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ELEC - bt1100.se

1. x EE A ry 2 uw cc SE N oc E T i I S u R 30A Mg TONG OHH fig 4 cc m ou cc B za B xor i ij DES zZ ea 19 DIS ca i i losco fa Ay ae E El deli A E d SE DE es E SA IE ea e 9 w lt lt La s E Se A N oc m m e n m ec Clila ar e ea ea Mc D C ug gt EECH ISO alk bel E zz EE Ss O OLI O l I ca lt a _ 0 DILE is jar i en co 8 I H tS i IE D Pickup coil 2 Rectifier regulator Starter relay 5 Battery 6 Wire minus lead 83 CHARGING system ELEC EAS00774 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 o Before troublesho
2. S HI BEAM Qa Qe IMOBILIZER p Sb DA 4 a Sb dl 66 EIE DA 7 5 2 fraler E kw Dg ch GL wir Tela 8 z oi ec H al 6 TO 8 ev SEI SEI LE BO IS d d G5 Son a ES GS ES E a dc agonia Red B W Black White Brown Yellow Sky blue B Y Black Yellow Blue Black Light green W White Br B Brown Black Blue Red Orange Y Yellow Br L Brown Blue Blue White nk BIL Black Blue Br W Brown White Blue Yellow mmu Red Black Red Green Red White Red Yellow WIRING DIAGRAM 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 ri
3. IGNITION SYSTEM CIRCUIT DIAGRAM 68 EASB0030 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 coll 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 Seat Side covers Fuel tank lift Cowling lift forward Storage compartment battery cover Cylinder head covers No OD e Troubleshoot with the following special tool s Ignition checker 90890 06754 Pocket tester 90890 03112 EAS00738 1 Main and ignition fuses Check the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in Chapter 3 Are the main and ignition fuses OK YES NO Replace the fuse s z IGNITION SYSTEM ELEC a EAS00739 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in Chapter 3 L ij Min open circuit voltage 12 8 V or more at 20 C 68 F s the battery OK Il YES J NO Clean the battery ter minals Recharge or replace the battery EAS00741 3 Spark plugs The following procedure applies to all of the spark plugs Check the condition of the s
4. SIGNALING SYSTEM CIRCUIT DIAGRAM 91 amp amp amp 9 amp amp amp amp amp amp E 9 Q Ce 6 e Q 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 92 SIGNALING SYSTEM EASB0035 TROUBLESHOOTING e Any of the following fail to light turn signal light brake light or an indicator light e 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 e Troubleshoot with the following special tool s Pocket tester 90890 03112 EAS00738 1 Main ignition and signaling system fuses Check the main ignition and signaling sys tem fuses for continuity CHECKING THE FUSES in Refer to Chapter 3 Are the main ignition and signaling system fuses OK YES Replace the fuse s 93 SIGNALING SYSTEM ELEC alli EAS00739 2
5. kaag 10 TIGETENING TORQUES ENGINE TU 11 MAINTENANCE SPECIFICATIONS CHASSIS sese 14 TIGHTENING TORQUES LP m 16 MAINTENANCE SPECIFICATIONS ELECTRICAL 18 GENERAL Kee TEE RE LE 20 CONVERSION TABLE asarsaran 20 LUBRICATION POINTS AND LUBRICANT TYPES esee 21 LUBRICATION DIAGRAMS E 9 ge 29 gula ejt 26 PERIODIC INSPECTIONS AND ADJUSTMENTS PERIODIC MAINTENANCE LUBRICATION INTERVALS esee 29 CHASSIS ADJUSTING THE FRONT BRAKE AAA 31 GHEORKING THE ge Oo ae sasabana 32 ENGINE ENGINE REMOVAL ae 34 CARBURETION ee TOT esse ass ee 36 CHASSIS FRONT BRAKE MASTER CYLINDER AA 3 FRONT BRAKE CALIPERS ai 39 FAN Eee ee ee ee 41 STEERING HEAD LOWER BRACKET ers et 45 ELECTRICAL ELECTRICAL COMPONENTS alleati 47 SNWITORE 49 CHECKING THE BULBS AND BULB EE 52 IMMOBIELIZER SYS TEM actos nasi sana ia anaa aa ak aana a ad jaba gak a anaa Dee eg a Na aa d ag a Ee 55 SELF DIAGNOSIS DEVICE eisen ee E 63 KEN LIION S dE 68 ELECTRIC STARTING SYSTEM arri 79 Be LEE EIERE KD TE NI m 83 LAKA ELING NR ON 86 SANA LING SE EE 91 PU El Een e HR E 99 CARBURETOR HEATER SYSTEM eege 104 TROUBLESHOOTING STARTING PALURBRE EIARD STAR IN sea ea 107 WIRING DIAGRAM GENERAL SP
6. IMMOBILIZER Key code registration error Same standard key was attempted Prepare the new standard UNIT to continuously two times register key and register it ECU IGNITER Underfinition code is re Noise interference or disconnected 1 Check the wire harness UNIT ceived lead cable and connector 2 Replace the immobilizer unit 3 Replace the ignitor unit 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 lt Example gt 52 Light ON Light OFF lt lt dM 1 5 en Kg pg 1 e a 1 5 8 H 1 8 oe 48 1 5 0 5 0 5 0 5 62 SELF DIAGNOSIS DEVICE SELF DIAGNOSIS DEVICE 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 soeedometer 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 e tachometer e throttle position sensor Speed sensor ignition coil No 1 e ignition coil No 2 fuel cut solenoid carbure
7. MAINTENANCE SPECIFICATIONS SPEC Tightening torques Tightening Part to be tightened Thread torque Remarks M6 Headlight assembly Cowling Lower headlight support Upper headlight support right and left l Headlight bracket right and left l Plastic cover l 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 See Note 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 l Swingarm pinch bolt Shock absorber fastener upper l Shock absorber fastener lower Connecting arm Relay arm i 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 MAINTENANCE SPECIFICATIONS SPEC
8. Replacement parts on troubles Required key registration Igniter Accessory lock 2 and Standard key is missing Standard key and replace it is required All keys have been lost Code re registering Including code key and standard keys re registering key Igniter unit is defective Code re registering key Immobilizer unit is defective Code re registering key and standard keys Main switch is defective Code re registering key and standard keys Accessory lock 2 is defective e 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 regis tered 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 igni
9. 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Starting circuit cut off relay 7 Starter motor Clutch switch 9 Sidestand switch Neutral switch D Start switch 2 Starter relay H ELECTRIC STARTING SYSTEM ELEC uUi EASBOOS1 EAS00739 TROUBLESHOOTING voeem The starter motor fails to turn Check the condition of the battery Refer to CHECKING AND CHARGING THE Check BATTERY in Chapter 3 1 Main and ignition fuses eme 2 Battery Min open circuit voltage E cades dis 12 8 V or more at 20 C 68 F 4 Starting circuit cut off relay Is the battery OK 5 Starter relay 6 Main switch Il TES NO 7 Engine stop switch 8 Neutral switch Clean the battery ter 9 Sidestand switch minals 10 Clutch switch Recharge or replace 11 Start switch the battery 12 Wiring of the entire starting system EAS00758 NOTE ee lt Before troubleshooting remove the following 3 Starter motor part s Connect the battery positive terminal 1 and 1 Seat starter motor lead with a jumper lead 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 EAS00738 1 Main and ignition fuses Check the main and ignition fuses for conti nuity AA WARNING e A wire that is used as a jumper lead must have at least the same capacity of the battery lead otherwise
10. ELECTRICAL SYSTEM Immobilizer system Switch and wiring e Refer to TROUBLESHOOTING of immobilizer Faulty main switch system in chapter ELECTRICAL of this manual Faulty engine stop switch Spark plug Broken or shorted wiring Improper plug gap Faulty neutral switch e Worn electrodes Faulty start switch Wire between terminals severed Faulty sidestand switch Improper heat range Faulty clutch switch Faulty spark plug cap Starter motor Ignition coil Faulty starter motor Broken or shorted primary secondary Faulty starter relay e Faulty spark plug lead Faulty relay unit starting circuit cut off relay Broken body Faulty starter clutch Full transistor system Faulty ignitor unit Faulty pickup coil 107 YAMAHA YAMAHA MOTOR ITALIA S P A PRINTED IN ITALY BT1100 WIRING DIAGRAM BLACK GI H w w WW W w Gu br OOO Fr E EMEN ap 4 tO e ls 5 30A oA 0 6 6 1 air RW hi ni COLOR CODE Bu
11. 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 lt max gt Output pressure 2 9 3 1mm 8 2 5 2 mm 4 1 9 2 1 mm 7 7 2 mm 4 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 1163 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 8A 12 kPa 0 12 kf cm MAINTENANCE SPECIFICATIONS SPEC ve Lubrication system Oil filter type Paper type Oil pump type Trochoid type Tip clearance A or B 0 03 0 09 mm Side clearance 0 03 0 08 mm Bypass valve opening pressure 80 120 kPa 0 8 1 2 kgf cm Relief valve operating pressure 450 550 kPa 4 5 5 5 kgf cm Shaft drive Middle gear backlash Final gear backlash MAINTENANCE SPECIFICATIONS SPEC Lubrication chart Needle bearing starter Connecting rod big end lt Pressure feed XD Splashed X Orifice gt Middle driveshaft Rocker arm EX Camshaft EX Rocker arm EX Rocker arm IN Camshaft IN Rocker arm IN Oil filter
12. 1 2 Check fuse vVVVVVVVVVVVVVVVVVVVVVVVVVVVV a Connect the pocket tester to the fuse and check it for continuity NOTE Set the pocket tester selector to Q x 1 b If the pocket tester indicates oo replace the fuse A A A A A A a A A A a A A A A A A A A A A A A A A A A A A 3 Replace e blown fuse VVVVVVVVVVVVVVVVVVVVVVVVVVVVYV a Turn off the ignition b Install a new fuse of the correct amperage rat ing c Turn on the switches to verify if the electrical circuit is operational d Ifthe fuse immediately blows again check the electrical circuit A A A A A A A A A A a A A A A A A A A A A A A A A A A A A INSP O CHECKING THE FUSES ADJ 33 om UNE Ta rating Mainfuse 304 Q Carburetor heater fuse 15A Headlight fuse 15A Signaling system fuse 10A Ignition fuse 10A Odometer fuse backup 10A Parking lighting fuse 10A lgniter fuse 5A Reservefuse 30A Reserve fuse 15A Q Reserve fuse 10A 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 sys tem cause the lighting and ignition systems to malfunction and could possibly cause a fire a NE NE EE NN Ee RE a ie SI EE NE E NN 1 o3 4 Install storage compartment seat Pg E
