Yamaha MT-01 T 2005 Service Manual

2005SERVICE MANUALMT-01(T)5YU1-AE1

IDENTIFICATION1-1EAS20130IDENTIFICATIONEAS20140VEHICLE IDENTIFICATION NUMBERThe vehicle identification number “1” is stamped on the right side of the

ENGINE3-15d. Place the other end of the hose into a con-tainer.e. Slowly squeeze the clutch lever several times.f. Fully squeeze the clutch lever with

ENGINE3-16EAS21010CHECKING THE THROTTLE BODY JOINTS1. Remove:• SeatRefer to “GENERAL CHASSIS” on page 4-1.• Fuel tankRefer to “FUEL TANK” on page 6-1.

ENGINE3-17• Fuel tankRefer to “FUEL TANK” on page 6-1.• SeatRefer to “GENERAL CHASSIS” on page 4-1.EAS21060CHECKING THE OIL TANK BREATHER HOSE1. Check

ENGINE3-184. Install:• SeatRefer to “GENERAL CHASSIS” on page 4-1.EAS21100ADJUSTING THE EXUP CABLES1. Remove:• EXUP valve pulley cover “1”2. Check:• E

ENGINE3-19e. Tighten both locknuts and then slide the rub-ber cover to its original position.f. Remove the pin.g. Turn the main switch to “ON”, check

CHASSIS3-20EAS21140CHASSISEAS21160ADJUSTING THE FRONT DISC BRAKE1. Adjust:• Brake lever position(distance “a” from the throttle grip to the brake leve

CHASSIS3-21WARNINGEW5YU1001A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. Before the vehicle is ope

CHASSIS3-22EAS21260CHECKING THE REAR BRAKE PADSThe following procedure applies to all of the brake pads.1. Operate the brake.2. Check:• Rear brake pad

CHASSIS3-23▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Hold the main body “1” of the rear brake light switch so that it does not rotate and turn the adj

CHASSIS3-24NOTE:Loosening the bleed screw will release the pres-sure and cause the brake lever to contact the throttle grip or the brake pedal to full

FEATURES1-2EAS20170FEATURESET5YU1009OUTLINE OF THE FI SYSTEMThe main function of a fuel supply system is to provide fuel to the combustion chamber at

CHASSIS3-25NOTE:Measure the drive chain slack 85 mm (3.35 in) “b” from the end of the drive chain guide.3. Adjust:• Drive chain slack▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼▼

CHASSIS3-26▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Remove the lock washer “1”, the upper ring nut “2”, and the rubber washer “3”.b. Loosen the lower

CHASSIS3-273. Hold the vehicle upright and apply the front brake.4. Check:• Front fork operationPush down hard on the handlebar several times and chec

CHASSIS3-28▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Turn the adjusting screw “1” in direction “a” or “b”.▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲Compr

CHASSIS3-29c. Tighten the locknut to specification.CAUTION:ECA13600Always tighten the locknut against the ad-justing nut and torque it to specificatio

CHASSIS3-30▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲EAS21650CHECKING THE TIRESThe following procedure applies to both of the tires.1. Check:• Tire press

CHASSIS3-31WARNINGEWA14080• Do not use a tubeless tire on a wheel de-signed only for tube tires to avoid tire fail-ure and personal injury from sudden

CHASSIS3-32NOTE:After a tire or wheel has been changed or re-placed, always balance the wheel.EAS21690CHECKING AND LUBRICATING THE CABLESThe following

ELECTRICAL SYSTEM3-33EAS21750ELECTRICAL SYSTEMEAS21760CHECKING AND CHARGING THE BATTERYRefer to “ELECTRICAL COMPONENTS” on page 7-85.EAS21770CHECKING

ELECTRICAL SYSTEM3-34CAUTION:ECA13690Avoid touching the glass part of the head-light bulb to keep it free from oil, otherwise the transparency of the

FEATURES1-3ET5YU1010FI SYSTEMThe fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure

CHAS4

4CHASSISGENERAL CHASSIS... 4-1CHECKING THE AIR FILTER CASE VALVE..

HANDLEBAR ...4-42REMOVING THE HANDLEBAR...

GENERAL CHASSIS4-1EAS21830GENERAL CHASSISRemoving the seat and batteryOrder Job/Parts to remove Q’ty Remarks1 Seat 12 Lead holder 13 Negative battery

GENERAL CHASSIS4-2Removing the side covers and headlight assemblyOrder Job/Parts to remove Q’ty Remarks1 Left side cover 12 Right side cover 13 Left s

GENERAL CHASSIS4-3Removing the tail/brake light assemblyOrder Job/Parts to remove Q’ty RemarksSeatRefer to “GENERAL CHASSIS” on page 4-1.1 Muffler coo

GENERAL CHASSIS4-4Removing the air filter case and oil catch tankOrder Job/Parts to remove Q’ty RemarksFuel tank Refer to “FUEL TANK” on page 6-1.1 Ai

GENERAL CHASSIS4-5ET5YU1013CHECKING THE AIR FILTER CASE VALVE1. Check:• Air filter case valve operation▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Remov

FRONT WHEEL4-6EAS21870FRONT WHEELRemoving the front wheel and brake discsOrder Job/Parts to remove Q’ty RemarksNOTE:Place the vehicle on a suitable st

FRONT WHEEL4-7Disassembling the front wheelOrder Job/Parts to remove Q’ty Remarks1 Oil seal 22 Wheel bearing 23 Spacer 1For assembly, reverse the disa

FEATURES1-4ET5YU1011INSTRUMENT FUNCTIONSMultifunction displayWARNINGEW5YU1005Be sure to stop the vehicle before making any setting changes to the mult

FRONT WHEEL4-8EAS21900REMOVING THE FRONT WHEEL1. Stand the vehicle on a level surface.WARNINGEWA13120Securely support the vehicle so that there is no

FRONT WHEEL4-9• Oil sealsDamage/wear → Replace.EAS21960ASSEMBLING THE FRONT WHEEL1. Install:• Wheel bearings • Oil seals ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼

FRONT WHEEL4-10b. Turn the front wheel 90° so that the heavy spot is positioned as shown.c. If the heavy spot does not stay in that posi-tion, install

FRONT WHEEL4-11• Front wheel axle pinch boltCAUTION:EC5YU1002Before tightening the wheel axle, push down hard on the handlebar several times and check

REAR WHEEL4-12EAS22020REAR WHEELRemoving the rear wheelOrder Job/Parts to remove Q’ty RemarksNOTE:Place the vehicle on a suitable stand so that the re

REAR WHEEL4-13Removing the rear brake disc and rear wheel sprocketOrder Job/Parts to remove Q’ty Remarks1 Rear brake disc 12 Rear wheel sprocket 13 Co

REAR WHEEL4-14Disassembling the rear wheelOrder Job/Parts to remove Q’ty Remarks1Collar 12 Bearing 13 Spacer 14 Oil seal 15 Circlip 16 Bearing 1For as

REAR WHEEL4-15EAS22040REMOVING THE REAR WHEEL1. Stand the vehicle on a level surface.WARNINGEWA13120Securely support the vehicle so that there is no d

REAR WHEEL4-162. Replace:• Rear wheel sprocket▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Remove the self-locking nuts and the rear wheel sprocket.b. Cl

REAR WHEEL4-17• Collar (brake disc side) “2”NOTE:The collar (brake disc side) has marks “a” to dis-tinguish it from the collar (wheel sprocket side).5

FEATURES1-5To set the clock:1. Push the “SELECT” button and “RESET” but-ton together for at least two seconds.2. When the hour digits start flashing,

FRONT BRAKE4-18EAS22210FRONT BRAKERemoving the front brake padsOrder Job/Parts to remove Q’ty RemarksThe following procedure applies to both of the fr

FRONT BRAKE4-19Removing the front brake master cylinderOrder Job/Parts to remove Q’ty RemarksBrake fluidDrain.Refer to “BLEEDING THE HYDRAULIC BRAKE S

FRONT BRAKE4-20*Apply silicon grease16 Front brake master cylinder 1For installation, reverse the removal procedure.Removing the front brake master cy

FRONT BRAKE4-21Disassembling the front brake master cylinderOrder Job/Parts to remove Q’ty Remarks1 Brake master cylinder kit 12 Bleed screw 13 Brake

FRONT BRAKE4-22Removing the front brake calipersOrder Job/Parts to remove Q’ty RemarksThe following procedure applies to both of the front brake calip

FRONT BRAKE4-23Disassembling the front brake calipersOrder Job/Parts to remove Q’ty RemarksThe following procedure applies to both of the front brake

FRONT BRAKE4-24EAS22220INTRODUCTIONWARNINGEWA14100Disc brake components rarely require disas-sembly. Therefore, always follow these pre-ventive measur

FRONT BRAKE4-25d. Measure the brake disc deflection.e. If out of specification, repeat the adjustment steps until the brake disc deflection is within

FRONT BRAKE4-26▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲3. Install:• Brake pad pin• Brake pad clips• Front brake caliper4. Check:• Brake fluid levelBelo

FRONT BRAKE4-27b. Remove the brake caliper piston seals.▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲EAS22390CHECKING THE FRONT BRAKE CALIPERS1. Check:• Bra

