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Yamaha 2014 MT-07, Service Manual

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Yamaha 2014 MT-07 Service Manual Download Page 442

FUEL INJECTION SYSTEM

8-37

Functions of the Yamaha diagnostic tool

However, the Diagnostic Tool cannot be used to freely change the basic vehicle functions, such as ad-
justing the ignition timing.
Connecting the Yamaha diagnostic tool
Remove the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler.

Operation of the Yamaha diagnostic tool (Malfunction mode)
Malfunction results are displayed in the top part of the window area.

Fault diagnosis mode:

Fault codes recorded on the ECU are read, and the contents are dis-
played.
The freeze frame data (FFD) is the operation data when a malfunction 
was detected. This data can be used to identify when the malfunction 
occurred and check the engine conditions and running conditions when 
it occurred.

Function diagnostic mode:

Check the operation of the output value of each sensor and actuator.

Inspection mode:

Determine whether each sensor or actuator is functioning properly.

CO adjustment mode:

Adjust the concentration of CO admissions during idling.

Monitoring mode:

Displays a graph of sensor output values for actual operating condi-
tions.

Logging mode:

Records and saves the sensor output value in actual driving conditions.

View log:

Displays the logging data.

ECU rewrite:

If necessary, the ECU is rewritten using ECU rewrite data provided by 
Yamaha.
Ignition timing adjustment, etc. cannot be changed from the vehicle’s 
original state.

1

Summary of Contents for 2014 MT-07

Page 1: ...2014 SERVICE MANUAL MT07A 1XB 28197 E0 ...

Page 2: ...07A 2014 SERVICE MANUAL 2014 by Yamaha Motor Co Ltd First edition October 2014 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ...nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP Designs and specifications are subject to change without notice EAS30001 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations This is the safety alert symbol I...

Page 4: ...ion 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 disas sembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS on page 1 4 A job instruction chart 6 accompanies the exploded diagram provid...

Page 5: ...rviceable 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 Silicone fluid G M BF B T R LS M S LT E New S ...

Page 6: ......

Page 7: ...EAS10003 TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 ...

Page 8: ......

Page 9: ...ERATION 1 13 ABS WARNING LIGHT AND OPERATION 1 16 MULTI FUNCTION METER UNIT 1 18 IMPORTANT INFORMATION 1 23 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 23 REPLACEMENT PARTS 1 23 GASKETS OIL SEALS AND O RINGS 1 23 LOCK WASHERS PLATES AND COTTER PINS 1 23 BEARINGS AND OIL SEALS 1 24 CIRCLIPS 1 24 RUBBER PARTS 1 24 BASIC SERVICE INFORMATION 1 25 QUICK FASTENERS 1 25 ELECTRICAL SYSTEM 1 26 SPECIAL TOOLS...

Page 10: ... IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS30003 MODEL LABEL The model label 1 is affixed to the frame under the passenger seat This information will be needed to order spare parts 1 1 ...

Page 11: ...quirements for the engine 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 accom modate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the en...

Page 12: ...ntrolled by the ECU Signals that are input from the throttle position sensor coolant temperature sensor lean angle sensor crankshaft position sensor in take air pressure sensor intake air temperature sensor rear wheel sensor and O2 sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position sensor As a result the vol...

Page 13: ...he basic maneuverability of the vehicle 3 The hydraulic unit assembly which is the main component of the ABS is centrally located on the vehicle to increase mass centralization ABS layout 1 7 8 9 10 1 2 4 3 5 6 1 Hydraulic unit assembly 2 ABS warning light 3 Front wheel sensor rotor 4 Front wheel sensor 5 Rear wheel sensor rotor 6 Rear wheel sensor 7 Yamaha diagnostic tool coupler 8 ABS control un...

Page 14: ...eed and the chassis speed Slip ratio is the value that shows the rate of wheel slippage and is defined by the following formula Slip ratio Chassis speed Wheel speed Chassis speed 100 0 There is no slipping between the wheel and the road surface The chassis speed is equal to the wheel speed 100 The wheel speed is 0 but the chassis is moving i e wheel lock Brake force and vehicle stability When the ...

Page 15: ...ished after the hydraulic pressure is reduced it increases the hydraulic pressure point B in the following figure The hydraulic pressure is initially increased quickly and then it is increased gradually ABS operation and vehicle control If the ABS starts operating there is a tendency of the wheel to lock and the vehicle is approaching the limit of control To make the rider aware of this condition ...

Page 16: ...ncy of the wheel to lock caused by applying the brakes The ABS cannot prevent wheel lock on slippery surfaces such as ice when it is caused by engine braking even if the ABS is operating Electronic ABS features The Yamaha ABS anti lock brake system has been developed with the most advanced electronic technology The ABS control is processed with good response under various vehicle travel conditions...

Page 17: ...ent 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 that it can be output The ABS ECU calculates the wheel rotation speed by detecting the pulse frequency 1 2 3 4 4 7 7 5 6 6 8 9 9 10 11 12 13 14 1 Rear brake master cylinder 2 Hydraulic unit assembly 3 Front brake master ...

Page 18: ...e completed the ABS warning light will go off when the vehicle is ridden or pushed at a speed of 7 km h 4 mi h or faster NOTICE ECA20950 If the rear wheel is raced with the vehicle on a suitable stand the ABS warning light may flash or come on If this occurs turn the main switch to OFF then back to ON The ABS operation is normal if the ABS warning light goes off after the vehicle starts off If the...

