW
25
L W BL BrW
GY Br
47
Dg BrW Ch
L W BL W L B
RY
BY
LB
LY
BrR
10A
BrG
24
HORN OFF ON
41
GY
Ch
BrW
Dg
BrL
15A
BrY
PASSING OFF ON
DIMMER HI LO
23
LY BY (BLACK)
TURN L N R
34
BrBBrY
RY B P G Y BY LY LB
G P B RY LB LY BY Y
26
Ch
Dg
BrY
22 44
12V5W LR GY 12V21/5W LR
HI BEAM
BrB B BrB
B B B
IMOBILIZER GL LR Y G
BrB
BrB
Dg
Dg
LR
Y G
12V10W
12V10W
12V10W
12V60/55W
12V10W
Dg
Ch
Ch
LR B
B LR
Ch
Dg
Ch
30
31
32
33
LR A
A Y
RG Br B GW W YB
Dg Ch GL Y BW SbW
29
12V5W
LR B GY
35
36 37
GY B LR
Ch B B G Y B B
Dg B B
Ch B B
Dg B B B
Sb
B A B
Sb
39
Ch
Dg B
Ch
Dg
Sb
27 28
COLOR CODE
B ...........Black Br ..........Brown Ch .........Chocolate Dg .........Dark green G ...........Green Gy .........Gray L............Blue Lg..........Light green O ...........Orange P ...........Pink R ...........Red Sb .........Sky blue W ..........White Y ...........Yellow B/L ........Black/Blue B/W .......Black/White B/Y ........Black/Yellow Br/B.......Brown/Black Br/L .......Brown/Blue Br/W......Brown/White Br/Y.......Brown/Yellow L/B ........Blue/Black L/R ........Blue/Red L/W .......Blue/White L/Y ........Blue/Yellow R/B........Red/Black R/G .......Red/Green R/W.......Red/White R/Y........Red/Yellow

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2005

SUPPLEMENTARY SERVICE MANUAL

BT1100 SERVICE MANUAL: 5JN1-AE1

NOTE: Designs and specifications are subject to change without notice.

HOW TO USE THIS MANUAL

Hypoid gear oil SAE 80 (API GL4)

3.0 L 3.1 L 3.6 L 0.2 L

1st 2nd 3rd 4th 5th

front rear front rear front rear

front rear 90 kg (198 lb) ~ Maximum load * front rear

MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS

Cylinder: Bore size Measuring point Max. out of round

Camshaft runout limit

2.0 mm 2.0 mm 43.5 mm 43.5 mm 2.5/1.9 mm 2.5/1.9 mm

Clockwise Clockwise 0.025 0.050 mm 94.960 94.975 mm

5 mm 0 mm 22.004 22.015 mm 21.991 22.000 mm

Plain 1.5 3.8 mm 0.3 0.5 mm 0.04 0.08 mm

Type Dimensions (B x T) End gap (installed) Side clearance Oil ring:

Taper 1.2 3.8 mm 0.30 0.45 mm 0.03 0.07 mm

Crank width A Runout limit C Big end side clearance D

101.95 102.00 mm 0.320 0.474 mm

Needle bearing (starter)

Connecting rod big end

Crankshaft Pressure feed

Pinin drive Splashed Orifice Middle driveshaft

Rocker arm (EX)

Rocker arm (EX)

Rocker arm (IN)

Rocker arm (IN)

Crankcase tightening sequence:

Use lock washer

Use lock washer

Use lock washer Stake Stake Stake

M6 M5 M6 M10 M5 M6 M10 M12 M22 M12

MAINTENANCE SPECIFICATIONS CHASSIS

Limit 0 mm 1.0 mm 0.5 mm 1.0 mm 0.5 mm

(K1) (K2) (K1) (K2)

15 mm 30.2 mm 27 mm DOT 4 Single disc 267 5 mm 5.5 mm 5.5 mm 13 mm 42.85 mm DOT 4 43 mm 5 10 mm 3 5 mm

4.5 mm 0.15 mm 0.5 mm 0.5 mm

MAINTENANCE SPECIFICATIONS Tightening torques

M8 M6 M8 M6 M6 M10 M10 M6 M10 M8 M5 M6 M8 M6 M6 M6 M6 M6 M8 M6 M12 M6 M6 M6 M6 M5 M5 M6 M6

MAINTENANCE SPECIFICATIONS ELECTRICAL

GENERAL TORQUE SPECIFICATIONS/ CONVERSION TABLE GENERAL TORQUE SPECIFICATIONS

LUBRICATION POINTS AND LUBRICANT TYPES

CABLE ROUTING CABLE ROUTING

. Throttle cables / Brake cable

Y Rubber cap for front wiring

U Spark plug lead (front) I Throttle cable

INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS

PERIODIC INSPECTIONS AND ADJUSTMENTS

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

Whenever worm to the limit     

Whenever worm to the limit        

Wheel bearings Swingarm Steering bearings Chassis fasteners Sidestand

Sidestand Switch Front fork Rear shock absorber assembly

INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS

ODOMETER READING (x 1,000 km) 1 10  20 

ADJUSTING THE FRONT BRAKE

CHECKING THE FUSES

3. Replace: blown fuse

CHECKING THE FUSES

Job name/Part name

Job name/Part name

For installation, reverse the removal procedure.

Whenever worm to the limit

Whenever worm to the limit

ODOMETER READING (x 1,000 km) 1 10 20