13. Check the wire harness for continuity Refer to CIRCUIT DIAGRAM e Is the wire harness OK YES NO Repair or replace the wire harness Place the motorcycle on a suitable stand so that the rear wheel is elevated Connect the pocket tester DC 20 V to the 2 Speed sensor speed sensor connector Tester lead White terminal 1 Tester lead gt Body earth 65 SELF DIAGNOSIS DEVICE ELEC 3 Ignition coil N 1 and 2 1 Wiring e Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM s the ignition system s wiring properly con nected and without defects YES NO Secondary coil resistance Repair or replace the 10 7 14 5 KQ at 20 C 68 F wire harness n e Is the ignition coil OK YES NO Replace the ignitor Replace the ignition 2 Ignition coil resistance unit coil The following procedure applies to all of the ignition coils e Disconnect the ignition coil connectors from the ignition coil terminals e Connect the pocket tester Q x 1 to the igni tion coil as shwon Tester positive probe gt Red Black Tester negative probe gt Orange Gray Measure the primary coil resistance Tu Primary coil resistance al 3 57 4 83 0 at 20 C 68 F Connect the pocket tester x 1k to the ignition coil as shown Measure the secondary coil resistance Tester positive probe gt spark plug lead 1 Tester negative prob
14. Ignition timing B T D C Advancer type T C l Pickup coil resistance color T C I unit model manufacturer Ignition coil Model manufacturer Primary winding resistance Secondary winding resistance Spark plug cap Type Hesistance 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 1 320 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 10 at 1 000 r min Digital type 189 231 Q at 20 C Gray Black J4T157 MITSUBISHI F6T552 MITSUBISHI 3 57 4 83 Q at 20 C 10 7 14 5 KQ at 20 C Resin type 10 kQ A C magneto FAT654 MITSUBISHI 14V 350W at 5 000 r min 0 36 0 44 Q at 20 C White White Semi conductor short circuit type SH650D 11 SHINDENGEN 14 1 14 9 V SH650D 11 SHINDENGEN 18A 200 V Constant mesh type SM 13 MITSUBA 0 6 kW 0 026 0 034 Q at 20 C 10 mm 7 65 10 01 N 780 1021 g 28 mm 0 7 mm MS5F 421 JIDECO 180A 4 18 4 62 Q at 20 C MAINTENANCE SPECIFICATIONS SPEC ve Horn Type Plane type Quantity 1 Model manufacturer K80 L 12V LEB Maximum amperage 3A F
15. Right side cowling Refer to COWLINGS AND COVERS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Clutch cover Clutch cover gasket Dowel pin Damper cover Damper For installation reverse the removal procedure 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 D General information 2 Specifications 3 Periodic inspections and adjustments 4 Engine 5 Carburetor 6 Chassis Electrical system Troubleshooting Illustrated symbols to 9 are used to identify the specifications appearing in the text 9 Can be serviced with engine mounted Filling fluid D Lubricant 2 Special tool 3 Torque Wear limit clearance 5 Engine speed Electrical data Illustrated symbols 7 to Q2 in the exploded dia grams indicate the types of lubricants and lubrica tion points D Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease GD Apply lightweight lithium soap base grease Apply molybdenum disulfide grease Illustrated symbols Q3 to amp in the exploded dia grams indicate the following 03 Apply locking agent LOCTITE Replace the part CONTENTS SPECIFICATIONS EI TE NN aane asirna akadang enna 1 MAINTENANCE SPECIFICATIONS ENGINE 4 LUBRICATION OHAR T c
16. el pump 4 Ignition fuse 5 Engine stop switch Ignitor unit 7 Fuel pump relay Fuel pump L B io 100 EASBO0037 TROUBLESHOOTING The fuel pump fails to operate Check Main and ignition fuses Battery Main switch Engine stop switch Starting circuit cutoff relay fuel pump relay Fuel pump Wiring of the entire charging system NOTE NO OUT P Go b i A Before troubleshooting remove the following part s Seat Side covers 4 2 3 Fuel tank lift 4 Storage compartment battery cover e Troubleshoot with the following special tool s Pocket tester 90890 03112 EAS00738 1 Main and ignition fuses Check the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in Chapter 3 Are the main and ignition fuses OK Il YES J NO Replace the fuse s z FUEL PUMP SYSTEM ELEC ulli EAS00739 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in Chapter 3 ij Open circuit voltage eL 12 8 V or more at 20 C 68 F s the battery OK Il YES J NO Clean the battery ter minals Recharge or replace the battery EAS00749 3 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES e Is the main switch OK p ves Replace the main switch EAS00750 4 Engine stop switch Check the engine stop switch for continui
17. 03112 Armature assembly Armature coil resistance 1 0 026 0 034 O at 20 C 68 F Insulation resistance 2 Above 1 MQ at 20 C 68 F b If any resistance is out of specification replace the starter motor A A A A A A A A A A A A A A A A A A A A A A A A A A A A A 80 z ELECTRIC STARTING SYSTEM ELEC ulli 5 Measure e brush length a Out of specification Replace the brushes as a set Min brush length 5 mm DA 6 Measure e brush spring force Out of specification gt Replace the brush springs as a set Bruch spring force 7 65 10 01 N 780 1 020 g DA N Check e gear teeth Damage wear gt Replace the gear Check oil seal Damage wear gt Replace the defective part s p EAS00772 Assembling the starter motor 1 Install e brush holder 1 NOTE Align the tab 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 8 on the front cover with the slot b on the end cover and starter motor yoke 81 ELECTRIC STARTING SYSTEM ELEC 3 Install e starter motor rear cover 1 NOTE MM Align the match marks on the rear cover with the match marks b on the front cover 82 H CHARGING SYSTEM ELEC F7 CHARGING SYSTEM CIRCUIT DIAGRAM
18. 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 s the battery OK Il YES J NO Clean the battery ter minals Recharge or replace the battery EAS00749 3 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES s the main switch OK IM NO Replace the main switch 4 Hazard switch e Check the hazard switch for continuity Refer to CHECKING THE SWITCHES e s the hazard switch OK ves J NO Replace the hazard switch EAS00795 5 Wiring Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM s the signaling system s wiring properly con nected and without defects Check the condition Properly connect or of each of the signal repair the signaling ing system s circuits system s wiring Refer to CHECKING THE SIGNALING SYSTEM 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 e Is the horn switch OK YES NO Replace the left han dlebar switch SIGNALING SYSTEM ELEC 2 Voltage Connect the pocket tester DC 20 V to the horn connector at the horn terminal as shown Tester positive probe gt Brown 1 Tester negative probe gt
19. Check conio DE I O EAR Check condition 4 Spark plugs Clean and regap Replace Lt Io A Check valve clearance Air fter Clean pote fl l1 plement Replace tw Lfl Check operation i eeu fluid level and vehicle for fluid 7 Front brake a Replace brake pads Whenever worm to the limit Check operation fluid level and vehicle for J J J J J J Rear brake fluid leakage lelele e e Replace brake pads Whenever worm to the limit hoses Replace Every 4 years Check tread depth and for damage Replace if necessary J 4 J 4 4 Check air pressure Correct if necessary Eu eem e m 71 7 70 Check operation and for excessive play o e ldg ele Lubrificate with lithium soap based grease Every 50 000 km Check bearing play and steering for roughness Every 20 000 km D o Steering bearings Lubrificate with lithium soap based grease Chassis e Make sure that all nuts bolts and screws are e Check ion ME n BEEZEZEZEZEZ ones epeaion nere TTT Rear shock absorber Check operation and shock absorber for oil leakage J 4 4 4 assembly N 29 INTRODUCTION PERIODIC MAINTENANCE INSP O LUBRICATION INTERVALS ADJ ITEM CHECK OR MAINTENANCE JOB check Rear suspension relay Check operation arm and connecting arm pivoting Lubricate with lithium soap based grease points Check starter choke operation Carb
20. Dimmer switch relay Igniter unit Wiring of the entire charging system NOTE E Before troubleshooting remove the following D art S EAS00749 Seat 3 Main switch 2 Side covers i mE 3 Fuel tank lift Check the main switch for continuity Clean the battery ter minals Recharge or replace the battery oO JO VAS WD 1 Refer to CHECKING THE SWITCHES 4 Cowling lift forward e Is the main switch OK 5 Storage compartment battery cover T lesh ith the followi ial tool s roubleshoot with the following special tool s ves J NO Pocket tester Replace the main 90890 03112 switch EAS00738 EAS00784 1 Main and headlight fuses Check the main and headlight fuses for con tinuity 4 Dimmer switch Check the dimmer switch for continuity Refer to CHECKING THE SWITCHES e Is the dimmer switch OK Refer to CHECKING THE FUSES in Chapter 3 lt Are the main and headlight fuses OK YES NO ves NO The dimmer switch is faulty Replace the Replace the fuse s right handlebar switch 87 LIGHTING SYSTEM ELEC D 7 Igniter unit EAS00786 5 Pass switch Disconnect the igniter unit from the coupler Check the pass switch for continuity and connect a new one s the lighting system s OK IM J NO Replace the igniter The igniter unit is OK Refer to CHECKING THE SWITCHES s the p
21. 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 stan dard key cannot be registered and only the first standard key is registered less than 5 0 s less than 5 0 s less than 5 0 s less than 5 0 s y haee js ch is complete ON registeri j k Second standard key Standard key SWITCH Code re registering key First standard key registration EE Registration mode method LED OFF AES EI Blinking ends when the registration a the second unregistered standard key is complete 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 less than 5 0 s less than 5 0 s less than 5 0 s lt ON registeri Remainin Standard k ey SWITCH M Code re registering key Stamet E
22. Tightening Part to be tightened Thread torque Remarks size 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 NOTE 1 First tighten the ring nut approximately 52 Nm 5 2 m kg by using the torque wrench then loosen the ring nut completely 2 Retighten the ring nut to specification MAINTENANCE SPECIFICATIONS SPEC ve ELECTRICAL Voltage aw Ignition system
