Yamaha 2012 TMAX XP500A Service Manual Download Page 171

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GENERAL CHASSIS

4-14

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a. Insert the five projections “1”.
b. Insert the five claws “2”.
c. Installing the bolts “3”.

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EAS59C1419

REMOVING THE SIDE COVER MOULDING

1. Remove:

• Side cover moulding

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a. Removing the quick fastener “1”.
b. Removing the screws “2”.
c. Pull the side moulding outside of the vehi-

cle and remove the five claws “3”.

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EAS59C1420

INSTALLING THE SIDE COVER MOULDING

1. Install:

• Side cover moulding

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Insert the five claws “1”.
b. Installing the screws “2”.
c. Installing the quick fastener “3”.

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EAS59C1421

REMOVING THE FOOTBOARD

1. Remove:

• Footboard

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a. Removing the screws “1”.
b. Removing the bolts “2”.

Summary of Contents for 2012 TMAX XP500A

Page 1: ...SERVICE MANUAL XP500A 2012 59C 28197 E1 ...

Page 2: ...P500A SERVICE MANUAL 2011 by Yamaha Motor Co Ltd First edition November 2011 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ... significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and will appear in future editions of this manual where applicable TIP Designs and specifications are subject to change without notice EAS20081 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations This is the safety alert sym...

Page 4: ...h page Sub section titles 2 appear in smaller print than the section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a dis assembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instru...

Page 5: ...ITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent LOCTITE Engine oil Replace the part with a new one G M BF B T R LS M S LT E New ...

Page 6: ......

Page 7: ...1 2 3 4 5 6 7 8 9 EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING ...

Page 8: ......

Page 9: ... 1 16 ABS OPERATION 1 22 ABS SELF DIAGNOSIS FUNCTION 1 25 ABS WARNING LIGHT AND OPERATION 1 28 IMPORTANT INFORMATION 1 29 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 29 REPLACEMENT PARTS 1 29 GASKETS OIL SEALS AND O RINGS 1 29 LOCK WASHERS PLATES AND COTTER PINS 1 29 BEARINGS AND OIL SEALS 1 30 CIRCLIPS 1 30 RUBBER PARTS 1 30 BASIC SERVICE INFORMATION 1 31 QUICK FASTENERS 1 31 ELECTRICAL SYSTEM 1 32...

Page 10: ...N EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the frame EAS20150 MODEL LABEL The model label 1 is affixed to the storage box This information will be needed to order spare parts ...

Page 11: ...gine As the requirements for engines to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To accommodate this need this model has adopted an electronically controlled fuel injection FI sys tem in place of a conventional carburetor system This system can achieve an optimum air fuel ratio required ...

Page 12: ...ed The injection duration and the injection timing are controlled by the ECU engine control unit Sig nals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor intake air temperature sensor coolant temperature sensor and O2 sensor enable the ECU engine control unit to determine the injection duration The injection timing is determined through the si...

Page 13: ...led since the last engine oil change A V belt replacement tripmeter which shows the distance traveled since the last V belt replacement TIP Be sure to turn the key to ON before using the left and right set buttons When the key is turned to ON all of the dis play segments of the multi function display will appear one after the other and then dis appear in order to test the electrical circuits Clock...

Page 14: ...yed push the left set button for at least one second If you do not reset the fuel reserve tripmeter manually it will reset itself automati cally and the display will return to the prior mode after refueling and traveling 5 km 3 mi Fuel meter With the key in the ON position the fuel meter indicates the amount of fuel in the fuel tank The display segments of the fuel meter disappear towards E Empty ...

Page 15: ...oil change indicator does not come on check the electrical circuit Refer to SIGNALING SYSTEM on page 8 19 V belt replacement indicator V Belt This indicator flashes every 20000 km 12500 mi when the V belt needs to be replaced After changing the V belt reset the V belt replacement indicator To reset the V belt replacement indicator select it by pushing the left set button until V Belt Trip is displ...

Page 16: ...ay to the average fuel consumption and instantaneous fuel consumption modes Average fuel consumption mode The average fuel consumption display can be set to either AVE_ _ _ km L or AVE_ _ _ L 100 km except for the UK For the UK only The average fuel consumption is displayed AVE_ _ _ MPG This display shows the average fuel consump tion since it was last reset When the display is set to AVE_ _ _ km ...

Page 17: ...rouble warning light comes on and the display indicates an error code If the display indicates any error codes note the code number and check the fuel injection system Refer to FUEL INJECTION SYSTEM on page 8 29 The self diagnosis device also detects prob lems in the immobilizer system circuits If a problem is detected in any of the immobi lizer system circuits the immobilizer system indicator lig...

Page 18: ...FEATURES 1 9 ECA11590 If the display indicates an error code the vehicle should be checked as soon as pos sible in order to avoid engine damage ...

Page 19: ...maha ABS brakes is the same as conventional brakes on other vehicles with a front brake lever for operating the front brake and a rear brake lever for operating the rear brake When wheel lock is detected during emergency braking hydraulic control is performed by the hydraulic system on the front and rear brakes independently 1 Hydraulic unit assembly ABS ECU 2 Fuse box right 3 Fuse box left 4 ABS ...

Page 20: ...e wheels has stopped but the vehicle continues to travel Side force The force on the tires which supports the vehicle when cornering Slip ratio When the brakes are applied slipping occurs between the tires and the road surface This causes a difference between the wheel speed and the chassis speed Slip ratio is the value that shows the rate of wheel slippage and is defined by the following formula ...

Page 21: ...eel slippage is represented by the slip ratio Side force is also closely related to wheel slippage See figure A If the brakes are applied while keeping the proper slip ratio it is possible to obtain the maximum brake force without losing much side force ABS allows full use of the tires capabilities even on slippery road surfaces or less slippery road sur faces See figure B a Friction force between...

Page 22: ... a tendency to lock When the wheel slip and the wheel speed reduction rate exceed the preset values the ABS ECU determines that the wheel has a tendency to lock If the slip is large and the wheel has a tendency to lock point A in the following figure the ABS ECU reduces the brake fluid pressure in the brake caliper Once the ABS ECU determines that the tendency of the wheel to lock has diminished a...

Page 23: ...cause the tire to slip side ways WARNING EWA59C2101 The braking of the vehicle even in the worst case is principally executed when the vehicle is advancing straight ahead During a turn sudden braking is liable to cause a loss of traction of the tires Even in vehicles equipped with ABS overturning of the vehicle cannot be pre vented if it is braked suddenly The ABS functions to prevent the tendency...

Page 24: ...l braking even if the ABS is not operating properly When this occurs the ABS warning light on the meter assembly comes on The ABS stores the fault codes in the memory of the ABS ECU for easy problem identification and troubleshooting ABS block diagram 1 Rear brake master cylinder 2 Hydraulic unit assembly 3 Front brake master cylinder 4 Inlet solenoid valve 5 ABS motor 6 Hydraulic pump 7 Outlet so...

Page 25: ...ate with the wheels The front sensor rotor has 80 magnetic poles 40 pairs and the rear sensor rotor has 92 magnetic poles 46 pairs They are installed close to the wheel sensors As the sensor rotor rotates the Hall element in the Hall IC installed in the wheel sensor generates pulses The pulse frequency which is proportional to the magnetic flux density is converted into a wave in the Hall IC so th...

Page 26: ...d The ABS warning light comes on to check the electrical circuit while the start switch is being pushed ECA59C2101 If the rear wheel is raced with the vehicle on a centerstand the system may determine that a malfunction has been detected and the ABS warning light may flash or come on If this occurs set the main switch to OFF then back to ON The system is normal if the ABS warning light goes off af...

Page 27: ... open and the outlet sole noid valve 2 is closed The brake line between the brake master cylinder and brake caliper is open 2 When the ABS is activated the inlet solenoid valve 1 closes and the outlet solenoid valve 2 opens using the power supplied from the ABS ECU signals This reduces the hydraulic pres sure 3 When the ABS ECU sends a signal to stop reducing the hydraulic pressure the outlet sole...

Page 28: ...ES 1 19 Buffer chamber The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating 1 Buffer chamber pressurizing phase 2 Buffer chamber depressurizing phase 3 Raised piston ...

Page 29: ...tifier regulator 4 Main fuse 5 Main switch 6 ABS ECU fuse 7 ABS motor fuse 8 ABS solenoid fuse 9 Front brake light switch 10 Rear brake light switch 11 Tail brake light 12 Hydraulic unit assembly 13 ABS ECU 14 Solenoid relay 15 ABS motor relay 16 Front brake inlet solenoid 17 Front brake outlet solenoid 18 Rear brake inlet solenoid 19 Rear brake outlet solenoid 20 ABS motor 21 ECU engine control u...

Page 30: ...ECU e g a blown ABS ECU fuse The ABS performs a self diagnosis test for a few seconds each time the vehicle starts up for the first time after the main switch was set to ON During this test a clicking noise can be heard from front side of the vehicle and if the front brake lever or rear brake lever are even slightly applied a vibration can be felt at the levers but these do not indicate a malfunct...

Page 31: ...ressure in the brake master cylinder increases and the brake fluid is sent to the brake caliper At this time the inlet and outlet check valves of the hydraulic pump are closed As a result of elimi nating the orifice the brake master cylinder directly pressurizes the brake caliper during normal braking When the brake lever is released the brake fluid in the brake caliper returns to the brake master...

Page 32: ...er Because the outlet solenoid valve is open the brake fluid is sent to the buffer chamber As a result the hydraulic pressure in the brake caliper is reduced The brake fluid stored in the buffer chamber is pumped back to the brake master cylinder by the hydraulic pump linked to the ABS motor 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Outlet solenoi...

Page 33: ...solenoid valve As the inlet solenoid valve opens the brake line from the brake master cylinder opens allowing the brake fluid to be sent to the brake caliper 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Outlet solenoid valve 7 Inlet solenoid valve 8 Brake caliper 9 Wheel sensor 10 ABS ECU 11 ABS warning light 12 Brake fluid pressure 13 Time ...

Page 34: ...et to ON The ABS warning light comes on while the ABS is performing a self diagnosis then goes off if there are no malfunctions The self diagnosis begins when the main switch is set to ON and is completed when the vehi cle is operated at a speed of about 10 km h 6 3 mi h Refer to ABS warning light on page 1 17 a ABS warning light b Main switch OFF c Main switch ON d Goes off e Comes on f The ABS s...

Page 35: ...es while riding there is no problem with the function of the ABS However the ABS ECU input has unstable factors For details refer to ABS TROUBLE SHOOTING OUTLINE on page 8 91 TIP The ABS warning light comes on or flashes if the vehicle is ridden with the test coupler adapter con nected to the ABS test coupler a ABS warning light b Main switch OFF c Main switch ON d Start switch ON e Start switch O...

Page 36: ...e test coupler adapter is connected to the ABS test coupler the ABS warning light starts flashing and the multi function display indicates all the fault codes recorded in the ABS ECU TIP The ABS warning light comes on or flashes if the vehicle is ridden with the test coupler adapter con nected to the ABS test coupler a ABS warning light b Comes on c Goes off d Unstable ABS ECU input Test coupler a...

Page 37: ... designed to shorten the braking distance or improve the cornering perfor mance Depending on the road conditions the braking distance may be longer compared to that of vehicles not equipped with ABS Therefore ride at a safe speed and keep a safe distance between yourself and other vehicles The braking of the vehicle even in the worst case is principally executed when the vehicle is advancing strai...

Page 38: ... correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals ...

Page 39: ...ir because this will damage the bearing surfaces EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives EAS59C1101 RUBBER PARTS Check rubber parts for deterioration during inspe...

Page 40: ...stener push its pin so that it protrudes from the fastener head then insert the fastener into the part to be secured and push the pin in with a screwdriver Make sure that the pin is flush with the fastener s head Screw type 1 Remove Quick fastener TIP To remove the quick fastener loosen the screw with a screwdriver then pull the fastener out 2 Install Quick fastener TIP To install the quick fasten...

Page 41: ...uld be gen erated which is extremely dangerous TIP If a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust using hot water ECA16760 Be sure to connect the battery leads to the correct battery terminals Reversing the battery lead connections could damage the electrical components ECA16771 When connecting the battery leads to the battery be sure to connect th...

Page 42: ...refore never touch the terminals and be sure to keep the contacts clean TIP When resetting the ECU by turning the main switch to OFF be sure to wait approximately 5 seconds before turning the main switch back to ON Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V ECA14371 Never insert the tester probes into the cou pler te...

Page 43: ...ecting a coupler release the coupler lock hold both sections of the coupler securely and then disconnect the coupler There are many types of coupler locks therefore be sure to check the type of coupler lock before disconnecting the coupler ECA16790 When disconnecting a connector do not pull the leads Hold both sections of the connector securely and then disconnect the connector 2 Check Lead Couple...

Page 44: ...er or connec tor together until they are connected securely Make sure all connections are tight 5 Check Continuity with the pocket tester TIP If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at most part stores 6 Check Resistance 1 Pocket tester 90890 03112 Analog pocket tester YU 03112 C Pocket ...

Page 45: ...es shown were obtained at the standard measuring temperature of 20 C 68 F If the measuring temperature is not 20 C 68 F the specified measuring conditions will be shown Intake air temperature sensor resistance 5 4 6 6 kΩ at 0 C 32 F 290 390 Ω at 80 C 176 F ...

Page 46: ...r refer to the list provided below to avoid any mistakes TIP For U S A and Canada use part numbers starting with YM YU or ACC For others use part numbers starting with 90890 Tool name Tool No Illustration Reference pages Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 35 8 125 8 126 8 127 8 131 8 133 8 134 8 135 8 136 8 137 8 138 8 139 8 141 Valve lapper 90890 04101 Valve lapping tool ...

Page 47: ...l pressure gauge set 90890 03120 3 28 Oil pressure adapter B 90890 03124 3 28 Test coupler adapter 90890 03149 1 27 4 73 4 74 Pressure gauge 90890 03153 YU 03153 3 28 7 4 Steering nut wrench 90890 01403 Exhaust flange nut wrench YU A9472 3 24 4 90 Damper rod holder 90890 01460 4 84 4 85 Tool name Tool No Illustration Reference pages 66 8 ...

Page 48: ...l driver attachment ø43 90890 01374 Replacement 43 mm YM A5142 3 4 86 Yamaha bond No 1215 90890 85505 Three Bond No 1215 5 17 5 48 5 55 5 72 Valve spring compressor 90890 04019 YM 04019 5 22 5 28 Valve spring compressor attachment 90890 04114 Valve spring compressor adapter 19 5 mm YM 04114 5 22 5 28 Tool name Tool No Illustration Reference pages YM A9409 7 YM A5142 4 ...

Page 49: ...alve guide installer 4 0 mm YM 04112 5 24 Valve guide reamer ø4 90890 04113 Valve guide reamer 4 0 mm YM 04113 5 24 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 30 Sheave holder 90890 01481 5 44 5 47 5 48 5 49 Locknut wrench 90890 01348 YM 01348 5 44 5 45 5 47 Tool name Tool No Illustration Reference pages YU 01304 ...

Page 50: ...t YM 04135 5 45 5 47 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 53 5 55 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 53 Rotor holding tool 90890 01235 Universal magneto rotor holder YU 01235 5 60 5 64 Clutch spring compressor 90890 01482 5 60 5 63 Tool name Tool No Illustration Reference pages ...

Page 51: ... 76 5 80 Radiator cap tester 90890 01325 Mityvac cooling system tester kit YU 24460 A 6 3 Radiator cap tester adapter 90890 01352 Pressure tester adapter YU 33984 6 3 Mechanical seal installer 90890 04132 Water pump seal installer YM 33221 A 6 12 Tool name Tool No Illustration Reference pages YU 24460 A YU 33984 ...

Page 52: ...03181 7 4 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 135 Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 5 19 5 61 Tension gauge 90890 03226 YM 03226 3 21 Test harness S pressure sensor 3P 90890 03207 YU 03207 8 140 Test harness lean angle sensor 6P 90890 03209 YU 03209 8 136 Tool name Tool No Illustration Reference pages ...

Page 53: ...L TOOLS 1 44 Digital circuit tester 90890 03189 Model 88 Multimeter with tachometer YU A1927 5 37 8 115 8 116 8 137 8 140 Yamaha diagnostic tool 90890 03215 8 35 Tool name Tool No Illustration Reference pages ...

Page 54: ...SPECIAL TOOLS 1 45 ...

Page 55: ...TORQUES 2 14 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 14 ENGINE TIGHTENING TORQUES 2 15 CHASSIS TIGHTENING TORQUES 2 18 LUBRICATION POINTS AND LUBRICANT TYPES 2 21 ENGINE 2 21 CHASSIS 2 23 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 ENGINE OIL LUBRICATION CHART 2 25 LUBRICATION DIAGRAMS 2 27 COOLING SYSTEM DIAGRAMS 2 35 CABLE ROUTING 2 39 ...

Page 56: ...s Overall length 2200 mm 86 6 in Overall width 775 mm 30 5 in Overall height 1420 1475 mm 55 9 58 1 in Seat height 800 mm 31 5 in Wheelbase 1580 mm 62 2 in Ground clearance 125 mm 4 92 in Minimum turning radius 2800 mm 110 2 in Weight Curb weight 221 kg 487 lb Maximum load 194 kg 428 lb ...

Page 57: ...otal amount 3 50 L 3 70 US qt 3 08 Imp qt Without oil filter cartridge replacement 2 70 L 2 85 US qt 2 38 Imp qt With oil filter cartridge replacement 2 90 L 3 07 US qt 2 55 Imp qt Oil pressure hot 120 0 kPa 1200 r min 1 20 kgf cm 1200 r min 17 4 psi 1200 r min Oil filter Oil filter type Cartridge Oil pump Oil pump type Trochoid Oil pressure 120 kPa 1200 r min 1 20 kgf cm 1200 r min 17 4 psi 1200 ...

Page 58: ...Drive system Chain drive left Camshaft cap inside diameter 23 000 23 021 mm 0 9055 0 9063 in Camshaft journal diameter 22 959 22 972 mm 0 9039 0 9044 in Camshaft journal to camshaft cap clearance 0 028 0 062 mm 0 0011 0 0024 in Limit 0 08 mm 0 0031 in Camshaft lobe dimensions Intake A 32 490 32 590 mm 1 2791 1 2831 in Limit 32 390 mm 1 2752 in Intake B 24 950 25 050 mm 0 9823 0 9862 in Limit 24 85...

Page 59: ...ness intake 0 50 0 90 mm 0 0197 0 0354 in Valve margin thickness exhaust 0 50 0 90 mm 0 0197 0 0354 in Valve stem diameter intake 3 975 3 990 mm 0 1565 0 1571 in Limit 3 945 mm 0 1553 in Valve stem diameter exhaust 3 960 3 975 mm 0 1559 0 1565 in Limit 3 930 mm 0 1547 in Valve guide inside diameter intake 4 000 4 012 mm 0 1575 0 1580 in Limit 4 050 mm 0 1594 in Valve guide inside diameter exhaust ...

Page 60: ... Clockwise Winding direction exhaust Clockwise Valve lifter Valve lifter outside diameter intake 24 482 24 488 mm 0 9639 0 9641 in Limit 24 457 mm 0 9629 in Valve lifter outside diameter exhaust 24 482 24 488 mm 0 9639 0 9641 in Limit 24 457 mm 0 9629 in Cylinder Bore 68 000 68 010 mm 2 6772 2 6776 in Wear limit 68 100 mm 2 6811 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 ...

Page 61: ...9 in Oil ring Dimensions B T 1 50 2 00 mm 0 06 0 08 in End gap installed 0 10 0 35 mm 0 0039 0 0138 in Connecting rod Oil clearance 0 040 0 064 mm 0 0016 0 0025 in Bearing color code 1 Blue 2 Black 3 Brown 4 Green Small end inside diameter 16 005 16 018 mm 0 6301 0 6306 in Crankshaft Width A 49 90 50 60 mm 1 964 1 992 in Width B 118 55 118 60 mm 4 67 4 67 in Runout limit C 0 050 mm 0 0020 in Big e...

Page 62: ...mm 0 14 in Minimum height 3 10 mm 0 12 in Spring quantity 7 pcs Clutch spring plate height 4 70 mm 0 19 in Minimum height 4 40 mm 0 17 in Spring quantity 1 pcs V belt V belt width 32 9 mm 1 30 in Limit 31 4 mm 1 24 in Transmission Transmission type V belt automatic Primary reduction ratio 1 000 Secondary reduction ratio 6 034 52 32 36 22 59 26 Final drive Belt Gear ratio 2 041 0 758 1 Primary shea...

Page 63: ... pressure output voltage 3 57 3 71 V at 101 32 kPa Intake air temperature sensor resistance 5 4 6 6 kΩ at 0 C 32 F 290 390 Ω at 80 C 176 F Idling condition Engine idling speed 1100 1300 r min Intake vacuum 29 3 31 9 kPa 220 239 mmHg 8 7 9 4 inHg Water temperature 85 0 105 0 C 185 00 221 00 F Oil temperature 60 0 80 0 C 140 00 176 00 F Throttle grip free play 3 0 5 0 mm 0 12 0 20 in Fuel line press...