FEATURES1-6The brightness can be adjusted for the following:• the tachometer panel (item number “1”)• the LCD (item number “2”)• the tachometer needle

FRONT BRAKE4-283. Install:• Front brake pads• Brake pad spring• Brake pad pin• Brake pad clips• Front brake caliperRefer to “REPLACING THE FRONT BRAKE

FRONT BRAKE4-292. Check:• Brake master cylinder kitDamage/scratches/wear → Replace.3. Check:• Brake fluid reservoirCracks/damage → Replace.• Brake flu

FRONT BRAKE4-30CAUTION:ECA13540Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately

REAR BRAKE4-31EAS22550REAR BRAKERemoving the rear brake padsOrder Job/Parts to remove Q’ty Remarks1 Screw plug 12 Brake pad pin 13 Rear brake caliper

REAR BRAKE4-32Removing the rear brake master cylinderOrder Job/Parts to remove Q’ty RemarksBrake fluidDrain.Refer to “BLEEDING THE HYDRAULIC BRAKE SYS

REAR BRAKE4-33Disassembling the rear brake master cylinderOrder Job/Parts to remove Q’ty Remarks1 Brake master cylinder kit 12 Brake hose joint 13Bush

REAR BRAKE4-34Removing the rear brake caliperOrder Job/Parts to remove Q’ty RemarksBrake fluidDrain.Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on

REAR BRAKE4-35Disassembling the rear brake caliperOrder Job/Parts to remove Q’ty Remarks1 Screw plug 12 Brake pad pin 13 Brake pad shim 24 Brake pad i

REAR BRAKE4-36EAS22560INTRODUCTIONWARNINGEWA14100Disc brake components rarely require disas-sembly. Therefore, always follow these pre-ventive measure

REAR BRAKE4-37NOTE:Always install new brake pads, brake pad shims, and a brake pad spring as a set.▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Connect a

IMPORTANT INFORMATION1-7EAS20180IMPORTANT INFORMATIONEAS20190PREPARATION FOR REMOVAL AND DISASSEMBLY1. Before removal and disassembly, remove all dirt

REAR BRAKE4-38▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Blow compressed air into the brake hose joint opening “a” to force out the pistons from the br

REAR BRAKE4-39EAS22670INSTALLING THE REAR BRAKE CALIPER1. Install:• Rear brake caliper “1”(temporarily)• Copper washers • Rear brake hose “2”• Rear br

REAR BRAKE4-40EAS22700REMOVING THE REAR BRAKE MASTER CYLINDERNOTE:Before removing the rear brake master cylinder, drain the brake fluid from the entir

REAR BRAKE4-41WARNINGEWA13090• Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and

HANDLEBAR4-42EAS22840HANDLEBARRemoving the handlebarOrder Job/Parts to remove Q’ty Remarks1 Rearview mirror 22 Front brake light switch connector 2 Di

HANDLEBAR4-4316 Lower handlebar holder 2For installation, reverse the removal procedure.Removing the handlebarOrder Job/Parts to remove Q’ty Remarks12

HANDLEBAR4-44EAS22860REMOVING THE HANDLEBAR1. Stand the vehicle on a level surface.WARNINGEWA13120Securely support the vehicle so that there is no dan

HANDLEBAR4-45▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Apply a thin coat of rubber adhesive onto the left end of the handlebar.b. Slide the handlebar

HANDLEBAR4-469. Install:• Front brake master cylinder assembly• Front brake master cylinder holder “1”NOTE:• Align the end of the brake master cylinde

FRONT FORK4-47EAS22950FRONT FORKRemoving the front fork legsOrder Job/Parts to remove Q’ty RemarksThe following procedure applies to both of the front

IMPORTANT INFORMATION1-8EAS20230BEARINGS AND OIL SEALSInstall bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible.

FRONT FORK4-48Disassembling the front fork legsOrder Job/Parts to remove Q’ty RemarksThe following procedure applies to both of the front fork legs.1

FRONT FORK4-4916 Inner tube 1For assembly, reverse the disassembly procedure.Disassembling the front fork legsOrder Job/Parts to remove Q’ty RemarksT

FRONT FORK4-50EAS22960REMOVING THE FRONT FORK LEGSThe following procedure applies to both of the front fork legs.1. Stand the vehicle on a level surfa

FRONT FORK4-51d. Remove the cap bolt.e. Remove the rod holder and fork spring com-pressor.f. Remove the spacer and nut.▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲

FRONT FORK4-52CAUTION:ECA14200• The front fork leg has a built-in damper ad-justing rod and a very sophisticated inter-nal construction, which are par

FRONT FORK4-53• Lubricate the outer surface of the inner tube with fork oil.• Before installing the oil seal, cover the top of the front fork leg with

FRONT FORK4-5410.Fully compress the front fork leg.11.Fill:• Front fork leg(with the specified amount of the recom-mended fork oil)CAUTION:ECA14230• B

FRONT FORK4-55d. Install the upper spring seat and nut.e. Reinstall the rod puller attachment.f. Install the spacer.g. Press down on the spacer with t

FRONT FORK4-56EAS23050INSTALLING THE FRONT FORK LEGSThe following procedure applies to both of the front fork legs.1. Install:• Front fork legTemporar

STEERING HEAD4-57EAS23090STEERING HEADRemoving the lower bracketOrder Job/Parts to remove Q’ty RemarksAir filter case/Headlight assemblyRefer to “GENE

CHECKING THE CONNECTIONS1-9EAS20250CHECKING THE CONNECTIONSCheck the leads, couplers, and connectors for stains, rust, moisture, etc.1. Disconnect:• L

STEERING HEAD4-5813 Lower bracket 114 Washer 115 Lower bearing 116 Lower bearing dust seal 117 Lower bearing inner race 118 Upper bearing cover 119 Up

STEERING HEAD4-59EAS23110REMOVING THE LOWER BRACKET1. Stand the vehicle on a level surface.WARNINGEWA13120Securely support the vehicle so that there i

STEERING HEAD4-602. Install:• Lower ring nut “1”• Rubber washer “2”• Upper ring nut “3”• Lock washer “4”Refer to “CHECKING AND ADJUSTING THE STEERING

REAR SHOCK ABSORBER ASSEMBLY4-61EAS23160REAR SHOCK ABSORBER ASSEMBLYRemoving the rear shock absorber assemblyOrder Job/Parts to remove Q’ty Remarks1 S

REAR SHOCK ABSORBER ASSEMBLY4-62EAS23180HANDLING THE REAR SHOCK ABSORBERWARNINGEWA13740This rear shock absorber contains highly compressed nitrogen ga

REAR SHOCK ABSORBER ASSEMBLY4-63• Oil sealsDamage/pitting → Replace.3. Check:• Collars• SpacersDamage/scratches → Replace.EAS23270INSTALLING THE CONNE

REAR SHOCK ABSORBER ASSEMBLY4-64EAS23310INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY1. Lubricate:• Spacers• Bearings2. Install:• Relay arm(to the swing

SWINGARM4-65EAS23330SWINGARMRemoving the swingarmOrder Job/Parts to remove Q’ty RemarksRear wheelRefer to “GENERAL CHASSIS” on page 4-1.Rear shock abs

SWINGARM4-6613 Rear fender 114 Drive chain guide 115 Swingarm 116 Spacer 117 Oil seal 118 Oil seal 119 Oil seal 220 Circlip 121 Bearing 122 Bearing 12

SWINGARM4-67EAS23350REMOVING THE SWINGARM1. Stand the vehicle on a level surface.WARNINGEWA13120Securely support the vehicle so that there is no dange

SPECIAL TOOLS1-10EAS20260SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropria

SWINGARM4-68• Bearing “3”• Oil seal “4”3. Adjust:• Drive chain slackRefer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-24. Installed depth of bearin

CHAIN DRIVE4-69EAS23400CHAIN DRIVERemoving the drive sprocket and drive chainOrder Job/Parts to remove Q’ty RemarksClutch fluidDrain.Refer to “BLEEDIN

CHAIN DRIVE4-70EAS23410REMOVING THE DRIVE CHAIN1. Stand the vehicle on a level surface.WARNINGEWA13120Securely support the vehicle so that there is no

CHAIN DRIVE4-71▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲4. Check:• O-rings “1”Damage → Replace the drive chain.• Drive chain rollers “2”Damage/wear → Re

CHAIN DRIVE4-723. Install:• Clutch release cylinderRefer to “INSTALLING THE CLUTCH RE-LEASE CYLINDER” on page 5-62.a123Newb

ENG5

5ENGINEENGINE REMOVAL ...5-1CHECKING THE OIL PIPES ...

CLUTCH ...5-46REMOVING THE CLUTCH ...

OIL PUMP...5-81CHECKING THE OIL PUMP ...