23. and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations AT The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFE TY IS INVOLVED A 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 mo torcycle CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy easy to read reference book for the mechanic Comprehensive ex planations of all installation removal disassembly assembly repair and check procedures are laid out with the individual steps in sequential order D 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 re moval and di
24. bulb socket A A A A A A A A A A A a A A A A A A A A A A A A A A A A A IMMOBILIZER SYSTEM ELEC IMMOBILIZER SYSTEM CIRCUIT DIAGRAM EB805000 o0 c mc es E i45 006 w Gna Gna pu d dk Teja O EJA zen l ssi L 5 DND WdH dS ag Hi om ss 5 Is aT S aNd SN Sd 9 Esami ajm Ti Lc Was nigi Om LSS A Ep SS Anti theft alarm option Immobilizer control unit Igniter fuse Multi function display 5 Ignition fuse Backup fuse 55 IMMOBILIZER SYSTEM GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re registering codes in the standard keys This system consists of the following e 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 e an immobilizer unit the igniter unit e 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 immobiliz er system cannot be operated with a new key until the key registered with a code If you lose the code re registering key the igniter unit and main switch included with an immobilizer unit needs to be re placed Therefore always us
25. connected gt Properly connect Incorrect continuity reading gt Repair or replace the bulb bulb socket or both TYPES OF BULBS Le lampadine utilizzate su questo motociclo sono illustrate nella figura a sinistra e The bulbs used on this motorcycle are shown in the illustration on the left Bulbs and B are used for headlights and usually use a bulb holder which must be de tached before removing the bulb The majority of these bulbs can be removed from their respec tive socket by turning them counterclockwise Bulb is used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise Bulbs and are used for meter and indicator lights and can be removed from their respective socket by turn D and pulling them out CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs 1 Remove bulb o3 z CHECKING THE BULBS AND BULB SOCKETS ELEC AA WARNING Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down CAUTION e Be sure to hold the socket firmly when removing the bulb Never pull the lead oth erwise it may be pulled out of the terminal in the coupler e 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 adversel
26. pler is faulty and must be repaired 89 EAS00790 3 Atail 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 orake light bulb and socket OK tail bulb Replace the brake light Socket or both 2 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 e Measure the voltage 12 V of Blue Red D on the tail brake light coupler wire harness side s the voltage within specification Il YES This circuit is OK The wiring circuit from the main switch to the tail brake light coupler is faulty and must be repaired 90 n LIGHTING SYSTEM ELEC EASB0034 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 Replace the license plate light bulb socket or both 2 Voltage Connect the pocket tester DC 20 V to the license plate light coupler wire harness side as shown Tester positive probe gt Blue Red 1 Tester negative probe Black 2 Set the main switch to ON Measure the voltage 12 V of Blue Red D on the license plate light couple
27. switches with the punch mark on the handle bar 8 Install e clutch cable 9 Connect clutch switch coupler NOTE ee 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 10mm 11 Adjust e 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 5mm STEERING HEAD CHAS STEERING HEAD LOWER BRACKET N 112152 Nm 5 2 mekg 712218 Nm 1 8 mekg Job name Part name Removing the lower bracket Remove the parts in the order listed Front wheel Refer to FRONT WHEEL AND BRAKE DISCS Front fork legs Refer to FRONT FORK Handlebar Refer to HANDLEBAR Crown nut washer plate Refer to INSTALLING THE STEERING Upper bracket HEAD Special washer Upper ring nut Refer to REMOVING THE LOWER Rubber seal BRACKET INSTALLING THE STEERING Lower ring nut HEAD Lower bracket Rubber washer Bearing cover Bearing O OO JO Om SS DN nil E ze umi nm ect amah eet n G es di oO 45 STEERING HEAD CHAS 1a 52 Nm 5 2 mekg Najis Nm 1 8 mekg Bearing Dust seal Lower handlebar holder For installation reverse the removal procedure 46 ELECTRICAL COMPON
28. the jumper lead may burn e This check is likely to produce sparks therefore make sure that no flammable Refer to CHECKING THE FUSES in Chapter 3 Are the main and ignition fuses OK YES NO gas or fluid is in the vicinity e Does the starter motor turn Replace the fuse s p i IG Repair or replace the starter motor 19 ELECTRIC STARTING SYSTEM ELEC EAS00739 EAS00761 4 Starting circuit cut off relay 5 Starter relay e Disconnect the relay unit from the coupler e Disconnect the starter relay from the coupler e Connect the pocket tester x 1 and bat e Connect the pocket tester x 1 and bat tery 12V to the relay unit terminals as tery 12V to the starter relay coupler as shown shown Battery positive terminal gt Red Black 1 Battery positive terminal Red White 1 Battery negative terminal Black Yellow 2 Battery negative terminal gt Blue D Tester positive probe gt Blue 3 Tester positive probe gt Red 3 Tester negative probe gt Blue White 4 Tester negative probe gt Black 4 so BY S Co e Does the starter relay have continuity between Red and Black ves J NO ves J NO Replace the relay Replace the starter re unit lay EAS00749 6 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES e Is the main switch OK Yes J NO Replace the main switch 76 z ELECTRIC STARTING SYSTEM ELE
29. to the immobilizer unit is faulty and must be repaired 3 Voltage e Connect the pocket tester DC 20 V to the immobilizer unit couplers as shown Tester positive probe red white 1 Tester negative probe black e Set the main switch to ON e Measure the voltage 12 V between red white and black on the immobilizer unit e Are the voltage within specification The wiring circuit from the main switch to the immobilizer unit is faulty and must be re paired 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 IN B2 RG GL RW B DW 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 immobi lizer unit S The wiring circuit from the immobilizer unit to z r IMMOBILIZER SYSTEM ELEC the multi function dis play is faulty and must be repaired 61 IMMOBILIZER SYSTEM SELF DIAGNOSIS ERROR CODE INDICATION 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 Detection Symptoms Trouble Measures IMMOBILIZER Cannot transmit code 1
30. 0038 FUEL PUMP TEST 4 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 e Stop the engine before refuelling e Do not smoke and keep away from open flames sparks or any other source of fire e Take care not to spill gasoline If you do accidentally spill some wipe it up immedi ately with dry rags e If gasoline touches the engine when the engine is still hot there is a danger of com bustion Make sure that the engine is com pletely cool before performing the following test 1 Check Fuel pump operation vVVVVVVVVVVVVVVVVVVVVVVVVVVVV a Fill up the fuel tank b Put the end of the fuel hose into an open con tainer Connect the battery 12 V to the fuel pump coupler terminals Battery lead Blue Black terminal 1 Battery lead Black terminal D Operate the engine starter to open the vacu um fuel cock If fuel flows out from the fuel hose the fuel pump is good If not replace the fuel pump assembly A A A A A A A A A A A A A A A A A A A A A A A A A A A A A e e D CARBURETOR HEATER SYSTEM CARBURETOR HEATER SYSTEM CIRCUIT DIAGRAM Main switch ee 5 E de EE 5 5 E amp Starter relay Sek E ME E he J Batter del a x y EH d d Wire minus lead Carburetor heater fuse Thermo switch Carburet
31. 050 mm 0 15 mm Piston size D 94 960 94 975 mm ecc a NG I ps VA H D Measuring point H 5 mm eee Piston off set 0 mm eee Piston pin bore inside diameter 22 004 22 015 mm 22 045 Piston pin outside diameter 21 991 22 000 mm 21 975 MAINTENANCE SPECIFICATIONS SPEC ve js Du aux Piston rings Top ring T Type Dimensions B x T End gap installed Side clearance installed 2 ring Type Dimensions B x T End gap installed Side clearance Oil ring Dimensions B x T End gap installed Connecting rod Oil clearance Color code corresponding size Crankshaft Crank width A Runout limit C Big end side clearance D Plain 1 5 X 3 8 mm 0 3 0 5 mm 0 04 0 08 mm Taper 1 2 X 3 8 mm 0 30 0 45 mm 0 03 0 07 mm 2 5 X 3 4 mm 0 2 0 7 mm 0 044 0 073 mm D Blue Black 3 Brown 4 Green 5 Yellow 101 95 102 00 mm 0 320 0 474 mm MAINTENANCE SPECIFICATIONS SPEC ve 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 D mark Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot outlet
32. 52 Pickup coil resistance 11 Sidestand switch 189 231 Q at 20 C 68 F between Gray and Black Check the sidestand switch for continuity Refer to CHECKING THE SWITCHES Is the pickup coil OK e Is the sidestand switch OK ves NO ves J NO Replace the pickup coll Replace the sidestand switch 71 IGNITION SYSTEM ELEC EAS00754 14 Wiring e Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM s the ignition system s wiring properly con nected and without defects NO YES Properly connect or Replace the ignitor repair the ignition sys unit tem s wiring 72 zm Biz IB S Wun 044U09 J0ZI IQOWILU d e uondo WalsAs uue y Q GE YOUMS EAINAN A ir Je peo youms EDD LU HE YOUMS uoinio TI l YoUMs seqa puey 1U6IY osnj uoniuf YOUMS pueljsepis E Ke eJ yo 1no noo Bues di JOJOW JSIEIS o k pee SNUIW SI S D d Maeg e e oJ Jouels nee Or YOUMS UN z ri