Page 19: ...tlet solenoid valve The electromagnetic force generated in the inlet solenoid valve varies proportionally with the duty cycle control voltage that is supplied to it Since this voltage is continuously variable the solenoid valve moves smoothly and the hydraulic pressure is adjusted linearly 1 When the brakes are operated normally the inlet solenoid valve 1 is open and the outlet solenoid valve 2 is...

Page 20: ...ke fluid in the lower brake lines brake caliper side Buffer chamber The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating ABS ECU The ABS ECU is integrated with the hydraulic unit to achieve a compact and lightweight design As shown in the following block diagram the ABS ECU receives wheel sensor signals from the front and rear wheels and also receives sig...

Page 21: ... the ABS ECU e g a blown ABS con trol unit fuse 14 7 4 5 6 2 3 1 9 10 11 12 13 17 15 24 20 22 23 21 26 27 18 19 16 25 8 1 Battery 2 AC magneto 3 Rectifier regulator 4 Main fuse 5 ABS motor fuse 6 ABS solenoid fuse 7 Main switch 8 ABS control unit fuse 9 Signaling system fuse 10 Rear brake light switch 11 Front brake light switch 12 Tail brake light 13 Yamaha diagnostic tool coupler 14 Hydraulic un...

Page 22: ... inlet solenoid valve is open and the outlet solenoid valve is closed because a control signal has not been transmitted from the ABS ECU Therefore when the brake lever is squeezed the hydraulic pressure 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 eliminating th...

Page 23: ...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 hy draulic pump linked to the ABS motor 12 13 7 6 11 3 4 5 9 8 10 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Ou...

Page 24: ...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 25: ...his occurs turn the main switch to OFF then back to ON The ABS operation is normal if the ABS warning light comes on then goes off The ABS operation is normal if the ABS warning light flashes Even if the ABS warning light remains on and does not go off or if it comes on after riding conven tional braking performance of the vehicle is maintained 1 Brake master cylinder 2 Brake light switch 3 ABS mo...

Page 26: ...g 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 be tween yourself and other vehicles The braking of the vehicle even in the worst case is principally executed when the vehicle is advancing straight ahead During a turn sudden...

Page 27: ...ightness control mode For the U K only To switch the speedometer and multi function display between kilometers and miles set the multi function display to the odometer mode or a tripmeter mode and then press the left set button for at least three sec onds Speedometer The speedometer shows the vehicle s traveling speed Tachometer The tachometer allows the rider to monitor the engine speed and keep ...

Page 28: ...n as possible TIP This fuel meter is equipped with a self diagnosis system If a problem is detected in the electrical circuit the following cycle is repeated until the malfunction is corrected fuel level segments and fuel level warning indicator flash eight times then go off for approximately 3 seconds If this occurs check the electrical circuit Refer to SIGNALING SYSTEM on page 8 21 Eco indicator...

Page 29: ...he right set button to switch the display in the reverse order If the fuel level warning indicator and left segment of the fuel meter start flashing the dis play automatically changes to the fuel reserve tripmeter mode TRIP F and starts counting the distance traveled from that point In that case push the left set button to switch the display be tween the various tripmeter odometer instanta neous f...

Page 30: ... select it by pushing the left set and then push the right set button for at least one second TIP After resetting an average fuel consumption dis play _ _ _ is shown for that display until the ve hicle has traveled 1 km 0 6 mi Coolant temperature display This display shows the coolant temperature from 40 C to 116 C in 1 C increments If the message HI flashes stop the vehicle then stop the engine a...

Page 31: ...mobilizer system keys may cause signal inter ference which may prevent the engine from starting 2 If the engine starts turn it off and try starting the engine with the standard keys 3 If one or both of the standard keys do not start the engine take the vehicle the code re reg istering key and both standard keys If the display indicates any fault codes note the code number and then check the vehicl...

Page 32: ... correct installation of all parts 5 Keep all parts away from any source of fire EAS30007 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 EAS30008 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals ...

Page 33: ...d air because this will damage the bearing surfac es EAS30011 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways 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 EAS30012 RUBBER PARTS Check rubber parts for deterioration during in...

Page 34: ...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 35: ...f a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct battery terminals Reversing the bat tery lead connections could damage the electrical components NOTICE ECA16771 When connecting the battery leads to the battery be sure to connect the positive bat tery lead first then ...

Page 36: ... 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 NOTICE ECA14371 Never insert the tester probes into the cou pler terminal slots Always insert the probes from the opposite end a of the coupler tak ing care not to loosen or damage the leads NOTICE ECA16640 For waterproof ...

Page 37: ...erefore be sure to check the type of cou pler lock before disconnecting the coupler NOTICE ECA16790 When disconnecting a connector do not pull the leads Hold both sections of the connec tor securely and then disconnect the con nector 2 Check Lead Coupler Connector Moisture Dry with an air blower Rust stains Connect and disconnect sev eral times 3 Connect Lead Coupler Connector TIP When connecting ...

Page 38: ...er available at most part stores 5 Check Resistance TIP The resistance values 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 Pocket tester 90890 03132 Pocket tester 90890 03112 Analog pocket tester YU 03112 C Intake air temperature sensor re sistance 5 40 6 60 kΩ at 0 C 32 F 290 3...

Page 39: ...o avoid any mistakes TIP For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Pocket tester 90890 03132 1 29 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 29 8 125 8 126 8 127 8 127 8 131 8 132 8 133 8 133 8 134 8 134 8 135 8 135 8 137 8 137 8 138 8 139 8 140 8 140 8 141 8 141 Thi...