Page 64: ...01 in Wheel sensor rotor deflection limit 0 15 mm 0 0059 in Front tire Type Tubeless Size 120 70R15 M C 56H Manufacturer model DUNLOP GPR 100F Manufacturer model BRIDGESTONE BT011F Wear limit front 1 6 mm 0 06 in Rear tire Type Tubeless Size 160 60R15 M C 67H Manufacturer model DUNLOP GPR 100L Manufacturer model BRIDGESTONE BT012R Wear limit rear 1 6 mm 0 06 in Tire air pressure measured on cold t...

Page 65: ... brake lock Rear brake lock pad Brake pad lining thickness 3 0 mm 0 12 in Limit 0 8 mm 0 03 in Rear brake lock cable length 43 45 mm 1 69 1 77 in Steering Steering bearing type Angular bearing Center to lock angle left 38 5 Center to lock angle right 38 5 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 120 0 mm 4 72 in Fork spring free leng...

Page 66: ...8 kgf mm 1678 74 lb in Spring stroke K1 0 0 28 8 mm 0 00 1 13 in Spring stroke K2 28 8 43 0 mm 1 13 1 69 in Optional spring available No Enclosed gas air pressure STD 4900 kPa 49 0 kgf cm 696 9 psi Swingarm Swingarm end free play limit radial 1 0 mm 0 04 in Swingarm end free play limit axial 1 0 mm 0 04 in Drive belt Drive belt slack scale position 13 4 ...

Page 67: ...in Stator coil resistance 0 224 0 336 Ω W W Rectifier regulator Regulator type Semi conductor short circuit Regulated voltage DC 14 1 14 9 V Rectifier capacity DC 22 0 A Battery Model YTZ12S Voltage capacity 12 V 11 0 Ah Specific gravity 1 310 Manufacturer GS YUASA Ten hour rate amperage 1 10 A Headlight Bulb type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 55 W 2 Auxiliary light 12 ...

Page 68: ... Quantity 1 pcs Maximum amperage 3 0 A Coil resistance 1 06 1 11 Ω Turn signal hazard relay Relay type Full transistor Built in self canceling device No Fuel sender unit Sender unit resistance full 4 0 10 0 Ω Sender unit resistance empty 93 0 100 0 Ω Fuses Main fuse 40 0 A Headlight fuse 20 0 A Signaling system fuse 15 0 A Ignition fuse 7 5 A Radiator fan fuse 15 0 A Parking lighting fuse 10 0 A F...

Page 69: ...l To avoid warpage tighten multi fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kgf ft lbf 10 mm 6 mm 6 0 6...

Page 70: ...pump housing cover bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Water pump assembly bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Water pump inlet and outlet pipes bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Thermostat cover bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Coolant pipe bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Coolant drain bolt M12 1 1 6 Nm 0 16 m kgf 1 2 ft lbf Oil pump bolt M6 3 10 Nm 1 0 m kgf 7 2 ft lbf Oil strainer...

Page 71: ...e air filter case screw M6 3 7 Nm 0 7 m kgf 5 1 ft lbf Generator cover protector screw M6 1 7 Nm 0 7 m kgf 5 1 ft lbf V belt case air filter case cover screw M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Generator cover protector cover screw M6 2 7 Nm 0 7 m kgf 5 1 ft lbf V belt case air filter element left bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf V belt case air duct joint clamp M4 1 3 0 Nm 0 30 m kgf 2 2 ft lbf V b...

Page 72: ...kgf 12 ft lbf and then tighten them further to reach the specified angle 90 TIP Generator rotor nut Tighten the generator rotor nuts to 65 Nm 6 5 m kgf 47 ft lbf and then tighten them further to reach the specified angle 120 Cylinder head tightening sequence Secondary shaft bearing retainer bolt M6 2 12 Nm 1 2 m kgf 8 7 ft lbf Stator coil bolt M6 3 10 Nm 1 0 m kgf 7 2 ft lbf Crankshaft position se...

Page 73: ...t shaft M22 1 7 Nm 0 7 m kgf 5 1 ft lbf Pivot shaft nut M22 1 100 Nm 10 m kgf 72 ft lbf Rear shock absorber assembly rear nut M12 1 53 Nm 5 3 m kgf 38 ft lbf Rear shock absorber assembly front bolt M16 1 68 Nm 6 8 m kgf 49 ft lbf Swingarm bolt M10 3 40 Nm 4 0 m kgf 29 ft lbf Drive pulley assembly bolt M10 5 48 Nm 4 8 m kgf 35 ft lbf L 25 mm 0 98 in L 90 mm 3 54 in Drive belt guard bolt M6 4 10 Nm ...

Page 74: ...f 2 9 ft lbf Windshield screw M5 4 0 5 Nm 0 05 m kgf 0 36 ft lbf Windshield stay bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Side cover bolt rear side M6 2 4 0 Nm 0 40 m kgf 2 9 ft lbf Storage compartment bolt M6 1 4 0 Nm 0 40 m kgf 2 9 ft lbf Recovery tank bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Front fender bolt hexagon socket bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Front fender bolt flange bolt M6 2 7 Nm 0 7...

Page 75: ...r brake hose holder bolt rear left footrest M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Front wheel sensor rotor bolt M5 3 8 Nm 0 8 m kgf 5 8 ft lbf Rear wheel sensor rotor bolt M5 5 8 Nm 0 8 m kgf 5 8 ft lbf Centerstand bracket nut M10 4 55 Nm 5 5 m kgf 40 ft lbf Centerstand nut M10 2 55 Nm 5 5 m kgf 40 ft lbf Sidestand nut M10 1 65 Nm 6 5 m kgf 47 ft lbf Rear footrest bracket bolt M8 4 30 Nm 3 0 m kgf 22 ft ...

Page 76: ... coolant pipe or silicone fluid Oil pump shaft and rotors inner and outer Oil pump gaskets V belt case air filter case screw bushing Water V belt case air filter case cover screw bushing Water Crankshaft end access cover screw bushing Water or silicone fluid Generator cover protector cover screw bushing Water or silicone fluid Generator cover protector screw bushing Water or silicone fluid Starter...

Page 77: ...haft taper roller bearing Crankcase mating surface Yamaha bond No 1215 Three bond No 1215 Inner V belt case seal mating surface Yamaha bond No 1215 Three bond No 1215 Crankshaft position sensor stator lead grommet Yamaha bond No 1215 Three bond No 1215 Lubrication point Lubricant LS LS ...

Page 78: ...EASE H or Polyurea Grease Rear shock absorber assembly bearing inner surface Rear shock absorber assembly spacer and collar Pivot shaft oil seal and collar Rear shock absorber assembly front bolt seats Seat lock metal to metal moving parts Seat hinge metal to metal moving parts Seat lock cable Passenger footrest pivoting point Centerstand pivoting point and metal to metal moving parts Centerstand ...

Page 79: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ...

Page 80: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART ...

Page 81: ...To piston 6 Starter clutch gear 7 Crankshaft 8 Balancer connecting rod 9 To balancer piston 10 Oil pipe 11 Check valve 12 Relief valve 13 Oil filter 14 Oil cooler 15 Oil tank 16 Oil strainer 17 Feed pump 18 Delivery pipe 19 Scavenge pump 20 Oil strainer 21 To starter idle gear 22 Clutch 23 Secondary shaft 24 To transmission ...

Page 82: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EAS20410 LUBRICATION DIAGRAMS ...

Page 83: ...CATION SYSTEM CHART AND DIAGRAMS 2 28 1 Exhaust camshaft 2 Intake camshaft 3 Delivery pipe 4 Oil pump assembly 5 Scavenge pump 6 Feed pump 7 Oil pipe 8 Oil cooler 9 Oil filter 10 Relief valve 11 Check valve ...

Page 84: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 ...

Page 85: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Crankshaft 2 Secondary shaft 3 Drive axle 4 Clutch 5 Generator cover ...

Page 86: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 ...

Page 87: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Oil strainer 2 Intake camshaft 3 Exhaust camshaft ...

Page 88: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 ...

Page 89: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Generator cover 2 Oil strainer 3 Main gallery 4 Right crankcase A Forward ...

Page 90: ...COOLING SYSTEM DIAGRAMS 2 35 EAS20420 COOLING SYSTEM DIAGRAMS ...

Page 91: ... Thermostat outlet hose 7 Oil cooler outlet hose 8 Thermostat 9 Oil cooler 10 Coolant hose 11 Water pump inlet pipe 12 Water pump outlet pipe 13 Oil cooler inlet hose 14 Radiator outlet hose 15 Coolant reservoir hose 16 Fast idle plunger outlet coolant hose 17 Coolant reservoir 18 Coolant reservoir breather hose 19 Radiator 20 Water pump ...

Page 92: ...COOLING SYSTEM DIAGRAMS 2 37 ...

Page 93: ...ostat 2 Thermostat outlet hose 3 Cooling system air bleed hose 4 Radiator cap 5 Radiator filler pipe 6 Radiator filler hose 7 Coolant reservoir hose 8 Radiator 9 Radiator inlet hose 10 Coolant pipe 11 Oil cooler 12 Oil cooler outlet hose ...

Page 94: ...CABLE ROUTING 2 39 EAS20430 CABLE ROUTING Handlebar top side view ...

Page 95: ... of the vehicle B Adjust the free play of the accelerator grip so that the free play is 3 to 5 mm 0 12 to 0 20 in when measured at the outer cir cumference of the rim C Tighten the union bolt pushing the brake pipe against the guide wire D Apply grease to the cable end and tube guide when installing the throttle cable Apply a pea sized amount approx 0 2 g 0 007 oz of grease to the cable end E Adju...

Page 96: ...CABLE ROUTING 2 41 Handlebar front side and left side view ...

Page 97: ... lock cable and through the upper bracket forward C Pass the brake pipe between the projec tions D Install the rear brake hose so that the yel low paint mark on the pipe faces to the front of the vehicle E Route the rear brake lock cable behind the handlebar switch leads and throttle cables F Pass the brake hoses through the guide wire G Route the throttle cables behind the han dlebar switch leads...

Page 98: ...CABLE ROUTING 2 43 Front brake front side and left side view ...

Page 99: ... I Insert the horn lead coupler Install the black lead to the bracket side bottom J Install the horn bracket aligning the projec tion of the horn bracket with the groove of the horn K 0 5 mm 0 0 20 in L Face the holder opening to the rear of the vehicle M Bring the both ends of the white tape on the horn lead into position between brake hose grommet flanges N White tape O Between brake hose gromme...

Page 100: ...CABLE ROUTING 2 45 Frame front side view ...

Page 101: ...witch leads and insert them into stay 1 The ratchet may be faced to any direction I Route the right and left handlebar switch leads between stay 1 J Pass the handlebar switch leads through the holder The opening can be oriented in any direction K Install the holder between the wire harness holder and meter lead The opening can be oriented in any direction L The left and right handlebar switch lead...

Page 102: ...CABLE ROUTING 2 47 Frame left side view ...

Page 103: ...g leads with the holder H Fasten spark plug 1 lead to the holder Face the opening to the bottom of the vehi cle I Install the AC magneto coupler to the bat tery box J With the rectifier regulator disconnected install the battery negative lead starter motor lead and wire harness Insert them into the battery box rib The harness may be placed anywhere in the rib K Route the starter motor lead outside...

Page 104: ...CABLE ROUTING 2 49 Frame right side view ...

Page 105: ...ss fur ther outside of the vehicle than the fuse box C Insert the wire harness holder into bracket 1 D Insert the wire harness holder into the frame E Install the seat lock cable to bracket 1 F Route the rear brake lock cable further inside of the vehicle than bracket 1 G Route the immobilizer lead over the main switch coupler H Pass the wire harness side of the immobi lizer lead and the main swit...

Page 106: ...CABLE ROUTING 2 51 Rear frame top side and right side view ...

Page 107: ... side of the fuel tank fitting bracket I Insert the wire harness holder into the rear frame 2 points J Fit it to the rib part of the side cover K Secure the O2 sensor coupler to the wire harness L Route the fuel tank breather hose between the storage box and fuel tank M Fasten the seat lock cable to the cable holder attached to the fuel tank N Route the coolant temperature sensor lead under the re...

Page 108: ...CABLE ROUTING 2 53 Rear brake top side and left side view ...

Page 109: ...ll the rear brake hose holder left first and then brake hose holder B Face the opening of the brake hose holder upward C Route the brake hose along the concave face of the left rear cowling D Install the cap pushing it against the nut and washer E Route the rear brake lock cable under the brake hose F Face the opening of the cable holder to the inside of the vehicle G Install the rear brake lock c...

Page 110: ...CABLE ROUTING 2 55 Throttle body left side view ...

Page 111: ...eads and radiator should be turned downwards slightly to the front I Insert the air filter case until it touches the throttle body Engine oil may be applied J 8 K 3 L 30 M 65 N Insert the intake air pressure sensor hose until it does not move any further O Position the clip 1 to 4 mm 0 04 to 0 16 in away from the end of the cylinder head breather hose Face the clip to the left of the vehicle P Ins...

Page 112: ...CABLE ROUTING 2 57 Fuel tank top side left side and right side view ...

Page 113: ...Install the fuel tank overflow hose and filler cover pressing them against the connector boss Q Apply the holder aligning it with the upper end of the damper Face the holder open ing upward or downwards Make sure that the end of the holder does not run on the bending part of the tank R Insert the intake pressure sensor hose until it touches the pipe of the intake air pres sure sensor S 0 to 3 mm 0...

Page 114: ...CABLE ROUTING 2 59 Hydraulic unit top side and front side view ...

Page 115: ...aulic unit assembly bracket A Tighten the union bolt pushing the brake pipe against the hydraulic unit assembly bracket B Pass the rear brake hose between the bat tery box 2 and stay 1 C Install the grommet fitting it into the hole of the stay 1 at the space between the pipe of the stay 1 and the battery box 2 D Pass the brake hoses through the hole of the relay stay E Install the end of the mold ...

Page 116: ...CABLE ROUTING 2 61 ...

Page 117: ...REAR BRAKE PADS 3 15 BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS 3 16 CHECKING THE FRONT BRAKE HOSES 3 17 CHECKING THE REAR BRAKE HOSE 3 17 ADJUSTING THE REAR BRAKE LOCK CABLE 3 17 CHECKING THE REAR BRAKE LOCK 3 18 CHECKING THE REAR BRAKE LOCK PADS 3 19 CHECKING THE WHEELS 3 19 CHECKING THE TIRES 3 19 CHECKING THE WHEEL BEARINGS 3 20 CHECKING THE SWINGARM 3 20 CHECKING THE DRIVE BELT 3 20 ADJUSTING TH...

Page 118: ...RAKE LIGHT SWITCHES 3 32 CHECKING AND LUBRICATING THE CABLES 3 32 LUBRICATING THE REAR SUSPENSION 3 32 CHECKING THE THROTTLE GRIP 3 32 CHECKING AND CHARGING THE BATTERY 3 33 CHECKING THE FUSES 3 33 REPLACING THE HEADLIGHT BULBS 3 33 ADJUSTING THE HEADLIGHT BEAMS 3 34 ...

Page 119: ......

Page 120: ...ear except if a kilometer based maintenance or for the UK a mileage based maintenance is performed instead From 50000 km 30000 mi repeat the maintenance intervals starting from 10000 km 6000 mi Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills EAS59C1302 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM NO ITEM CHE...

Page 121: ...ires Check tread depth and for damage Replace if necessary Check air pressure Correct if necessary 10 Wheel bearings Check bearing for looseness or damage 11 Drive belt Check belt condition Replace if damaged Check belt tension Adjust if necessary Every 10000 km 6000 mi until 40000 km 24000 mi and every 5000 km 3000 mi thereafter 12 Drive pulley and drive axle Lubricate 13 Steering bearings Check ...

Page 122: ...internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 23 Cooling system Check coolant level and vehi cle for coolant leakage Change with ethylene glycol anti freeze coolant Every 3 years 24 V belt Replace When the V belt replacement indicator flashes every 20000 km 12500 mi 25 Front and rear brak...

Page 123: ...ENERAL CHASSIS on page 4 1 Center cover Refer to GENERAL CHASSIS on page 4 1 EAS20680 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Remove Radiator cover Refer to GENERAL CHASSIS on page 4 1 2 Disconnect Spark plug cap 3 Remove Spark plug ECA13320 Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to pre...

Page 124: ... Remove Radiator bracket Refer to RADIATOR on page 6 1 3 Remove Storage box Refer to GENERAL CHASSIS on page 4 1 4 Remove Fuel tank Refer to FUEL TANK on page 7 1 5 Remove Air filter case Throttle body Intake manifold Refer to THROTTLE BODY on page 7 5 6 Remove Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS on page 5 8 7 Remove Timing mark accessing plug 1 Crankshaft...

Page 125: ...he valve clearance in the following sequence d To measure the valve clearances of the other cylinders starting with cylinder 1 at TDC turn the crankshaft clockwise as specified in the following table 9 Remove Camshafts TIP Refer to CAMSHAFTS on page 5 8 When removing the timing chain and cam shafts fasten the timing chain with a wire to retrieve it if it falls into the crankcase 10 Adjust Valve cl...

Page 126: ...pad thickness is 1 55 mm 0 061 in d Calculate the sum of the values obtained in steps b and c to determine the required valve pad thickness and the valve pad number Example 1 55 mm 0 061 in 0 03 mm 0 001 in 1 58 mm 0 062 in The valve pad number is 158 e Round off the valve pad number according to the following table and then select the suitable valve pad TIP Refer to the following table for the av...

Page 127: ...er to CHECKING THE THROTTLE GRIP on page 3 32 EAS20610 ADJUSTING THE ENGINE IDLING SPEED TIP Prior to adjusting the engine idling speed the throttle body synchronization should be adjusted properly the air filter element should be clean and the engine should have ade quate compression 1 Start the engine and let it warm up for sev eral minutes 2 Remove Radiator cover Refer to GENERAL CHASSIS on pag...

Page 128: ...or cover Refer to GENERAL CHASSIS on page 4 1 Center cover Refer to GENERAL CHASSIS on page 4 1 Side covers Refer to GENERAL CHASSIS on page 4 1 Footboards Refer to GENERAL CHASSIS on page 4 1 3 Remove Intake air pressure sensor hose for cylin der 1 1 Synchronizing pipe cap for cylinder 2 2 4 Install Hose 1 Parts No 5JW 24311 00 3 Way joint 2 Parts No 68V 24376 00 Cylinder 1 intake air pressure se...

Page 129: ... 1 33 kPa 10 mm Hg 8 Measure Engine idling speed Out of specification Adjust Make sure that the vacuum pressure is within specification 9 Stop the engine and remove the measuring equipment 10 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 32 11 Install All removed parts EAS21010 CHECKING THE THROTTLE BODY JOINTS 1 Remove Center cover Refer to GENERAL CHASSIS on page 4...

Page 130: ...r more to execute the selection 5 Press the left set and right set buttons to select a cylinder TIP The selected cylinder number appears on the clock LCD To decrease the selected cylinder number press the right set button To increase the selected cylinder number press the left set button 6 After selecting the cylinder simultaneously press the left set and right set buttons for 2 seconds or more to...

Page 131: ...ase cover ECA4B51003 Never operate the engine without the air fil ter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect throttle body synchronization leading to poor engine performance and possible overheating TIP When installing the air filter element into the air filter case cover ...

Page 132: ...or water contact it 6 Install V belt case air filter element right V belt case air filter case V belt case air filter case cover 7 Install V belt case air filter element left 8 Install Footboards Refer to GENERAL CHASSIS on page 4 1 Center cover Refer to GENERAL CHASSIS on page 4 1 EAS30921 CHECKING THE BRAKE OPERATION 1 Check Brake operation Brake not working properly Check the brake system Refer...

Page 133: ...ster cylinder reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately TIP In order to ensure a correct reading of the brake fluid level make sure the top of the brake master cylinder reservoir is horizontal EAS21160 ADJUSTI...

Page 134: ... the adjusting dial 1 until the brake lever is in the desired position Be sure to align the setting on the adjusting dial with the arrow mark 2 on the brake lever holder WARNING EWA13060 After adjusting the brake lever position make sure the pin on the brake lever holder is firmly inserted in the hole in the adjusting dial A soft or spongy feeling in the brake lever can indicate the presence of ai...

Page 135: ...e hose have disappeared 1 Bleed ABS a Fill the brake master cylinder reservoir to the proper level with the specified brake fluid b Install the brake master cylinder reservoir diaphragm c Connect a clear plastic hose 1 tightly to the bleed screw 2 d Place the other end of the hose into a con tainer e Slowly apply the brake several times f Fully squeeze the brake lever and hold it in position g Loo...