33. BAR CHAS EASB0025 INSTALLING THE HANDLEBAR 1 Stand the motorcycle on a level surface A WARNING Securely support the motorcycle so that there is no danger of it falling over 2 Install e handlebar upper handlebar holders CAUTION e First tighten the bolts on the front side of the handlebar holder then on the rear side e 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 e throttle grip e throttle cable A WARNING en NN Make sure that the pin on the throttle cable Wu housing is aligned with the hole in the han 22 dlebar SS E 4 Install master cylinder 1 Refer to FRONT AND REAR BRAKES NOTE MEME Align the slit in the brake lever holder with the punch mark a in the handlebar 43 44 HANDLEBAR CHAS 5 Install e master cylinder holder 10 Nm 1 0 mekg NOTE _ A D5 A WP Install the master cylinder holder 2 with the mark UP facing up 6 Install e clutch lever holder 1 NOTE _ P P__ _D 1__aua _ A__j mm8 Align the slit in the clutch lever holder with the punch mark in the handlebar 7 Install left handlebar switch NOTE __ Aligh the matching surface on the handlebar
34. 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 e Troubleshoot with the following special tool s Pocket tester 90890 03112 EAS00738 1 Main and carburetor heater fuses e Check the main and carburetor heater fuses for continuity Refer to CHECKING THE FUSES in Chapter 3 e Are the main and carburetor heater fuses OK Il YES J NO Replace the fuse s EAS00739 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in Chapter 3 ij Open circuit voltage eL 12 8 V or more at 20 C 68 F s the battery OK Il YES J NO Clean the battery ter minals Recharge or replace the battery EAS00749 3 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES e Is the main switch OK p ves Replace the main switch EASB0040 4 Thermo switch e Remove the thermo switch from the thermo switch plate Connect the pocket tester to the thermo switch lead Tester lead gt Brown Yellow terminal 1 Tester lead gt Brown Black 2 CARBURETOR HEATER SYSTEM ELEC D e Immerse the thermo switch in the water Check the thermo switch for continuity Note the temperature
35. C ulli EAS00750 EAS00764 7 Engine stop switch Check the engine stop switch for continuity 11 Start switch Check the start switch for continuity Refer to CHECKING THE SWITCHES e ls the start switch OK Refer to CHECKING THE SWITCHES e Is the engine stop switch OK yes NO IM J NO Replace the right han Replace the right dlebar switch handlebar switch EAS00751 EAS00766 12 Wiring Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM e ls the starting system s wiring properly con 8 Neutral switch Check the neutral switch for continuity Refer to CHECKING THE SWITCHES s the neutral switch OK nected and without defects IM J NO J NO YES switch Properly connect or The starting system repair the starting system s wiring EAS00752 9 Sidestand switch Check the sidestand switch for continuity Refer to CHECKING THE SWITCHES s the sidestand switch OK Il YES J NO Replace the side stand switch EAS00763 10 Clutch switch Check the clutch switch for continuity Refer to CHECKING THE SWITCHES e Is the clutch switch OK ves J NO Replace the clutch switch IT ELECTRIC STARTING SYSTEM ELEC aMili STARTER MOTOR Job name Part name Hemarks Removing the starter motor Remove the parts in the order listed Starter motor lead otarter motor assembly For installation reverse the rem
36. C ve CHASSIS 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 owingarm pivot bearing inner surface Swingarm pivot oil seal lip Relay arm bearing collar and oil seal Drive shaft spline Drive shaft dust cover anm Drive shaft coupling gear oil seal 22 EB205000 LUBRICATION DIAGRAMS SPEC ve LUBRICATION DIAGRAMS D Rocker arm shaft intake 3 Oil filter 5 Drive axle 2 Rocker arm shaft exhaust 4 Oil pump Middle drive shaft 23 LUBRICATION DIAGRAMS SPEC ve 3 Oil filter D Oil pump 4 Middle drive shaft 2 Releaf valve DD 4d ng 019 4 4 4724 07074 4 0747 1 1 0 0 0 4 4 0 EA Ims 8 SE j UU ie err DoD een 9 eR ee ee n e nS Ces or d 24 LUBRICATION DIAGRAMS SPEC ve CABLE ROUTING Relays group Flasher relay Speed sensor Sidestand switch Fuel drain hose Engine earth Neutral switch Carburetor heater 9 6 6 amp 3 9 O 6000090060 CABLE ROUTING Filler tank cap fuel drain pipe Fill
37. ECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Model code BT1100 5JN4 Dimensions Overall length 2 200 mm Overall width 800 mm Overall height 1 140 mm Seat height 812 mm Wheelbase 1 530 mm Ground clearance 168 mm Minimum turning radius 2 980 mm 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 Air cooled 4 stroke SOHC Cylinder arrangement V type 2 cylinder Displacement 1 063 L Bore X stroke 95 x 75 mm Compression ratio 8 3 1 Compression pressure STD 1 000 kPa 10 kg cm 10 bar at 400 r min Starting system Electric starter Engine oil Type C SAE20W40SE or SAE10W30SE 20 10 Recommended engine oil classification API Service SE SF SG or higher 20W 50 BS Hypoid gear oil SAE 80 API GL4 Oil quantity Engine oll Periodic oil change With oil filter replacement Total amount Final gear case oil Total amount GENERAL SPECIFICATIONS SPEC ve Air filter Dry type element Fuel Type Fuel tank capacity Fuel reserve amount Carburetor Type quantity Manufacturer Spark plug Type Manufacturer Spark plug gap Clutch type Wet multiple disc Transmission Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear rati
38. EDs X Fh j d a LU N x UN p TN d RIZ 4 JANGGA Al N NG AN A ANG NG d J 4 I Na NN VECA X d YAN y RY NS gt 2322777 ac 7 77 LZ me SFERE WH XE fimo GE O JL TS gt LI LT WAY zag LI LIZA ZZ Y RRS IZ C LIS AN LIL SS VON GC NA mm O er LT fona AEN V NN A ne yo 28 SPEC Rubber cap for front wiring connections 67 Spark plug lead front Throttle cable Position the spark plug wire of the rear cylinder below the fuel hose INTRODUCTION PERIODIC MAINTENANCE INSP gei LUBRICATION INTERVALS 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 techni cians should be familiar with this entire chapter PERIODIC MAINTENANCE LUBRICATION INTERVALS ODOMETER READING x 1 000 km Annual D in LLL Kern x Check fuel hoses and vacuum hose for cracks or JiiEMidG b i i I EEA 2 Fuettiter
39. ENTS ELEC ELECTRICAL ELECTRICAL COMPONENTS D Main switch 6 Oil level gauge assembly Igniter unit 7 Neutral switch 3 Ignition coil rear cylinder Sidestand switch Ignition coil front cylinder 9 Speed sensor 5 Horn Immobilizer control unit CB Be 47 ELECTRICAL COMPONENTS ELEC D Fuel meter senser unit Relay assembly 2 Battery 7 Fuse assembly 3 Starter relay Rectifier regulator Relay assembly Thermo switch 5 Flasher relay 48 49 SWITCHES 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 D 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 A e Before checking for continuity set the pocket tester to 0 and to the Q x 1 range e 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 illus tration similar to the one on the left The switch positions are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration NOTA ooo The sym
40. Ground Set the main switch to ON Measure the voltage 12 V of Brown at the horn terminal e Is the voltage within specification The wiring circuit from the main switch to the horn connector is faulty and must be repaired e Disconnect the Black connector at the horn terminal e Connect a jumper lead D to the horn termi nal and Ground the jumper lead Set the main switch to ON Does the horn sound NO YES Thehorn is OK 94 SIGNALING SYSTEM ELEC 4 Voltage e Connect the pocket tester DC 20 V to the horn connecter at the black terminal as Tester positive probe gt Black 1 Tester negative probe gt Ground MIR alte Set the main switch to ON Measure the voltage 12 V of Black at the horn terminal e Is the voltage within specification YES NO Repair or replace the horn EAS00797 2 Atail 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 the tail lightbulb Replace brake socket or both Replace the horn 99 2 Brake light switches Check the brake light switches for continuity Refer to CHECKING THE SWITCHES s the brake light switch OK pe es Replace the brake light switch 3 Voltage Connect th
41. I i I Relief valve Oil pump 10 MAINTENANCE SPECIFICATIONS SPEC ve Cylinder head tightening sequence Crankcase tightening sequence o Qu G amp 4 M 10 W HERR Gr SIN S Le d_ qv ON 0 oo o Left crankcase Right crankcase MAINTENANCE SPECIFICATIONS SPEC ve Tightening torques Tightenin Thread 9 9 Remarks size Part to be tightened Cylinder head Nut Cylinder head Nut Plate Bolt Cylinder head cover Screw Cylinder head exhaust pipe Stud bolt Rocker arm shaft Union bolt Camshaft sprocket cover Bolt Tappet cover Bolt Rocker arm shaft Bolt oil passage Stopper plate camshaft Bolt iN Use lock washer Spark plug Cylinder Bolt Lower cylinder head cover Bolt Upper cylinder head cover Screw Connecting rod Nut Rotor Nut Valve adjusting locknut Nut Camshaft sprocket Bolt Timing chain tensioner Bolt Timing chain tentioner cap Bolt Timing chain guide Bolt Oil pump Bolt Oil strainer cover Bolt Oil filter cover Bolt Oil pump gear Bolt Oil pump cap Bolt Oil delivery pipe cylinder head Union bolt crankcase Union bolt Oil drain bolt Air filter Air filter cover fastener Screw Carburetor cover fastener Screw A I S system A I S system fastener pump and piping Screw A I S system pipe fastener to engine starter Screw A I S pump fastener to A I S bracket Screw Exhaust system Cylinder head and exhaust pipe joint Nut Exhaust pipe bracket Screw Exha
42. NGINE REMOVAL ENG ENGINE ENGINE REMOVAL SEAT STORAGE COMPARTMENT SIDE COVERS FUEL TANK AIR FILTER CASE ASSEMBLY CARBURETOR ASSEMBLY AND EXHAUST SYSTEM y gy 4 Nm 0 4 mekg 7 Nm 0 7 mekg SOC 0 20 Nm 2 0 mekg DT da Sy 10 Nm 1 0 mek A m 1 0 m 4 Nm 04 mekg 9 18 Nm 1 8 mekg Removing the seat storage Remove the parts in the order listed compartment side covers fuel tank Stand the motorcycle on a level surface air filter case assembly carburetor A WARNING assembly and exhaust system Securely support the motorcycle so there is no danger of it falling over Seat Storage compartment 34 A N A 7 Nm 0 7 mekg 4 Nm 0 4 mekg 9 0 da 4 Nm 0 4 mekg 2 DT 10 Nm 1 0 mekg ENGINE REMOVAL ENG Pd 20 Nm 2 0 mekg 18 Nm 1 8 mekg 2 Battery leads Side covers Fuel tank Air filter case assembly Carburetor assembly A I S system cover A I S system Muffler assembly Exhaust pipes 35 Disconnect NOTE First disconnect the negative lead then disconnect the positive lead Refer to SEAT SIDE COVERS AND FUEL TANK in Chapter 3 Refer to CARBURETOR in Chapter 5 For installation reverse the procedure removal CARBURETOR CARB e CARBURETION CARBURETOR 4 Nm 0 4 mekg Job name Part name Removing the carburetors Remove the parts in the order listed Seat Refer to SEAT SIDE COVERS AND Fuel tank FUEL TA