EAS20040MT-01(T) 2005SERVICE MANUAL©2004 by Yamaha Motor Co., Ltd.First edition, December 2004All rights reserved.Any reproduction or unauthorized use

SPECIAL TOOLS1-11Compression gauge90890-03081Engine compression testerYU-332233-10Extension90890-040823-10Oil filter wrench90890-01426YU-384113-12Stee

ENGINE REMOVAL5-1EAS23710ENGINE REMOVALRemoving the oil tankOrder Job/Parts to remove Q’ty RemarksEngine oilDrain.Refer to “CHANGING THE ENGINE OIL” o

ENGINE REMOVAL5-2ET5YU1027CHECKING THE OIL PIPES1. Check:• Oil pipesDamage → Replace.Obstruction → Wash and blow out with com-pressed air.ET5YU1028CHE

ENGINE REMOVAL5-3Removing the exhaust pipeOrder Job/Parts to remove Q’ty RemarksSeatRefer to “GENERAL CHASSIS” on page 4-1.1 EXUP valve pulley cover 1

ENGINE REMOVAL5-4ET5YU1029REMOVING THE MUFFLER END COVERS1. Remove:• Muffler end covers “1”NOTE:Before removing a muffler end cover, turn it in the di

ENGINE REMOVAL5-5Removing the EXUP servo motor and rear exhaust pipe jointOrder Job/Parts to remove Q’ty RemarksFuel tank Refer to “FUEL TANK” on page

ENGINE REMOVAL5-65 Horn connector 2 Disconnect.6Horn 17 Oil pump outlet pipe 18 Oil pump inlet pipe 19 Sidestand switch coupler 1 Disconnect.10 Shift

ENGINE REMOVAL5-722 Rear exhaust pipe joint cover 123 Rear exhaust pipe joint 124 Gasket 1For installation, reverse the removal procedure.Removing the

ENGINE REMOVAL5-8Removing the leadsOrder Job/Parts to remove Q’ty Remarks1 Stator coil assembly lead 12 Horn lead 13 Wire harness 14 Decompression sol

ENGINE REMOVAL5-9Removing the down tubeOrder Job/Parts to remove Q’ty RemarksNOTE:Place a suitable stand under the frame and engine.1 Engine mounting

ENGINE REMOVAL5-1015 Down tube nut (front side) 216 Down tube spacer bolt 2 Loosen.17 Down tube bolt (front side) 218 Engine mounting nut (front lower

SPECIAL TOOLS1-12Rod puller90890-01437Universal damping rod bleeding tool setYM-A87034-53, 4-55Rod puller attachment (M10)90890-01436Universal damping

ENGINE REMOVAL5-11Removing the engineOrder Job/Parts to remove Q’ty RemarksNOTE:Place a suitable stand under the frame and engine.1 Engine mounting nu

ENGINE REMOVAL5-1214 Engine bracket (rear upper side) 1For installation, reverse the removal procedure.Removing the engineOrder Job/Parts to remove Q’

ENGINE REMOVAL5-13ET5YU1031REMOVING THE ENGINENOTE:Pass a suitable rod through the hole in the swin-garm pivot shaft and secure the rod to support the

ENGINE REMOVAL5-14NOTE:Do not fully tighten the bolts and nuts.7. Tighten:• Down tube nut (front side) “14”• Engine mounting nut (rear lower side) “15

ENGINE REMOVAL5-1525101128261229271430262422119181819232220913

CAMSHAFTS5-16EAS23750CAMSHAFTSRemoving the camshaft sprocket coverOrder Job/Parts to remove Q’ty RemarksEngine Refer to “ENGINE REMOVAL” on page 5-1.1

CAMSHAFTS5-17Removing cylinder head coversOrder Job/Parts to remove Q’ty Remarks1 Tappet cover bolt 42 Tappet cover 23O-ring 24 Cylinder head cover bo

CAMSHAFTS5-18Removing the push rods and rocker armsOrder Job/Parts to remove Q’ty Remarks1 Rear rocker arm base assembly 12 Front rocker arm base asse

CAMSHAFTS5-19Removing the valve liftersOrder Job/Parts to remove Q’ty RemarksFront cylinderRefer to “CYLINDERS AND PISTONS” on page 5-41.1 Push rod co

CAMSHAFTS5-20Removing the camshaftsOrder Job/Parts to remove Q’ty Remarks1 Decompression solenoid 12 Long decompression push rod 1 92 mm (3.6 in)3 Sho

SPECIAL TOOLS1-13Valve guide reamer (ø6)90890-04066Valve guide reamer (6.0 mm)YM-040665-36Piston pin puller set90890-01304Piston pin pullerYU-013045-4

CAMSHAFTS5-21EAS23790REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS1. Align:• TDC mark “a” on the crankshaft position sen-sor rotor(with the po

CAMSHAFTS5-223. Remove:• Camshaft drive gear “1”• Camshaft driven gear “2”• Straight keys• Front cylinder camshaft end coverNOTE:Cover the crankcase h

CAMSHAFTS5-233. Measure:• Camshaft journal diameter (crankcase side) “a”Out of specification → Replace the camshaft.4. Measure:• Camshaft journal diam

CAMSHAFTS5-24NOTE:Calculate the clearance by subtracting the cam-shaft journal diameter (camshaft cover side) from the camshaft cover hole inside diam

CAMSHAFTS5-25EAS23920CHECKING THE VALVE LIFTERS AND VALVE LIFTER CASES1. Check:• Valve lifterBlue discoloration/excessive wear/pitting/ scratches → Re

CAMSHAFTS5-26• O-ringDamage/wear → Replace the oil seal and O-ring as a set.EAS23980CHECKING THE DECOMPRESSION SYSTEM1. Check:• Decompression systemNO

CAMSHAFTS5-27• Align the punch mark “a” on the camshaft drive gear “1” with the punch mark “b” on the cam-shaft driven gear “2”.• Insert a cross-heade

CAMSHAFTS5-28CAUTION:ECA14630• Do not pump the valve lifter excessively.• Kerosene is highly flammable.b. Install the valve lifter into the engine.CAU

CAMSHAFTS5-29i. Leave the camshaft drive and driven gears aligned for five minutes to allow the valve lift-er to bleed.j. If necessary, repeat steps (

CAMSHAFTS5-30c. Install the rocker arm base bolts (M6) “1”, “2” and the rocker arm base bolts (M8) “3”.NOTE:Tighten the rocker arm base bolts in stage

SPECIAL TOOLS1-14Fuel pressure adapter90890-03176YM-031766-9Digital circuit tester90890-031746-10Ignition checker90890-06754Opama pet-4000 spark check

CYLINDER HEADS5-31EAS24110CYLINDER HEADSRemoving the cylinder headsOrder Job/Parts to remove Q’ty RemarksCylinder head covers/Rocker arms Refer to “CA

CYLINDER HEADS5-32EAS24140REMOVING THE CYLINDER HEADS1. Remove:• Cylinder head nutsNOTE:• Loosen the nuts in the proper sequence as shown.• Loosen eac

CYLINDER HEADS5-33EAS24250INSTALLING THE CYLINDER HEADS1. Tighten:• Cylinder head nuts (M12) “1”–“4”• Cylinder head nuts (M10) “5”, “6”NOTE:• Lubricat

VALVES AND VALVE SPRINGS5-34EAS24270VALVES AND VALVE SPRINGSRemoving the valves and valve springsOrder Job/Parts to remove Q’ty RemarksThe following p

VALVES AND VALVE SPRINGS5-35EAS24280REMOVING THE VALVESThe following procedure applies to all of the valves and related components.NOTE:Before removin

VALVES AND VALVE SPRINGS5-362. Replace:• Valve guideNOTE:To ease valve guide removal and installation, and to maintain the correct fit, heat the cylin

VALVES AND VALVE SPRINGS5-376. Measure:• Valve stem runoutOut of specification → Replace the valve.NOTE:• When installing a new valve, always replace

VALVES AND VALVE SPRINGS5-38▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Apply a coarse lapping compound “a” to the valve face.CAUTION:ECA13790Do not let

VALVES AND VALVE SPRINGS5-393. Measure:• Valve spring tilt “a”Out of specification → Replace the valve spring.EAS24340INSTALLING THE VALVESThe followi

VALVES AND VALVE SPRINGS5-40• Upper spring seat “7”(into the cylinder head)NOTE:Install the valve springs with the larger pitch “a” facing up.4. Insta

SPEC2

CYLINDERS AND PISTONS5-41EAS24360CYLINDERS AND PISTONSRemoving the cylinders and pistonsOrder Job/Parts to remove Q’ty RemarksCylinder head Refer to “

CYLINDERS AND PISTONS5-42EAS24380REMOVING THE PISTONSThe following procedure applies to all of the pis-tons.1. Remove:• Piston pin clips “1”• Piston p

CYLINDERS AND PISTONS5-43b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set.c. Measure pisto

CYLINDERS AND PISTONS5-443. Measure:• Piston ring end gapOut of specification → Replace the piston ring.NOTE:The oil ring expander spacer’s end gap ca

CYLINDERS AND PISTONS5-452. Install:• Piston “1”• Piston pin “2”• Piston pin clips “3” NOTE:• Apply engine oil onto the piston pin.• Make sure the arr

CLUTCH5-46EAS25060CLUTCHRemoving the clutch coverOrder Job/Parts to remove Q’ty RemarksEngine oilDrain.Refer to “CHANGING THE ENGINE OIL” on page 3-11

CLUTCH5-47Removing the crankshaft position sensorOrder Job/Parts to remove Q’ty Remarks1 Oil seal 12 Bearing 13 Crankshaft position sensor lead holder

CLUTCH5-48Removing the clutchOrder Job/Parts to remove Q’ty Remarks1 Clutch spring plate retainer 12 Clutch spring plate 13 Clutch spring plate seat 1

CLUTCH5-4918 Washer 119 Circlip 120 Oil pump drive gear 121 Dowel pin 122 Collar 123 Thrust washer 2 124 Ball 125 Long clutch push rod 126 Spacer 127

CLUTCH5-50Removing the clutch master cylinderOrder Job/Parts to remove Q’ty RemarksClutch fluidDrain.Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” o

2SPECIFICATIONSGENERAL SPECIFICATIONS ...2-1ENGINE SPECIFICATIONS ...