Page 136: ... REAR BRAKE HOSE 1 Check Brake hose 1 Cracks damage wear Replace 2 Check Brake hose holders Loose connection Tighten the holder bolt 3 Hold the vehicle upright and apply the rear brake several times 4 Check Brake hose Brake fluid leakage Replace the dam aged hose Refer to REAR BRAKE on page 4 50 EAS21320 ADJUSTING THE REAR BRAKE LOCK CABLE WARNING EWA59C1301 Do not use the rear brake lock lever wh...

Page 137: ...he rear brake lock is acti vated g Install the cap of the rear brake lock adjust ing nut EAS59C1305 CHECKING THE REAR BRAKE LOCK 1 Check Rear brake lock operation Apply the rear brake lock and then push ing the vehicle for properly locks the rear brake lock Rear brake lock not working properly Check the rear brake lock cable and rear brake lock pads Refer to ADJUSTING THE REAR BRAKE LOCK CABLE on ...

Page 138: ...s to both of the tires 1 Check Tire pressure Out of specification Regulate WARNING EWA13180 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature The tire pressure and the suspension must be adjusted according to the total weight including cargo rider passenger and accessories and the anticipated riding speed Operation of an overloaded ...

Page 139: ...on of wheel rotation Align the mark 2 with the valve installation point EAS30780 CHECKING THE WHEEL BEARINGS The following procedure applies to all of the wheel bearings 1 Check Wheel bearings Refer to CHECKING THE FRONT WHEEL on page 4 20 and CHECKING THE REAR WHEEL on page 4 32 EAS30790 CHECKING THE SWINGARM 1 Check Swingarm operation Swingarm not working properly Check the swingarm Refer to REM...

Page 140: ...p and damage the swingarm or cause an accident Therefore keep the drive belt slack within the specified limits TIP Measure the drive belt slack when the drive belt is at room temperature and when the drive belt is dry 1 Stand the vehicle on a level surface WARNING EWA59C1302 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on the centerstand 2 Remove...

Page 141: ... on the left side and then adjust the distance on the right side to the same value as measured on the left side The difference in the distance c between the left and right sides should be 0 5 mm 0 02 in or less c Tighten the wheel axle nut to specification d Tighten the locknuts to specification EAS59C1304 LUBRICATING THE DRIVE PULLEY AND DRIVE AXLE 1 Remove Drive belt upper guard and lower guard ...

Page 142: ...RNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on a suitable stand so that the front wheel is elevated 2 Check Steering head Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head 3 Remove Upper bracket Refer to STEERING HEAD on page 4 89 4 Adjust Steering head Recommended lu...

Page 143: ...g Finger tighten the upper ring nut 2 then align the slots of both ring nuts If neces sary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 TIP Make sure the lock washer tabs a sit correctly in the ring nut slots b 5 Install Upper bracket Refer to STEERING HEAD on page 4 89 EAS30840 CHECKING THE CHASSIS FASTENERS Make sure that all nu...

Page 144: ...ck Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK on page 4 81 EAS59C1306 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Check Rear shock absorber assembly operation Push down hard on the seat several times and check if the rear shock absorber rebound smoothly Rough movement Replace Refer to RE...

Page 145: ...l again TIP Before checking the engine oil level wait a few minutes until the oil has settled EAS20791 CHANGING THE ENGINE OIL 1 Start the engine warm it up for several minutes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove Engine oil filler cap 1 along with the O ring Engine oil drain bolt 2 along with the gasket 4 Drain Engine oil completely from the crankcase ...

Page 146: ...el Refer to CHECKING THE ENGINE OIL LEVEL on page 3 25 12 Check Engine oil pressure a Remove the bottom side cowling and bot tom center cowling Refer to GENERAL CHASSIS on page 4 1 b Slightly loosen the oil check bolt 1 c Start the engine and keep it idling until engine oil starts to seep from the oil check bolt If no engine oil comes out after one minute turn the engine off so that it will not se...

Page 147: ...se WARNING EWA12980 The engine muffler and engine oil are extremely hot 4 Install Oil pressure gauge 1 Adapter 2 5 Measure Engine oil pressure at the following conditions Out of specification Adjust 6 Install Engine oil pressure check point plug TIP Lubricate the O ring of the engine oil pressure check point plug with a thin coat of lithium soap based grease Engine oil check bolt 20 Nm 2 0 m kgf 1...

Page 148: ...d water However if dis tilled water is not available soft water may be used 3 Start the engine warm it up for several minutes and then turn it off 4 Check Coolant level TIP Before checking the coolant level wait a few minutes until it settles EAS21120 CHECKING THE COOLING SYSTEM 1 Remove Center cover Refer to GENERAL CHASSIS on page 4 1 Side covers Refer to GENERAL CHASSIS on page 4 1 Footboards R...

Page 149: ... is hot Scalding hot fluid and steam may be blown out which could cause seri ous injury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radia tor cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape When the hissing sound has stopped press down on the radiator cap and turn it counterclockw...

Page 150: ...rvoir with the recommended coolant to the maximum level mark a 12 Install Coolant reservoir cap 13 Start the engine warm it up for several minutes and then stop it 14 Check Coolant level Refer to CHECKING THE COOLANT LEVEL on page 3 29 TIP Before checking the coolant level wait a few minutes until the coolant has settled 15 Install Footboard left Refer to GENERAL CHASSIS on page 4 1 Side cover lef...

Page 151: ...le and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricate TIP Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension EAS30890 CHECKING THE THROT...

Page 152: ... CHECKING AND CHARGING THE BATTERY Refer to CHECKING AND CHARGING THE BATTERY on page 8 127 EAS21770 CHECKING THE FUSES Refer to CHECKING THE FUSES on page 8 127 EAS21790 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs 1 Remove Front cover Refer to GENERAL CHASSIS on page 4 1 2 Disconnect Headlight coupler 1 3 Remove Headlight bulb 1 WARNING EWA13320 Si...

Page 153: ...djust Headlight beam vertically a Turn the adjusting screw 1 in direction a or b TIP Other than the socket wrench the adjusting screws can be turned with a screwdriver Phil lips No 2 2 as shown in the illustration 2 Adjust Headlight beam horizontally a Turn the adjusting screw 1 in direction a or b TIP Other than the socket wrench the adjusting screws can be turned with a screwdriver Phil lips No ...

Page 154: ...PERIODIC MAINTENANCE 3 35 ...

Page 155: ...NG THE REAR COVER 4 16 REMOVING THE INNER PANEL CENTER COVER 4 16 INSTALLING THE INNER PANEL CENTER COVER 4 16 REMOVING THE FUEL HOSE 4 17 INSTALLING THE FUEL HOSE 4 17 FRONT WHEEL 4 18 REMOVING THE FRONT WHEEL 4 20 DISASSEMBLING THE FRONT WHEEL 4 20 CHECKING THE FRONT WHEEL 4 20 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR 4 21 ASSEMBLING THE FRONT WHEEL 4 22 ADJUSTING THE FRONT WHEEL S...

Page 156: ...R BRAKE CALIPER 4 60 ASSEMBLING THE REAR BRAKE CALIPER 4 61 INSTALLING THE REAR BRAKE CALIPER 4 61 REMOVING THE REAR BRAKE MASTER CYLINDER 4 62 CHECKING THE REAR BRAKE MASTER CYLINDER 4 62 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 62 INSTALLING THE REAR BRAKE MASTER CYLINDER 4 62 REPLACING THE REAR BRAKE LOCK PADS 4 64 REPLACING THE REAR BRAKE LOCK CABLE 4 65 REMOVING THE REAR BRAKE LOCK CALIPER...

Page 157: ...EAD 4 90 INSTALLING THE STEERING HEAD 4 91 BELT DRIVE 4 92 CHECKING THE DRIVE BELT 4 93 INSTALLING THE DRIVE BELT 4 93 REAR SHOCK ABSORBER ASSEMBLY 4 94 HANDLING THE REAR SHOCK ABSORBER 4 95 DISPOSING OF A REAR SHOCK ABSORBER 4 95 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 95 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 95 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 95 SWINGARM 4 97 REMOVING THE...

Page 158: ...ERAL CHASSIS on page 4 1 Radiator cover Refer to GENERAL CHASSIS on page 4 1 Side panel Refer to GENERAL CHASSIS on page 4 1 1 Windshield cover 2 2 Windshield bracket 2 3 Windshield 1 4 Front cover 1 5 Rear view mirror 2 6 Windshield inner panel 1 7 Headlight sub wire harness coupler 1 Disconnect 8 Front cowling assembly 1 For installation reverse the removal proce dure ...

Page 159: ...Q ty Remarks 1 Side cowling 2 2 Headlight under panel 1 3 Turn signal light coupler 2 Disconnect 4 Auxiliary light coupler 1 Disconnect 5 Left turn signal light 1 6 Right turn signal light 1 7 Headlight sub wire harness 1 8 Headlight bulb 2 For assembly reverse the disassembly pro cedure ...

Page 160: ...ng assembly Refer to GENERAL CHASSIS on page 4 1 1 Inner panel center cover 1 2 Front left storage box 1 3 Battery 1 4 Meter coupler 1 Disconnect 5 Meter panel assembly 1 6 Meter assembly 1 7 Meter cover 1 8 Front right storage box 1 9 Storage compartment 1 For installation reverse the removal proce dure ...

Page 161: ...r Job Parts to remove Q ty Remarks 1 Footboard mat 4 2 Radiator cover 1 3 Side panel 2 4 Center cover 1 5 Side cover 2 6 Bottom side cowling 2 7 Bottom center cowling 1 8 Side cover moulding 2 9 Footboard 2 For installation reverse the removal proce dure ...

Page 162: ...d Refer to ENGINE REMOVAL on page 5 3 1 Seat 1 2 Fuel tank cover 1 3 Grab bar 2 4 Rear cover 1 5 Taillight lead cover 1 6 Taillight lead guide 1 7 Storage box light switch coupler 1 Disconnect 8 Storage box light switch 1 9 Seat hinge assembly 1 10 Taillight assembly coupler 1 Disconnect 11 License plate light lead coupler 1 Disconnect 12 Rear turn signal light lead coupler 2 Disconnect 13 Mud gua...

Page 163: ...GENERAL CHASSIS 4 6 Removing the rear cowling assembly Order Job Parts to remove Q ty Remarks 14 Rear fender 1 15 Rear cowling assembly 1 For installation reverse the removal proce dure ...

Page 164: ... assembly Order Job Parts to remove Q ty Remarks 1 Taillight bracket 1 2 Left rear cowling 1 3 Right rear cowling 1 4 Left turn signal light 1 5 Right turn signal light 1 6 Taillight 1 7 Taillight cover 1 For assembly reverse the disassembly pro cedure ...

Page 165: ...er 1 2 Fuel pump coupler 1 Disconnect 3 Fuel hose connector cover 1 4 Fuel hose 1 Disconnect 5 Fuel tank overflow hose 1 6 Storage box inner mat 1 7 Seat lock 1 8 Storage box light connector 2 Disconnect 9 Rollover valve stay 1 10 Storage box 1 11 Storage box light 1 For installation reverse the removal proce dure ...

Page 166: ...rews 2 d Removing the windshield brackets 3 EAS59C1408 INSTALLING THE WINDSHIELD 1 Install Windshield a Assembling the windshield 1 and wind shield brackets 2 with the windshield screws 3 b Installing the windshield assembly with the windshield bracket bolts 4 2 Install Windshield cover a Insert the projection into the hole and slide it downwards b Installing the quick fastener 1 Windshield screw ...

Page 167: ...esired position by installing the bolts 1 e Tighten the bolts to the specified torque f Installing the windshield cover Refer to INSTALLING THE WINDSHIELD on page 4 9 EAS59C1409 REMOVING THE FRONT COVER 1 Remove Front cover a Remove the two metal clips 1 and six claws 2 from the front cover b Pull the three projections 3 of the front cover to the front side and remove them c Remove the quick faste...

Page 168: ... of the end of the front cover c Installing the quick fastener 3 d Fit the two metal clips 4 and six claws 5 of the front cover EAS59C1411 REMOVING THE WINDSHIELD INNER PANEL 1 Remove Windshield inner panel a Removing the quick fasteners 1 b Removing the bolts 2 c Pull the two projections 3 of the wind shield inner panel to the front side and remove them ...

Page 169: ...inner panel b Installing the bolts 2 c Installing the quick fasteners 3 EAS59C1413 REMOVING THE SIDE PANEL 1 Remove Side panel a Removing the quick fasteners 1 b Removing the screws 2 c Remove the metal clip 3 EAS59C1414 INSTALLING THE SIDE PANEL 1 Install Side panel a Insert the metal clip 1 b Installing the screws 2 c Installing the quick fasteners 3 ...

Page 170: ...d remove the four claws 3 EAS59C1416 INSTALLING THE CENTER COVER 1 Install Center cover a Insert the four claws 1 b Installing the screws 2 EAS59C1417 REMOVING THE SIDE COVER 1 Remove Side cover a Removing the bolts 1 b Pull the five claws 2 outside of the vehicle and raise them c When the side cover is raised pull the side cover outsides of the vehicle and remove the five projections 3 EAS59C1418...

Page 171: ...ng the quick fastener 1 b Removing the screws 2 c Pull the side moulding outside of the vehi cle and remove the five claws 3 EAS59C1420 INSTALLING THE SIDE COVER MOULDING 1 Install Side cover moulding a Insert the five claws 1 b Installing the screws 2 c Installing the quick fastener 3 EAS59C1421 REMOVING THE FOOTBOARD 1 Remove Footboard a Removing the screws 1 b Removing the bolts 2 ...

Page 172: ...it EAS59C1422 INSTALLING THE FOOTBOARD 1 Install Footboard a Insert the three hooks of the footboard b Fit the three claws 1 c Installing the bolts 2 d Installing the screws 3 EAS59C1423 REMOVING THE REAR COVER 1 Remove Rear cowling a Removing the quick fasteners 1 A Left side B Right side A Left side B Right side ...

Page 173: ...though the holes of the rear cowling assembly Slide the cover forward to install it b Installing the quick fasteners 2 EAS59C1425 REMOVING THE INNER PANEL CENTER COVER 1 Remove Inner panel center cover a Removing the screws 1 b There are six claws 2 Remove them starting from the top EAS59C1426 INSTALLING THE INNER PANEL CENTER COVER 1 Install Inner panel center cover a Fit the six claws 1 starting...

Page 174: ...ere may be fuel remaining in it Do not disconnect the fuel hose from the fuel hose connector Disconnect the con nector from the fuel pump TIP Before removing the hose place a few rags in the area under where it will be removed EAS59C1429 INSTALLING THE FUEL HOSE 1 Connect Fuel hose 2 Install Fuel hose connector cover ECA59C1702 When installing the fuel hose make sure that it is securely connected ...

Page 175: ... wheel sensor coupler 1 Disconnect 2 Front brake hose holder 2 3 Cable guide 1 4 Front wheel sensor 1 5 Front brake caliper 2 6 Front wheel axle pinch bolt 1 Loosen 7 Front wheel axle 1 8 Front wheel 1 9 Front wheel sensor housing 1 10 Collar 1 Length 12 mm 0 47 in 11 Collar 1 Length 18 mm 0 71 in 12 Front brake disc 2 13 Front fender 1 For installation reverse the removal proce dure ...

Page 176: ...embling the front wheel Order Job Parts to remove Q ty Remarks 1 Front wheel sensor rotor 1 2 Oil seal 2 3 Wheel bearing right 1 4 Collar 1 5 Wheel bearing left 1 6 Air valve 1 For assembly reverse the disassembly pro cedure ...

Page 177: ... wheel axle pinch bolt 5 Remove Front wheel axle Front wheel sensor housing Collars Front wheel EAS21910 DISASSEMBLING THE FRONT WHEEL ECA59C2406 Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the wheel sensor rotor Do not drop the wheel sensor rotor or subject it to shocks If any solvent gets on the wheel sensor rotor wipe it off immediately 1 Remove Front wheel...

Page 178: ...dirt and do not sub ject them to shocks The front wheel sensor cannot be disas sembled Do not attempt to disassemble it If faulty replace with a new one Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the wheel sensor rotor Do not drop or shock the wheel sensor or the wheel sensor rotor 1 Check Front wheel sensor 1 Cracks bends distortion Replace Iron powder dust ...

Page 179: ...ts with new ones d If the deflection is still above specification replace the wheel sensor rotor EAS21960 ASSEMBLING THE FRONT WHEEL 1 Install Wheel bearings Oil seals a Install the new wheel bearing left side ECA4B51004 Do not apply pressure to the wheel bearing inner race 1 or balls 2 Pressure should only be applied to the outer race 3 TIP Use a socket 4 that matches the diameter of the wheel be...

Page 180: ...ANCE TIP After replacing the tire wheel or both the front wheel static balance should be adjusted Adjust the front wheel static balance with the brake disc installed 1 Remove Balancing weight s 2 Find Front wheel s heavy spot TIP Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 9...

Page 181: ... 90 so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wheel is balanced 4 Check Front wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain station ary at all of the positions rebalance it EAS21990 INSTALLING THE FR...

Page 182: ...r replace the wheel sensor rotor 7 Install Front brake calipers Cable guide Front wheel sensor Front brake hose holders TIP When installing the front wheel sensor check the wheel sensor lead for twists and the sensor electrode for foreign materials ECA59C2409 Make sure there are no foreign materials in the wheel hub Foreign materials cause damage to the inner sensor rotor and wheel sensor To route...

Page 183: ...FRONT WHEEL 4 26 8 Check Front wheel sensor installation Check if the wheel sensor housing is installed properly ...

Page 184: ... 1 Rear wheel sensor coupler 1 Disconnect 2 Rear brake hose holder right 1 3 Rear wheel sensor lead holder 1 4 Rear wheel sensor 1 5 Rear brake caliper 1 6 Rear brake pad 2 7 Rear brake lock cable adjusting nut 1 8 Pin 1 9 Rear brake lock spring 1 10 Rear brake lock caliper 1 11 Drive belt upper guard 1 Non disassemble 12 Drive belt lower guard 1 Non disassemble 13 Drive belt adjusting locknut 2 L...

Page 185: ...ob Parts to remove Q ty Remarks 15 Wheel axle nut 1 16 Washer 1 17 Adjusting block right 1 18 Rear wheel axle 1 19 Adjusting block left 1 20 Rear wheel 1 21 Rear brake caliper bracket 1 22 Caliper bolt boot 2 23 Rear wheel sensor housing 1 24 Collar right 1 25 Collar left 1 26 Dust cover 1 For installation reverse the removal proce dure ...

Page 186: ...rear brake disc and rear wheel pulley Order Job Parts to remove Q ty Remarks 1 Rear brake disc 1 2 Rear wheel sensor rotor 1 3 Drive belt guide 1 4 Rear wheel pulley 1 5 Rear wheel 1 For installation reverse the removal proce dure ...

Page 187: ...WHEEL 4 30 Disassembling the rear wheel assembly Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing left 1 3 Collar 1 4 Wheel bearing right 1 For assembly reverse the disassembly pro cedure ...

Page 188: ...ear brake lock caliper 3 TIP Do not apply the brake lever when removing the brake caliper 3 Loosen Locknuts 1 Adjusting bolts 2 left side and right side 4 Remove Wheel axle nut 1 Washer Rear wheel axle 2 Rear wheel Rear brake caliper bracket Rear wheel sensor housing Collars TIP Push the rear wheel forward and remove the drive belt from the rear wheel pulley EAS22080 DISASSEMBLING THE REAR WHEEL E...

Page 189: ...Replace the rear wheel pulley Bent teeth Replace the rear wheel pul ley Drive belt guide Cracks damage wear Replace the drive belt guide 2 Replace Rear wheel pulley a Remove the drive belt guide bolts and the drive belt guide b Remove the rear wheel pulley bolts and the rear wheel pulley c Clean the rear wheel drive hub with a clean cloth especially the surfaces that contact the pulley d Install t...

Page 190: ... Clean the installa tion surface of the wheel sensor rotor and correct the wheel sensor rotor deflection or replace the wheel sensor rotor a Hold the dial gauge at a right angle against the wheel sensor rotor surface b Measure the deflection 5 5 mm 0 22 in below the edge of the wheel sensor rotor TIP Do not touch the surface of the rotor magnet with a sharp object c If the deflection is above spec...

Page 191: ...talled 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 23 EAS22160 INSTALLING THE REAR WHEEL DISC 1 Install Rear brake disc ECA59C1401 Replace the brake disc bolts with new ones TIP Tighten the brake disc bolts in stages and in a crisscross pattern 2 Check Rear brake disc Refer to CHECKING THE REAR BRAKE DISC on page 4 58 3 Lubricate Oil seal lips 4 I...

Page 192: ...block so that upper chamfer h faces to the top of the vehicle and lower chamfer h faces to the bottom of the vehicle 5 Install Rear brake caliper Rear brake lock caliper temporarily 6 Adjust Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 21 7 Tighten Wheel axle nut Rear brake caliper bolts Rear brake lock caliper bolts WARNING EWA13500 Make sure the brake hose is routed prop er...