43. NK in Chapter 3 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 Disconnect Disconnect Disconnect Disconnect O OONO Om P INA NOTE After removing the carburetor assembly remove the starter cable and throttle cables D sch N sch sch HS NI sch oO For installation reverse the removal procedure 36 FRONT BRAKE CHAS CHASSIS FRONT BRAKE MASTER CYLINDER Job name Part name dy Removing the front brake master Remove the parts in the order listed cylinder Drain the brake fluid Brake lever Front brake switch lead Front brake switch Union bolt Copper washers brake hose Refer to REMOVING INSTALLING THE Master cylinder bracket FRONT BRAKE MASTER CYLINDER Master cylinder For installation reverse the removal procedure 37 FRONT BRAKE CHAS Job name Part name Remarks Disassembling the front brake Remove the parts in the order listed master cylinder Dust boot Circlip Master cylinder cup Spring For assembly reverse the disassembly procedure 38 FRONT BRAKE CHAS FRONT BRAKE CALIPERS Job name Part name Removing the front brake calipers Remove the parts in the order listed Drain the brake fluid Union bolt Copper washers Refer to REMOVING INSTALLING THE Brake hose FRONT BRAKE CALIPERS Brake caliper asse
44. Objects that may keep off radio 1 Keep clear of magnets between the key and waves exist around the keys and metals and other keys immobilizer unit antennas from the surroundings of 2 Immobilizer unit failure keys and antennas 3 Key failure 2 Replace the immobilizer unit 3 Replace the key IMMOBILIZER Codes do not match 1 Disturbed by other transponder 1 Place the immobilizer between the key and Failed to verify continually for ten unit away more than 50 immobilizer unit times mm from the transpon 2 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 tween the ignitor unit and lead cable and connector immobilizer unit 1 Obstruction due to radio wave 2 Replace the immobilizer noise unit 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 re UNIT tween ignitor unit and im lead cable registering key ID mobilizer unit 1 Obstruction due to radio wave 2 Replace the immobilizer noise unit 2 Immobilizer unit failure 3 Replace the ignitor unit 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
45. SPEC ve CHASSIS Steering system Steering bearing type Angular bearing Front suspension Front fork travel 130 mm Fork spring free length 364 8 mm Fitting length 339 8 mm Collar length 150 mm Spring rate 7 5 N mm 0 75 kg mm 12 N mm 1 2 kg mm Stroke 83 mm 47mm Optional spring No Oil capacity 0 537 L Oil level 117 mm Oil grade Fork oil 10W or equivalent Rear suspension Shock absorber travel 60 mm Spring free length 175 mm Fitting length 162 mm Spring rate K1 120 N mm 12 23 kg mm Stroke K1 0 60 mm Optional spring No Swingarm Free play limit Front wheel Rim size Cast wheel Dimensioni cerchio 17 K MT3 50 Rim material Aluminium Rim runout limit radial lateral Rear wheel Type Cast wheel Rim size 17 K MT5 50 Rim material Aluminium Rim runout limit radial lateral MAINTENANCE SPECIFICATIONS SPEC ve Front brake Type Dual disc Disc outside diameter x thickness 298 x 5 mm Disc deflection limit eec Pad thickness inner 4 5 mm outer 4 5 mm Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Rear brake Type Single disc Disc outside diameter x thickeness 267 x 5mm Disc deflection limit ecc Pad thickness inner 5 5 mm outer 5 5 mm Master cylinder inside diameter 13 mm Caliper cylinder inside dimeter 42 85 mm Brake fluid type DOT 4 Brake pedal position Clutch lever free play at lever end Throttle grip free play
46. WITCHES e Is the main switch OK I ves Replace the main switch EAS00787 Check the entire immobilizer system s wiring Refer to CIRCUIT DIAGRAM e ls the immobilizer system s wiring properly connected and without defects P ves Properly connect or Check the condition of each of the immo repair the immobilizer bilizer system s cir system s wiring cuits Refer to CHECKING THE 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 mi zi ZE Y BWsbw 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 NO Replace the multi function display 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 60 IMMOBILIZER SYSTEM ELEC e Set the main switch to ON e Measure the voltage 12 V between red green and black on the immobilizer unit e Are the voltage within specification The wiring circuit from the battery
47. YAMAHA 2005 B11100 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 to gether 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 motorcy cles 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 ap pear in future editions of this manual where applicable NOTE a ln Designs
48. ass switch OK Il YES The pass switch is faulty Replace the right handlebar switch unit EAS00787 8 Wiring Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM s the lighting system s wiring properly con nected and without defects 6 Dimmer switch relay Disconnect the dimmer switch relay from the coupler e Connect the pocket tester Q x 1 and bat J YES J NO tery 12V to the dimmer switch relay coupler Battery positive terminal gt White Black 1 Battery negative terminal Red Yellow 2 Tester positive probe gt Blue Black 3 Tester negative probe gt Red Yellow 4 Check the condition of Properly connect or each of the lighting repair the lighting sys system s circuits tem s wiring Refer to CHECKING THE LIGHTING SYS TEM EAS00788 CHECKING THE LIGHTING SYSTEM 1 The headlight and the high beam indicator light fail to came on 1 Headlight bulb and socket J YES J NO e the headlight bulb and socket for con inuity Replace the dimmer Refer to CHECKING THE BULBS AND BULB SOCKETS switch relay Are the headlight bulb and socket OK Replace the head light bulb socket or both 88 z LIGHTING SYSTEM ELEC EAS00789 2 Voltage 2 A meter light fails to come on Connect the pocket tester DC 20 V to the headlight and high beam indicator light co
49. bol o o indicates a continuity of elec tricity between switch terminals i e a closed cir cuit 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 PS 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 CHECKING THE SWITCHES ELEC P EAS00731 CHECKING THE SWITCHES zl E SE IE Ji h li Li S ECH and also for continuity between the termi leg Incorrect continuity reading Replace the switch Improperly connected gt Properly connect Check each switch for damage or wear proper connections Damage wear gt Repair or replace the switch nals Refer to CHECKING SWITCH CONTINUITY 90 D Clutch switch 2 Pass switch 3 Horn switch Dimmer switch 5 Turn switch 6 Main switch CO Front brake switch CHECKING THE SWITCHES ELEC Hazard switch 9 Engine stop switch Start switch D Fuses 2 Rear brake switch 3 Sidestand switch Neutral switch 52 n CHECKING THE BULBS AND BULB SOCKETS ELEC EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear proper connections and also for continuity between the terminals Damage wear gt Repair or replace the bulb bulb socket or both Improperly
50. e gt Orange gray lead D 66 SELF DIAGNOSIS DEVICE ELEC 4 Fuel cut solenoid EUR CIRCUIT DIAGRAM mm tg LR YB Y iw B w r wa d W8 Sb W DUR c a Igniter unit Fuel cut solenoid 1 Fuel cut solenoid 2 1 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM e Is the wire harness OK IM J NO Replace the fuel cut Repair or replace the solenoid 1 or 2 wire harness 67 jun O4JUOD Jezijiqouuuu 09 uondo wass wey yonms eJneN G peaj yoy ms jenen D T youms 1egejpueu 10 I e asnj uous G LLI pee l YOUMS pueisepis G joo uous QOO TT yun saub QD 7 nana E Ap yo 1no unoJro Bues 8 2 peej suu AM 9 gt AManeg KejeJ J9MEIS D YOUMS URN Z oo dnyoid D TA EA a oe mahi Tee Fe S RS m E fel BEN Gal T E 4 iF ELLE EET pmo EM PM D AEs He ATE
51. e 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 vehi cle 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 unit s code re registering key and main switch 56 IMMOBILIZER SYSTEM KEY CODES REGISTRATION METHOD 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 Ze Each standard key is registered during production therefore re registering at purchase is not neces sary
52. e harness side as shown YES Turn signal light Turn signal indicator light Replace the neutral indicator light bulb socket or both Left turn signal light Tester positive probe gt Chocolate 1 Tester negative probe gt Ground Right turn signal light Tester positive probe gt Dark green 2 Tester negative probe gt Ground B nd S 1 2 Neutral switch Al Check the neutral switch for continuity Refer to CHECKING THE SWITCHES e s the neutral switch OK RG Br B G Dg Ch GL YES NO DD Bois es Replace the neutral switch 97 SIGNALING SYSTEM ELEC 3 Voltage 2 Oil level switch e Connect the pocket tester DC 20 V to the e Drain the engine oil and remove the oil level meter assembly coupler wire harness side switch from the oil pan as shown e Check the oil level switch for continuity Refer Tester positive probe gt Brown 1 to CHECKING THE SWITCHES Tester negative probe gt Sky Blue White e Is the oil level switch OK IM J NO Replace the oil level switch 3 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler wire harness side as shown Set the main switch to ON e Measure the voltage 12 V of Brown and Sky blue White 2 at the meter assembly coupler Tester positive probe Red White 1 e Is the voltage within specification Tester negative probe gt Black White 2 Il YES This ci