Page 40: ...t wrench YU A9472 3 19 4 89 Oil filter wrench 90890 01426 Oil filter wrench YU 38411 3 22 Pressure gauge 90890 03153 Pressure gauge YU 03153 3 23 7 16 7 17 Oil pressure adapter H 90890 03139 3 23 Damper rod holder 90890 01460 4 81 4 83 T handle 90890 01326 T handle 3 8 drive 60 cm long YM 01326 4 81 4 83 Tool name Tool No Illustration Reference pages YU 44456 ...

Page 41: ...4136 5 1 Compression gauge 90890 03081 Engine compression tester YU 33223 5 1 Rotor holding tool 90890 01235 Universal magneto and rotor holder YU 01235 5 17 5 21 Yamaha bond No 1215 90890 85505 Three bond No 1215 5 24 5 44 5 71 5 73 Valve spring compressor 90890 04019 Valve spring compressor YM 04019 5 32 5 37 Tool name Tool No Illustration Reference pages YM A9409 7 YM A5142 4 90890 03081 YU 332...

Page 42: ...e installer 4 5 mm YM 04117 5 34 Valve guide reamer ø4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 5 34 Rotor holding tool 90890 04166 YM 04166 5 42 5 42 5 43 5 43 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 42 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 5 48 8 136 8 139 Universal clutch holder 90890 04086 Universal clutch holder YM 91042 5 5...

Page 43: ...mpressor YM 08037 5 84 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 01304 YU 24460 A YU 33984 ...

Page 44: ...90890 03210 Fuel injector pressure adapter YU 03210 7 16 Fuel pressure adapter 90890 03176 Fuel pressure adapter YM 03176 7 17 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 134 Test harness lean angle sensor 6P 90890 03209 Test harness lean angle sensor 6P YU 03209 8 135 Test harness S pressure sensor 3P 90890 03207 Test harness S pressure sensor 3P YU 03207 8 139 Tool name...

Page 45: ...ENING TORQUES 2 14 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 14 ENGINE TIGHTENING TORQUES 2 15 CHASSIS TIGHTENING TORQUES 2 20 LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ENGINE 2 24 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 ENGINE OIL LUBRICATION CHART 2 25 LUBRICATION DIAGRAMS 2 27 COOLING SYSTEM DIAGRAMS 2 39 CABLE ROUTING 2 41 ...

Page 46: ...L CHE CZE DNK FIN GBR GRC HU N IRL NLD NOR POL PRT SVK SVN S WE TUR ZAF 1XB7 BEL CHE CZE DNK FIN GBR GRC HU N IRL NLD NOR POL PRT SVK SVN S WE TUR ZAF 1XB8 BEL CHE CZE DNK FIN GBR GRC HU N IRL NLD NOR POL PRT SVK SVN S WE TUR ZAF Dimensions Overall length 2085 mm 82 1 in Overall width 745 mm 29 3 in Overall height 1090 mm 42 9 in Seat height 805 mm 31 7 in Wheelbase 1400 mm 55 1 in Ground clearanc...

Page 47: ...unt 2 7 L 0 71 US gal 0 59 Imp gal Engine oil Lubrication system Wet sump Recommended brand YAMALUBE Type SAE 10W 30 10W 40 10W 50 15W 40 20W 40 or 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Quantity disassembled 3 00 L 3 17 US qt 2 64 Imp qt Without oil filter cartridge replacement 2 30 L 2 43 US qt 2 02 Imp qt With oil filter cartridge ...

Page 48: ... 0 8 0 9 mm 0 031 0 035 in Cylinder head Combustion chamber volume 18 48 20 08 cm 1 13 1 23 cu in Warpage limit 0 05 mm 0 0020 in Camshaft Drive system Chain drive right Camshaft cap inside diameter 22 000 22 021 mm 0 8661 0 8670 in Camshaft journal diameter 21 959 21 972 mm 0 8645 0 8650 in Camshaft journal to camshaft cap clearance 0 028 0 062 mm 0 0011 0 0024 in Camshaft lobe dimensions Lobe he...

Page 49: ... 41 39 mm 1 63 in Limit 39 32 mm 1 55 in Installed length intake 34 34 mm 1 35 in Installed length exhaust 35 84 mm 1 41 in Spring rate K1 intake 26 03 N mm 2 65 kgf mm 148 63 lbf in Spring rate K2 intake 42 21 N mm 4 30 kgf mm 241 02 lbf in Spring rate K1 exhaust 28 90 N mm 2 95 kgf mm 165 02 lbf in Spring rate K2 exhaust 44 19 N mm 4 51 kgf mm 252 32 lbf in Installed compression spring force int...

Page 50: ...end side clearance 0 160 0 262 mm 0 0063 0 0103 in Journal oil clearance 0 018 0 042 mm 0 0007 0 0017 in Bearing color code 1 Violet Pink 0 White Pink 1 Blue Pink 2 Black Pink 3 Brown Pink Balancer Balancer drive method Gear Balancer shaft runout limit 0 030 mm 0 0012 in Balancer shaft journal to balancer shaft bearing clearance 0 020 0 054 mm 0 0008 0 0021 in Clutch Clutch type Wet multiple disc ...

Page 51: ...lter element Oil coated paper element Fuel pump Pump type Electrical Maximum consumption amperage 3 3 A Fuel injector Model quantity 297500 2310 2 Throttle body Type quantity EHDW38 1 ID mark 1WS1 00 1XB1 1XB5 1XB6 1WS2 20 1XB2 1XB7 1XB8 Throttle position sensor Resistance 2 64 6 16 kΩ Output voltage at idle 0 63 0 73 V Fuel injection sensor Crankshaft position sensor resistance 228 342 Ω Intake a...