Page 193: ...tall Rear wheel sensor 1 TIP When installing the rear wheel sensor check the rear wheel sensor lead for twists and the sensor electrode for foreign materials ECA14500 To route the rear wheel sensor lead refer to CABLE ROUTING on page 2 39 10 Check Rear wheel sensor installation Check if the wheel sensor housing is installed properly Distance a between the wheel sensor rotor and wheel sensor housin...

Page 194: ...plies to both of the front brake calipers 1 Front brake hose holder bolt 1 2 Front brake caliper bolt 2 3 Front brake caliper 1 4 Brake pad clip 2 5 Brake pad pin 1 6 Brake pad spring 1 7 Front brake pad 2 8 Bleed screw 1 Left brake caliper side 9 Bleed screw 1 Right brake caliper side For installation reverse the removal proce dure ...

Page 195: ...6 1 Brake master cylinder reservoir cap 1 2 Brake master cylinder reservoir diaphragm holder 1 3 Brake master cylinder reservoir diaphragm 1 4 Front brake lever 1 5 Front brake light switch connector 2 Disconnect 6 Brake hose union bolt 1 7 Front brake hose 1 8 Brake hose gasket 2 9 Front brake master cylinder holder 1 10 Front brake master cylinder 1 11 Front brake light switch 1 For installation...

Page 196: ...T BRAKE 4 39 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure ...

Page 197: ...es to both of the front brake calipers Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 16 1 Front brake hose holder bolt 1 2 Brake hose union bolt 1 3 Brake hose gasket 2 4 Front brake hose 1 5 Front brake caliper bolt 2 6 Front brake caliper 1 For installation reverse the removal proce dure ...

Page 198: ... both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Front brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston dust seal 4 7 Brake caliper piston seal 4 8 Bleed screw 1 Left brake caliper side 9 Bleed screw 1 Right brake caliper side For assembly reverse the disassembly pro cedure ...

Page 199: ...es to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 18 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflection turn the handlebar to the left or right ...

Page 200: ...ary to disconnect the brake hose or disas semble the brake caliper 1 Remove Brake hose holder Front brake caliper Brake pad clips 1 Brake pad pin 2 Brake pad spring 2 Remove Brake pads 1 3 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 4 Install Brake pads Brake pad spring TIP Always install new brake pads and new brake pad spring as a set a Connect a clear pla...

Page 201: ...KE SYSTEM ABS on page 3 16 EAS22300 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Front brake hose holder bolt 1 Brake hose union bolt 2 Brake hose gaskets 3 Front brake hose 4 TIP Put the end of the brake hose into a container and pump out the brake f...

Page 202: ...aliper pistons Brake caliper cylinders 2 Scratches wear Replace the brake cal iper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA13611 Whenever a brake caliper is disassembled replace the brake caliper piston dust seals and brake caliper piston seals EAS22411 ASSEMB...

Page 203: ...e hose holder Refer to REPLACING THE FRONT BRAKE PADS on page 4 43 4 Fill Brake master cylinder reservoir with the specified amount of the speci fied brake fluid WARNING EWA59C2401 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing b...

Page 204: ...e a container under the master cylinder and the end of the brake hose EAS22500 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder Damage scratches wear Replace Brake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage scratches wear Replace 3 Check Brake master cylinder reservoir cap 1 Brake master...

Page 205: ... the specified amount of the speci fied brake fluid WARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be caref...

Page 206: ...FRONT BRAKE 4 49 6 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 16 ...

Page 207: ... BRAKE Removing the rear brake pads Order Job Parts to remove Q ty Remarks 1 Rear brake caliper bolt 2 2 Rear brake caliper 1 3 Rear brake pad 2 4 Brake pad support 2 5 Bleed screw 1 For installation reverse the removal proce dure ...

Page 208: ... 16 1 Brake master cylinder reservoir cap 1 2 Brake master cylinder reservoir diaphragm holder 1 3 Brake master cylinder reservoir diaphragm 1 4 Rear brake lever 1 5 Rear brake light switch connector 2 Disconnect 6 Brake hose union bolt 1 7 Rear brake hose 1 8 Brake hose gasket 2 9 Rear brake master cylinder holder 1 10 Rear brake master cylinder 1 11 Rear brake light switch 1 For installation rev...

Page 209: ...R BRAKE 4 52 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure ...

Page 210: ...d Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 16 1 Brake hose union bolt 1 2 Brake hose gasket 2 3 Rear brake hose 1 4 Rear brake caliper bolt 2 5 Rear brake caliper 1 6 Rear brake pad 2 7 Brake pad support 2 8 Caliper bolt boot 2 For installation reverse the removal proce dure ...

Page 211: ... rear brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 5 Brake caliper body 1 For assembly reverse the disassembly pro cedure ...

Page 212: ...ar brake lock pads Order Job Parts to remove Q ty Remarks 1 Rear brake lock cable adjusting nut 1 2 Pin 1 3 Rear brake lock spring 1 4 Rear brake lock caliper 1 5 Rear brake lock pad 2 For installation reverse the removal proce dure ...

Page 213: ...ving the rear brake lock caliper Order Job Parts to remove Q ty Remarks 1 Rear brake lock cable adjusting nut 1 2 Pin 1 3 Rear brake lock spring 1 4 Rear brake lock caliper 1 For installation reverse the removal proce dure ...

Page 214: ... lock adjusting nut 1 3 Rear brake lock caliper arm 1 4 Boot 1 5 Rear brake lock pad 2 6 Caliper piston assembly 1 7 Boot 1 8 Sleeve 1 9 Boot 2 10 Rear brake lock caliper bracket bolt 1 11 Rear brake lock caliper bracket 1 12 Slide pin bolt 1 13 Rear brake lock caliper 1 For assembly reverse the disassembly pro cedure ...

Page 215: ...e Rear wheel Refer to REAR WHEEL on page 4 27 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 42 4 Measure Brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace Refer to CHECKING THE FR...

Page 216: ...brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 14 7 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 16 EAS22590 REMOVING THE REAR BRAKE CALIPER TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolt 1 Brake hose gas...

Page 217: ...BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scratches wear Replace the brake cal iper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA59C1403 Whenever a brake caliper is disassembled replac...

Page 218: ...aliper 2 Remove Rear brake caliper 3 Install Brake pad supports Rear brake pads Rear brake caliper Rear brake caliper bolt Refer to REPLACING THE REAR BRAKE PADS on page 4 58 4 Fill Brake master cylinder reservoir with the specified amount of the speci fied brake fluid WARNING EWA4B51011 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakag...

Page 219: ...the master cylinder and the end of the brake hose EAS22710 CHECKING THE REAR BRAKE MASTER CYLINDER 1 Check Brake master cylinder Damage scratches wear Replace Brake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage scratches wear Replace 3 Check Brake master cylinder reservoir cap Brake master cylinder reservoir Bra...

Page 220: ...ARNING EWA4B51011 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the brake master cylin...

Page 221: ...2 Remove Rear brake lock caliper bolts 1 Rear brake lock caliper 2 3 Remove Rear brake lock pad left side 1 TIP Push on the back of the pad using a rod with a round end 4 Remove Rear brake lock pad right side 2 a Slide the rear brake lock caliper bracket b Insert a flathead screwdriver in between the piston adjusting bolt and rear brake lock pad and then remove the rear brake lock pad ECA59C1404 A...

Page 222: ...CK CABLE on page 3 17 EAS59C1431 REPLACING THE REAR BRAKE LOCK CABLE 1 Remove Rear brake lock cable 2 Check Rear brake lock cable Cracks damage wear Replace the rear brake lock cable 3 Install Rear brake lock cable WARNING EWA59C1405 Proper brake lock cable routing is essential to insure safe vehicle operation Refer to CABLE ROUTING on page 2 39 4 Adjust Rear brake lock cable length a Adjust the c...

Page 223: ...er bracket 2 Sleeve 3 Rear brake lock caliper 4 Locknut 5 Shaft L 6 Piston adjusting bolt 7 Boots 8 Cracks damage Replace EAS59C1405 ASSEMBLING THE REAR BRAKE LOCK CALIPER 1 Install Slide pin bolt 1 to the rear brake lock caliper bracket 2 Install Rear brake lock caliper bracket 3 Install Boots 1 Sleeve 2 4 Install Boot 1 Slide pin bolt 17 Nm 1 7 m kgf 12 ft lbf Recommended lubricant Silicone grea...

Page 224: ...closest to cable holder 2 8 Install Rear brake lock adjusting nut Cap 9 Install Rear brake lock pads ECA59C1405 After installing the rear brake lock pad to the caliper check that the pad rotates smoothly EAS59C1406 INSTALLING THE REAR BRAKE LOCK CALIPER 1 Install Rear brake lock caliper 1 Rear brake lock caliper bolts 2 Rear brake lock spring 3 Pin 4 Rear brake lock cable adjusting nut 5 2 Adjust ...

Page 225: ...to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 16 Front brake hose front brake master cylinder side Disconnect Refer to FRONT BRAKE on page 4 37 Rear brake hose rear brake master cylinder side Disconnect Refer to REAR BRAKE on page 4 50 1 ABS ECU coupler 1 Disconnect 2 Brake hose holder 1 3 Front brake hose hydraulic unit to front brake hose joint 1 4 Front brake hose front brake master cyli...

Page 226: ...to remove Q ty Remarks 6 Rear brake hose rear brake pipe joint assembly to rear brake caliper 1 Disconnect 7 Rear brake pipe joint assembly hydraulic unit to rear brake hose 1 8 Hydraulic unit assembly bracket 1 9 Hydraulic unit assembly 1 For installation reverse the removal proce dure ...

Page 227: ...lic unit assembly have been removed be sure to tighten them to the specified torque and bleed the brake system 1 Remove Brake hoses Rear brake pipe joint assembly TIP Do not operate the brake levers while remov ing the brake hoses and rear brake pipe joint assembly ECA59C2412 When removing the brake hoses and rear brake pipe joint assembly cover the area around the hydraulic unit assembly to catch...

Page 228: ...pipe joint assembly bolt Brake hose gaskets Brake hose union bolt 2 ECA59C2401 If the brake pipe flare nut does not turn eas ily replace the hydraulic unit brake pipes and related parts as a set TIP When installing the rear brake pipe joint assembly hydraulic unit to rear brake hose temporarily tighten the flare nut and rear brake pipe joint assembly bolt first After that tighten the flare nut and...

Page 229: ... poor brake perfor mance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 7 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTE...

Page 230: ...P If the battery voltage is lower than 12 8 V charge the battery and then perform hydrau lic unit operation test 1 If the battery voltage is lower than 10 V the ABS does not operate 5 Connect the test coupler adapter 1 to the ABS test coupler 2 6 Set the main switch to ON while operating the front brake lever and the rear brake lever simultaneously TIP Do not push the start switch when setting the...

Page 231: ...ace the vehicle on the centerstand 2 Set the main switch to OFF 3 Remove Front left storage box Refer to GENERAL CHASSIS on page 4 1 4 Check Battery voltage Lower than 12 8 V Charge or replace the battery TIP If the battery voltage is lower than 12 8 V charge the battery and then perform hydrau lic unit operation test 2 If the battery voltage is lower than 10 V the ABS does not operate 5 Connect t...

Page 232: ...econds TIP The reaction force pulsating action consists of quick pulses ECA59C2403 Check that the pulse is felt in the front brake lever rear brake lever and again in the front brake lever in this order If the pulse is felt in the rear brake lever before it is felt in the front brake lever check that the brake hoses and brake pipes are connected correctly to the hydraulic unit assembly If the puls...

Page 233: ...efer to GENERAL CHASSIS on page 4 1 Meter assembly Refer to GENERAL CHASSIS on page 4 1 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 16 1 Upper handlebar cover 1 2 Holder 3 3 Grip end 2 4 Front brake light switch connector 2 Disconnect 5 Right handlebar switch 1 6 Throttle cable 2 Disconnect 7 Throttle grip 1 8 Front brake hose 1 Disconnect 9 Front brake master cyli...

Page 234: ...brake lock lever 1 14 Rear brake lock cable 1 Disconnect 15 Left handlebar switch 1 16 Rear brake hose 1 Disconnect 17 Rear brake master cylinder holder 1 18 Rear brake master cylinder assembly 1 19 Handlebar grip 1 20 Lower handlebar cover 1 21 Upper handlebar holder 2 22 Handlebar 1 23 Front brake pipe joint assembly 1 24 Lower handlebar holder 1 25 Brake hose bracket 1 For installation reverse ...

Page 235: ...ace WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Brake hose bracket Lower handlebar holder Front brake pipe joint assembly 3 Install Handlebar Upper handlebar holder TIP Align the punch mark on the handlebar to the end of the lower handlebar holder First tighten the bolts on the front side of the upper handlebar holder and then on the rear s...

Page 236: ... 1 Rear brake lock lever Rear brake lock lever holder TIP Align the projection a on the left handlebar switch with the hole b in the handlebar Install the rear brake lock cable after rotating the lever to the position shown in the illustra tion 9 Connect Rear brake light switch connector 10 Install Front brake master cylinder assembly 1 Front brake master cylinder holder 2 TIP Install the front br...

Page 237: ...oothly TIP Align the projection a on the right handlebar switch with the hole b in the handlebar 13 Connect Front brake light switch connector 14 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 32 15 Adjust Rear brake lock cable length Refer to ADJUSTING THE REAR BRAKE LOCK CABLE on page 3 17 16 Install Grip end Holder Upper handlebar cover Throttle grip free play 3 0 ...

Page 238: ...Storage compartment Refer to GENERAL CHASSIS on page 4 1 Front wheel Front fender Refer to FRONT WHEEL on page 4 18 1 Cap bolt cover 1 Right front fork side 2 Upper bracket pinch bolt 1 Loosen 3 Cap bolt 1 Loosen 4 Horn lead coupler 1 Disconnect 5 Brake pipe joint 1 6 Horn 1 7 Lower bracket pinch bolt 2 Loosen 8 Front fork leg 1 9 Lower bracket cover 1 10 Horn bracket 1 For installation reverse th...

Page 239: ...1 Cap bolt 1 2 O ring 1 3 Spacer 1 4 Fork spring seat 1 5 Fork spring 1 6 Dust seal 1 7 Oil seal clip 1 8 Damper rod bolt 1 9 Copper washer 1 10 Damper rod 1 11 Rebound spring 1 12 Inner tube 1 13 Oil seal 1 14 Washer 1 15 Outer tube bushing 1 16 Inner tube bushing 1 17 Oil flow stopper 1 18 Outer tube 1 For assembly reverse the disassembly pro cedure ...

Page 240: ...NING EWA13640 Before loosening the upper and lower bracket pinch bolts support the front fork leg 4 Remove Front fork leg EAS22980 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove Cap bolt Spacer Fork spring seat Fork spring 2 Drain Fork oil TIP Stroke the inner tube several times while drain ing the fork oil 3 Remove Dust seal 1 Oil seal cl...

Page 241: ... will be damaged EAS23011 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check Inner tube 1 Outer tube 2 Bends damage scratches Replace WARNING EWA13650 Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure Spring free length a Out of specification Replace 3 Check Damper rod 1 Damage wear Replace Obstruction Blow o...

Page 242: ...nents are clean 1 Install Damper rod 1 Rebound spring 2 ECA14210 Allow the damper rod assembly to slide slowly down the inner tube 3 until it pro trudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Install Oil flow stopper 1 3 Lubricate Inner tube s outer surface 2 4 Install Inner tube into the outer tube Copper washer Damper rod bolt 5 Tighten Damper rod bolt 1 TIP ...

Page 243: ... oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation 8 Install Oil seal clip 1 TIP Adjust the oil seal clip so that it fits into the outer tube s groove 9 Install Dust seal 1 with the fork seal driver weight 2 10 Fill Front fork leg with the specified amount of the recom mended fork oil Fork seal driver weight 90890 01367 Replacement hammer Y...

Page 244: ...leed the front fork leg of any resid ual air 13 Measure Front fork leg oil level a Out of specification Correct 14 Install Fork spring Fork spring seat Spacer Cap bolt along with the O ring TIP Temporarily tighten the cap bolt EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower brack...

Page 245: ...FRONT FORK 4 88 3 Install Cap bolt cover right front fork side Upper bracket pinch bolt 30 Nm 3 0 m kgf 22 ft lbf 1 ...

Page 246: ...SIS on page 4 1 Front wheel Refer to FRONT WHEEL on page 4 18 Handlebar Refer to HANDLEBAR on page 4 76 Front fork legs Refer to FRONT FORK on page 4 81 1 Steering stem nut 1 2 Upper bracket 1 3 Lock washer 1 4 Upper ring nut 1 5 Rubber washer 1 6 Lower ring nut 1 7 Lower bracket 1 8 Upper bearing cover 1 9 Upper bearing 1 10 Lower bearing 1 11 Dust seal 1 For installation reverse the removal proc...

Page 247: ... Wash Bearings Bearing races 2 Check Bearings 1 Bearing races 2 Damage pitting Replace 3 Replace Bearings Bearing races a Remove the bearing races from the steer ing head pipe 1 with a long rod 2 and hammer b Remove the bearing race from the lower bracket 3 with a floor chisel 4 and ham mer c Install a new rubber seal and new bearing races ECA14270 If the bearing race is not installed properly the...

Page 248: ...er ring nut 3 Lock washer 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 23 3 Install Upper bracket Washer Steering stem nut TIP Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 81 TIP Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut Recommended lubricant Lithium soap based grease Steering stem n...

Page 249: ... Rear wheel Refer to REAR WHEEL on page 4 27 1 Rear brake lock cable holder swingarm 1 2 Rear brake hose bracket 1 3 Rear brake hose holder right 1 4 Rear brake hose holder left 1 5 Drive pulley cover 1 6 Dust cover 1 7 Drive pulley 1 8 Circlip 1 9 Bearing 1 10 Holder 1 11 Collar 2 12 Drive belt 1 For installation reverse the removal proce dure ...

Page 250: ... belt from the mixture and rinse it off with clean water Then let the drive belt thoroughly dry 2 Check Drive belt Refer to CHECKING THE DRIVE BELT on page 3 20 3 Check Drive pulley 1 Rear wheel pulley 2 Bent teeth Replace the drive belt and pulleys as a set 4 Check Holder 1 Cracks damage Replace EAS23540 INSTALLING THE DRIVE BELT 1 Install Drive belt 2 Adjust Drive belt slack Refer to ADJUSTING T...

Page 251: ...arts to remove Q ty Remarks Exhaust assembly Refer to ENGINE REMOVAL on page 5 3 1 Rear shock absorber assembly front bolt 1 2 Lock washer 1 3 Collar 1 4 Rear shock absorber assembly rear nut bolt 1 1 5 Rear shock absorber assembly 1 6 Collar 1 7 Washer 1 8 Spacer 1 9 Bearing 2 For installation reverse the removal proce dure ...

Page 252: ...h the rear shock absorber at a point from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23210 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on the centerstand so that the rear wheel is ...

Page 253: ...r shock absorber assembly front bolt TIP With the swingarm and rear wheel lowered by own weight tighten the rear shock absorber assembly front bolt and rear shock absorber assembly rear nut After tightening the rear shock absorber assembly front bolt align the wide claw with the bolt head and bent it Recommended lubricant Lithium soap based grease Rear shock absorber assembly rear nut 53 Nm 5 3 m ...

Page 254: ...BSORBER ASSEMBLY on page 4 94 Drive belt Refer to BELT DRIVE on page 4 92 Exhaust assembly Refer to ENGINE REMOVAL on page 5 3 1 Drive belt inner guard 1 Non disassemble 2 Left swingarm 1 3 Right swingarm 1 4 Dowel pin 2 5 Swingarm stopper 1 6 Pivot shaft 1 7 Oil seal 1 8 Oil seal 1 9 Outer race 1 10 Bearing 1 11 Bearing housing 1 12 O ring 1 ...

Page 255: ...SWINGARM 4 98 Removing the swingarm Order Job Parts to remove Q ty Remarks 13 Collar 1 14 Oil seal 1 15 Bearing 1 For installation reverse the removal proce dure ...

Page 256: ... swingarm vertical movement is not smooth or if there is binding check the bearings 3 Remove Drive belt Refer to BELT DRIVE on page 4 92 4 Remove Drive pulley assembly bolt Swingarm bolt Pivot shaft nut EAS23371 CHECKING THE SWINGARM 1 Check Left swingarm 1 Right swingarm 2 Bends cracks damage Replace 2 Check Drive pulley assembly bolts Swingarm bolts Damage wear Replace EAS28780 INSTALLING THE SW...