53. e pocket tester DC 20 V to the tail brake light coupler wire harness side as shown Tester positive probe gt Green Yellow 1 Tester negative probe gt Black e 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 e Is the voltage within specification Il YES This circuit is OK The wiring circuit from the main switch to the tail brake light coupler is faulty and must be repaired SIGNALING SYSTEM ELEC EAS00799 3 Aturn signal light turn signal indicator light or 3 Voltage both fail to blink Connect the pocket tester DC 20 V to the ire h 1 Turn signal light bulb and socket foley SI DEF EES 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 Tester positive probe gt Brown Green 1 Tester negative probe gt Ground Replace the turn sig nal light bulb socket or both e Set the main switch to ON Measure the voltage 12 V of Brown Green D at the flasher relay coupler wire harness side e Is the voltage within specification 2 Turn signal switch YES Check the turn signal for continuity The wiring circuit from the main switch to the flasher relay Refer to CHECKING THE SWITCHES s th
54. e turn signal switch OK YES NO coupler flasher relay side is faulty and Replace the left han must be repaired dlebar switch 4 Voltage Connect the pocket tester DC 20 V to the flasher relay coupler wire harness side as shown 96 z SIGNALING SYSTEM ELEC e Set the main switch to ON e Set the turn signal switch to a or gt Measure the voltage 12 V of Chocolate 1 Tester positive probe gt Brown White 1 Tester negative probe gt Ground or Dark green at the turn signal light con nector wire harness side s the voltage within specification YES NO This circuit is OK The wiring circuit from the turn signal switch to the turn signal light connector is faulty and must repaired e Set the main switch to ON e Set the turn signal switch to or gt Measure the voltage 12 V of Brown White at the flasher relay coupler wire harness side s the voltage within specification EAS00800 The flasher relay is 4 The neutral indicator light fails to come on faulty and must be 1 Neutral indicator light bulb and socket replaced 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 sock et OK 5 Voltage Connect the pocket tester DC 20 V to the turn signal light connectors or the meter assembly coupler wir
55. ear 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 Standard Dual disc brake Right hand operation Single disc brake Right foot operation Telescopic fork Swingarm link suspension Coil spring Oil damper Coil spring Gas oil damper Spring preload adjustable T C l digital A C magneto GT14B 4 12V 12Ah Quartz bulb halogen 12 V 60 W 55 W x 1 12V 5W x1 12V 5W 21W x1 12V 5Wx 1 12V 10W x2 12V 10W x2 LED x 12 LED x 1 LED x 1 LED x 1 LED x 1 LED x 1 LED x 1 MAINTENANCE SPECIFICATIONS SPEC ve MAINTENANCE SPECIFICATIONS ENGINE Cylinder head Volume Warp limit 3 57 0 58 4 cm Cylinder Bore size Measuring point Max out of round 95 00 95 01 mm 40 mm Camshaft Drive method Chain drive left amp right Cam cap inside diameter 25 000 25 021 mm Camshaft outside diameter 24 96 24 98 mm Shaft to cap clearance 0 020 0 061 mm Cam dimensions A B Intake A 39 112 39 212 mm 39 012 mm B 1 32 093 32 193 mm 1 31 993 mm 2 32 127 32 227 mm 2 32 027 mm O 7 162 mm 7 012 mm Exhaust A 39 145 39 245 mm 39 045 mm B 32 200 32 300 mm 32 100 mm ges 7 195 mm 7 045 mm Camshaft runout limit eec 0 03 mm MAINTENANCE SPECIFICATIONS SPEC ve Timing chain Timing chain type No o
56. ensor speed sensor error code einen Check YES NO 1 Throttle position sensor 2 Speed sensor Repair or replace the 3 Ignition coil N 1 and 2 wire harness 4 Fuel cut solenoid N 1 and 2 NOTE EB812401 2 Throttle position sensor Before troubleshooting remove the following part s 1 Seat e Check the throttle position sensor for conti 2 Side cover left nuity 3 Fuel tank lift Refer to CHECKING AND ADJUSTING THE 4 Air filter case THROTTLE POSITION SENSOR in e Troubleshoot with the following special tool s Chapter 5 Is the throttle position sensor OK pe Replace the ignitor Replace the throttle unit position sensor YES Pocket tester 90890 03112 EAS00836 1 Throttle position sensor CIRCUIT DIAGRAM LR YB ByllYRBRW B Brlor 2 gt WB sb W RL BL G 6y2 KS Y IMB 3E BLACK VCC TPS NS S GND SL1 SP_RPM GND lia cene mim Ignitor unit 3 Throttle position sensor 64 SELF DIAGNOSIS DEVICE ELEC F7 1 Speed sensor CIRCUIT DIAGRAM Set the main switch to ON Turn the rear wheel slowly e Check the tester voltage 0 V 5 V 0 V e Is the speed sensor OK ves J NO Replace the ignitor Replace the speed unit sensor Ignitor unit Speed sensor 1 Wire harness
57. er tank cap fuel drain pipe Fuel hose carburetor 3 way Handlebar switch leads left Rectifier regulator Spark plug cap front cilinder Throttle cables Wireharness 26 SPEC 7 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 CABLE ROUTING SPEC Rubber cap for front wiring Ignition coil rear cylinder Throttle cables connections Starter relay assy Brake cable 33 Front brake hose right A I S pipe to the front cylinder 5 Starter motor Spark plug cap rear cylinder Thermo swicth Pos Dpto Mie THp nn Check that the wires of the igni 0090000066 A I S system tion coil do not remain tensioned tater Moorea Throttle position sensor TPS 5 Fix the wires of the right switch Oil level gauge Ignition coil front cylinder assy to the handlebar by means of Brake fluid reservoir hose Q9 N N x N N NS ped aL ni N Lr x 21 Carburetor pipe vent Depression fuel cock Battery Fuel hose Spark plug lead rear Battery positive terminal Fuse box CABLE ROUTING Battery negative terminal Igniter unit 5 Fuel filter 52 Fuel pump 63 Fuel sender Air intake pipe A I S system 65 Anti theft alarm connectors
58. f links Timing chain adjustment method SILENT 98L Automatic Rocker arm rocker arm shaft Bearing inside diameter Shaft outside diameter Arm to shaft clearance 14 000 mm 14 018 mm 14 036 mm 13 985 mm 13 991 mm 13 95 mm 0 009 mm 0 033 mm 0 086 mm Valve valve seat valve guide Valve clearance cold IN 0 07 0 12 mm ecc Valve dimensions Np SCH Bey AU X i Head Diameter Face Width Seat Width Margin Thickness A head diameter IN 47 0 47 2 mm ecc EX 39 0 39 2 mm eec B face width IN 2 1 mm ecc EX 2 1mm 000 C seat width IN 1 2 1 4 mm 1 8 mm EX 1 2 1 4 mm 1 8 mm D margin thickness IN 1 1 1 5 mm 0 8 mm EX 1 1 1 5 mm 0 8 mm Stem outside diameter IN 7 975 7 990 mm 7 955 mm EX 7 960 7 975 mm 7 935 mm Guide inside diameter IN 8 000 8 012 mm 8 042 mm EX 8 000 8 012 mm 8 042 mm Stem to guide clearance IN 0 010 0 037 mm 0 08 mm EX 0 025 0 052 mm 0 10 mm MAINTENANCE SPECIFICATIONS SPEC ve Stem runout limit Valve seat width Valve spring Free length 44 6 mm 44 6 mm Set length valve closed 40 mm 40 mm Compressed pressure installed 160 7 N 16 4 kg 160 7 N 16 4 kg opring rate K1 35 28 N mm 3 6 kgf mm 35 28 N mm 3 6 kgf mm Spring rate K2 45 37 N mm 4 63 kgf mm 45 37 N mm 4 63 kgf mm Tilt limit a 2 59 1 9 mm 2 51 9 mm Direction of winding top view Clockwise Clockwise Piston Piston to cylinder clearance 0 025 0
59. ght 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 amp amp 2 amp G 2 6 6 amp amp 6 G O S 6 60 O9 o G OG OO 9 C 6G 6 O0 90
60. lasher relay Type Full transistor Model manufacturer FE218BH DENSO Self cancelling device No Hazard flasher device Yes Flasher frequency 75 95 cycle min Wattage 10W kX 2 3 4W Oil level gauge Model manufacturer 5JN DENSO Starting circuit cut off relay Model manufacturer G8R 30Y U0 OMRON Coil resistance 162 198 Q at 20 C Throttle position sensor Hesistance 4 0 6 0 kQ at 20 C Blue Black Fuel pump relay Model manufacturer G8R 30Y U0 OMRON Coil resistance 162 198 Q at 20 C Thermostat switch Model manufacturer 5FU NIPPON THERMOSTAT 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 GENERAL TORQUE SPECIFICATIONS GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard S O pitch threads Torque specifi cations 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 tempera ture A Distance between flats B Outside thread diameter General torque specifications
61. m QD ee O CC gt ui TT ma ER a oe ep oar tra ee a a alta EF En as sein Es e ES ES km Mi m E cmn dug D t5 e sa Mo A 4 id gt Lm H 9 anna bone omn ug N aa y d Le 5 OO zZ EE EO V oll a o Lj Ze De Qe D lt dp O CC j O LLI LU CIRCUIT DIAGRAM Cie E CO E EE EC 73 ELECTRIC STARTING SYSTEM ELEC 14 EB803010 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 con ditions have been met In this instance the start ing 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 press ing the starter switch WHEN THE TRANSMISSION IS IN NEUTRAL xx WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED IN D Battery 2 Main fuse
62. m code lost one ON Registration mode voiding methed LED OFF E M Blinking ends when it elapses 5 seconds elpses and the 0 5s 0 5 S registration for the second standard key is impossible 58 EAS00781 TROUBLESHOOTING The immobilizer system fail to operate The immobilizer system indicator light starts to blinking the self diagnosis code se quence 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 e Troubleshoot with the following special tool s 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 chap ter 3 Are the main ignition and backup fuses OK YES J NO Replace the fuse s z IMMOBILIZER SYSTEM ELEC ulli EAS00739 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BAT TERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C s the battery OK YES J NO e Clean the battery terminals Recharge or replace the battery EAS00749 3 Main switch Check the main switch for continuity Refer to CHECKING THE S
63. mbly For installation reverse the removal procedure 39 FRONT BRAKE CHAS Job name Part name OVYOOSWVO Disassembling the front brake calipers Pad pin clips Pad pin Pad spring Brake pads Bleed screw Brake caliper pistons Dust seals Caliper piston seals P EP Ah A Ah 40 Remove the parts in the order listed Refer to REPLACING THE FRONT BRAKE PADS Refer to DISASSEMBLING THE FRONT BRAKE CALIPER For assembly reverse the disassembly procedure HANDLEBAR 23 Nm 2 3 mekg wj 10 Nm 1 0 mekg Job name Part name Removing the handlebar 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 HANDLEBAR CHAS Hemarks 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 Refer to INSTALLING THE HANDLEBAR Refer to REMOVING THE HANDLEBAR Refer to INSTALLING THE HANDLEBAR HANDLEBAR CHAS 23 Nm 2 3 mekg xj 10 Nm 1 0 mekg Job name Part name Hemarks Throttle grip assembly Handlebar holders upper Refer to INSTALLING THE HANDLEBAR Handlebar Handlebar holders lower For installation reverse the removal procedure 42 HANDLE