Page 52: ...PECIFICATIONS 2 7 Intake vacuum 29 8 32 4 kPa 224 243 mmHg 8 8 9 6 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 ...

Page 53: ... 58W Manufacturer model MICHELIN PILOT ROAD 3 Manufacturer model BRIDGESTONE BT023F F Wear limit front 1 6 mm 0 06 in Rear tire Type Tubeless Size 180 55 ZR17M C 73W Manufacturer model MICHELIN PILOT ROAD 3A Manufacturer model BRIDGESTONE BT023R M Wear limit rear 1 6 mm 0 06 in Tire air pressure measured on cold tires Loading condition 0 173 kg 0 381 lb Front 225 kPa 2 25 kgf cm 33 psi Rear 250 kP...

Page 54: ...0 in Specified brake fluid DOT 4 Steering Steering bearing type Angular bearing Center to lock angle left 35 0 Center to lock angle right 35 0 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 130 0 mm 5 12 in Fork spring free length 345 4 mm 13 60 in Limit 331 6 mm 13 06 in Collar length 150 0 mm 5 91 in Fork spring installed length 338 4 mm...

Page 55: ...80 kPa 9 8 kgf cm 139 4 psi Spring preload adjusting positions Minimum 1 Standard 3 Maximum 9 Drive chain Type manufacturer 525VAZ DAIDO Number of links 108 15 link length limit 239 3 mm 9 42 in Drive chain slack 51 0 56 0 mm 2 01 2 20 in Limit 58 0 mm 2 28 in ...

Page 56: ...0 V 29 3 A 5000 r min Stator coil resistance 0 128 0 192 Ω W W Rectifier regulator Regulator type Semi conductor short circuit Regulated voltage DC 14 1 14 9 V Rectifier capacity 50 0 A Battery Model YTZ10S Voltage capacity 12 V 8 6 Ah Specific gravity 1 310 Manufacturer GS YUASA Ten hour rate charging current 0 86 A Headlight Bulb type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 60 ...

Page 57: ...0 03 in Starter relay Amperage 180 0 A Coil resistance 4 18 4 62 Ω Horn Horn type Plane Quantity 1 Maximum amperage 3 0 A Turn signal hazard relay Relay type Full transistor Built in self canceling device No Fuel sender unit Sender unit resistance full 9 0 11 0 Ω Sender unit resistance empty 213 0 219 0 Ω Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 10 0 ...

Page 58: ...ELECTRICAL SPECIFICATIONS 2 13 Spare fuse 2 0 A ...

Page 59: ... To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components 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 ...

Page 60: ... 10 Nm 1 0 m kgf 7 2 ft lbf Timing chain tensioner cap bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Timing mark accessing bolt M8 1 15 Nm 1 5 m kgf 11 ft lbf Crankshaft end cover M36 1 10 Nm 1 0 m kgf 7 2 ft lbf Cylinder head cover bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Breather plate bolt M5 6 4 0 Nm 0 40 m kgf 2 9 ft lbf Cylinder head bolt M10 6 See TIP Cylinder head bolt M6 2 See TIP Timing chain guide bo...

Page 61: ... Crankcase bolt M8 2 See TIP l 65 mm 2 56 in Crankcase bolt M6 2 See TIP l 65 mm 2 56 in Crankcase bolt M6 3 See TIP l 60 mm 2 36 in Crankcase bolt M6 8 See TIP l 40 mm 1 57 in Oil pressure switch PT1 8 1 15 Nm 1 5 m kgf 11 ft lbf Three bond No 1215 Oil pressure switch lead bolt M4 1 1 8 Nm 0 18 m kgf 1 3 ft lbf Oil pressure switch lead holder bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Blind plate bolt M...

Page 62: ...M10 1 16 Nm 1 6 m kgf 12 ft lbf Thermostat cover bolt M6 2 12 Nm 1 2 m kgf 8 7 ft lbf Water pump housing bolt M6 3 10 Nm 1 0 m kgf 7 2 ft lbf Water pump inlet outlet pipe bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Coolant drain bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Intake air pressure sensor bolt M5 1 3 8 Nm 0 38 m kgf 2 8 ft lbf Intake air temperature sensor bolt M5 1 3 8 Nm 0 38 m kgf 2 8 ft lbf Air duc...

Page 63: ... the embossed numbers on the crankcase 1 Lubricate the crankcase bolts 1 27 threads mating surfaces washers and O rings with the en gine oil 2 Tighten the crankcase bolts 1 6 to 24 Nm 2 4 m kgf 17 ft lbf 3 Loosen and retighten the crankcase bolts 1 6 to 17 Nm 1 7 m kgf 12 ft lbf in the proper tight ening sequence and then tighten them further to reach the specified angle 60 in the proper tight eni...

Page 64: ...onnecting rod bolt Tighten the connecting rod bolts to 20 Nm 2 0 m kgf 14 ft lbf and then tighten them further to reach the specified angle 175 185 8 3 2 6 2 6 11 10 5 4 7 8 1 2 13 16 6 3 12 9 20 19 15 21 22 17 18 14 26 27 24 23 25 ...

Page 65: ... mm M8 2 16 Nm 1 6 m kgf 12 ft lbf Rear side cover bolt M6 12 mm M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Tail brake light bolt M6 2 3 3 Nm 0 33 m kgf 2 4 ft lbf Mudguard assembly bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf License plate turn signal light bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Center cover screw M5 2 1 5 Nm 0 15 m kgf 1 1 ft lbf Upper tail cover screw M5 2 1 5 Nm 0 15 m kgf 1 1 ft lbf Headlight asse...