CLUTCH5-5116 Clutch master cylinder holder 117 Clutch master cylinder 1For installation, reverse the removal procedure.Removing the clutch master cyli

CLUTCH5-52Disassembling the clutch master cylinderOrder Job/Parts to remove Q’ty Remarks1 Clutch master cylinder push rod 12 Clutch master cylinder ki

CLUTCH5-53Removing the clutch release cylinderOrder Job/Parts to remove Q’ty RemarksClutch fluidDrain.Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM”

CLUTCH5-54Disassembling the clutch release cylinderOrder Job/Parts to remove Q’ty Remarks1 Boots 12 Clutch release cylinder piston 13 Clutch release c

CLUTCH5-55EAS25080REMOVING THE CLUTCH1. Loosen:• Clutch boss nut “1”NOTE:While holding the clutch boss “2” with the univer-sal clutch holder “3”, loos

CLUTCH5-56EAS25110CHECKING THE CLUTCH PLATESThe following procedure applies to all of the clutch plates.1. Check:• Clutch plateDamage → Replace the cl

CLUTCH5-57EAS25190CHECKING THE CLUTCH PUSH RODS1. Check:• O-ring• Short clutch push rod• Long clutch push rod• BallCracks/damage/wear → Replace the de

CLUTCH5-58EAS25260INSTALLING THE CLUTCH1. Install:• Clutch housing• Thrust washerNOTE:• Lubricate the clutch housing bearings with en-gine oil.• Make

CLUTCH5-596. Install:• Clutch spring plate “1”• Clutch spring plate retainer “2”NOTE:Tighten the clutch spring bolts in stages and in a crisscross pat

CLUTCH5-60EAS25290CHECKING THE CLUTCH MASTER CYLINDER1. Check:• Clutch master cylinder bodyCracks/damage → Replace the clutch mas-ter cylinder.• Clutc

CLUTCH5-613. Fill:• Clutch fluid reservoir(with the specified amount of the recom-mended clutch fluid)WARNINGEWA13370• Use only the designated clutch

CLUTCH5-621. Check:• Clutch release cylinder bodyCracks/damage → Replace the clutch re-lease cylinder.2. Check:• Clutch release cylinder• Clutch relea

CLUTCH5-635. Check:• Clutch lever operationSoft or spongy feeling → Bleed the clutch system.Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 3-

SHIFT SHAFT5-64EAS25410SHIFT SHAFTRemoving the shift shaft and stopper leverOrder Job/Parts to remove Q’ty RemarksClutch housing Refer to “CLUTCH” on

SHIFT SHAFT5-65EAS25420CHECKING THE SHIFT SHAFT1. Check:• Shift shaftBends/damage/wear → Replace.• Shift shaft springDamage/wear → Replace.EAS25430CHE

GENERATOR AND STARTER CLUTCH5-66EAS24480GENERATOR AND STARTER CLUTCHRemoving the stator coil assemblyOrder Job/Parts to remove Q’ty RemarksEngine oilD

GENERATOR AND STARTER CLUTCH5-67Removing the generator rotorOrder Job/Parts to remove Q’ty Remarks1 Starter clutch idle gear shaft #2 12 Starter clutc

GENERATOR AND STARTER CLUTCH5-68EAS24490REMOVING THE GENERATOR1. Remove:• Generator rotor bolt “1”• WasherNOTE:While holding the generator rotor “2” w

GENERATOR AND STARTER CLUTCH5-692. Tighten:• Generator rotor bolt “1”NOTE:Tighten the generator rotor bolt “1” while holding the generator rotor “2” w

ELECTRIC STARTER5-70EAS24780ELECTRIC STARTERRemoving the starter motorOrder Job/Parts to remove Q’ty RemarksOil tank Refer to “ENGINE REMOVAL” on page

GENERAL SPECIFICATIONS2-1EAS20280GENERAL SPECIFICATIONSModelModel 5YU1 (Europe)5YU2 (AUS)DimensionsOverall length 2185 mm (86.0 in)Overall width 790 m

ELECTRIC STARTER5-71Disassembling the starter motorOrder Job/Parts to remove Q’ty Remarks1 Circlip 12 Starter motor gear 13 Starter motor rear cover 1

ELECTRIC STARTER5-72EAS24790CHECKING THE STARTER MOTOR1. Check:• CommutatorDirt → Clean with 600 grit sandpaper.2. Measure:• Commutator diameter “a”Ou

ELECTRIC STARTER5-737. Check:• Gear teethDamage/wear → Replace the gear.8. Check:• Bearing• Oil sealDamage/wear → Replace the defective part(s).EAS248

CRANKCASE5-74EAS25540CRANKCASESeparating the crankcaseOrder Job/Parts to remove Q’ty RemarksEngine Refer to “ENGINE REMOVAL” on page 5-1.Camshafts Ref

CRANKCASE5-7510 Right crankcase 1For installation, reverse the removal procedure.Separating the crankcaseOrder Job/Parts to remove Q’ty Remarks

CRANKCASE5-76Removing the oil baffle plate and bearingsOrder Job/Parts to remove Q’ty RemarksOil pump Refer to “OIL PUMP” on page 5-81.Crankshaft Refe

CRANKCASE5-77EAS25570DISASSEMBLING THE CRANKCASENOTE:Loosen the generator shaft bolt before removing the generator rotor.1. Loosen:• Generator shaft b

CRANKCASE5-78• Tap on one side of the crankcase with a soft-face hammer. Tap only on reinforced portions of the crankcase, not on the crank-case matin

CRANKCASE5-79• Tap lightly on the left crankcase with a soft-face hammer.4. Install:• Crankcase bolts (M8)• Crankcase bolts (M6)NOTE:• Lubricate the b

CRANKCASE5-80

ENGINE SPECIFICATIONS2-2EAS20290ENGINE SPECIFICATIONSEngineEngine type Air cooled 4-stroke, OHVDisplacement 1670.0 cm³ (101.90 cu.in)Cylinder arrangem

OIL PUMP5-81EAS24910OIL PUMPRemoving the oil pumpOrder Job/Parts to remove Q’ty RemarksCrankcaseSeparate.Refer to “CRANKCASE” on page 5-74.1 Oil strai

OIL PUMP5-82Disassembling the oil pumpOrder Job/Parts to remove Q’ty Remarks1 Spring retainer 12Spring 13Relief valve 14 Oil pump housing cover 1 15Pi

OIL PUMP5-8318 Oil seal 219 Oil pump housing 1For assembly, reverse the disassembly procedure.Disassembling the oil pumpOrder Job/Parts to remove Q’ty

OIL PUMP5-84EAS24960CHECKING THE OIL PUMP1. Check:• Oil pump housing• Oil pump housing coverCracks/damage/wear → Replace the defec-tive part(s).2. Mea

OIL PUMP5-85• Oil pump shaft “6”• Pins “7”• Oil pump housing cover 2 “8”• Pin “9”• Oil pump inner rotor 1 “10”• Oil pump outer rotor 1 “11”• Ball “12”

CRANKSHAFT5-86EAS25960CRANKSHAFTRemoving the crankshaftOrder Job/Parts to remove Q’ty RemarksCrankcaseSeparate.Refer to “CRANKCASE” on page 5-74.1 Cra

CRANKSHAFT5-87EAS26010REMOVING THE CONNECTING RODSThe following procedure applies to all of the con-necting rods.1. Remove:• Connecting rod caps “1”•

CRANKSHAFT5-88c. Put a piece of Plastigauge® “1” on the crank-shaft pin.d. Assemble the connecting rod halves.NOTE:• Do not move the connecting rod or

CRANKSHAFT5-89▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲4. Select:• Big end bearings (“P1”–“P2”)NOTE:• The numbers “a” stamped into the crankshaft web an

CRANKSHAFT5-907. Calculate:• Crankshaft journal-to-crankshaft journal bearing clearanceOut of specification → Replace the crank-shaft and crankshaft j

ENGINE SPECIFICATIONS2-3Spark plug (s)Manufacturer/model NGK/DPR7EA-9Manufacturer/model DENSO/X22EPR-U9Spark plug gap 0.8–0.9 mm (0.031–0.035 in)Cylin

CRANKSHAFT5-91a. Tighten the connecting rod bolts to the spec-ified torque.b. Put a mark “1” on the connecting rod bolts “2” and the connecting rod ca

TRANSMISSION5-92EAS26240TRANSMISSIONRemoving the transmission, shift drum assembly, and shift forksOrder Job/Parts to remove Q’ty RemarksCrankcaseSepa

TRANSMISSION5-93Disassembling the main axle assemblyOrder Job/Parts to remove Q’ty Remarks1 Circlip 12Washer 13 5th pinion gear 14Collar 15Washer 16 2

TRANSMISSION5-94Disassembling the drive axle assemblyOrder Job/Parts to remove Q’ty Remarks1 5th wheel gear 12 Circlip 13Washer 14 2nd wheel gear 15Co

TRANSMISSION5-95EAS26260CHECKING THE SHIFT FORKSThe following procedure applies to all of the shift forks.1. Check:• Shift fork cam follower “1”• Shif

TRANSMISSION5-96• Transmission gear dogsCracks/damage/rounded edges → Replace the defective gear(s).4. Check:• Transmission gear engagement(each pinio

FUEL6

6FUEL SYSTEMFUEL TANK...6-1REMOVING THE FUEL TANK ..