Page 257: ...embly Drive pulley assembly bolt 4 Tighten Pivot shaft Pivot shaft nut a With your fingers screw in the pivot shaft until it touches the collar and then tighten the pivot shaft to the specified torque b Tighten the pivot shaft nut to the specified torque Swingarm bolt 40 Nm 4 0 m kgf 29 ft lbf Drive pulley assembly bolt 48 Nm 4 8 m kgf 35 ft lbf Pivot shaft 7 Nm 0 7 m kgf 5 1 ft lbf Pivot shaft nu...

Page 258: ...SWINGARM 4 101 ...

Page 259: ... THE CYLINDER HEAD 5 19 INSTALLING THE CYLINDER HEAD 5 19 VALVES AND VALVE SPRINGS 5 21 REMOVING THE VALVES 5 22 CHECKING THE VALVES AND VALVE GUIDES 5 23 CHECKING THE VALVE SEATS 5 24 CHECKING THE VALVE SPRINGS 5 26 CHECKING THE VALVE LIFTERS 5 27 INSTALLING THE VALVES 5 27 CYLINDER AND PISTONS 5 29 REMOVING THE PISTONS 5 30 CHECKING THE CYLINDERS AND PISTONS 5 30 CHECKING THE PISTON RINGS 5 31 C...

Page 260: ...E STARTER CLUTCH 5 53 CHECKING THE STARTER CLUTCH 5 53 CHECKING THE OIL STRAINER 5 54 ASSEMBLING THE OIL TANK 5 54 INSTALLING THE STARTER CLUTCH 5 54 INSTALLING THE GENERATOR 5 55 CLUTCH 5 57 REMOVING THE CLUTCH 5 60 DISASSEMBLING THE CLUTCH 5 60 CHECKING THE FRICTION PLATES 5 61 CHECKING THE CLUTCH PLATES 5 61 CHECKING THE CLUTCH DAMPER SPRINGS 5 61 CHECKING THE CLUTCH SPRING PLATE 5 61 CHECKING ...

Page 261: ...KCASE 5 72 CRANKSHAFT 5 74 REMOVING THE CONNECTING RODS 5 76 REMOVING THE CRANKSHAFT JOURNAL BEARINGS 5 76 CHECKING THE CRANKSHAFT AND CONNECTING RODS 5 76 INSTALLING THE CRANKSHAFT JOURNAL BEARINGS 5 80 INSTALLING THE CONNECTING RODS 5 80 INSTALLING THE CRANKSHAFT ASSEMBLY 5 82 TRANSMISSION 5 83 CHECKING THE TRANSMISSION 5 84 ...

Page 262: ...k the engine until the reading on the compres sion gauge stabilizes TIP The difference in compression pressure between cylinders should not exceed 100 kPa 1 kgf cm 14 psi c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the minimum specificati...

Page 263: ...ENGINE INSPECTION 5 2 9 Connect Spark plug caps 10 Install Radiator cover Refer to GENERAL CHASSIS on page 4 1 ...

Page 264: ...sor coupler 1 Disconnect 2 O2 sensor 1 3 Exhaust assembly 1 4 Gasket 2 5 Front muffler protector 1 6 Center muffler protector 1 7 Upper muffler protector 1 8 Muffler end 1 TIP When installing the muffler end face the dummy bolt to the upper side of the muffler It is not required to remove the dummy bolt 9 Muffler end bracket 1 For installation reverse the removal proce dure ...

Page 265: ...uel tank Refer to FUEL TANK on page 7 1 Front wheel Front fender Refer to FRONT WHEEL on page 4 18 Intake manifold Refer to THROTTLE BODY on page 7 5 Radiator bracket Refer to RADIATOR on page 6 1 Water pump inlet pipe Refer to WATER PUMP on page 6 9 Oil cooler outlet hose Refer to OIL COOLER on page 6 5 Exhaust assembly Refer to ENGINE REMOVAL on page 5 3 Rear wheel Refer to REAR WHEEL on page 4 ...

Page 266: ...n sensor coupler 1 Disconnect 3 Stator coil coupler 1 Disconnect 4 Sidestand switch coupler 1 Disconnect 5 Coolant temperature sensor coupler 1 Disconnect 6 Ground lead 1 Disconnect 7 Starter motor lead 1 Disconnect 8 Rear brake lock cable holder crankcase 1 9 Wire harness 1 Disconnect For installation reverse the removal proce dure ...

Page 267: ...olt 2 3 Engine mounting nut rear side 1 4 Engine mounting bolt rear side 1 5 Spacer 1 6 Rear frame 1 7 Engine mounting bolt front left lower side 2 8 Left footboard bracket 1 9 Sidestand 1 10 Engine mounting bolt front right lower side 2 11 Engine mounting nut front upper side 1 12 Engine mounting bolt front upper side 1 13 Engine 1 For installation reverse the removal proce dure ...

Page 268: ...ear side 4 Rear frame bolts 5 TIP When tightening the engine mounting nuts and engine mounting bolts do not apply an upward load to the frame such as supporting the area around steering head of the frame upwards Also do not apply an upward or downward load on the rear frame such as supporting the rear end of the rear frame upwards or pushing it downwards Engine mounting nut front upper side 88 Nm ...

Page 269: ...ANGING THE ENGINE OIL on page 3 26 Air filter case Refer to THROTTLE BODY on page 7 5 1 Spark plug cap 2 Disconnect 2 Spark plug 2 3 Cylinder head breather hose 1 Disconnect 4 Cylinder head cover 1 5 Cylinder head cover gasket 1 6 Dowel pin 2 7 Gasket 2 8 Timing chain guide upper side 1 For installation reverse the removal proce dure ...

Page 270: ... SION on page 5 39 Storage box Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Intake manifold Refer to THROTTLE BODY on page 7 5 Cylinder head cover Refer to CAMSHAFTS on page 5 8 1 Timing mark accessing plug 1 2 Timing chain tensioner rod accessing plug 1 3 Timing chain tensioner 1 4 Timing chain tensioner gasket 1 5 Intake camshaft cap 1 6 Exhaust camshaft cap 1 ...

Page 271: ...camshafts Order Job Parts to remove Q ty Remarks 7 Dowel pin 4 TIP During removal the dowel pins may still be connected to the camshaft caps 8 Intake camshaft 1 9 Exhaust camshaft 1 For installation reverse the removal proce dure ...

Page 272: ...re that the piston is at TDC the alignment marks c on the intake cam shaft sprocket and the alignment marks d on the exhaust camshaft sprocket must align with the cylinder head mating surface as shown in the illustration 2 Remove Timing chain tensioner 1 Timing chain tensioner gasket 3 Remove Intake camshaft cap 1 Exhaust camshaft cap 2 Dowel pins ECA13720 To prevent damage to the cylinder head ca...

Page 273: ...am shaft 3 Measure Camshaft runout Out of specification Replace Camshaft lobe dimensions Intake A 32 490 32 590 mm 1 2791 1 2831 in Limit 32 390 mm 1 2752 in Intake B 24 950 25 050 mm 0 9823 0 9862 in Limit 24 850 mm 0 9783 in Exhaust A 32 690 32 790 mm 1 2870 1 2909 in Limit 32 590 mm 1 2831 in Exhaust B 24 950 25 050 mm 0 9823 0 9862 in Limit 24 850 mm 0 9783 in Camshaft runout limit 0 030 mm 0 ...

Page 274: ...amshaft cap from cracking tighten the camshaft cap carefully by tapping the camshaft using a soft face hammer both for temporary and final tightening Do not turn the camshaft when measuring the camshaft journal to camshaft cap clear ance with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 5 Measure Camshaft journal diameter a Out of specification Replac...

Page 275: ...e pushing the timing chain tensioner rod a turn it clockwise b with the timing chain tensioner body 2 until if stops b Lock the timing chain tensioner rod by set ting the circlip 3 to groove 4 while push ing the timing chain tensioner rod c Push the timing chain tensioner rod c d Make sure that the timing chain tensioner rod comes out d of the timing chain tensioner housing smoothly If there is ro...

Page 276: ...be installed onto the cylinder head so that the alignment marks c on the intake camshaft sprocket and the alignment marks d on the exhaust camshaft sprocket align with the cylinder head mating surface as shown in the illustration ECA4B51015 Do not turn the crankshaft when installing the camshafts to avoid damage or improper valve timing 2 Install Dowel pins Exhaust camshaft cap 1 Intake camshaft c...

Page 277: ...by hand TIP While pushing the timing chain tensioner rod a turn it clockwise b with the timing chain tensioner body 2 until if stops b Lock the timing chain tensioner rod by set ting the circlip 3 into groove 4 while pushing the timing chain tensioner rod c Install the timing chain tensioner to the cyl inder block TIP Always use a new gasket d Release the timing chain tensioner rod by pushing up t...

Page 278: ...o the cylinder head cover TIP Apply Yamaha bond No 1215 1 onto the mat ing surfaces of the cylinder head cover and gaskets 9 Install Cylinder head cover gasket Cylinder head cover TIP Tighten the cylinder head cover bolts in stages and in a crisscross pattern Yamaha bond No 1215 90890 85505 Three bond No 1215 New New Cylinder head cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf ...

Page 279: ...shafts Refer to CAMSHAFTS on page 5 8 Exhaust assembly Refer to ENGINE REMOVAL on page 5 3 Thermostat Coolant temperature sensor Refer to THERMOSTAT on page 6 7 Radiator bracket Refer to RADIATOR on page 6 1 1 Cylinder head 1 2 Cylinder head gasket 1 3 Dowel pin 2 For installation reverse the removal proce dure ...

Page 280: ...age scratches Replace Cylinder head water jacket Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cyl inder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface th...

Page 281: ...9 TIP Using the indicated tightening sequence tighten the cylinder head nuts cylinder head bolts and cylinder bolt when the cylinder head and cylinder are cold Use three steps to tighten the cylinder head nuts 4 Install Exhaust camshaft Intake camshaft Refer to INSTALLING THE CAM SHAFTS on page 5 14 Cylinder head nut 1st 10 Nm 1 0 m kgf 7 2 ft lbf 2nd 20 Nm 2 0 m kgf 14 ft lbf 3rd 120 Cylinder hea...

Page 282: ...der Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 18 1 Valve lifter 8 2 Valve pad 8 3 Valve cotter 16 4 Valve spring retainer 8 5 Valve spring 8 6 Intake valve 4 7 Exhaust valve 4 8 Valve stem seal 8 9 Valve spring seat 8 10 Valve guide 8 For installation reverse the removal proce dure ...

Page 283: ...lve seat width Refer to CHECKING THE VALVE SEATS on page 5 24 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal TIP There should be no leakage at the valve seat 1 3 Remove Valve cotters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attach ment 2 4 Remove Valve spring ret...

Page 284: ... oven a Remove the valve guide with the valve guide remover 1 b Install the new valve guide with the valve guide installer 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide clearance Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valv...

Page 285: ...moved or replaced always replace the valve stem seal EAS24300 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylin der head Valve guide remover ø4 90890 04111 Valve guide...

Page 286: ...Apply a coarse lapping compound a to the valve face ECA13790 Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound TIP For the best lapping results light...

Page 287: ...l of the valve springs 1 Measure Valve spring free length a Out of specification Replace the valve spring 2 Measure Compressed valve spring force a Out of specification Replace the valve spring 3 Measure Valve spring tilt a Out of specification Replace the valve spring Free length intake 36 73 mm 1 45 in Limit 34 89 mm 1 37 in Free length exhaust 36 73 mm 1 45 in Limit 34 89 mm 1 37 in Installed c...

Page 288: ...e stem end with an oil stone 2 Lubricate Valve stem 1 Valve stem seal 2 with the recommended lubricant 3 Install Valve spring seat 1 Valve stem seal 2 Valve 3 Valve spring 4 Valve spring retainer 5 into the cylinder head TIP Make sure each valve is installed in its origi nal place Install the valve springs with the larger pitch a facing up 4 Install Valve cotters 1 TIP Install the valve cotters by...

Page 289: ...ended lubricant 8 Install Valve pad Valve lifter ECA4B51016 After making sure that the valve pads are fully inserted install the valve lifter taking care so that the pads do not fall TIP The valve lifter must move smoothly when rotated with a finger Each valve lifter and valve pad must be rein stalled in its original position Valve spring compressor 90890 04019 YM 04019 Valve spring compressor att...

Page 290: ...y Remarks Cylinder head Refer to CYLINDER HEAD on page 5 18 Coolant hose Refer to WATER PUMP on page 6 9 1 Timing chain guide exhaust side 1 2 Cylinder 1 3 Cylinder gasket 1 4 Dowel pin 2 5 Piston pin clip 4 6 Piston pin 2 7 Piston 2 8 Top ring 2 9 2nd ring 2 10 Oil ring 2 For installation reverse the removal proce dure ...

Page 291: ...he piston pin puller set 4 2 Remove Top ring 2nd ring Oil ring TIP When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS24400 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cylinders and pistons 1 Check Piston wall Cylinder wall Vertical scratches Replace the cylin der piston and piston rings a...

Page 292: ...ear ance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder TIP Level the piston ring into the cylinder with the piston crown Bore maximum of D1 D2 Taper limit maximum of D1 or D2 maxi mum of D5 or D6 Out of round limit maximum of D1 D3 or D5 minimum of D2 D4 or D6 b 9 0 mm 0 35 in from the bottom edge of the piston Piston Diameter 6...

Page 293: ...eter b Out of specification Replace the pis ton 4 Calculate Piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set Piston ring Top ring End gap installed 0 25 0 35 mm 0 0098 0 0138 in Limit 0 60 mm 0 0236 in 2nd ring End gap installed 0 35 0 50 mm 0 0138 0 0197 in Limit 0 75 mm 0 0295 in Oil ring End gap installed 0 10 0 35 mm 0 0039 0 0138 in a 40 ...

Page 294: ... mark a on the piston points towards the exhaust side of the cylinder Before installing the piston pin clip cover the crankcase opening with a clean rag to pre vent the piston pin clip from falling into the crankcase Install the piston pin clips so that the clip ends are 3 mm 0 12 in b or more from the cutout in the piston Reinstall each piston into its original cylinder 3 Install Dowel pins Cylin...

Page 295: ... Cylinder Cylinder bolt TIP While compressing the piston rings install the cylinder Pass the timing chain and timing chain guide intake side through the timing chain cavity 7 Tighten Cylinder bolt Cylinder bolt 10 Nm 1 0 m kgf 7 2 ft lbf ...

Page 296: ...motor Order Job Parts to remove Q ty Remarks Storage box Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Ground lead 1 Disconnect 2 Starter motor lead 1 Disconnect 3 Starter motor assembly 1 For installation reverse the removal proce dure ...

Page 297: ...starter motor rear cover replace the starter motor assembly Disassembling the starter motor Order Job Parts to remove Q ty Remarks 1 Starter motor front cover 1 2 Armature assembly 1 3 Starter motor yoke 1 4 O ring 2 5 Brush holder set 1 6 Insulator 1 7 Starter motor rear cover 1 For assembly reverse the disassembly pro cedure ...

Page 298: ...e armature assembly resis tances with the digital circuit tester b If any resistance is out of specification replace the starter motor assembly 4 Measure Brush length a Out of specification Replace the brush holder set 5 Measure Brush spring force Out of specification Replace the brush holder set Mica undercut depth 0 70 mm 0 03 in Digital circuit tester 90890 03189 Model 88 Multimeter with tachom...

Page 299: ...d as shown in the illustration 2 Install Starter motor yoke 1 Starter motor rear cover 2 Starter motor front cover 3 TIP Align tab a of the starter motor rear cover with notch b of the starter motor yoke Align the match mark c on the starter motor yoke with the match mark d on the starter motor front cover EAS24810 INSTALLING THE STARTER MOTOR 1 Connect Battery negative lead 1 TIP Make sure that t...

Page 300: ...case air filter element left Refer to WATER PUMP on page 6 9 Fuel tank Refer to FUEL TANK on page 7 1 Exhaust assembly Refer to ENGINE REMOVAL on page 5 3 1 Right passenger footrest 1 2 Crankshaft end access cover 1 3 V belt case air filter case cover 1 4 V belt case air filter case 1 5 V belt case air filter element right 1 6 Rear brake lock cable holder crankcase 1 7 Rear brake lock cable holder...

Page 301: ... TRANSMISSION 5 40 Water Removing the V belt case cover Order Job Parts to remove Q ty Remarks 10 Bearing retainer 1 11 Bearing 1 12 Circlip 1 13 Oil seal 1 14 Bearing 1 For installation reverse the removal proce dure ...

Page 302: ...marks 1 Primary sheave nut 1 2 Spacer 1 3 O ring 2 4 Primary sheave assembly 1 5 Secondary sheave nut 1 6 Secondary sheave assembly 1 7 V belt 1 8 Primary fixed sheave 1 9 V belt case air duct joint clamp 1 Loosen 10 V belt case air duct 1 11 Inner V belt case plate 1 12 Inner V belt case 1 13 Dowel pin 2 14 Plate 1 15 Inner V belt case seal 1 For installation reverse the removal proce dure ...

Page 303: ... replacing the primary sliding sheave or collar replace them as a set Disassembling the primary sheave Order Job Parts to remove Q ty Remarks 1 Cam 1 2 Slider 8 3 Primary sheave weight 8 4 Primary sliding sheave 1 5 Collar 1 6 Oil seal 2 For assembly reverse the disassembly pro cedure ...

Page 304: ...y sheave Order Job Parts to remove Q ty Remarks 1 Secondary sheave spring seat nut 1 2 Upper spring seat 1 3 Secondary sheave compression spring 1 4 Spring seat 1 5 Guide pin 6 6 Secondary sliding sheave 1 7 O ring 2 8 Oil seal 2 9 Secondary fixed sheave 1 For assembly reverse the disassembly pro cedure ...

Page 305: ...E SECONDARY SHEAVE 1 Loosen Secondary sheave spring seat nut 1 TIP While holding the secondary fixed sheave 2 with the sheave holder 3 loosen the sec ondary sheave spring seat nut with the lock nut wrench 4 Do not loosen the secondary sheave spring seat nut 1 more than 1 4 turn 2 Remove Secondary sheave spring seat nut 1 TIP Install the sheave spring compressor 2 and sheave fixed block 3 onto the ...

Page 306: ...ASE AIR DUCT 1 Check V belt case air duct Cracks damage Replace EAS24690 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the primary sheave weights 1 Check Primary sheave weight Cracks damage wear Replace 2 Measure Primary sheave weight outside diameter Out of specification Replace EAS24700 CHECKING THE SLIDERS The following procedure applies to all of the sliders 1 C...

Page 307: ...Primary sheave weights 2 Install Primary sheave weights 1 Sliders 2 Cam 3 TIP Do not apply the grease inside of the primary sheave EAS24730 ASSEMBLING THE SECONDARY SHEAVE 1 Lubricate Secondary fixed sheave inner surface 1 Secondary sliding sheave inner surface 2 Oil seals with the recommended lubricant 2 Install Guide pins TIP Before installing the guide pin align the posi tion where fixed sheave...

Page 308: ...pring and temporarily tighten the secondary sheave spring seat nut 5 Tighten Secondary sheave spring seat nut 1 TIP While holding the secondary fixed sheave 2 with the sheave holder 3 tighten the second ary sheave spring seat nut 1 with the locknut wrench 4 Recommended lubricant YAMAHA GREASE H or Polyurea Grease Sheave spring compressor 90890 04134 YM 04134 Sheave fixed block 90890 04135 Sheave f...

Page 309: ... belt primary and secondary sheave TIP When installing the belt screw M6 more than 45 mm 1 77 in bolts 4 to spread apart the secondary sheave and then install the V belt Make sure to install the V belt with the arrow facing in the direction shown Install the V belt and secondary sheave assembly then pass the V belt the primary sheave side Align the a and b during reassembly 4 Tighten Secondary she...

Page 310: ...Install Oil seal 1 into outer V belt case 2 Fill the space b shown in the illustration with 10 g 0 35 oz or more of lithium soap based grease 3 Install Bearing retainer 1 TIP Install the bearing retainer 1 with its mark a facing outward Apply locking agent LOCTITE to the threads of the bearing retainer bolt Recommended lubricant Shell Sunlight Grease 3 Primary sheave nut 160 Nm 16 m kgf 116 ft lbf...

Page 311: ...e 3 30 Front cowling assembly Storage box Refer to GENERAL CHASSIS on page 4 1 Water pump assembly Refer to WATER PUMP on page 6 9 Fuel tank Refer to FUEL TANK on page 7 1 V belt case air duct Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 39 1 Rear brake hose holder 1 2 Left passenger footrest 1 3 Crankshaft position sensor coupler 1 Disconnect 4 Stator coil coupler 1 Disconnect 5 Generator co...

Page 312: ...Order Job Parts to remove Q ty Remarks 9 Starter clutch idle gear shaft 1 10 Starter clutch idle gear 1 11 Generator rotor nut 1 12 Spacer 1 13 Generator rotor 1 14 Starter clutch 1 15 Woodruff key 1 16 Starter clutch gear 1 17 Washer 1 For installation reverse the removal proce dure ...