Page 66: ...inder reservoir cap bolt M4 2 1 5 Nm 0 15 m kgf 1 1 ft lbf Brake lever pivot bolt M6 1 1 0 Nm 0 10 m kgf 0 72 ft lbf Brake lever pivot nut M6 1 6 Nm 0 6 m kgf 4 3 ft lbf Front brake light switch screw M4 1 1 2 Nm 0 12 m kgf 0 87 ft lbf Brake caliper bleed screw M8 3 5 Nm 0 5 m kgf 3 6 ft lbf Front brake caliper bolt M10 2 40 Nm 4 0 m kgf 29 ft lbf Front brake hose union bolt M10 5 30 Nm 3 0 m kgf ...

Page 67: ...7 Nm 0 7 m kgf 5 1 ft lbf Front brake hose lead holder bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Front fender side cover bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Front brake hose holder bracket bolt M5 1 3 8 Nm 0 38 m kgf 2 8 ft lbf Front brake hose lower holder bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Cap nut M25 1 See TIP Drive chain guard bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Relay arm nut M10 1 40 Nm 4 0 m kgf ...

Page 68: ...side M6 1 9 Nm 0 9 m kgf 6 5 ft lbf Shift rod locknut shift pedal side M6 1 9 Nm 0 9 m kgf 6 5 ft lbf Left hand threads Shift arm pinch bolt M6 1 14 Nm 1 4 m kgf 10 ft lbf Shift rod upper joint bolt M6 1 9 Nm 0 9 m kgf 6 5 ft lbf Fuel pump bolt M5 4 4 0 Nm 0 40 m kgf 2 9 ft lbf Fuel tank bolt front side M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank bolt rear side M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Rear fue...

Page 69: ...aft journals Balancer shaft journals Generator rotor bolt thread and washer Balancer shaft buffer plate bolt Oil pump rotors inner and outer Oil pump shaft Oil cooler union bolt Starter clutch idle gear inner surface and end Starter clutch outer assembly Starter clutch gear Primary driven gear end Crankcase cover and clutch pull rod Clutch housing thrust washer Clutch boss nut and conical washer T...

Page 70: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 1 2 7 3 4 5 6 8 9 9 10 11 12 13 14 15 ...

Page 71: ...trainer 2 Oil pump 3 Relief valve 4 Oil cooler 5 Oil filter cartridge 6 Main gallery 7 Oil pressure switch 8 Crankshaft 9 Oil nozzle 10 Balancer shaft assembly 11 Timing chain tensioner 12 Intake camshaft 13 Exhaust camshaft 14 Main axle 15 Drive axle ...

Page 72: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EAS30021 LUBRICATION DIAGRAMS Crankcase cylinder and cylinder head right side view 1 2 3 4 5 6 7 8 9 ...

Page 73: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Timing chain tensioner 2 Intake camshaft 3 Exhaust camshaft 4 Crankshaft 5 Oil filter cartridge 6 Oil cooler 7 Oil drain bolt 8 Oil strainer 9 Oil pump ...

Page 74: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 Crankcase and cylinder left side view 1 2 3 4 5 ...

Page 75: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Crankshaft 2 Balancer shaft assembly 3 Connecting rod 4 Oil cooler 5 Oil filter cartridge ...

Page 76: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 Oil pump bottom view 2 3 4 5 1 ...

Page 77: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Oil pump 2 Oil pressure switch 3 Oil filter cartridge 4 Oil cooler 5 Oil strainer ...

Page 78: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 Camshaft top view 2 3 3 1 3 ...

Page 79: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Intake camshaft 2 Cylinder head 3 Exhaust camshaft ...

Page 80: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 Crankshaft front view 3 4 1 2 1 ...

Page 81: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Oil nozzle 2 Piston 3 Crankshaft 4 Main gallery ...

Page 82: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 Crankshaft and transmission top view 1 2 4 3 ...

Page 83: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Balancer shaft assembly 2 Crankshaft 3 Main axle 4 Drive axle ...

Page 84: ...COOLING SYSTEM DIAGRAMS 2 39 EAS20020 COOLING SYSTEM DIAGRAMS 1 2 3 4 5 6 7 7 8 9 10 6 3 4 5 8 ...

Page 85: ...AMS 2 40 1 Thermostat 2 Oil cooler inlet hose 3 Oil cooler 4 Oil cooler outlet hose 5 Water jacket joint inlet hose 6 Water pump outlet pipe 7 Water pump inlet pipe 8 Radiator outlet hose 9 Water jacket joint 10 Water pump ...

Page 86: ...CABLE ROUTING 2 41 EAS20021 CABLE ROUTING Handlebar front view 2 1 2 3 4 4 3 5 6 7 7 8 8 A B C 9 9 10 11 12 13 14 15 11 12 4 5 19 20 21 13 J H H H H M N H K L 15 16 17 G F 1 1 2 2 22 22 E 1 3 4 18 D I ...

Page 87: ...older completely into the hole in the guide B Route the throttle cables through the guide C Route the throttle cable decelerator cable over the throttle cable accelerator cable D Route the handlebar switch lead left handlebar switch to the rear of the wire harness E Route the brake hose front brake master cylinder to hydraulic unit to the rear of the right handlebar switch lead and throttle cables...