FUEL TANK6-1EAS26620FUEL TANKRemoving the fuel tank and fuel pumpOrder Job/Parts to remove Q’ty RemarksSeatRefer to “GENERAL CHASSIS” on page 4-1.1 Fu

EAS20070NOTICEThis manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not

ENGINE SPECIFICATIONS2-4Valve, valve seat, valve guideValve clearance (cold)Intake 0.00–0.04 mm (0.0000–0.0016 in)Exhaust 0.00–0.04 mm (0.0000–0.0016

FUEL TANK6-2EAS26630REMOVING THE FUEL TANK1. Extract the fuel in the fuel tank through the fuel tank cap with a pump.2. Disconnect:• Fuel hose• Fuel r

FUEL TANK6-3CAUTION:EC5YU1017When installing the fuel hose and the fuel re-turn hose, make sure that they are securely connected, and that the fuel ho

THROTTLE BODIES6-4EAS26970THROTTLE BODIESRemoving the pressure regulator and rollover valvesOrder Job/Parts to remove Q’ty RemarksFuel tank Refer to “

THROTTLE BODIES6-514 Rollover valve 2 115 Rollover valve bracket 1For installation, reverse the removal procedure.Removing the pressure regulator and

THROTTLE BODIES6-6Removing the throttle bodiesOrder Job/Parts to remove Q’ty RemarksSeat/Air filter caseRefer to “GENERAL CHASSIS” on page 4-1.Fuel ta

THROTTLE BODIES6-7Removing the intake manifoldsOrder Job/Parts to remove Q’ty Remarks1 Fuel hose 12Fuel hose (intake manifold assembly to pressure reg

THROTTLE BODIES6-8Removing the injectorsOrder Job/Parts to remove Q’ty Remarks1 Fuel pipe 12 Injector joint 1 13 Injector joint 2 14Injector 25 Intake

THROTTLE BODIES6-9EAS26980CHECKING THE INJECTORS1. Check:• InjectorsDamage → Replace.EAS26990CHECKING THE THROTTLE BODIES1. Check:• Throttle bodiesCra

THROTTLE BODIES6-10h. Use the vacuum/pressure pump gauge set to adjust the fuel pressure in relation to the vac-uum pressure as described below.NOTE:T

ISC (IDLE SPEED CONTROL) UNIT6-11ET5YU1012ISC (IDLE SPEED CONTROL) UNITRemoving the ISC (idle speed control) unit and intake solenoidOrder Job/Parts t

ENGINE SPECIFICATIONS2-5Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in)Limit 0.080 mm (0.0032 in)Valve-stem-to-valve-gu

ISC (IDLE SPEED CONTROL) UNIT6-1212 ISC (idle speed control) unit coupler 1 Disconnect.13Cylinder-#1 ISC (idle speed control) unit outlet hose1 Discon

ISC (IDLE SPEED CONTROL) UNIT6-13ET5YU1015CHECKING THE ISC (IDLE SPEED CONTROL) SYSTEM1. Check:• HosesLoose connections → Connect properly.Cracks/dama

ELEC7–+

7ELECTRICAL SYSTEMIGNITION SYSTEM ...7-1CIRCUIT DIAGRAM ...

ELECTRICAL COMPONENTS...7-85CHECKING THE SWITCHES ...

IGNITION SYSTEM7-1EAS27090IGNITION SYSTEMEAS27110CIRCUIT DIAGRAMBr/WBL/BR/YB/YPGYBDgChBr/WL/YG/LR/YB/YBGYBDgChSb/WR/LL/W1L/YL/GSbL/RB/RB/YLRB1 B2B1B2B

IGNITION SYSTEM7-23. Main switch4. Battery8. Main fuse10.ECU fuse13.Relay unit14.Starting circuit cut-off relay16.Neutral switch19.Sidestand switch20.

IGNITION SYSTEM7-3EAS27150TROUBLESHOOTINGThe ignition system fails to operate (no spark or intermittent spark).NOTE:• Before troubleshooting, remove t

IGNITION SYSTEM7-4 NG →OK ↓ NG →OK ↓ NG →OK ↓ NG →OK ↓ NG →OK ↓ NG →OK ↓ NG →OK ↓ NG →OK ↓ NG →OK ↓8. Check the main switch.Refer to “CHECKIN

ENGINE SPECIFICATIONS2-6Installed compression spring force (exhaust) 139.00–161.00 N (31.25–36.19 lb) (14.17–16.42 kgf)Spring tilt (intake) 2.5°/1.9 m

ELECTRIC STARTING SYSTEM7-5EAS27160ELECTRIC STARTING SYSTEMEAS27170CIRCUIT DIAGRAMBr/WBL/BR/YB/YPGYBDgChBr/WL/YG/LR/YB/YBGYBDgChSb/WR/LL/W1L/YL/GSbL/R

ELECTRIC STARTING SYSTEM7-63. Main switch4. Battery6. Starter relay7. Starter motor8. Main fuse10.ECU fuse13.Relay unit14.Starting circuit cut-off rel

ELECTRIC STARTING SYSTEM7-7EAS27180STARTING CIRCUIT CUT-OFF SYSTEM OPERATIONIf the engine stop switch is set to “” and the main switch is turned “ON”

ELECTRIC STARTING SYSTEM7-8a. WHEN THE TRANSMISSION IS IN NEUTRALb. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR1. Battery

ELECTRIC STARTING SYSTEM7-9EAS27190TROUBLESHOOTINGThe starter motor fails to turn.NOTE:• Before troubleshooting, remove the following part(s):1. Seat2

ELECTRIC STARTING SYSTEM7-10 NG →OK ↓ NG →OK ↓ NG →OK ↓ NG →OK ↓ NG →OK ↓ NG →OK ↓ NG →OK ↓8. Check the engine stop switch.Refer to “CHECKING T

CHARGING SYSTEM7-11EAS27200CHARGING SYSTEMEAS27210CIRCUIT DIAGRAMB1 B2B1B2R/GB2LgY/LR/WBBBONOFFBBBRRBBYLBGL/GL/GB(BLUE)L/GB(BLUE)(DARK GREEN)BBWLBLW/Y

CHARGING SYSTEM7-121. AC magneto2. Rectifier/regulator4. Battery8. Main fuse

CHARGING SYSTEM7-13EAS27220TROUBLESHOOTINGThe battery is not being charged.NOTE:• Before troubleshooting, remove the following part(s):1. Seat NG →OK

CHARGING SYSTEM7-14

ENGINE SPECIFICATIONS2-7Piston ringTop ringRing type BarrelDimensions (B × T) 1.20 × 3.80 mm (0.05 × 0.15 in)End gap (installed) 0.30–0.50 mm (0.01–0.

LIGHTING SYSTEM7-15EAS27240LIGHTING SYSTEMEAS27250CIRCUIT DIAGRAMBr/WBL/BR/YB/YPGYBDgChBr/WL/YG/LR/YB/YBGYBDgChB1 B2B1B2R/GB2LgY/LR/WBBBLGGSb/WR/GLgDg

LIGHTING SYSTEM7-163. Main switch4. Battery8. Main fuse10.ECU fuse29.ECU (electronic control unit)47.High beam indicator light50.Meter light54.Headlig

LIGHTING SYSTEM7-17EAS27260TROUBLESHOOTINGAny of the following fail to light: headlight (high beam), headlight (low beam), high beam indicator light,

LIGHTING SYSTEM7-18 NG →OK ↓8. Check the entire lighting system wiring.Refer to “CIRCUIT DIAGRAM” on page 7-15.Properly connect or repair the lightin

SIGNALING SYSTEM7-19EAS27270SIGNALING SYSTEMEAS27280CIRCUIT DIAGRAMBr/WBL/BR/YB/YPGYBDgChBr/WL/YG/LR/YB/YBGYBDgChB1 B2B1B2R/GB2LgY/LR/WBBBLGGSb/WR/GLg

SIGNALING SYSTEM7-203. Main switch4. Battery8. Main fuse10.ECU fuse12.Backup fuse (odometer, clock and immobilizer system)13.Relay unit16.Neutral swit

SIGNALING SYSTEM7-21EAS27290TROUBLESHOOTING• Any of the following fail to light: turn signal light, brake light or indicator light.• The horn fails to

SIGNALING SYSTEM7-22 NG →OK ↓The tail/brake light fails to come on. NG →OK ↓ NG →OK ↓ NG →OK ↓The turn signal light, turn signal indicator light o

SIGNALING SYSTEM7-23 NG →OK ↓The neutral indicator light fails to come on. NG →OK ↓ NG →OK ↓The fuel level warning light fails to come on. NG →OK

SIGNALING SYSTEM7-24

ENGINE SPECIFICATIONS2-8CrankshaftWidth A 132.80–133.20 mm (5.23–5.24 in)Runout limit C 0.040 mm (0.0016 in)Big end side clearance D 0.320–0.474 mm (0