Page 313: ...them as a set Removing the stator coil and oil tank Order Job Parts to remove Q ty Remarks 1 Oil tank 1 2 Oil tank gasket 1 3 Dowel pin 2 4 Oil strainer 1 5 Crankshaft position sensor 1 6 Stator coil 1 7 Bearing cover 1 8 Oil seal 1 9 Bearing 1 10 Bearing 1 For installation reverse the removal proce dure ...

Page 314: ...Generator rotor 1 with the flywheel puller 2 Woodruff key TIP Make sure the flywheel puller is centered over the generator rotor EAS24560 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts 1 Starter clutch TIP While holding the generator rotor 2 with the sheave holder 3 remove the starter clutch bolts Do not allow the sheave holder to touch the projection on the generator rotor EAS24570 CHE...

Page 315: ...s faulty and must be replaced c When turning the starter clutch gear clock wise B it should turn freely otherwise the starter clutch is faulty and must be replaced EAS24990 CHECKING THE OIL STRAINER 1 Check Oil strainer Damage Replace Contaminants Clean with solvent EAS59C1505 ASSEMBLING THE OIL TANK 1 Install Bearing TIP Seal a is adhered only on one side of the bearing Note the press in orientat...

Page 316: ...ding the generator rotor 2 with the sheave holder 3 tighten the generator rotor nut Do not allow the sheave holder to touch the projection on the generator rotor ECA4B51018 When tightening the generator rotor nut be sure to use a beam type torque wrench Tighten the nut until it is at the specified angle 3 Apply Sealant onto the crankshaft position sensor sta tor lead grommet Sheave holder 90890 01...

Page 317: ...GENERATOR AND STARTER CLUTCH 5 56 4 Install Generator cover TIP Tighten the generator cover bolts in stages and in a crisscross pattern Generator cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf ...

Page 318: ... Removing the clutch Order Job Parts to remove Q ty Remarks Generator cover Refer to GENERATOR AND STARTER CLUTCH on page 5 50 1 Clutch assembly nut 1 2 Clutch assembly 1 3 Washer 1 For installation reverse the removal proce dure ...

Page 319: ...Clip 1 2 Spring stopper plate 1 3 Clutch spring plate 1 4 Pressure plate 1 5 Clutch plate 2 2 6 Clutch damper spring 7 7 Friction plate 6 8 Clutch plate 1 5 9 Clutch spring 6 10 Thrust plate 1 11 Clutch boss nut 1 12 Primary drive gear 1 13 Bearing 2 14 Clutch boss 1 15 Collar 1 ...

Page 320: ...CLUTCH 5 59 Disassembling the clutch Order Job Parts to remove Q ty Remarks 16 Thrust plate 1 17 Clutch weight 12 18 Clutch housing 1 For assembly reverse the disassembly pro cedure ...

Page 321: ...2 Remove Spring stopper plate 1 TIP To ensure proper balance of the clutch assem bly one to three holes a or no hole at all may have been drilled in the spring stopper plate Before removing the spring stopper plate make alignment marks on both the plate and the clutch housing so that the plate can be reinstalled in its original position 3 Loosen Clutch boss nut 1 TIP While holding the clutch boss ...

Page 322: ...n Replace the clutch plates as a set EAS4B51027 CHECKING THE CLUTCH DAMPER SPRINGS The following procedure applies to all of the clutch damper springs 1 Check Clutch damper spring Damage Replace 2 Measure Clutch damper spring free height a Out of specification Replace the clutch damper springs as a set EAS25130 CHECKING THE CLUTCH SPRING PLATE 1 Check Clutch spring plate Damage Replace 2 Measure C...

Page 323: ... clutch housing dogs or replace the clutch hous ing TIP Pitting on the clutch housing dogs will cause erratic clutch operation EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss TIP Pitting on the clutch boss splines will cause erratic clutch operation EAS59C1504 CHECKING THE PRESSURE PLATE AND THRUST PLATE 1 Check Pressure plate 1 Thrust plat...

Page 324: ... 2 Clutch plates 2 3 Friction plates 4 Clutch plates 1 5 Pressure plate 6 Clutch spring plate 7 TIP Clutch damper spring a installed at the end must be installed backwards The pressure plate 6 and thrust plate 1 can be identified by punch mark b on the pressure plate 4 Install Clip 1 TIP While compressing the clutch springs with the clutch spring compressor 2 install the clip Clutch boss nut 130 N...

Page 325: ...lutch assembly nut 2 TIP Align the a and b during reassembly While holding the clutch assembly with the rotor holding tool 3 tighten the clutch assembly nut Clutch assembly nut 65 Nm 6 5 m kgf 47 ft lbf Rotor holding tool 90890 01235 Universal magneto rotor holder YU 01235 ...

Page 326: ...Job Parts to remove Q ty Remarks Starter clutch gear Refer to GENERATOR AND STARTER CLUTCH on page 5 50 1 Oil pump assembly 1 2 Oil pump drive chain 1 3 Gasket 2 4 Oil delivery pipe 1 5 Oil pipe 1 6 Relief valve assembly 1 For installation reverse the removal proce dure ...

Page 327: ...rts to remove Q ty Remarks 1 Oil pump housing 1 1 2 Dowel pin 2 3 Oil pump outer rotor 1 1 4 Oil pump inner rotor 1 1 5 Pin 1 6 Washer 1 7 Oil pump housing center 1 8 Oil pump outer rotor 2 1 9 Oil pump inner rotor 2 1 10 Pin 1 11 Oil pump driven gear 1 12 Oil pump housing 2 1 For assembly reverse the disassembly pro cedure ...

Page 328: ...and blow out with compressed air EAS4B51031 CHECKING THE OIL PUMP DRIVE CHAIN 1 Check Oil pump drive chain Cracks stiffness Replace the oil pump chain and oil pump assembly as a set EAS25000 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor Oil pump shaft with the recommended lubricant 2 Install Inner rotors TIP When installing the inner rotor align the pins 1 in the oil pump shaft with ...

Page 329: ...OIL PUMP 5 68 ECA13890 After tightening the bolts make sure the oil pump turns smoothly ...

Page 330: ...il cooler Refer to OIL COOLER on page 6 5 Starter motor Refer to ELECTRIC STARTER on page 5 35 Starter clutch gear Refer to GENERATOR AND STARTER CLUTCH on page 5 50 Clutch assembly Refer to CLUTCH on page 5 57 Oil pump assembly Refer to OIL PUMP on page 5 65 Inner V belt case Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 39 Bearing housing Refer to SWINGARM on page 4 97 1 Centerstand assembly...

Page 331: ...CRANKCASE 5 70 Separating the crankcase Order Job Parts to remove Q ty Remarks 4 Left crankcase 1 5 Dowel pin 2 6 Oil strainer 1 7 Right crankcase 1 For installation reverse the removal proce dure ...

Page 332: ... bearings Order Job Parts to remove Q ty Remarks Crankshaft assembly Refer to CRANKSHAFT on page 5 74 Transmission Refer to TRANSMISSION on page 5 83 1 Bearing retainer 2 2 Oil seal 2 3 Bearing 5 For installation reverse the removal proce dure ...

Page 333: ...all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air EAS4B51032 CHECKING THE TIMING CHAIN 1 Check Timing chain Damage stiffness Replace the timing chain camshafts and crankshaft assem bly as a set EAS25700 ASSEMBLING THE CRANKCASE 1 Install Cylinder stud bolts 1 TIP For the cylinder stud bolt em...

Page 334: ...of a turn at a time in stages and in a crisscross pattern M8 110 mm 4 33 in bolts 1 M6 50 mm 1 97 in bolts 2 M6 35 mm 1 38 in bolts 3 6 Check Crankshaft and transmission operation Rough movement Repair Crankcase bolt M8 24 Nm 2 4 m kgf 17 ft lbf Crankcase bolt M6 10 Nm 1 0 m kgf 7 2 ft lbf ...

Page 335: ...shaft assembly Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 69 1 Dowel pin 2 2 Balancer cylinder 1 3 Crankshaft assembly 1 4 Oil seal 1 5 Crankshaft journal bearing 2 For installation reverse the removal proce dure ...

Page 336: ...r bearing 2 3 Connecting rod 2 4 Big end upper bearing 2 5 Circlip 2 6 Balancer piston pin 1 7 Balancer piston 1 8 Balancer connecting rod cap 1 9 Balancer big end lower bearing 1 10 Balancer connecting rod 1 11 Balancer big end upper bearing 1 For installation reverse the removal proce dure 60 Nm 6 0 m kgf 43 ft Ibf T R ...

Page 337: ...nkshaft journal bearings 1 Remove Crankshaft assembly Crankshaft journal bearing 1 TIP Remove the crankshaft journal bearing using the plane bearing installer 2 TIP Identify the position of each crankshaft journal bearing so that it can be reinstalled in its origi nal place EAS26090 CHECKING THE CRANKSHAFT AND CON NECTING RODS 1 Measure Crankshaft runout Out of specification Replace the crank shaf...

Page 338: ...ng rod cap c Put a piece of Plastigauge 1 on the crankshaft pin d Assemble the connecting rod halves TIP Do not move the connecting rod or crank shaft until the clearance measurement has been completed Lubricate the bolts threads and nut seats with molybdenum disulfide grease Make sure the Y mark c on the connecting rod faces towards the left side of the crank shaft Make sure the characters d on b...

Page 339: ...the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crankshaft journal bearings must be installed in their original positions ECA4B51026 On the journal the larger value is used as a basis for calculation of the oil clearance and on the journal bearing the smaller value is used a Clean the crankshaft journal bearings crankshaft journals and bearing ...

Page 340: ...ct Crankshaft journal bearings J1 J2 TIP The numbers A stamped into the crank shaft web and the numbers B on the crank case are used to determine the replacement crankshaft journal bearing size J1 J2 refer to the bearings shown in the crankshaft illustration For example if the crankcase J1 and the crankshaft web J1 numbers are 4 and 2 respectively then the bearing size for J1 is Crankshaft journal...

Page 341: ...rankshaft pins Big end bearings inner surface Balancer big end bearings inner surface with the recommended lubricant 3 Install Big end bearings Connecting rods Connecting rod caps onto the crankshaft pins TIP Align the projections a on the big end bear ings with the notches b in the connecting rods and connecting rod caps Be sure to reinstall each big end bearing in its original place Make sure th...

Page 342: ...d replace the connecting rod bolt and nut with a new one and perform the procedure again ECA4B51019 Do not use a torque wrench to tighten the connecting rod nut to the specified angle Tighten the nut until it is at the specified angle TIP On a hexagonal nut note that the angle from one corner to another is 60 5 Install Balancer big end bearings Balancer connecting rod Balancer connecting rod cap o...

Page 343: ... kgf 22 ft lbf DO NOT STOP TIGHTENING until the specified torque is achieved If the tightening is interrupted between 30 Nm 3 0 m kgf 22 ft lbf and 60 Nm 6 0 m kgf 43 ft lbf loosen the nut to less than 30 Nm 3 0 m kgf 22 ft lbf and start again EAS4B51033 INSTALLING THE CRANKSHAFT ASSEM BLY 1 Install Crankshaft assembly 1 Balancer cylinder 2 ECA4B51023 To avoid scratching the crankshaft and to ease...

Page 344: ...arate Refer to CRANKCASE on page 5 69 1 Secondary shaft 1 2 Collar 1 3 Primary driven gear 1 4 Main axle 1 TIP When installing main axle install the main axle with groove a facing to the primary driven gear 5 1st pinion gear 1 6 Drive axle 1 7 1st wheel gear 1 8 Circlip 1 For installation reverse the removal proce dure ...

Page 345: ...ve part s 3 Check Main axle Cracks damage wear Replace the main axle 4 Measure Drive axle runout with a centering device and dial gauge Out of specification Replace the drive axle 5 Measure Secondary shaft runout with a centering device and dial gauge Out of specification Replace the sec ondary shaft Drive axle runout limit 0 100 mm 0 0039 in Secondary shaft runout limit 0 120 mm 0 0047 in ...

Page 346: ...TRANSMISSION 5 85 ...

Page 347: ...COOLER 6 5 CHECKING THE OIL COOLER 6 6 INSTALLING THE OIL COOLER 6 6 THERMOSTAT 6 7 CHECKING THE THERMOSTAT 6 8 INSTALLING THE THERMOSTAT ASSEMBLY 6 8 WATER PUMP 6 9 DISASSEMBLING THE WATER PUMP 6 11 CHECKING THE WATER PUMP 6 11 ASSEMBLING THE WATER PUMP 6 11 INSTALLING THE WATER PUMP 6 12 ...

Page 348: ...nt reservoir hose 1 2 Coolant reservoir 1 3 Coolant reservoir cap 1 4 Coolant reservoir breather hose 1 5 Radiator cap 1 TIP Remove Install it with the radiator filler pipe held 6 Cooling system air bleed hose 1 Disconnect 7 Radiator filler pipe 1 8 Radiator filler hose 1 9 Fast idle plunger outlet coolant hose 1 Disconnect 10 Radiator outlet hose 1 Disconnect 11 Radiator fan motor coupler 1 Disco...

Page 349: ...RADIATOR 6 2 Removing the radiator Order Job Parts to remove Q ty Remarks 12 Radiator 1 13 Radiator fan 1 14 Radiator inlet hose 1 15 Radiator bracket 1 For installation reverse the removal proce dure ...

Page 350: ... Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 25 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 30 2 Check Cooling system Leaks Repair or replace any faulty part a Attach the radiator cap tester 1 and radia tor cap tester adapter 2 to the radiator Radi...

Page 351: ...RADIATOR 6 4 b Apply 137 3 kPa 1 37 kgf cm2 19 9 psi of pressure c Measure the indicated pressure with the gauge ...

Page 352: ...ge 7 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 26 Coolant Drain Refer to CHANGING THE COOLANT on page 3 30 1 Oil filter cartridge 1 2 Oil cooler inlet hose 1 3 Oil cooler outlet hose 1 4 Radiator inlet hose 1 Disconnect 5 Coolant pipe 1 6 Thermostat outlet hose 1 7 Oil filter cartridge union bolt 1 8 Oil cooler 1 For installation reverse the removal proce dure ...

Page 353: ...3 Install Oil filter cartridge Refer to CHANGING THE ENGINE OIL on page 3 26 4 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 30 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 26 5 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADI...

Page 354: ...t Drain Refer to CHANGING THE COOLANT on page 3 30 1 Coolant temperature sensor coupler 1 Disconnect 2 Coolant temperature sensor 1 3 Copper washer 1 4 Cooling system air bleed hose 1 Disconnect 5 Thermostat outlet hose 1 Disconnect 6 Thermostat cover 1 7 Thermostat 1 8 Fast idle plunger inlet coolant hose 1 Disconnect 9 Coolant hose 1 Disconnect For installation reverse the removal proce dure ...

Page 355: ...d cause seri ous overheating or overcooling 2 Check Thermostat cover Cracks damage Replace EAS26480 INSTALLING THE THERMOSTAT ASSEM BLY 1 Install Thermostat TIP Install the thermostat with its breather hole a facing forward 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 30 3 Check Cooling system Leaks Repair or replace any faulty...

Page 356: ...E COOLANT on page 3 30 1 V belt case air filter element joint clamp 1 Loosen 2 V belt case air filter element left 1 3 Generator cover protector cover 1 4 Generator cover protector 1 5 Oil cooler inlet hose 1 Disconnect 6 Coolant hose 1 Disconnect 7 Radiator outlet hose 1 Disconnect 8 Water pump inlet pipe 1 9 Water pump outlet pipe 1 10 Water pump assembly 1 For installation reverse the removal p...

Page 357: ... the water pump Order Job Parts to remove Q ty Remarks 1 Water pump housing cover 1 2 Circlip 1 3 Impeller shaft 1 4 Water pump seal 1 5 Bearing 1 6 Oil seal 1 7 Water pump housing 1 For assembly reverse the disassembly pro cedure ...

Page 358: ...26541 CHECKING THE WATER PUMP 1 Check Water pump housing cover 1 Water pump housing 2 Impeller shaft 3 Cracks damage wear Replace 2 Check Water pump inlet pipe Water pump outlet pipe Cracks damage wear Replace EAS26560 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 Bearing 2 into the water pump housing TIP Before installing the oil seal apply tap water or coolant onto its outer surface Install the...

Page 359: ...r holder are flush with the impeller EAS26590 INSTALLING THE WATER PUMP 1 Install O ring Water pump assembly TIP Align the slit a on the impeller shaft with the projection b on the oil pump shaft Lubricate the O ring with a thin coat of lith ium soap based grease Mechanical seal installer 90890 04132 Water pump seal installer YM 33221 A Middle driven shaft bearing driver 90890 04058 Middle drive b...

Page 360: ...nt Refer to CHANGING THE COOLANT on page 3 30 3 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR on page 6 3 4 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 ...

Page 361: ...HECKING THE ROLLOVER VALVE 7 2 INSTALLING THE FUEL PUMP 7 3 INSTALLING THE FUEL TANK 7 3 INSTALLING THE FUEL HOSE 7 3 CHECKING THE FUEL PRESSURE 7 3 THROTTLE BODY 7 5 REMOVING THE FUEL HOSE INJECTOR SIDE 7 8 CHECKING THE INJECTORS 7 8 CHECKING THE THROTTLE BODY 7 8 INSTALLING THE INJECTORS 7 8 INSTALLING THE FUEL HOSE INJECTOR SIDE 7 9 ADJUSTING THE THROTTLE POSITION SENSOR 7 9 ...

Page 362: ... on page 4 1 1 Fuel pump coupler 1 Disconnect 2 Fuel hose connector cover 1 3 Fuel hose 1 Disconnect 4 Fuel tank overflow hose 1 5 Fuel tank breather hose 2 6 Rollover valve 1 7 Fuel tank 1 8 Fuel tank cap 1 9 Filler cover 1 10 Fuel pump bracket 1 11 Fuel pump 1 12 Fuel pump gasket 1 For installation reverse the removal proce dure ...

Page 363: ...REMOVING THE FUEL TANK 1 Extract the fuel in the fuel tank through the fuel tank cap with a pump 2 Remove Fuel tank overflow hose Fuel tank breather hoses Rollover valve 3 Disconnect Fuel pump coupler 4 Remove Fuel tank EAS26640 REMOVING THE FUEL PUMP 1 Remove Fuel pump bracket Fuel pump Fuel pump gasket ECA14720 Do not drop the fuel pump or give it a strong shock Do not touch the base section of ...

Page 364: ...ose connector cover ECA59C1702 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover is in the correct position otherwise the fuel hose will not be properly installed TIP Wipe up any fuel remaining in the recess a in the fuel pump with a dry rag 1 After installing the fuel hose connector cover make sure that it is installed securely EAS31950 C...

Page 365: ... the hose place a few rags in the area under where it will be removed b Connect the pressure gauge 1 and fuel pressure adapter 2 to the fuel pump and the fuel hose 3 c Start the engine d Measure the fuel pressure Faulty Replace the fuel pump e Set the main switch to OFF f Remove the pressure gauge and fuel pres sure adapter TIP Before removing the special tools place a few rags in the area under w...

Page 366: ...ING THE COOLANT on page 3 30 1 Intake air temperature sensor coupler 1 Disconnect 2 Intake air temperature sensor 1 3 Cylinder head breather hose 1 4 Fast idle plunger intake hose 1 5 Air filter case joint clamp 2 Loosen 6 Air filter case cover 1 7 Air filter element 1 8 Air filter case 1 9 Throttle cable 2 Disconnect 10 Fast idle plunger outlet coolant hose 1 Disconnect 11 Fast idle plunger inlet...

Page 367: ...nnect 13 Throttle body joint clamp 4 Loosen 14 Throttle body assembly 1 15 Throttle position sensor sub wire harness 1 16 Throttle body joint 2 17 Fuel hose 1 18 Fuel injector coupler 2 Disconnect 19 Fuel rail 1 20 Fuel injector 2 21 Intake air pressure sensor hose 1 Disconnect 22 Intake manifold 1 For installation reverse the removal proce dure ...

Page 368: ...sassembling the throttle body assembly make sure to note the number of times the air screw is turned out from the seated position to its set position 1 Throttle position sensor 1 2 Idling speed adjusting screw set 1 3 Plunger 1 4 Plunger spring 1 5 Air screw set 2 For assembly reverse the disassembly pro cedure ...

Page 369: ...CHECKING THE THROTTLE BODY 1 Check Throttle body Cracks damage Replace 2 Check Fuel passages Obstructions Clean ECA59C1703 Do not adjust the stop screw 1 a Wash the throttle body in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages with com pressed air EAS31930 INSTALLING THE INJECTORS ECA59C1704 Always use new gaskets seals and O rings Wh...

Page 370: ...C1701 Handle the throttle position sensor with special care Never subject the throttle position sensor to strong shocks If the throttle position sensor is dropped replace it TIP Before adjusting the throttle position sensor the engine idling speed should be properly adjusted 1 Check Throttle position sensor Refer to CHECKING THE THROTTLE POSITION SENSOR on page 8 139 2 Adjust Throttle position sen...