Page 88: ...CABLE ROUTING 2 43 Clutch cable right side view 1 2 3 6 A 7 8 9 B C 13 12 D E 16 19 18 1 2 20 23 1 2 I H 14 15 21 22 4 5 11 10 K J 17 G F ...

Page 89: ...il pressure switch lead through the guide and then secure the lead by bending the guide around the lead C Route the oil pressure switch lead to the inside of the O2 sensor lead and then secure the leads by bending the guides around the leads D Fasten the rear brake light switch lead and O2 sensor lead with the holder E Connect the O2 sensor coupler and then insert the projection on the coupler int...

Page 90: ...CABLE ROUTING 2 45 Rectifier regulator left side view 1 2 3 4 5 6 7 8 9 8 10 A B C D E F G H I 11 13 12 22 23 15 16 17 18 19 20 21 K L L N M 10 J 14 ...

Page 91: ...in the illustration Make sure that there is no slack in the AC magneto lead D Secure the holder by inserting the projection on the holder into the hole in the radiator fan motor bracket and then fasten the AC magneto lead horn lead and coolant reservoir hose with the holder Make sure that the coolant reservoir hose and leads do not cross between the oil cooler inlet hose and this holder E Fasten t...

Page 92: ...CABLE ROUTING 2 47 Engine left side view 1 2 3 4 5 6 7 7 A B C D E F 16 17 18 19 20 21 M 22 23 1 1 N O 24 11 12 13 14 15 J K L 16 G 9 I 10 8 H P 7 8 24 8 19 20 ...

Page 93: ...n the starter motor lead and engine ground lead with the holder Align the white tape on the starter motor lead with the holder D Blue paint mark E White paint mark F 0 10 mm 0 0 39 in G Make sure that there is no twist in the starter motor lead and sidestand switch lead H Fasten the starter motor lead gear position switch lead and sidestand switch coupler with the plastic band Face the buckle of t...

Page 94: ... 1 2 4 5 5 6 9 7 8 12 14 13 15 16 17 A B C D E 21 22 23 24 25 26 27 29 29 29 F 30 31 32 33 33 34 G 35 I J 36 H 35 M 22 23 23 28 29 27 29 28 35 37 38 10 11 18 20 19 28 34 35 N 35 39 40 41 42 43 44 45 O 35 14 33 L L 29 K 46 37 43 35 23 29 P Q R ...

Page 95: ... in the bracket B Route the ECU lead and sub wire harness through the guide C Connect the sub wire harness coupler 7 pins and then insert the projection on the coupler into the hole in the bracket D Fasten the wire harness with the battery band Do not route the wire harness through the hole in the battery band E Route the positive battery lead through the hole in the battery band F Insert the proj...

Page 96: ...CABLE ROUTING 2 51 Rear fender top view A 1 2 3 1 2 3 4 4 5 5 6 6 7 8 9 10 11 12 13 13 13 13 14 13 14 13 B C D E F ...

Page 97: ...ight turn signal light lead and license plate light lead through the hole in the frame B Install fuse box 1 completely onto the tab on the battery box C Route the seat lock cable through the guide on the battery box D Install fuse box 2 completely onto the tab on the battery box E Route the tail brake light assembly lead rear turn signal light leads and license plate light lead through the hole in...

Page 98: ...CABLE ROUTING 2 53 Rear fender left side view B A D D D E 1 1 2 2 2 3 3 3 4 5 6 6 6 6 2 3 6 2 3 6 7 8 8 9 10 10 11 11 12 12 13 C ...

Page 99: ...t the seat lock cable completely into the hole in the seat lock key cylinder bracket B Fasten the tail brake light assembly lead rear turn signal light leads and license plate light lead with a plastic locking tie The leads may be fastened in any order Cut off the excess end of the plastic locking tie so that it does not contact the seat lock assembly C Insert the seat lock cable completely into t...

Page 100: ...CABLE ROUTING 2 55 Rear brake hose right side view A B C D D E E F G H I J K L 1 1 1 1 2 3 3 3 3 3 4 4 4 4 4 4 4 4 5 5 6 6 ...

Page 101: ...r F Fasten the grommets on the rear wheel sensor lead and the brake hose hydraulic unit to rear brake caliper with the holder G Fasten the rear wheel sensor lead and brake hose hydraulic unit to rear brake caliper with the holder Route the rear wheel sensor lead over the brake hose hydraulic unit to rear brake caliper Align the holder with the pipe section of the brake hose hydraulic unit to rear ...

Page 102: ...CABLE ROUTING 2 57 Front brake hose left and right side view A B C D E D F G G H 1 1 2 2 2 3 2 3 4 1 ...

Page 103: ... and route the lead over the hose C Face the catch of the holder forward and then close the holder until three clicks or more are heard D Make sure that the holder contacts the end of the hose protector on the brake hose E Fasten the front wheel sensor lead and brake hose hydraulic unit to left front brake caliper with the holder as shown in the illustration Position the holder 30 50 mm 1 18 1 97 ...

Page 104: ...CABLE ROUTING 2 59 Hydraulic unit assembly top and right side view A 1 1 2 2 3 3 4 4 ...

Page 105: ...ose front brake master cylinder to hydraulic unit 3 Brake hose hydraulic unit to left front brake caliper 4 Brake hose hydraulic unit to rear brake caliper A Make sure that the pipe section of the brake hose rear brake master cylinder to hydraulic unit does not contact the hydraulic unit ...

Page 106: ...CABLE ROUTING 2 61 Fuel tank left side view A B C 1 2 3 4 B ...