FUEL INJECTION SYSTEM7-25EAS27330FUEL INJECTION SYSTEMEAS27340CIRCUIT DIAGRAMBr/WBL/BR/YB/YPGYBDgChBr/WL/YG/LR/YB/YBGYBDgChB1 B2B1B2R/GB2LgY/LR/WBBBLG

FUEL INJECTION SYSTEM7-263. Main switch4. Battery5. Fuel injection system fuse8. Main fuse10.ECU fuse15.Fuel pump relay16.Neutral switch17.Fuel pump19

FUEL INJECTION SYSTEM7-27EAS27350ECU SELF-DIAGNOSTIC FUNCTIONThe ECU is equipped with a self-diagnostic function in order to ensure that the fuel inje

FUEL INJECTION SYSTEM7-28EAS27380SELF-DIAGNOSTIC FUNCTION TABLEIf the ECU detects an abnormal signal from a sensor while the vehicle is being driven,

FUEL INJECTION SYSTEM7-2924O2 sensorNo normal signal is received from the O2 sensor.Able Able25Cylinder-#2 intake air pressure sensor(open or short ci

FUEL INJECTION SYSTEM7-30Communication error with the meter42Speed sensorNo normal signals are received from the speed sensor.Able AbleNeutral switchO

FUEL INJECTION SYSTEM7-31EAS27400TROUBLESHOOTING METHODThe engine operation is not normal and the engine trouble warning light comes on.1. Check:• Fau

FUEL INJECTION SYSTEM7-32NOTE:• All displays on the meter disappear except the clock and odometer/trip meter/fuel reserve trip meter displays.•“dIAG”

FUEL INJECTION SYSTEM7-3314Cylinder-#1 intake air pressure sensor: hose system malfunction (clogged or detached hose).• Cylinder-#1 intake air pressur

FUEL INJECTION SYSTEM7-3433Malfunction detected in the primary wire of the cylinder-#1 left or right ignition coil.• Open or short circuit in wire sub

ENGINE SPECIFICATIONS2-9Shifting mechanismShift mechanism type Guide barShift fork guide bar bending limit 0.025 mm (0.0010 in)Shift fork thickness 6.

FUEL INJECTION SYSTEM7-3542No normal signals are received from the speed sensor.Open circuit is detected in the neutral switch.• Open circuit in wire

FUEL INJECTION SYSTEM7-36Sensor operation tableEr-4Non-registered data has been received from the meter.• Improper connection in wire harness.• Malfun

FUEL INJECTION SYSTEM7-3711 Engine temperature Displays the engine temperature.Compare the actually measured engine temperature with the meter display

FUEL INJECTION SYSTEM7-38Actuator operation table63 Stopping the flashing of the engine trouble warning light (erasing the muffler cooling fan tempera

FUEL INJECTION SYSTEM7-39EAS27460TROUBLESHOOTING DETAILSThis section describes the measures per fault code number displayed on the meter. Check and se

FUEL INJECTION SYSTEM7-40Code number displayed on the meter when the engine failed to work normally. Refer to “Self-Diagnos-tic Function table”.Diagno

FUEL INJECTION SYSTEM7-41Fault code No. 13 Symptom Cylinder-#1 intake air pressure sensor: open or short cir-cuit detected.Diagnostic code No. 03 Cyli

FUEL INJECTION SYSTEM7-42Fault code No. 14 Symptom Cylinder-#1 intake air pressure sensor: hose system mal-function (clogged or detached hose).Diagnos

FUEL INJECTION SYSTEM7-43Fault code No. 15 Symptom Throttle position sensor: open or short circuit detected.Diagnostic code No. 01 Throttle position s

FUEL INJECTION SYSTEM7-44Fault code No. 17 Symptom EXUP servo motor circuit: open or short circuit detected.Diagnostic code No. 53 EXUP servo motorOrd

CHASSIS SPECIFICATIONS2-10EAS20300CHASSIS SPECIFICATIONSChassisFrame type Double cradleCaster angle 25.00°Trail 103.0 mm (4.06 in)Front wheelWheel typ

FUEL INJECTION SYSTEM7-45Fault code No. 19 Symptom A break or disconnection of the blue/yellow lead of the ECU is detected.Diagnostic code No. 20 Side

FUEL INJECTION SYSTEM7-46Fault code No. 24 Symptom No normal signal is received from the O2 sensor.Diagnostic code No. ——Order Item/components and pro

FUEL INJECTION SYSTEM7-47Fault code No. 25 Symptom Cylinder-#2 intake air pressure sensor: open or short cir-cuit detected.Diagnostic code No. 04 Cyli

FUEL INJECTION SYSTEM7-48Fault code No. 26 Symptom Cylinder-#2 intake air pressure sensor: hose system mal-function (clogged or detached hose).Diagnos

FUEL INJECTION SYSTEM7-49Fault code No. 28 Symptom Engine temperature sensor: open or short circuit detect-ed.Diagnostic code No. 11 Engine temperatur

FUEL INJECTION SYSTEM7-50Fault code No. 29 Symptom Decompression solenoid (thermistor): open or short cir-cuit detected.Diagnostic code No. 55 Decompr

FUEL INJECTION SYSTEM7-51Fault code No. 33 Symptom Malfunction detected in the primary wire of the cylinder-#1 left or right ignition coil.Diagnostic

FUEL INJECTION SYSTEM7-52Fault code No. 34 Symptom Malfunction detected in the primary wire of the cylinder-#2 left ignition coil.Diagnostic code No.

FUEL INJECTION SYSTEM7-53Fault code No. 35 Symptom Malfunction detected in the primary wire of the cylinder-#1 left or right ignition coil.Diagnostic

FUEL INJECTION SYSTEM7-54Fault code No. 36 Symptom Malfunction detected in the primary wire of the cylinder-#2 right ignition coil.Diagnostic code No.

CHASSIS SPECIFICATIONS2-11Front brakeType Dual disc brakeOperation Right hand operationFront brake lever free play 7.0–19.0 mm (0.28–0.75 in)Front dis

FUEL INJECTION SYSTEM7-55Fault code No. 37 Symptom Engine speed is high when the engine is idling.Diagnostic code No. 54 ISC valveOrder Item/component

FUEL INJECTION SYSTEM7-56Fault code No. 38 Symptom Decompression solenoid: open or short circuit detected.Diagnostic code No. 55 Decompression solenoi

FUEL INJECTION SYSTEM7-57Fault code No. 41 Symptom Lean angle cut-off switch: open or short circuit detected.Diagnostic code No. 08 Lean angle cut-off

FUEL INJECTION SYSTEM7-58Fault code No. 42 Symptom A. No normal signals are received from the speed sensor.B. Open circuit is detected in the neutral

FUEL INJECTION SYSTEM7-59B-1 Connections• Neutral switch coupler• Main wire harness ECU coupler• Check the coupler for any pins that may be pulled out

FUEL INJECTION SYSTEM7-60Fault code No. 43 Symptom The ECU is unable to monitor the battery voltage (an open or short circuit in the line to the ECU).

FUEL INJECTION SYSTEM7-61Fault code No. 46 Symptom Power supply to the fuel injection system is not normal.Diagnostic code No. ——Order Item/components

FUEL INJECTION SYSTEM7-62Fault code No. 62 Symptom Muffler cooling fan temperature sensor: open or short cir-cuit detected.Diagnostic code No. 12 Muff

FUEL INJECTION SYSTEM7-63Fault code No. 63 Symptom Engine trouble warning light is flashing. (Abnormally high temperature is detected by muffler cooli

FUEL INJECTION SYSTEM7-64Fault code No. Er-2 Symptom No signals are received from the ECU within the specified duration.Diagnostic code No. ——Order It

CHASSIS SPECIFICATIONS2-12Front suspensionType Telescopic forkSpring/shock absorber type Coil spring/oil damperFront fork travel 120.0 mm (4.72 in)For

FUEL INJECTION SYSTEM7-65Fault code No. Er-4 Symptom Non-registered data has been received from the meter.Diagnostic code No. ——Order Item/components

FUEL INJECTION SYSTEM7-66

FUEL PUMP SYSTEM7-67EAS27550FUEL PUMP SYSTEMEAS27560CIRCUIT DIAGRAMBr/WBL/BR/YB/YPGYBDgChBr/WL/YG/LR/YB/YBGYBDgChB1 B2B1B2R/GB2LgY/LR/WBBBONOFFBBBRRBB

FUEL PUMP SYSTEM7-683. Main switch4. Battery5. Fuel injection system fuse8. Main fuse10.ECU fuse15.Fuel pump relay17.Fuel pump29.ECU (electronic contr

FUEL PUMP SYSTEM7-69EAS27570TROUBLESHOOTINGIf the fuel pump fails to operate.NOTE:• Before troubleshooting, remove the following part(s):1. Seat2. Fue

FUEL PUMP SYSTEM7-70

MUFFLER COOLING SYSTEM7-71ET5YU1002MUFFLER COOLING SYSTEMET5YU1003CIRCUIT DIAGRAMBr/WBL/BR/YB/YPGYBDgChBr/WL/YG/LR/YB/YBGYBDgChB1 B2B1B2R/GB2LgY/LR/WB