64. nut Bolt BE mka om omm e os KENE MIE MN M CONVERSION TABLE SPEC ve 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 MULTIPLIER IMP mm X 0 03937 In 2 mm x 0 03937 0 08 in CONVERSION TABLE METRIC TO IMP cc cm cc cm It liter It liter 0 03527 oz IMP liq 0 06102 cuin 0 8799 qt IMP liq 0 2199 gal IMP liq 55 997 Ib in 14 2234 psi Ib in Centigrade 9 5 C 32 Fahrenheit F Volume Capacity Miscel laneous LUBRICATION POINTS AND LUBRICANT TYPES SPEC 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 21 Symbol i i Ld Qaa l 2 l SEIE 0AA LUBRICATION POINTS AND LUBRICANT TYPES SPE
65. o Chassis Frame type Caster angle Trail Tire Type Size Manufacturer Type Tire pressure cold tire 0 90 kg load front rear 90 kg 198 Ib Maximum load front rear Maximum load Regular unleaded gasoline 20L 5 8 L BSR37 2 MIKUNI BPR7ES W22EPR U NGK DENSO 0 0 8 mm Spur gear 78 47 1 660 Shaft drive 44 47 x 19 18 x 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 cm 2 30 bar 250 kPa 2 50 kg cm 2 50 bar 250 kPa 2 50 kg cm 2 50 bar 270 kPa 2 70 kg cm 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 GENERAL SPECIFICATIONS SPEC ve Brake Front brake type operation type operation Hear brake Suspension Front suspension Rear suspension Shock absorber Front shock absorber Hear shock absorber Wheel travel Front wheel travel Hear 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 R
66. o ADJUSTING THE FRONT BRAKE ADJ 31 EB304001 CHASSIS ADJUSTING THE FRONT BRAKE 1 Adjust brake lever position distance a between the brake lever and the handlebar grip VVVVVVVVVVVVVVVVVVVVVVVVVVVVYV a Turn the adjusting dial D while holding the lever pushed away from the handlebar grip NOTE SS Align the setting on the adjusting dial with the arrow mark 2 Position n 1 Maximum a distance Position n 5 Minimum a distance WARNING After adjusting the brake lever position make sure the pin on the brake lever holder is firm ly inserted in the hole in the adjusting dial A A A A A A A A A A A A A A A A A A A A A A A A A A A A A WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the brake sys tem Before the vehicle is operated the air must be removed by bleeding the brake sys tem 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 370 003 INSP OC CHECKING THE FUSES ADJ 32 EAS00181 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
67. or heater earth ER Carburetor heater 1 Carburetor heater 2 Carburetor heater 3 4 amp amp 6 amp amp amp 6 9 Ne m T AER gt gt a oo e Un eu B RW B Br Or Lg LR YB Y L LY R YLI WB WIR zeg BLUE Ars Tle Tele BLUE ug u9 O a 8 p E im n ci da EE Tal a E 4 m OW WI Re DE a jal EM m B Ta i gl are 4 dl CH 3b ei ME ojs z ma u S BE i EM e To 152 EE 3 Tan deli OM i d el De 15A CONSO e Beer T ELS EDU Aa Loo AI B4 T I ol V Ba i nd l I I Ll tf L 10A TING SIT E Si OOO iE lo O BrL H R Brl B R R L e B2 B1 4 BB3 104 z CARBURETOR HEATER SYSTEM ELEC ulli EASB0039 TROUBLESHOOTING The carburetor heater fails to operate Check 1 Main and carburetor heater fuses 2
68. oting remove the following part S 1 Seat 2 Side covers 3 Storage compartment battery cover e Troubleshoot with the following special tool s Engine tachometer 90890 03113 Pocket tester 90890 031 12 EAS00738 1 Main fuse Check the main fuse for continuity Refer to CHECKING THE FUSES in Chapter 3 e ls the main fuse OK Il YES J NO Replace the fuse EAS00739 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in Chapter 3 Min open circuit voltage mi 12 8 V or more at 20 C 68 F e Is the battery OK Il YES J NO Clean the battery ter minals Recharge or replace the battery 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 gt battery positive terminal Tester negative probe gt battery negative terminal e Start the engine and let it run at approxi mately 5 000 r min Measure the charging voltage Charging voltage 14 V at 5 000 r min z CHARGING SYSTEM ELEC F7 EAS00779 5 Wiring Check the wiring connections of the entire charging system NOTE 1 1 ______ Make sure that the battery is fully charged e Is the charging voltage within specification Refer to CIRCUIT DIAGRAM NO Il YES els the charging system s
69. oval procedure Disassembling the starter motor Disassembly the pats in the order listed Circlip Starter motor drive gear otarter motor rear cover Refer to Assembling the starter motor Washer set Starter motor front cover Refer to Assembling the starter motor 78 ELECTRIC STARTING SYSTEM ELEC Job name Part name Remarks Washer set End bracket Refer to Assembling the starter motor Planetary gears Armature assembly Brush holder brush Starter motor yoke Cam QO Refer to Assembling the starter motor For assembly reverse the disassembly procedure 79 ELECTRIC STARTING SYSTEM ELEC D EAS00769 Checking the starter motor Check e commutator Dirt Clean with 600 grit sandpaper Measure e commutator diameter a Out of specification gt Replace the starter motor Min commutator diameter 27 mm 3 Measure e mica undercut a Out of specification gt 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 esch N DA 4 Measure e armature assembly resistances commuta tor and insulation Out of specification gt Replace the starter motor VVVVVVVVVVVVVVVVVVVVVVVVVVVVYV a Measure the armature assembly resistances with the pocket tester e 4 Pocket tester i 90890
70. park 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 e Is the spark plug in good condition is it of the correct type and its gap within specification Il VES J NO Re gap or replace the spark plug IGNITION SYSTEM ELEC C Spark plug cap resistance 10 KO at 20 C 68 F EAS00743 4 Ignition spark gap The following procedure applies to all of the spark plugs Disconnect the spark plug cap from the spark i YES J NO s the spark plug cap OK plug Connect the ignition checker 1 as shown e Spark plug cap Replace the spark Set the main switch to ON plug cap Measure the ignition spark gap a Crank the engine by pushing the start switch and gradually increase the spark gap until a misfire occurs 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 O x 1 to the igni tion coil as shwon Tester positive probe gt Red Black Tester negative probe gt Orange Gray Min ignition spark gap 6 mm s there a spark and is the spark gap within specification NO iji YES The ignition system is OK EAS00745 Measure the primary coil resistance 5 Spark plug cap re
71. r wire har ness side s the voltage within specification gs J NO This circuit is OK The wiring circuit from the main switch to the license plate light coupler is faulty and must be re paired sO a Ka o missi DS i FRI CRT ca Gl GA X 8 inj a po A SEN SCH S SC amp amp os 69 ees Jo e 03 1 908 1 O8 1 ER E ni TU TH La 5 gy 3 aip 3 i esa EM al LS 1 LL and L ale a ee t9 09 dun I be e E S PEF CD Tg lm pad guess e an ng a 9 ES uiu BER ER d Et EE K il oe N T mum Gab 109 gt Le Gia jae S pes CHES HL RO a s A SIGNALING SYSTEM ELEC D De UU I31V3H J SS3NHVH NIVIN AE an ama rm LE Hi inc Minnie 1911 awa SS D fel La Els ER Seana IG s oja a ab alaka wa majas a jen 41 91 fau Dil ai pem a 19 Le e B BB hal ea a J
72. rcuit is OK The wiring circuit from the main switch to the meter light bulb coupler is faulty and must be repaired EE e Set the main switch to ON 5 The oil level warning light fails to come on Measure the voltage 12 V of Brown D and Black White 2 at the meter assembly coupler 1 Oil level warning light bulb and socket s the voltage within specification Check the oil level warning light bulb and YES socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the oil level warning light bulb and sock et OK This circuit is OK The wiring circuit from the main switch to the meter assem bly coupler is faulty paired Replace the oil level warning light bulb socket or both 98 FUEL PUMP SYSTEM ELEC FUEL PUMP SYSTEM CIRCUIT DIAGRAM E uou s Jeqajpuey 1UDIY osnj uoniuf yun Jeu dund jang eja 4o 1N9 noo Bues pes SNUIW SIM A sneg Aejas Jouels YOUMS UIEIN of I 19 Is 0900000896 E e lt Ta an1a l ania TT FT Ge CS PU st el Ging Fel Fek j quvzvu m pa HE lie ag Ovi u 99 FUEL PUMP SYSTEM ELEC EB808010 FUEL PUMP CIRCUIT OPERATION The fuel pump circuit consists of the fuel pump re D Battery lay fuel pump engine stop switch and ignitor unit 2 Main fuse The ignitor unit includes the control unit for the fu Main switch
73. rns Black Br Brown RW B LW SEI SE AE SS Si poeta E G STOP OFF RUN JOYO Gy Br Dg o W Ch V Sb 9 0 0 lt 9 rai a Sa BLUE BLUE EA G B LR Y HEAD LIGHT Gar CHE ea CARB HEATER pera een i e me SS St ee en Sal B B er ce UU Ud OBrw Bri BLACK rutti L du DIMMER HORN HI LO d BY 7 BLACK 23 TURN OC
74. s while heating the water with the temperature gauge Test step Water temperature Good condition 3 enen o _ 2 More then 292 9 0 x 9 More them 224 C x a tess than 122476 0 _ Test 1 amp 2 Heat up test Test 3 amp 4 Cool down test O Continuity X No continuity Thermoswitch 2343 G e Is the thermo switch OK yes J NO Replace the thermo switch Thermoswitch 12 4 C EASBO0041 5 Carburetor heater e Remove the carburetor heater from the car buretor body Connect the pocket tester to the carburetor heater Tester lead gt Heater terminal 1 Tester lead gt Heater body D Carburetor heater resistance 12 V 30 W 6 10 at 20 C 68 F J NO Replace the carbure tor heater EASB0042 Check the entire carburetor heater system s wiring Refer to CIRCUIT DIAGRAM els the carburetor heater system s wiring properly connected and without defects NO YES Properly connect The carburetor heater or repair the carbure system circuit is OK tor heater system s wiring TREL 9 STARTING FAILURE HARD STARTING SHTG TROUBLESHOOTING NOTE ooo 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 inspec tion adjustment and replacement of parts STARTING FAILURE HARD STARTING
75. sassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number indicates a dis assembly step Symbols indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction chart accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc Jobs requiring more information such as special tools and technical data are described sequentially n gt in CLUTCH r V sem REMOVING THE CLUTCH 93 CLUTCH COVER POT o 1 Remove E rear balancer weight Refer to BALANCERS 2 Remove clutch cover 1 NOTE see Loosen each bolt 1 4 of a turn at a time in stages and in a crisscross pattern After all of the bolts are fully loosened remove them 3 Straighten the lock washer tab 4 Loosen clutch boss nut NOTE L ni While holding the clutch boss 2 with the uni versal clutch holder loosen the clutch boss nut Universal clutch holder 8 90890 04086 5 Remove clutch boss nut 1 lock washer 2 clutch boss assembly 3 NOTE There is a built in damper between the clutch boss and the clutch plate It is not necessary to remove the wire circlip 4 and disassemble the built in damper unless there is serious clutch chattering Job Part Remarks Removing the clutch cover Remove the parts in the order listed
76. sistance arr The following procedure applies to all of the al 3 57 4 83 at 20 C 68 F Spark plug caps Disconnect the spark plug cap from the spark Connect the pocket tester x 1k to the plug ignition coil as shown Connect the pocket tester O x 1k to the Measure the secondary coil resistance spark plug cap as shown Tester positive probe gt Measure the spark plug cap resistance spark plug lead 1 Tester negative probe gt Orange gray lead 2 70 z IGNITION SYSTEM ELEC a EAS00749 8 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES e s the main switch OK ves J NO Replace the main switch AN Secondary coil resistance 10 7 14 5 kO at 20 C 68 F s the ignition coil OK EAS00750 9 Engine stop switch MES J ER Check the engine stop switch for continuity Ren gan Refer to CHECKING THE SWITCHES s the engine stop switch OK il YES J NO Replace the right 7 Pickup coil resistance handlebar switch EAS00748 Disconnect the pickup coil coupler from the wire harness e Connect the pocket tester x 100 to the pickup coil terminal suli Tester positive probe gt Gray 1 We ACUTA SWA Tester negative probe gt Black e Check the neutral switch for continuity Refer to CHECKING THE SWITCHES e s the neutral switch OK YES NO Replace the neutral switch EAS007
77. ter 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 ES NS SWITCH S a Standby mode ia wre m mi ee 2 45 S ON STANDBY MODE OFF 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 mem ory 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
78. tor 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 oper ation 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 Faulty electrical T 4 Throttle position Disconnected Fixes the throttle sensor Short circuit position sensor to fully open Throttle position Locked Fixes the throttle sensor position sensor to fully open Fuel cut solenoid Disconnected carburetor No 1 Short circuit Fuel cut solenoid Disconnected carburetor No 2 Short circuit T Open circuit the Fuel is cut off only to the cylinder Ignition coil No 1 in which a malfunction is detected we i Open circuit the Fuel is cut off only to the cylinder Ignition coil No 2 in which a malfunction is detected Disconnected Short circuit Speed sensor 63 SELF DIAGNOSIS DEVICE ELEC ME TROUBLESHOOTING Check the wire harness for continuity The tachometer displays the throttle posi Refer to CIRCUIT DIAGRAM tion s
79. ty Refer to CHECKING THE SWITCHES e Is the engine stop switch OK Il YES E Replace the right han dlebar switch EB803023 5 Starting circuit cutoff relay fuel pump relay Remove the relay unit from the wire harness Connect the pocket tester x 1 and bat tery 12 V to the relay unit terminals Battery terminal gt Red Black terminal 1 Battery terminal gt Blue Red terminal 2 Tester lead Red Black terminal 1 Tester lead gt Blue Black terminal 3 L ow RB L LG lY Sb BY LW A S Does the fuel pump relay have continuity between Red Black and Blue Black ves J NO Replace the starting circuit cutoff relay n FUEL PUMP SYSTEM ELEC EB808021 6 Fuel pump resistance Disconnect the fuel pump coupler from the wire harness e Connect the pocket tester Q x 1 to the fuel pump coupler terminals Tester lead gt Blue Black terminal 1 Tester lead gt Black terminal 4 Measure the fuel pump resistance _ Fuel pump resistance 1 6 2 2 0 at 20 C 68 F Is the fuel pump OK YES NO Replace the fuel pump Check the entire fuel pump system s wiring Refer to CIRCUIT DIAGRAM e ls the fuel pump system s wiring properly connected and without defects YES Properly connect or Replace the ignitor repair the fuel pump unit system s wiring 103 FUEL PUMP SYSTEM ELEC EASB
80. u plers as shown Check the meter light bulb and socket for When the dimmer switch is set to ZO continuity When the dimmer switch is set to ZO Refer to CHECKING THE BULBS AND BULB SOCKETS Are the meter light bulb and socket OK 1 Meter light bulb and socket Headlight Tester positive probe gt Yellow 1 or Green Tester negative probe gt Black 3 High beam indicator light Tester positive probe gt Yellow 4 light bulb socket or Tester negative probe Black 5 both Replace the meter Headlight coupler wire harness side 2 Voltage Connect the pocket tester 20 V to the meter assembly coupler wire harness side as Tester positive probe gt Brown 1 Tester negative probe gt Black e Set the main switch to ON e Set the dimmer switch to O or D Set the main switch to ON Measure the voltage 12 V of Brown 1 on the meter assembly coupler wire harness side Measure the voltage 12 V of Yellow 1 or Is the voltage within specification Green 2 on the headlight coupler headlight side Il YES Measure the voltage 12V of Yellow 4 on the meter assembly coupler This circuit is OK The wiring circuit s the voltage within specification from the main switch to the meter assem YES J NO bly coupler is faulty and must be re This circuit is OK paired The wiring circuit from the main switch to the headlight cou
81. urators Adjust engine idling speed and synchronization Change e Check oil level and vehicle for oil leakage Engine oil filter element e Replace e Check oil level and vehicle for Final gear oil leakage Front and rear brake e Check operation switch Moving parts and e Lubricate cables Throttle grip e Check operation and free play housing e Adjust the throttle cable free play if necessary and cable e Lubricate the throttle grip housing and cable Air ind e Check the air cut valve reed valve and ir induction hose for damage system Replace the entire air induction system if necessary ki cui Check the screw clamp for looseness EAE Lights signals Check operation and switches Adjust headlight beam Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills NOTE e The annual checks must be performed every year except if a kilometer based maintenance is per formed instead e From 50 000 km repeat the maintenance intervals starting from 10 000 km he 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 INSP d
82. ust pipe exhaust pipe guard fastener rear Screw Exhaust pipe strap Screw Silencer fastener to passenger board support Screw Exhaust pipe guard fastener Screw 2 2 6 8 4 4 4 2 4 2 4 3 3 5 1 1 2 N e a a a aaO OONOOO O 0 N O gt Co MAINTENANCE SPECIFICATIONS SPEC ad 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 Guide bar stopper Shift dram segment Shift arm Shift pedal adjuster 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 Part name Stud bolt Stud bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Nut Bolt Nut Nut Screw Nut Nut Nut Bolt Bolt Screw Screw Bolt Screw Bolt Screw Screw Special screw Nut Tightening Thread Q ty Remarks size D Use lock washer Use lock washer Stake Stake Stake Use lock washer el 1 of 2 has LH thread O A MAINTENANCE SPECIFICATIONS
83. wiring properly conected and without defects The charging circuit J NO YES Properly connect or Replace the rectifier repair the charging regulator 4 Stator coil assembly resistances Remove the left side cover e Connect the pocket tester Q x 1 to the sta tor coil assembly coupler as shown Tester positive probe gt White 1 Tester negative probe gt White Tester positive probe gt White 1 system s wiring Tester negative probe gt White 3 Measure the stator coil assembly resistanc es Stator coil resistance al 0 36 0 44 at 20 C 68 F s the stator coil assembly OK ves J NO Replace the stator coil assembly 85 e 84 UOUMS JOWWIG Du ayejd esusorq UBI eyeugy iel YBijpeaH Jojeujopeedg YOUMS JEQ9S DUEU 4977 esn 1uDiipeeH uos reqe pueu WD yun Jejub pes SNUIW SUM A oyeg Aejas 14011e1S YOUMS UIEN LIGHTING SYSTEM ELEC LIGHTING SYSTEM CIRCUIT DIAGRAM Cie 9 O9 GE E GC e 86 z LIGHTING SYSTEM ELEC EASB0033 EAS00739 TROUBLESHOOTING 2 Battery Any of the following fail to light headlight e Check the condition of the battery high beam indicator light license plate light Refer to CHECKING AND CHARGING THE or meter light BATTERY in Chapter 3 Min open circuit voltage 12 8 V or more at 20 C 68 F Check Main and headlight fuses Battery Main switch Dimmer switch Pass switch
84. y affect ed If the headlight bulb gets soiled thor oughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bult for continuity with the pocket tester No continuity gt Replace Pocket tester 90890 03112 NOTE oo Before checking for continuity set the pocket tester to 0 and to the Q x 1 range vVVVVVVVVVVVVVVVVVVVVVVVVVVVV a Connect the tester positive probe to terminal D and the tester negative probe to terminal 2 and check the continuity b Connect the tester positive probe to terminal D and the tester negative probe to terminal 3 and check the continuity c If either of the readings indicate no continuity replace the bulb A A A A A A A A A A A A A A A A A A A A A A A A A A A A A 54 CHECKING THE BULBS AND BULB SOCKETS ELEC CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets 1 Check e bulb socket for continuity with the pocket tester No continuity gt Replace Pocket tester 90890 03112 NOTE O Check each bulb socket for continuity in the same manner as described in the bulb section howev er note the following VVVVVVVVVVVVVVVVVVVVVVVVVVVVYV 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

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