Page 107: ... up to the wide portion of the pipe B Align the ends of the hose clamp with the paint mark on the hose Make sure not to install the hose clamp on the raised portion of the hose fitting Make sure that the hose clamp does not contact the bottom of the fuel tank C Face the white paint mark on the fuel tank overflow hose to the right Install the hose up to the wide portion of the pipe ...

Page 108: ...CABLE ROUTING 2 63 Throttle bodies top view A B C D 1 2 3 4 5 6 7 8 9 10 11 ...

Page 109: ... solenoid vacuum hose intake solenoid to air filter case valve 11 Air filter case valve A Face the yellow paint mark on the cylinder head breather hose to the left Install the crankcase breather hose completely onto the hose fitting B Position the hose clamp 1 4 mm 0 04 0 16 in from the end of the hose Point the ends of the hose clamp to the left C Position the hose clamp 1 4 mm 0 04 0 16 in from ...

Page 110: ...CABLE ROUTING 2 65 Air filter case left and right side view A B C D E B F G H J I K L M N O O O O P Q 1 2 3 4 5 6 9 9 9 7 8 9 10 10 11 12 11 12 12 13 13 14 14 15 15 16 16 16 D ...

Page 111: ...intake solenoid to air filter case valve with the holders as shown in the illustration G Face the green paint mark on the intake solenoid vacuum hose intake solenoid to air filter case valve to the right Align the center of the green paint mark with the center of the holder on the air filter case H Install the intake solenoid vacuum hose throttle body to one way valve onto the throttle body assemb...

Page 112: ...CABLE ROUTING 2 67 Radiator front view A B 1 2 3 4 5 6 ...

Page 113: ... Coolant reservoir hose 4 Radiator inlet hose 5 Coolant reservoir 6 Radiator outlet hose A Connect the end of the coolant reservoir hose that is identified by the white paint mark to the radiator B Point the ends of the hose clamp toward the frame ...

Page 114: ...CABLE ROUTING 2 69 Radiator left side view A B C D I F H G E 1 1 2 6 5 5 3 4 4 4 5 6 7 8 9 10 10 11 ...

Page 115: ...c locking tie inward with the end pointing downward B Align the white paint mark on the radiator inlet hose with the projection on the thermostat housing Install the radiator inlet hose onto the thermostat housing making sure that the hose contacts the projection on the housing C Point the ends of the hose clamp outward D Install the coolant reservoir hose onto the coolant reservoir cap making sur...

Page 116: ...CABLE ROUTING 2 71 Radiator right side view A B C 3 4 2 1 5 7 8 6 ...

Page 117: ...paint marks on the radiator inlet hose and coolant reservoir hose B Point the ends of the hose clamp in the direction shown in the illustration Make sure that the ends of the hose clamp do not contact the coolant reservoir hose C Align the yellow paint mark on the radiator inlet hose with the projection on the radiator pipe Install the radiator inlet hose onto the radiator pipe making sure that th...

Page 118: ...CABLE ROUTING 2 73 ...

Page 119: ... 3 15 CHECKING THE WHEELS 3 16 CHECKING THE TIRES 3 16 CHECKING THE WHEEL BEARINGS 3 17 CHECKING THE SWINGARM OPERATION 3 17 LUBRICATING THE SWINGARM PIVOT 3 17 ADJUSTING THE DRIVE CHAIN SLACK 3 17 LUBRICATING THE DRIVE CHAIN 3 19 CHECKING AND ADJUSTING THE STEERING HEAD 3 19 LUBRICATING THE STEERING HEAD 3 19 CHECKING THE FASTENERS 3 20 LUBRICATING THE BRAKE LEVER 3 20 LUBRICATING THE PEDAL 3 20 ...

Page 120: ...NG AND LUBRICATING THE CABLES 3 27 CHECKING THE THROTTLE GRIP OPERATION 3 27 CHECKING AND CHARGING THE BATTERY 3 28 CHECKING THE FUSES 3 28 REPLACING THE HEADLIGHT BULB 3 28 ADJUSTING THE HEADLIGHT BEAM 3 29 ...

Page 121: ......

Page 122: ... TIP The annual checks must be performed every year 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 NO ITEM CHECK OR MAINTENANCE JOB ...

Page 123: ...at all nuts bolts and screws are properly tight ened 15 Brake lever pivot shaft Lubricate with silicone grease 16 Brake pedal pivot shaft Lubricate with lithium soap based grease 17 Clutch lever pivot shaft Lubricate with lithium soap based grease 18 Shift pedal pivot shaft Lubricate with lithium soap based grease 19 Sidestand Check operation Lubricate with lithium soap based grease 20 Sidestand s...

Page 124: ...uid level Every two years replace the 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 28 Moving parts and cables Lubricate 29 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 30 Lights signals and switches Check operation A...

Page 125: ...0 Make sure the fuel tank breather overflow hose is routed correctly 3 Install Rear fuel tank bracket bolt 4 Install Fuel tank front cover Fuel tank center cover Fuel tank cover left Fuel tank cover right Fuel tank top cover Refer to GENERAL CHASSIS 4 on page 4 11 Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 EAS30620 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark...

Page 126: ...0622 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves TIP Valve clearance adjustment should be made on a cold engine at room temperature When the valve clearance is to be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Drain Coolant Refer to CHANGING THE COOLANT on page 3 24 2 Remove Fuel tank top cover Fuel tank cover le...