MUFFLER COOLING SYSTEM7-724. Battery8. Main fuse9. Muffler cover fan fuse10.ECU fuse26.Muffler cooling fan temperature sensor29.ECU (electronic contro

MUFFLER COOLING SYSTEM7-73ET5YU1004TROUBLESHOOTINGThe muffler cooling fan motor fails to turn.NOTE:• Before troubleshooting, remove the following part

MUFFLER COOLING SYSTEM7-74

CHASSIS SPECIFICATIONS2-13Rear suspensionType Swingarm (link suspension)Spring/shock absorber type Coil spring/gas-oil damperRear shock absorber assem

IMMOBILIZER SYSTEM7-75EAS27640IMMOBILIZER SYSTEMEAS27650CIRCUIT DIAGRAMBr/WBL/BR/YB/YPGYBDgChBr/WL/YG/LR/YB/YBGYBDgChB1 B2B1B2R/GB2LgY/LR/WBBBLGGSb/WR

IMMOBILIZER SYSTEM7-763. Main switch4. Battery8. Main fuse10.ECU fuse11.Immobilizer unit12.Backup fuse (odometer, clock and immobilizer system)29.ECU

IMMOBILIZER SYSTEM7-77EAS27670GENERAL INFORMATIONThis vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in

IMMOBILIZER SYSTEM7-78* Accessory locks mean the seat lock and fuel tank cap.Code re-registering key registration:When the immobilizer unit or ECU is

IMMOBILIZER SYSTEM7-79Standby modeStandard key registration:Standard key registration is required when a standard key is lost and needs to be replaced

IMMOBILIZER SYSTEM7-80Standard key registrationVoiding the standard key code:If a standard key has been lost, it is possible to disable its use by re-

IMMOBILIZER SYSTEM7-81EAS27700TROUBLESHOOTINGWhen the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flash

IMMOBILIZER SYSTEM7-82Immobilizer system indicator light fault code indicationUnits of 10: Cycles of on for 1 second and off for 1.5 seconds.Units of

IMMOBILIZER SYSTEM7-83Example: fault code 52aba. Light onb. Light off

IMMOBILIZER SYSTEM7-84

EAS20090HOW TO USE THIS MANUALThis manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all inst

ELECTRICAL SPECIFICATIONS2-14EAS20310ELECTRICAL SPECIFICATIONSVoltageSystem voltage 12 VIgnition systemIgnition system Transistorized coil ignition (d

ELECTRICAL COMPONENTS7-85EAS27970ELECTRICAL COMPONENTS435768910121314151211

ELECTRICAL COMPONENTS7-861. Air temperature sensor2. Cylinder-#2 left ignition coil3. Cylinder-#2 right ignition coil4. ISC (idle speed control) unit5

ELECTRICAL COMPONENTS7-87346587911121314151617181210

ELECTRICAL COMPONENTS7-881. Cylinder-#1 intake air pressure sensor2. Cylinder-#2 intake air pressure sensor3. Immobilizer unit4. Throttle position sen

ELECTRICAL COMPONENTS7-89EAS27980CHECKING THE SWITCHESBr/WBL/BR/YB/YPGYBDgChBB(BLACK)R/WL/WR/BBB/YB(BLUE)(BROWN)BB(BLUE)BBBBB1112138569101273B BR/YYYL

ELECTRICAL COMPONENTS7-901. Front brake light switch2. Engine stop switch3. Start switch4. Main switch5. Neutral switch6. Sidestand switch7. Rear brak

ELECTRICAL COMPONENTS7-91Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections

ELECTRICAL COMPONENTS7-92EAS27990CHECKING THE BULBS AND BULB SOCKETSNOTE:Do not check any of the lights that use LEDs.Check each bulb and bulb socket

ELECTRICAL COMPONENTS7-93Checking the condition of the bulb socketsThe following procedure applies to all of the bulb sockets.1. Check:• Bulb socket (

ELECTRICAL COMPONENTS7-94cal system, cause the lighting and ignition systems to malfunction and could possibly cause a fire.▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲

ELECTRICAL SPECIFICATIONS2-15Bulb voltage, wattage × quantityLow beam headlight 12 V, 51.0 W × 1High beam headlight 12 V, 55.0 W × 1Auxiliary light 12

ELECTRICAL COMPONENTS7-95b. Check the charge of the battery, as shown in the charts and the following example.▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲5

ELECTRICAL COMPONENTS7-96▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼Charging method using a constant volt-age chargera. Measure the open-circuit voltage p

ELECTRICAL COMPONENTS7-97Relay unit (starting circuit cut-off relay)Relay unit (fuel pump relay)Headlight relayMuffler cooling fan motor relayET5YU102

ELECTRICAL COMPONENTS7-98b. Turn the main switch to “ON”.c. Measure the turn signal/hazard relay input voltage.▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

ELECTRICAL COMPONENTS7-99▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Disconnect the relay unit coupler from the wire harness.b. Connect the pocket teste

ELECTRICAL COMPONENTS7-100c. Measure the secondary coil resistance.▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ET5YU1032CHECKING THE IGNITION SPARK GAP1. C

ELECTRICAL COMPONENTS7-1012. Check:• Lean angle cut-off switch output voltageOut of specification → Replace.▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a.

ELECTRICAL COMPONENTS7-102▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Set the engine tachometer to the cylinder-#1 left spark plug lead or right spark p

ELECTRICAL COMPONENTS7-103▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Connect the pocket tester (Ω × 1k) to the en-gine temperature sensor terminal as s

ELECTRICAL COMPONENTS7-104b. Turn the main switch to “ON”.c. Elevate the rear wheel and slowly rotate it.d. Measure the voltage of white/yellow and bl

ELECTRICAL SPECIFICATIONS2-16Starting circuit cut-off relayModel/manufacturer G8R-30Y-U3/OMRONCoil resistance 162–198 ΩHeadlight relayModel/manufactur

ELECTRICAL COMPONENTS7-105▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Insert a plug “1” into the fuel return hose end.b. Fill the fuel tank.c. Put the e

ELECTRICAL COMPONENTS7-106▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Disconnect the decompression solenoid cou-plers from the wire harness.b. Connect t

ELECTRICAL COMPONENTS7-107ET5YU1007CHECKING THE AIR TEMPERATURE SENSOR1. Remove:• Air temperature sensorWARNINGEW5YU1002• Handle the air temperature s

ELECTRICAL COMPONENTS7-108c. Check the muffler cooling fan motor move-ment.▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ET5YU1006CHECKING THE MUFFLER COOLIN

TRBLSHTG8

8TROUBLESHOOTINGTROUBLESHOOTING... 8-1GENERAL INFORMATION ...

TROUBLESHOOTING8-1EAS28450TROUBLESHOOTINGEAS28460GENERAL INFORMATIONNOTE:The following guide for troubleshooting does not cover all the possible cause

TROUBLESHOOTING8-2Electrical system1. Battery• Discharged battery• Faulty battery2. Spark plug(s)• Incorrect spark plug gap• Incorrect spark plug heat

TROUBLESHOOTING8-3EAS28590OVERHEATINGEngine1. Cylinder head(s) and piston(s)• Heavy carbon buildup2. Engine oil• Incorrect oil level• Incorrect oil vi

TIGHTENING TORQUES2-17EAS20320TIGHTENING TORQUESEAS20330GENERAL TIGHTENING TORQUE SPECIFICATIONSThis chart specifies tightening torques for stan-dard

TROUBLESHOOTING8-4• Incorrect connection• Improperly grounded circuit• Poor contacts (main or light switch)• Burnt-out headlight bulbHeadlight bulb bu

EAS28740WIRING DIAGRAMMT-01(T) 20051. AC magneto2. Rectifier/regulator3. Main switch4. Battery5. Fuel injection system fuse6. Starter relay7. Starter

L/B Blue/BlackL/G Blue/GreenL/R Blue/RedL/W Blue/WhiteL/Y Blue/YellowP/L Pink/BlueP/W Pink/WhiteP/Y Pink/YellowR/B Red/BlackR/G Red/GreenR/L Red/BlueR

YAMAHA MOTOR CO., LTD.2500 SHINGAI IWATA SHIZUOKA JAPAN

MT-01(T) 2005 WIRING DIAGRAMBr/WBL/BR/YB/YPGYBDgChBr/WL/YG/LR/YB/YBGYBDgChSb/WR/LL/W1L/YL/GSbL/RB/RB/YLRB1 B2B1B2BB2LgR/WY/LR/GR/GB2LgY/LR/WBBBLGGSb/W

TIGHTENING TORQUES2-18EAS20340ENGINE TIGHTENING TORQUESItemThread sizeQ’ty Tightening torque RemarksOil tank:Oil pipe bolt M6 11 13 Nm (1.3 m·kg, 9.4

TIGHTENING TORQUES2-19Cylinder head cover bolt M6 24 10 Nm (1.0 m·kg, 7.2 ft·lb)Rocker arm base bolt M6 8 10 Nm (1.0 m·kg, 7.2 ft·lb)Rocker arm base b

TIGHTENING TORQUES2-20Stopper lever bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)Generator and starter clutch:Oil pipe 2 bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)

TIGHTENING TORQUES2-21NOTE:• Tighten the connecting rod bolts to 15 Nm (1.5 m·kg, 11 ft·lb), and then tighten them further to reach the specified angl