Page 371: ...THROTTLE BODY 7 10 Throttle position sensor screw 3 5 Nm 0 35 m kgf 2 5 ft lbf ...

Page 372: ...THROTTLE BODY 7 11 ...

Page 373: ...8 19 TROUBLESHOOTING 8 21 COOLING SYSTEM 8 25 CIRCUIT DIAGRAM 8 25 TROUBLESHOOTING 8 27 FUEL INJECTION SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 ECU SELF DIAGNOSTIC FUNCTION 8 31 TROUBLESHOOTING METHOD 8 33 DIAGNOSTIC MODE 8 34 YAMAHA DIAGNOSTIC TOOL 8 35 TROUBLESHOOTING DETAILS 8 37 DIAGNOSTIC CODE TABLE 8 68 FUEL PUMP SYSTEM 8 71 CIRCUIT DIAGRAM 8 71 TROUBLESHOOTING 8 73 IMMOBILIZER SYSTEM 8 75 CIRCUIT D...

Page 374: ...HECK 8 117 ELECTRICAL COMPONENTS 8 119 CHECKING THE SWITCHES 8 123 CHECKING THE BULBS AND BULB SOCKETS 8 126 CHECKING THE FUSES 8 127 CHECKING AND CHARGING THE BATTERY 8 127 CHECKING THE RELAYS 8 131 CHECKING THE TURN SIGNAL HAZARD RELAY 8 132 CHECKING THE DIODE 8 133 CHECKING THE SPARK PLUG CAPS 8 134 CHECKING THE IGNITION COIL 8 134 CHECKING THE IGNITION SPARK GAP 8 135 CHECKING THE CRANKSHAFT P...

Page 375: ......

Page 376: ...IGNITION SYSTEM 8 1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM ...

Page 377: ...rame ground 5 Joint 6 Main switch 8 Joint coupler 16 Ignition fuse 19 Battery 20 Negative lead 21 Main fuse 26 Right handlebar switch 27 Engine stop switch 38 Sidestand switch 39 ECU engine control unit 40 Ignition coil 41 Spark plug 49 Lean angle sensor ...

Page 378: ...battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 4 Re gap or replace the spark plugs 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 135 Ignition system is OK 5 Check the spark plug caps Refer to CHECKING THE SPARK PLUG CAPS on page 8 134 Replace the spark plug caps 6 Check the ignition coil Ref...

Page 379: ...stop switch is faulty Replace the right handlebar switch 10 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 123 Replace the sidestand switch 11 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 135 Replace the lean angle sensor 12 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or repair the ignition sy...

Page 380: ...ELECTRIC STARTING SYSTEM 8 5 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM ...

Page 381: ...Battery 20 Negative lead 21 Main fuse 22 Starter relay 23 Starter motor 24 Starting circuit cut off relay 2 25 Diode 1 26 Right handlebar switch 27 Engine stop switch 28 Start switch 30 Front brake light switch 33 Diode 2 34 Starting circuit cut off relay 1 38 Sidestand switch 67 Left handlebar switch 72 Rear brake light switch ...

Page 382: ...idestand switch is closed The rear brake lever is pulled to the handlebar the rear brake light switch is closed and the side stand is up the sidestand switch is closed The starting circuit cut off relays 1 and 2 prevents the starter motor from operating when neither of these conditions has been met In this instance the starting circuit cut off relays 1 and 2 are open so current cannot reach the st...

Page 383: ...naling system fuse 5 Ignition fuse 6 Engine stop switch 7 Diode 2 8 Starting circuit cut off relay 1 9 Front brake light switch 10 Rear brake light switch 11 Sidestand switch 12 Starting circuit cut off relay 2 13 Start switch 14 Diode 1 15 Starter relay 16 Starter motor ...

Page 384: ...eplace the battery 3 Check the starter motor operation Refer to CHECKING THE STARTER MOTOR OPERATION on page 8 136 Starter motor is OK Perform the elec tric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE STARTER MOTOR on page 5 37 Repair or replace the starter motor 5 Check the diode 2 Refer to CHECKING THE DIODE on page 8 133 Replace the diode...

Page 385: ... the sidestand switch Refer to CHECKING THE SWITCHES on page 8 123 Replace the sidestand switch 12 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 123 Replace the front brake light switch 13 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 123 Replace the rear brake light switch 14 Check the start switch Refer to CHECKING THE SWITCHES on page 8...

Page 386: ...CHARGING SYSTEM 8 11 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ...

Page 387: ...CHARGING SYSTEM 8 12 2 AC magneto 3 Rectifier regulator 4 Frame ground 5 Joint 19 Battery 20 Negative lead 21 Main fuse ...

Page 388: ...CHECKING AND CHARGING THE BATTERY on page 8 127 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 136 Replace the crankshaft position sen sor stator assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 137 Replace the rectifier regulator 5 Check the entire charging system s wiring...

Page 389: ...CHARGING SYSTEM 8 14 ...

Page 390: ...LIGHTING SYSTEM 8 15 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM ...

Page 391: ...ing fuse 19 Battery 20 Negative lead 21 Main fuse 39 ECU engine control unit 63 License plate light 64 Tail brake light 67 Left handlebar switch 68 Pass switch 69 Dimmer switch 76 Auxiliary light 77 Headlight relay 78 Headlight low beam 79 Headlight high beam 82 Meter assembly 86 High beam indicator light 91 Meter light 92 Multi function meter B Wire harness C Headlight sub wire harness ...

Page 392: ...t ignition parking lighting and backup Refer to CHECKING THE FUSES on page 8 127 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 127 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 123 Replace the main switch immobilizer unit 5 Check the dimmer switch Refer to CHECKING THE SWITC...

Page 393: ...efer to CHECKING THE SWITCHES on page 8 123 Replace the storage box light switch 9 Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM on page 8 15 Properly connect or repair the lighting system s wiring Replace the ECU engine control unit or meter assembly ...

Page 394: ...SIGNALING SYSTEM 8 19 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...

Page 395: ...nd 52 ABS ECU electronic control unit 53 Front wheel sensor 62 Turn signal hazard relay 64 Tail brake light 65 Rear right turn signal light 66 Rear left turn signal light 67 Left handlebar switch 70 Horn switch 71 Turn signal switch 72 Rear brake light switch 73 Horn 74 Front right turn signal light 75 Front left turn signal light 81 ABS ECU fuse 82 Meter assembly 84 Left turn signal indicator lig...

Page 396: ...and backup Refer to CHECKING THE FUSES on page 8 127 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 127 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 123 Replace the main switch immobilizer unit 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 1...

Page 397: ...eplace the rear brake light switch 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signal ing system s wiring This circuit is OK 1 Check the turn signal light bulb and socket Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 126 Replace the turn signal light bulb socket or both 2 Check the turn signal switch Refer to CHECKING T...

Page 398: ...IRCUIT DIAGRAM on page 8 19 Properly connect or repair the signal ing system s wiring Replace the meter assembly 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 8 138 Replace the fuel pump assembly 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signal ing system s wiring Replace the meter assembly 1 Check the fron...

Page 399: ...SIGNALING SYSTEM 8 24 ...

Page 400: ...COOLING SYSTEM 8 25 EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM ...

Page 401: ...er 13 Backup fuse 16 Ignition fuse 17 Radiator fan fuse 19 Battery 20 Negative lead 21 Main fuse 39 ECU engine control unit 44 Coolant temperature sensor 50 Diagnostic tool coupler 60 Radiator fan motor relay 61 Radiator fan motor 82 Meter assembly 92 Multi function meter ...

Page 402: ...ERY on page 8 127 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 123 Replace the main switch immobilizer unit 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 138 Replace the radiator fan motor 5 Check the radiator fan motor relay Refer to CHECKING THE RELAYS on page 8 131 Replace the ra...

Page 403: ... SYSTEM 8 28 NG OK 7 Check the entire cooling system s wiring Refer to CIRCUIT DIAGRAM on page 8 25 Properly connect or repair the cooling system s wiring Replace the ECU engine control unit or meter assembly ...

Page 404: ...FUEL INJECTION SYSTEM 8 29 EAS27331 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM ...

Page 405: ...gine control unit 40 Ignition coil 41 Spark plug 42 Fuel injector 1 43 Fuel injector 2 44 Coolant temperature sensor 45 Intake air temperature sensor 46 Intake air pressure sensor 47 O2 sensor 48 Throttle position sensor 49 Lean angle sensor 50 Diagnostic tool coupler 51 Wheel sensor shield ground 52 ABS ECU electronic control unit 53 Front wheel sensor 56 Grip warmer relay 60 Radiator fan motor r...

Page 406: ...emains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation The warning light flashes when any one of the following conditions is present and the start switch is pushed Checking the engine trouble warning light The engine trouble warning light comes on for 1 4 seconds after the main switch has been set to ON and it comes on...

Page 407: ...ng light and provides the engine with alternate operating instruc tions that are appropriate for the type of malfunction When an abnormal signal is received from a sensor the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue operating or stop operating depending on the condi...

Page 408: ...r to TROUBLESHOOT ING DETAILS on page 8 37 TIP Setting the main switch to OFF will not erase the malfunction history The engine operation is not normal but the engine trouble warning light does not come on 1 Check the operation of the following sen sors and actuators in the diagnostic mode Refer to TROUBLESHOOTING DETAILS on page 8 37 If a malfunction is detected in the sensors or actuators repair...

Page 409: ...t the diagnostic code number that applies to the item that was verified with the fault code number by pressing the left set and right set buttons TIP The diagnostic code number appears on the clock LCD d 01 d 70 To decrease the selected diagnostic code number press the right set button Press the right set button for 1 second or longer to automatically decrease the diagnostic code numbers To increa...

Page 410: ...the ECU Functions of the Yamaha diagnostic tool However the diagnostic tool cannot be used to freely change the basic vehicle functions such as adjusting the ignition timing Yamaha diagnostic tool 90890 03215 Fault diagnosis mode Error codes recorded on the ECU are read and the con tents are displayed Function diagnostic mode Check the operation of the output value of each sensor and actuator Insp...

Page 411: ...ct the coupler Yellow blue Red green Black white 1 and then connect the Yamaha diagnostic tool to the coupler TIP When the Yamaha diagnostic tool is connected to the vehicle the operation of the multi function meter and indicators will be different from the normal operation ...

Page 412: ... the connection of the coupler is secure Disconnect the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Crank the engine and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of wire harness ECU coupler Check the connection of the coupler is secure Dis...

Page 413: ...ion of intake air pres sure sensor coupler Check the connection of the coupler is secure Disconnect the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of wi...

Page 414: ... main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step Fault code No 13 Item Intake air pressure sensor open or short circuit detected no nor mal signals are received from the intake air pressure sensor Fail safe system Able to start engine Able to drive vehicle Diagnostic code No d 03 Meter display Displays th...

Page 415: ...dication Sensor malfunction Replace the intake air pressure sensor Sensor inspection procedure Refer to CHECKING THE INTAKE AIR PRESSURE SENSOR on page 8 140 Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 13 Item Intake air pressure sensor open or...

Page 416: ... intake air pressure Procedure Set the engine stop switch to and then operate the throttle while pushing the start switch If the display value changes the performance is OK Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 The intake air pressure sen sor hose is damaged discon nected clogged twisted or bent Repair or replace the sensor hose Start and idle t...

Page 417: ... Make sure that the indication value changes The value does not change when engine is cranking Replace the intake air pres sure sensor Sensor inspection procedure Refer to CHECKING THE INTAKE AIR PRESSURE SENSOR on page 8 140 Fault code No 14 Item Intake air pressure sensor hose system malfunction clogged or detached hose Intake system malfunction the pressure is not sup plied to the intake air pr...

Page 418: ...ar or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Connection of throttle posi tion sensor sub wire harness coupler Check the connection of the coupler is secure Disconnect the coupler and check each pin for bend...

Page 419: ...n throttle is fully closed A value of 14 20 is indicated When throttle is fully open A value of 97 107 is indicated If the indication is outside of range Replace the throttle position sensor Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 8 ECU malfunction Replace the ECU Fault code No 15 Item T...

Page 420: ...le cause Check or maintenance job Sensor inspection proce dure 1 Sensor installation status Check for loose mounting pinched mounting or hard mounting Make sure that the mounting position is correct Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 7 9 Place the main switch to the ON position and then open and close the throttle No fault code indicated Recovered Fault code indicated Check t...

Page 421: ... harness ECU coupler Check the connection of the coupler is secure Disconnect the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication when the sidestand is retracted and extended No fault code indicated Recovered Fault code indicated Check the next ...

Page 422: ...ct it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Continuity of wire harness Open or short circuit Replace the wire harness Black blue Black blue Green red Green red Place the main switch to the ON position and check the fault code indication No ...

Page 423: ...indicated Check the next step 2 Connection of wire harness ECU coupler Check the connection of the coupler is secure Disconnect the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the ...

Page 424: ...ing A tem perature close to the ambient temperature is indicated Indication is incorrect Replace the intake air tem perature sensor Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 22 Item Intake air temperature sensor open or short circuit detected...

Page 425: ...No d 63 No fault code indicated Recovered Fault code indicated Check the next step 3 Connection of wire harness ECU coupler Check the connection of the coupler is secure Disconnect the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Either start and warm up the engine and then racing it or reset it with diagnostic code N...

Page 426: ...ngle sensor output voltage 0 4 1 4 upright 3 7 4 4 overturned Procedure Remove the lean angle sensor and incline it more than 45 degrees Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Turnover of vehicle Raise the vehicle to the upright position Rotate the main switch to the OFF position first and then rotate it to the ON position again Then check the fa...

Page 427: ...tion 0 4 1 4 V When turned over 3 7 4 4 V Indication is incorrect Replace the lean angle sen sor Rotate the main switch to the OFF position first and then rotate it to the ON position again Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 4 ECU malfunction Replace the ECU Fault code No 30 Item Latch up detected No normal signals are re...

Page 428: ...eck the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of wire harness ECU coupler Check the connection of the coupler is secure Disconnect the coupler and check each pin for bending wear or locking Poor connection Connect it securely or replace the wire harness Start and idle the engine for approximately 5 seconds Then check the fault...

Page 429: ...heck in the diagnostic mode Code No d 07 Front wheel stop The pulse integrated value should be constant Rotate the front wheel a few turns manually and enter the speed pulse The pulse inte grated value will be added Indication is incorrect Refer to Fault code No 42 Start and idle the engine for approximately 10 seconds Then check the fault code indication No fault code indicated Recovered Fault co...

Page 430: ...LE GRIP on page 3 32 Start and idle the engine for approximately 10 seconds Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Stuck fast idle plunger detected Check the throttle body Refer to THROTTLE BODY on page 7 5 Start and idle the engine for several minutes Then check the fault code indication No fault code indicated Recovered F...

Page 431: ... the OFF position first and then rotate it to the ON position again Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of wire harness ECU coupler Check the connection of the coupler is secure Disconnect the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the harne...

Page 432: ...reset each time the wheel is stopped Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Connection of front wheel sensor meter coupler Check the connection of the coupler is secure Disconnect the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON positi...

Page 433: ...enter the speed pulse Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 4 Continuity of wire harness Open or short circuit Replace the wire harness Between front wheel sensor coupler and ABS ECU cou pler White White Black Black Between ABS ECU coupler and ECU coupler White White Place the main switch to the ON position and then rotate t...

Page 434: ...the main switch to the ON position and then rotate the front wheel a few turns manually to enter the speed pulse Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 6 ECU or ABS ECU malfunc tion Replace the ECU or ABS ECU Fault code No 42 Item No normal signals are received from the front wheel sensor Fail safe system Able to start engine...

Page 435: ...tart and idle the engine for approximately 5 seconds Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of wire harness ECU coupler Check the connection of the coupler is secure Disconnect the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Start a...

Page 436: ... or maintenance job Sensor inspection proce dure 1 Locate the malfunction Check in the diagnostic mode Code No d 60 00 indication Check number 4 01 indication Check number 2 02 indication Check number 3 Fault code No 43 Item Fuel system voltage incorrect voltage supplied to the fuel injector and fuel pump Fail safe system Able to start engine Able to drive vehicle Diagnostic code No d 09 d 50 d 09...

Page 437: ...ncentra tion of cylinder 2 and rewrite in EEPROM Refer to ADJUSTING THE EXHAUST GAS VOLUME on page 3 11 After this adjustment is made the main switch is set to OFF Place the main switch to the ON position Then check the fault code indication No fault code indicated Recovered Fault code indicated Return to Step 1 to carry out the check again If the condi tion persists proceed to Step 4 4 ECU malfun...

Page 438: ...11 Check the rectifier regulator AC magneto and wire har ness Replace if defective Start and idle the engine for approximately 5 seconds Then check the fault code indication No fault code indicated Recovered Fault code indicated Recheck Fault code No 50 Item Faulty ECU memory When this malfunction is detected in the ECU the fault code number might not appear on the meter Fail safe system Unable to...

Page 439: ...onnect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Connection of diagnostic tool coupler Check the connection of the coupler is secure Disconnect the coupler and check each pin for bending wear or locking Poor connection Connect it securely or...

Page 440: ...it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Connection of diagnostic tool coupler Check the connection of the coupler is secure Disconnect the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair...

Page 441: ...y or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Connection of diagnostic tool coupler Check the connection of the coupler is secure Disconnect the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace t...

Page 442: ...rely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Connection of diagnostic tool coupler Check the connection of the coupler is secure Disconnect the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replac...

Page 443: ... the engine trou ble warning light Check the operating sound of the fuel injector 2 five times ECA59C1801 Disconnect the fuel pump coupler d 51 Radiator fan motor relay Actuates the radiator fan motor relay for five cycles of five seconds ON 2 sec onds OFF 3 seconds Illuminates the engine trou ble warning light Check the operating sound of the radiator fan motor relay five times d 52 Headlight rel...

Page 444: ... 12 50 If more than one code number is detected the dis play alternates every two seconds to show all the detected code numbers When all code numbers are shown the display repeats the same process d 62 Malfunction history code erasure No history 00 History exists Displays the total number of malfunctions including the current malfunction that have occurred since the his tory was last erased For ex...

Page 445: ...FUEL INJECTION SYSTEM 8 70 ...

Page 446: ...FUEL PUMP SYSTEM 8 71 EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM ...

Page 447: ...oint 6 Main switch 8 Joint coupler 12 Fuel injection system fuse 16 Ignition fuse 19 Battery 20 Negative lead 21 Main fuse 26 Right handlebar switch 27 Engine stop switch 35 Fuel injection system relay 36 Fuel pump 39 ECU engine control unit ...

Page 448: ...e battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 123 Replace the main switch immobilizer unit 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 123 The engine stop switch is faulty Replace the right handlebar switch 5 Check the fuel injection system relay Refer to CHECKING THE RELAYS on page 8 131 Replace the fuel injection system relay 6 Check the f...

Page 449: ...FUEL PUMP SYSTEM 8 74 ...

Page 450: ...IMMOBILIZER SYSTEM 8 75 EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM ...

Page 451: ...ain switch 7 Immobilizer unit 8 Joint coupler 13 Backup fuse 16 Ignition fuse 19 Battery 20 Negative lead 21 Main fuse 39 ECU engine control unit 50 Diagnostic tool coupler 82 Meter assembly 83 Immobilizer system indicator light 92 Multi function meter ...

Page 452: ... registered during production therefore re registering at purchase is not neces sary ECA14971 DO NOT LOSE THE CODE RE REGISTERING KEY If the code re registering key is lost reg istering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made or all keys are lost the entire imm...

Page 453: ... key TIP Check that the immobilizer system indicator light comes on for one second then goes off When the immobilizer system indicator light goes off the code re registering key has been registered 2 Check that the engine can be started 3 Register the standard key following the instructions in the section below Parts to be replaced Key registration requirement Main switch immo bilizer unit Standar...

Page 454: ...ng key set the main switch to ON then OFF and then remove the key within 5 seconds 3 Insert the first standard key to be registered into the main switch then set the key to ON within 5 seconds to activate the key registration mode TIP The existing standard key code is erased from the memory when the key registration mode is acti vated When the key registration mode is activated the immobilizer sys...

Page 455: ... Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g First standard key h Second standard key i Registration mode A Registration of the second standard key is complete B Immobilizer system indicator light stops flashing when the registration of the second standard key is complete a Main switch ON b Main switch OFF c LED on d LED off e Less than 5 0 s f Code re register...

Page 456: ...tery Refer to CHECKING AND CHARGING THE BATTERY on page 8 127 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 123 Replace the main switch immobilizer unit 4 Check the entire immobilizer sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 75 Properly connect or repair the immobi lizer system s wiring Check the condition of...

Page 457: ...nnas 2 Replace the main switch immobilizer unit 3 Replace the key 52 IMMOBILIZER UNIT Codes between the key and immobilizer unit do not match 1 Signal received from other transponder failed to recognize code after ten con secutive attempts 2 Signal received from unregistered stan dard key 1 Place the immo bilizer unit at least 50 mm 1 97 in away from the tran sponder of other vehicles 2 Register t...