TIGHTENING TORQUES2-22Oil tank tightening sequence:Cylinder head tightening sequence:15732684101615131114129A. Front cylinderB. Rear cylinder

TIGHTENING TORQUES2-23EAS20350CHASSIS TIGHTENING TORQUESItemThread sizeQ’ty Tightening torque RemarksEngine mounting:Engine mounting bolt (left upper

EAS20100SYMBOLSThe following symbols are used in this manual for easier understanding.NOTE:The following symbols are not relevant to every vehicle.GME

TIGHTENING TORQUES2-24Cylinder-#2 right ignition coil bracket boltM6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)Cylinder-#2 left ignition coil bracket boltM6 2 10 N

TIGHTENING TORQUES2-25Shift arm bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)Left rider footrest assembly bolt M8 2 30 Nm (3.0 m·kg, 22 ft·lb)Right rider foot

TIGHTENING TORQUES2-26Grip end M16 2 29 Nm (2.9 m·kg, 21 ft·lb)Clutch master cylinder holder bolt M6 2 13 Nm (1.3 m·kg, 9.4 ft·lb)Rearview mirror M10

TIGHTENING TORQUES2-27NOTE:1. First, tighten the lower ring nut to approximately 52 Nm (5.2 m·kg, 37 ft·lb) with a torque wrench, then loosen the lowe

LUBRICATION POINTS AND LUBRICANT TYPES2-28EAS20360LUBRICATION POINTS AND LUBRICANT TYPESEAS20370ENGINELubrication point LubricantOil seal lipsO-ringsB

LUBRICATION POINTS AND LUBRICANT TYPES2-29Shift forks and shift fork guide barsShift drumShift shaft and shift shaft oil seal lipCrankcase mating surf

LUBRICATION POINTS AND LUBRICANT TYPES2-30EAS20380CHASSISLubrication point LubricantDown tube bolt (front and rear)Steering bearings and upper bearing

LUBRICATION SYSTEM CHART AND DIAGRAMS2-31EAS20390LUBRICATION SYSTEM CHART AND DIAGRAMSEAS20400ENGINE OIL LUBRICATION CHART9101176512121413151617181920

LUBRICATION SYSTEM CHART AND DIAGRAMS2-321. Oil pan2. Engine oil drain bolt (crankcase)3. Oil strainer (crankcase)4. Oil pump5. Oil pump rotor 16. Oil

LUBRICATION SYSTEM CHART AND DIAGRAMS2-33EAS20410LUBRICATION DIAGRAMS3531B-BD-DE-EACEE21BBDD42AC

EAS20110TABLE OF CONTENTSGENERAL INFORMATION1SPECIFICATIONS2PERIODIC CHECKS AND ADJUSTMENTS3CHASSIS4ENGINE5FUEL SYSTEM6ELECTRICAL SYSTEM7TROUBLESHOOTI

LUBRICATION SYSTEM CHART AND DIAGRAMS2-341. Oil delivery pipe2. Push rod3. Oil filter cartridge4. Rocker arm shaft5. Oil delivery pipe 2

LUBRICATION SYSTEM CHART AND DIAGRAMS2-351432

LUBRICATION SYSTEM CHART AND DIAGRAMS2-361. Rocker arm shaft2. Crankshaft3. Valve lifter4. Push rod

LUBRICATION SYSTEM CHART AND DIAGRAMS2-373211A-AB-BBBAA

LUBRICATION SYSTEM CHART AND DIAGRAMS2-381. Oil pump2. Oil strainer (crankcase)3. Oil pipe 1

LUBRICATION SYSTEM CHART AND DIAGRAMS2-393421A

LUBRICATION SYSTEM CHART AND DIAGRAMS2-401. Main axle2. Drive axle3. Oil pump4. Oil strainer (crankcase)A. To oil filter cartridge

CABLE ROUTING2-41EAS20430CABLE ROUTINGA101112131234566689141516177HDEGIJBCF

CABLE ROUTING2-421. Air temperature sensor coupler2. Sub-wire harness 3 coupler3. Front turn signal light coupler4. Headlight assembly coupler5. Headl

CABLE ROUTING2-43DDCBBC17ABCDEFGHIJKLMMNOPQRSSTUVWXYZACABAAAEAFAGAGAHAIADAKALAMANAJD-DC-CB-BAFEFAE1234567891011121213131414151515151515161920202116171

GENINFO1

CABLE ROUTING2-441. Meter assembly lead2. Clutch hose3. Left handlebar switch lead4. Cylinder-#1 intake air pressure sensor5. Cylinder-#1 intake air p

CABLE ROUTING2-45ABC129ZABBCDEFGIHJKLMNQOPSTUYAFABAAABACAEADD-DECABEDD12334567891011121313141415161718191920212222232425261528273130WVXR

CABLE ROUTING2-461. Fuel pump lead2. Cylinder-#1 right spark plug lead3. Sub-wire harness 24. Cylinder-#2 left ignition coil lead5. Sub-wire harness 2

CABLE ROUTING2-47AAKLUABCDEDFGHIJA12345667891011121314151617181920212223232426272829RQMNOP2425STUVWXAFAAABACADAEYZ

CABLE ROUTING2-481. Sub-wire harness 22. Intake solenoid lead3. ISC (idle speed control) unit lead4. Cylinder-#2 left ignition coil5. Lean angle cut-o

CABLE ROUTING2-49AAKLUABCDEDFGHIJA12345667891011121314151617181920212223232426272829RQMNOP2425STUVWXAFAAABACADAEYZ

CABLE ROUTING2-50AB.Route the starter motor lead and sub-wire harness 1 under the battery box, making sure that they are routed between the bolt holes

CABLE ROUTING2-51AABDDEFGC12334456789

CABLE ROUTING2-521. Fuel tank2. Pressure regulator3. Fuel return hose4. Fuel hose5. Fuel return pipe6. Fuel return hose (fuel return pipe to fuel pump

CABLE ROUTING2-53AAAAABCDDEFAA11225368101011AGHIKJ47999

1GENERAL INFORMATIONIDENTIFICATION ...1-1VEHICLE IDENTIFICATI

CABLE ROUTING2-541. Fuel tank overflow hose2. Fuel tank breather hose3. Rollover valve hose 14. Rollover valve hose 25. Rollover valve 16. Rollover va

CABLE ROUTING2-55BABACCAABCDEJ123458678910111213GHIKLMNF1415161710E3

CABLE ROUTING2-561. Cylinder-#2 intake air pressure sensor2. Cylinder-#2 ISC (idle speed control) unit outlet hose3. ISC (idle speed control) unit4. I

CHKADJ3

3PERIODIC CHECKS AND ADJUSTMENTSPERIODIC MAINTENANCE ...3-1INTRODUCTION ...

ELECTRICAL SYSTEM...3-33CHECKING AND CHARGING THE BATTERY...

PERIODIC MAINTENANCE3-1EAS20450PERIODIC MAINTENANCEEAS20460INTRODUCTIONThis chapter includes all information necessary to perform the recommended chec

PERIODIC MAINTENANCE3-2EAU36771NOTE:• Air filter• This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cl

ENGINE3-3EAS20470ENGINEEAS20530ADJUSTING THE VALVE CLEARANCEThe following procedure applies to all of the valves.NOTE:• The valve clearance is automat

ENGINE3-4▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼Piston #1 TDC (rear cylinder)a. Turn the crankshaft counterclockwise.b. When piston #1 is at TDC on th

ENGINE3-5▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Loosen the locknut “1” with the locknut wrench “2”.b. Insert a thickness gauge “3” between the end

ENGINE3-62. Remove:• SeatRefer to “GENERAL CHASSIS” on page 4-1.• Fuel tankRefer to “FUEL TANK” on page 6-1.• Air filter caseRefer to “GENERAL CHASSIS

ENGINE3-79. Install:• Air filter caseRefer to “GENERAL CHASSIS” on page 4-1.• Fuel tankRefer to “FUEL TANK” on page 6-1.• SeatRefer to “GENERAL CHASSI

ENGINE3-8c. Tighten the locknut “1”.WARNINGEWA12910After adjusting the throttle cable free play, start the engine and turn the handlebar to the right

ENGINE3-91. Stand the vehicle on a level surface.2. Remove:• Air duct “1”• Timing mark accessing screw “2”3. Connect:• Timing light “1”• Digital tacho

ENGINE3-105. Disconnect:• Spark plug cap6. Remove:• Spark plugCAUTION:ECA13340Before removing the spark plugs, use com-pressed air to blow away any di

ENGINE3-11EAS20730CHECKING THE ENGINE OIL LEVEL1. Stand the vehicle on a level surface.NOTE:• Place the vehicle on a suitable stand.• Make sure the ve

ENGINE3-126. Remove:• Engine oil drain bolt (crankcase) “1”7. Drain:• Engine oil(completely from the oil tank and crankcase)8. If the oil filter cartr

ENGINE3-13NOTE:Pour the engine oil in two stages. First, pour in 2.5 L of oil, then start the engine and rev it 3 to 5 times. Stop the engine, and the

ENGINE3-14▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲EAS20890CHECKING THE CLUTCH FLUID LEVEL1. Stand the vehicle on a level surface.NOTE:• Place the vehic