Page 458: ...nit failure The ECU engine control unit or immo bilizer unit was replaced with a used unit from another vehicle 1 Register the code re register ing key 2 Check the wire harness and con nector 3 Replace the main switch immobilizer unit 4 Replace the ECU engine control unit 55 IMMOBILIZER UNIT Key code registra tion malfunction Same standard key was attempted to be regis tered two consecutive times ...

Page 459: ...IMMOBILIZER SYSTEM 8 84 ...

Page 460: ...ABS ANTI LOCK BRAKE SYSTEM 8 85 EAS28790 ABS ANTI LOCK BRAKE SYSTEM EAS27730 CIRCUIT DIAGRAM ...

Page 461: ...gine stop switch 28 Start switch 30 Front brake light switch 31 ABS motor fuse 32 ABS solenoid fuse 33 Diode 2 34 Starting circuit cut off relay 1 39 ECU engine control unit 50 Diagnostic tool coupler 51 Wheel sensor shield ground 52 ABS ECU electronic control unit 53 Front wheel sensor 54 Rear wheel sensor 55 ABS test coupler 64 Tail brake light 67 Left handlebar switch 72 Rear brake light switch...

Page 462: ...ABS ANTI LOCK BRAKE SYSTEM 8 87 EAS27740 ABS COMPONENTS CHART ...

Page 463: ...RAKE SYSTEM 8 88 1 Hydraulic unit assembly ABS ECU 2 Fuse box right 3 Fuse box left 4 ABS warning light 5 ABS test coupler 6 Rear wheel sensor rotor 7 Rear wheel sensor 8 Front wheel sensor 9 Front wheel sensor rotor ...

Page 464: ...ABS ANTI LOCK BRAKE SYSTEM 8 89 EAS27750 ABS COUPLER LOCATION CHART ...

Page 465: ...ABS ANTI LOCK BRAKE SYSTEM 8 90 1 Front wheel sensor coupler 2 Meter assembly coupler 3 ABS test coupler 4 Rear wheel sensor coupler 5 ABS ECU coupler ...

Page 466: ...n display For troubleshooting items other than the following items follow the normal service method WARNING EWA59C2801 When maintenance or checks have been performed on components related to the ABS be sure to perform a final check before delivering the vehicle to the customer Refer to C 3 FINAL CHECK on page 8 117 ABS operation when the ABS warning light comes on 1 The ABS warning light remains o...

Page 467: ...ts by subjecting them to shocks or pulling on them with too much force since the ABS components are precisely adjusted The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled The malfunction history is stored in the memory of the ABS ECU Delete the fault codes when the service is finished This is because the past fault codes will be displayed again if another malfunc tion o...

Page 468: ...ABS ANTI LOCK BRAKE SYSTEM 8 93 EAS27810 BASIC PROCESS FOR TROUBLESHOOTING ...

Page 469: ...ness 2 Disconnect the ABS ECU coupler and check that the ABS warning light comes on when the main switch is set to ON If the ABS warning light does not come on the meter assembly circuit including the ABS warning light LED is defective Replace the meter assembly If the ABS warning light comes on the ABS ECU is defective Replace the hydraulic unit assembly EAS59C2802 A 2 THE ABS WARNING LIGHT AND A...

Page 470: ...not short circuited to the ground check the internal circuit of the meter assembly Set the main switch to OFF Disconnect the ABS ECU coupler Set the main switch to ON and then check the ABS warning light If the ABS warning light flashes the internal circuit of the meter assembly is defective Replace the meter assembly If the ABS warning light comes on the ABS ECU is defective Replace the hydraulic...

Page 471: ...on of the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 127 If the battery voltage is low clean the battery terminals and recharge it or replace the battery 2 ABS ECU fuse Check the ABS ECU fuse for continuity Refer to CHECKING THE FUSES on page 8 127 If the ABS ECU fuse is blown replace the fuse 3 ABS ECU coupler Check that the ABS ECU coupler is connected properly Connect the coup...

Page 472: ...t ABS_11 ABS_25 Front wheel sensor signal is not received properly Installation of the front wheel sensor Front wheel Front wheel sensor housing Front wheel sensor rotor ABS_12 Rear wheel sensor signal is not received properly Installation of the rear wheel sensor Rear wheel Rear wheel sensor housing Rear wheel sensor rotor ABS_13 ABS_26 Incorrect signal from the front wheel sensor is detected Ins...

Page 473: ...mbly ABS_33 ABS motor is defective Power is not supplied to the ABS motor Battery voltage ABS motor fuse Wire harness ABS circuit Connection of the ABS ECU coupler and starter relay coupler Hydraulic unit assembly ABS_34 Hydraulic unit ABS motor relay is short circuited Hydraulic unit assembly ABS_41 Front wheel will not recover from the locking tendency even though the sig nal is continuously tra...

Page 474: ...rmal Hydraulic unit assembly ABS_63 Front wheel sensor power is abnormal Front wheel sensor lead Wire harness Hydraulic unit assembly ABS_64 Rear wheel sensor power is abnormal Rear wheel sensor lead Wire harness Hydraulic unit assembly Fault code No ABS_11 ABS_25 Symptom Front wheel sensor signal is not received prop erly Order Item components and probable cause Check or maintenance job 1 Install...

Page 475: ... housing and sensor rotor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 33 4 Defective sensor rotor Check the surface of the sensor rotor for damage Replace the sensor rotor if there is visible damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 33 Fault code No ABS_13 ABS_26 Symptom Incorrect signal from the front wheel sensor is...

Page 476: ...f wheel bear ings axle sensor housing and sensor rotor Check the components for looseness distortion and bends Refer to CHECKING THE REAR WHEEL on page 4 32 3 Foreign material inside sensor housing Check the interior of the sensor housing and the sur face of the sensor rotor for foreign material such as metal particles Clean the sensor housing and sensor rotor if necessary Refer to MAINTENANCE OF ...

Page 477: ...k that there is no continuity between the ground and the white terminal 1 or white terminal 3 and between the ground and the black terminal 2 or black terminal 4 If there is continuity the wire harness is defective Properly repair or replace the wire harness Check that there is no continuity between the white terminal 1 and the black terminal 2 and between the white terminal 3 and the black termin...

Page 478: ...ck that there is no continuity between the ground and the white terminal 1 or white terminal 3 and between the ground and the black terminal 2 or black terminal 4 If there is continuity the wire harness is defective Properly repair or replace the wire harness Check that there is no continuity between the white terminal 1 and the black terminal 2 and between the white terminal 3 and the black termi...

Page 479: ...ntenance job 1 Installed condition of wheel bear ings axle sensor housing and sensor rotor Check the components for looseness distortion and bends Refer to CHECKING THE REAR WHEEL on page 4 32 2 Foreign material inside sensor housing Check the interior of the sensor housing and the sur face of the sensor rotor for foreign material such as metal particles Clean the sensor housing and sensor rotor i...

Page 480: ...ake light operation Defective tail brake light Check the tail brake light Repair or replace the tail brake light if necessary Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 126 2 Connections ABS ECU coupler Front brake light switch connec tors Rear brake light switch connec tors Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a m...

Page 481: ...n wire har ness Repair or replace if there is an open or short circuit Between ABS ECU coupler and ABS solenoid fuse Red Red Between ABS ECU coupler and ground Black Black 5 Hydraulic unit assembly internal malfunction Replace the hydraulic unit assembly Fault code No ABS_32 Symptom Hydraulic unit solenoid relay is short circuited Order Item components and probable cause Check or maintenance job 1...

Page 482: ...nt wheel will not recover from wheel lock even though the signal is continuously transmitted from the ABS ECU and the hydraulic pressure has been released when the battery voltage is normal Order Item components and probable cause Check or maintenance job 1 Rotation of wheel Check that there is no brake disc drag on the front wheel and make sure that it rotates smoothly Check the front wheel axle ...

Page 483: ...the final check on page C 3 FINAL CHECK on page 8 117 is performed 4 Brake lines Check the brake lines for kinks and deterioration WARNING EWA59C2804 Only use genuine Yamaha parts Using other brake pipes hoses and union bolts may close the brake lines Check that the connections of the brake lines from the brake master cylinder to the hydraulic unit and from the hydraulic unit to the front brake ca...

Page 484: ...s when the lever is released 3 Brake fluid Visually check the brake fluid in the brake master cylinder reservoir for water foreign materials solidi fication and contamination Check for air in the brake lines 4 Brake lines Check the brake lines for kinks and deterioration particularly between the hydraulic unit and the rear brake caliper WARNING EWA59C2804 Only use genuine Yamaha parts Using other ...

Page 485: ... 2 Installed condition of wheel bear ings axle sensor housing and sensor rotor Check the components for looseness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 20 3 Foreign material inside sensor housing Check the interior of the sensor housing and the sur face of the sensor rotor for foreign material such as metal particles Clean the sensor housing and sensor rotor if necessary...

Page 486: ...ery Refer to CHECKING AND CHARGING THE BAT TERY on page 8 127 2 Connections ABS ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely TIP Set the main switch to OFF before disconnecting or connecting a coupler 3 Open or short circuit in wire har ness Repair or replace if ther...

Page 487: ...age 8 11 Fault code No ABS_56 Symptom Hydraulic unit sensor power monitor circuit is abnormal Order Item components and probable cause Check or maintenance job 1 Defective internal monitor circuit sensor power Replace the hydraulic unit assembly Fault code No ABS_63 Symptom Front wheel sensor power is abnormal Order Item components and probable cause Check or maintenance job 1 Short circuit in wir...

Page 488: ... unit assembly Fault code No ABS_64 Symptom Rear wheel sensor power is abnormal Order Item components and probable cause Check or maintenance job 1 Short circuit in wire harness Check that there is no short circuit between the white terminal 1 and the black terminal 2 Check that there is no short circuit between the frame ground and the black terminal 2 If there is a short circuit the wire harness...

Page 489: ...uit between the frame ground and the white terminal 3 If there is a short circuit the rear wheel sensor is defective Properly repair or replace the rear wheel sensor 5 ABS ECU 6 Rear wheel sensor 3 Hydraulic unit internal malfunction Replace the hydraulic unit assembly Fault code No ABS_64 Symptom Rear wheel sensor power is abnormal Order Item components and probable cause Check or maintenance job...

Page 490: ...re being deleted 6 Set the main switch to OFF 7 Set the main switch to ON again TIP If fault codes are still displayed in the multi function display the malfunctions have not been repaired Diagnose the malfunctions using the fault codes 8 Set the main switch to OFF 9 Disconnect the test coupler adapter from the ABS test coupler and then install the protective cap onto the ABS test coupler Deleting...

Page 491: ...e digital circuit tester DC 12 V to the ABS ECU coupler b Push the start switch c Measure the ABS ECU voltage 8 If the above mentioned checks are within specification replace the hydraulic unit assembly Continuity is all right Digital circuit tester 90890 03189 Model 88 Multimeter with tachometer YU A1927 Positive tester probe Green white 1 ABS ECU Negative tester probe Green white 2 right handleb...

Page 492: ...nd wheel sensors for proper installation Refer to INSTALLING THE FRONT WHEEL DISCS on page 4 24 3 Perform hydraulic unit operation test 1 or 2 Refer to HYDRAULIC UNIT OPERATION TESTS on page 4 72 4 Delete the fault codes Refer to C 1 DELETING THE FAULT CODES on page 8 115 5 Checking the ABS warning light Ensure that the ABS warning light goes off by walking the vehicle at a speed of faster than 7 ...

Page 493: ...ABS ANTI LOCK BRAKE SYSTEM 8 118 ...

Page 494: ...ELECTRICAL COMPONENTS 8 119 EAS27973 ELECTRICAL COMPONENTS ...

Page 495: ...rting circuit cut off relay 1 7 Starting circuit cut off relay 2 8 Main fuse 9 Starter relay 10 Diode 2 11 Diode 1 12 Rectifier regulator 13 Ignition coil 14 Horn 15 Radiator fan motor relay 16 Headlight relay 17 Turn signal hazard relay 18 Lean angle sensor 19 Diode 3 20 Fuse box right 21 Front brake light switch 22 ECU engine control unit ...

Page 496: ...ELECTRICAL COMPONENTS 8 121 ...

Page 497: ...ssure sensor 3 Coolant temperature sensor 4 Fuel pump 5 Rear wheel sensor 6 O2 sensor 7 Crankshaft position sensor 8 Stator coil 9 Sidestand switch 10 Radiator fan 11 Front wheel sensor 12 Throttle position sensor 13 Intake air temperature sensor 14 Ambient temperature sensor ...

Page 498: ...ELECTRICAL COMPONENTS 8 123 EAS27981 CHECKING THE SWITCHES ...

Page 499: ... Pass switch 2 Dimmer switch 3 Horn switch 4 Turn signal switch 5 Rear brake light switch 6 Engine stop switch 7 Start switch 8 Hazard switch 9 Front brake light switch 10 Sidestand switch 11 Main switch 12 Storage box light switch ...

Page 500: ...he Ω 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch...

Page 501: ... the headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down ECA4B51010 Be sure to hold the socket firmly when removing the bulb Never pull the lead otherwise it may be pulled out of the ter minal in the coupler Avoid touching the glass part of the head light bulb to keep it free from oil other wise the transparency of the glass the life ...

Page 502: ...erational d If the fuse immediately blows again check the electrical circuit WARNING EWA13310 Never use a fuse with an amperage rating other than that specified Improvising or using a fuse with the wrong amperage rat ing may cause extensive damage to the electrical system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install Front cover Refer to GENERAL C...

Page 503: ...overcharged the electrolyte level will drop considerably Therefore take special care when charging the battery TIP Since VRLA Valve Regulated Lead Acid bat teries are sealed it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals 1 Remove ...

Page 504: ...oded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process disconnect the battery charger and let the battery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of a VRLA Valve Regulated Lead Acid batter...

Page 505: ...g TIP Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the battery TIP If the current is lower than the standard charg ing current written on the battery this type of battery charger cannot charge the VRLA Valve Regulated Lead Acid...

Page 506: ...fication Replace Starting circuit cut off relay 1 Starting circuit cut off relay 2 Starter relay Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive ...

Page 507: ...y terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 R Y L B R Y W Y 4 1 2 3 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Posit...

Page 508: ... TIP The pocket tester or the analog pocket tester reading are shown in the following table a Disconnect the diode 2 from the wire har ness b Connect the pocket tester Ω 1 to the diode 2 terminals as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Blue 1 Negative tester probe Ground Turn signal hazard relay output voltage DC 12 V Pocket tester 90890 03112 Anal...

Page 509: ...t of specification Replace a Disconnect the ignition coil connectors from the ignition coil terminals b Connect the pocket tester Ω 1 to the ignition coil as shown c Measure the primary coil resistance 2 Check Secondary coil resistance Out of specification Replace a Disconnect the spark plug cap from the ignition coil b Connect the pocket tester Ω 1k to the ignition coil as shown Resistance 7 5 12...

Page 510: ...dually increase the spark gap until a misfire occurs EAS28120 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace the crank shaft position sensor stator assembly a Connect the pocket tester Ω 100 to the crankshaft position sensor coupler as shown b Measure the cranks...

Page 511: ...NING EWA13810 A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resista...

Page 512: ... resistance Out of specification Replace a Disconnect the horn leads from the horn terminals b Connect the digital circuit tester to the horn terminals Digital circuit tester 90890 03189 Model 88 Multimeter with tachometer YU A1927 Positive tester probe White 1 Negative tester probe White 2 Positive tester probe White 1 Negative tester probe White 3 Positive tester probe White 2 Negative tester pr...

Page 513: ...ped with a self diagnosis device for the fuel level detection circuit 1 Check Fuel meter fuel level warning light 1 Set the main switch to ON Fuel meter fuel level warning light comes on for a few seconds then goes off Fuel meter fuel level warning light is OK Fuel meter fuel level warning light does not come on Replace the meter assembly Fuel meter fuel level warning light flashes eight times the...

Page 514: ...rature sensor ter minals do not get wet c Place a thermometer 3 in the coolant d Heat the coolant or let it cool down to the specified temperature e Measure the coolant temperature sensor resistance 3 Install Coolant temperature sensor EAS28300 CHECKING THE THROTTLE POSITION SENSOR 1 Remove Throttle position sensor from the throttle body 2 Check Throttle position sensor a Connect the pocket tester...

Page 515: ... shown ECA16730 Pay attention to the installing direction of the test harness S pressure sensor 3P coupler a b Connect the digital circuit tester DCV to the test harness S pressure sensor 3P c Set the main switch to ON d Measure the intake air pressure sensor output voltage EAS28421 CHECKING THE INTAKE AIR TEMPERA TURE SENSOR 1 Remove Intake air temperature sensor from the air filter case WARNING ...

Page 516: ...ied temperatures e Measure the intake air temperature sensor resistance 3 Install Intake air temperature sensor EAS59C1801 CHECKING THE FUEL INJECTORS 1 Check Fuel injector resistance Out of specification Replace the fuel injector a Disconnect the fuel injector coupler from wire harness b Connect the pocket tester Ω 1 to the fuel injector coupler c Measure the fuel injector resistance Intake air t...

Page 517: ...ERFORMANCE 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 TROUBLESHOOTING AT THE ABS WARNING LIGHT 9 4 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 5 ...

Page 518: ...contaminated fuel Clogged or damaged fuel hose 2 Fuel pump Faulty fuel pump Faulty fuel injection system relay Damaged vacuum hose Improperly routed hose 3 Throttle body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spa...

Page 519: ...ngine operates but scooter will not move 1 V belt Bent damaged or worn V belt Slipping V belt 2 Primary pulley cam and primary pulley slider Damaged or worn primary pulley cam Damaged or worn primary pulley slider 3 Clutch spring s Damaged clutch spring 4 Transmission gear s Damaged transmission gear Clutch slips 1 Clutch Improperly assembled clutch Fatigued clutch spring Worn clutch weight Worn f...

Page 520: ...d brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS28660 FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high Loose damper rod bolt Damaged damper rod bolt copper washer Cracked or damaged cap bolt O ring Malfunction Bent o...

Page 521: ...l accessories Incorrect connection Burnt out tail brake light bulb Tail brake light bulb burnt out Wrong tail brake light bulb Faulty battery Tail brake light bulb life expired Turn signal does not come on Faulty turn signal switch Faulty turn signal hazard relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged ...

Page 522: ...iping system 8 41 37 Fast idle plunger stuck fully open 8 54 15 Throttle position sensor open or short cir cuit 8 43 41 Lean angle sensor open or short cir cuit 8 56 16 Throttle position sensor stuck 8 45 42 Front wheel sensor 8 57 19 Sidestand switch open circuit wire harness to ECU 8 46 43 Fuel system voltage monitor voltage 8 60 21 Coolant tempera ture sensor open or short cir cuit 8 47 44 Erro...

Page 523: ...e intake air pres sure Set the engine stop switch to and then push the start switch If the dis play value changes the per formance is OK d 05 Intake air temperature When engine is cold Dis plays temperature closer to air temperature When engine is hot Air tem perature approx 20 C 68 F Compare the actually mea sured intake air temperature with the meter display value d 06 Coolant temperature When e...

Page 524: ... Fault code Nos 12 50 If more than one code number is detected the dis play alternates every two seconds to show all the detected code numbers When all code numbers are shown the display repeats the same process d 62 Malfunction history code erasure No history 00 History exists Displays the total number of malfunctions including the current malfunction that have occurred since the his tory was las...

Page 525: ...59C1801 Disconnect the fuel pump coupler d 50 Fuel injection system relay Actuates the fuel injection system relay five times at one second intervals Illuminates the engine trou ble warning light Check the operating sound of the fuel injection system relay five times d 51 Radiator fan motor relay Actuates the radiator fan motor relay for five cycles of five seconds ON 2 sec onds OFF 3 seconds Illu...

Page 526: ...relay 61 Radiator fan motor 62 Turn signal hazard relay 63 License plate light 64 Tail brake light 65 Rear right turn signal light 66 Rear left turn signal light 67 Left handlebar switch 68 Pass switch 69 Dimmer switch 70 Horn switch 71 Turn signal switch 72 Rear brake light switch 73 Horn 74 Front right turn signal light 75 Front left turn signal light 76 Auxiliary light 77 Headlight relay 78 Hea...

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Page 529: ...WIRING DIAGRAM XP500A SCHEMA DE CABLAGE XP500A SCHALTPLAN XP500A SCHEMA ELETTRICO XP500A DIAGRAMA DE CONEXIONES DE XP500A ...

Page 530: ...WIRING DIAGRAM XP500A SCHEMA DE CABLAGE XP500A SCHALTPLAN XP500A SCHEMA ELETTRICO XP500A DIAGRAMA DE CONEXIONES DE XP500A ...

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Yamaha 2012 TMAX XP500A, Service Manual

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