Page 127: ...clearances of cylinder 2 turn the crankshaft 270 counterclock wise 6 Remove Camshaft TIP Refer to CHANGING THE COOLANT on page 3 24 When removing the timing chain and cam shafts fasten the timing chain with a wire to re trieve it if it falls into the crankcase 7 Adjust Valve clearance a Remove the valve lifter 1 and the valve pad 2 with a valve lapper 3 Valve clearance cold Intake 0 11 0 20 mm 0 0...

Page 128: ...f the values obtained in steps b and c to determine the required valve pad thickness and the valve pad num ber Example 1 58 mm 0 0622 in 0 05 mm 0 0020 in 1 63 mm 0 0641 in The valve pad number is 163 e Round off the valve pad number according to the following table and then select the suit able valve pad TIP Refer to the following table for the available valve pads Example Valve pad number 163 Ro...

Page 129: ...d Out of specification Go to next step 3 Check ISC idle speed control learning value 00 or 01 Check the intake system 02 Clean the ISC idle speed control valve Refer to CLEANING THE ISC IDLE SPEED CONTROL VALVE on page 7 12 a Connect the Yamaha diagnostic tool Use the diagnostic code number 67 Refer to SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 9 5 b Check the ISC idle speed contro...

Page 130: ...engine warm it up for several min utes and then let it run at the specified en gine idling speed b With throttle body 1 as standard adjust throttle body 2 using the air screw 1 TIP Turn the bypass air screw using the carburetor angle driver After each step rev the engine two or three times each time for less than a second and check the synchronization again If a bypass air screw was removed turn t...

Page 131: ...t Fuel tank center cover Fuel tank front cover Refer to GENERAL CHASSIS 4 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 2 Disconnect Intake solenoid vacuum hose throttle body to one way valve Intake air pressure sensor hose Refer to THROTTLE BODIES on page 7 9 3 Remove Throttle bodies Refer to THROTTLE BODIES on page 7 9 4 Check Throttle body joints Cracks damage Replace 5 Install Throttle...

Page 132: ...ce the air filter element every 40000 km 24000 mi of operation The air filter needs more frequent service if you are riding in unusually wet or dusty areas 5 Install Air filter element Air duct bracket NOTICE ECA14401 Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air ...

Page 133: ...properly Check the brake system Refer to FRONT BRAKE on page 4 35 and REAR BRAKE on page 4 49 TIP Drive on the dry road operate the front and rear brakes separately and check to see if the brakes are operating properly EAS30630 ADJUSTING THE FRONT DISC BRAKE 1 Adjust Brake lever position distance a from the throttle grip to the brake lever TIP While pushing the brake lever forward turn the adjusti...

Page 134: ...sc Replace the brake pads as a set Refer to FRONT BRAKE on page 4 35 EAS30631 ADJUSTING THE REAR DISC BRAKE 1 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained WARNING EWA13070 After adjusting the brake pedal position check that the end of the adjusting bolt c is visible through the hole d c Tight...

Page 135: ... brake related parts are removed NOTICE ECA18050 Bleed the brake system in the following or der 1st step Front brake calipers 2nd step Rear brake caliper WARNING EWA16530 Bleed the ABS whenever the system is disassembled a brake hose is loosened disconnected or replaced the brake fluid level is very low brake operation is faulty TIP Be careful not to spill any brake fluid or allow the brake master...

Page 136: ...he operation of the hydraulic unit k After operating the ABS repeat steps e to i and then fill the brake master cylinder res ervoir or brake fluid reservoir to the proper level with the specified brake fluid l Tighten the bleed screw to specification m Fill the brake master cylinder reservoir or brake fluid reservoir to the proper level with the specified brake fluid Refer to CHECKING THE BRAKE FL...

Page 137: ...make any repairs to the wheel TIP After a tire or wheel has been changed or re placed always balance the wheel EAS30640 CHECKING THE TIRES The following procedure applies 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 t...

Page 138: ...1 Check Wheel bearings Refer to CHECKING THE FRONT WHEEL on page 4 20 and CHECKING THE REAR WHEEL on page 4 30 EAS30802 CHECKING THE SWINGARM OPERATION 1 Check Swingarm operation Swingarm not working properly Check the swingarm Refer to SWINGARM on page 4 95 2 Check Swingarm excessive play Refer to SWINGARM on page 4 95 EAS30643 LUBRICATING THE SWINGARM PIVOT 1 Lubricate Bearing Spacer Refer to IN...

Page 139: ...ck is more than the specified limit the chain can dam age the frame swingarm and other parts To prevent this from occurring keep the drive chain slack within the specified limits 4 Loosen Wheel axle nut 1 5 Adjust Drive chain slack a Loosen both of the drive chain puller locknuts 1 b Turn both of the drive chain puller adjusting nuts 2 in direction a or b until the speci fied drive chain slack is ...

Page 140: ...tom of the front fork legs and gently rock the front fork Blinding looseness Adjust the steering head 3 Remove Upper bracket Refer to FRONT FORK on page 4 75 4 Adjust Steering head a Loosen the cap nut 1 and then tighten it to specification with a steering nut wrench 2 TIP Set the torque wrench at a right angle to the steering nut wrench Move the steering to the left and right a couple of times to...

Page 141: ...T FORK 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Check Inner tube Damage scratches Replace Front fork leg Oil leaks between inner tube and outer tube Replace the oil seal 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check ...

Page 142: ...ark a and maximum level mark b Below the minimum level mark Add the recommended engine oil to the proper level TIP Before checking the engine oil level wait a few minutes until the oil has settled NOTICE ECA13361 Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD or...

Page 143: ...e 1 with an oil filter wrench 2 b Lubricate the O ring 3 of the new oil filter cartridge with a thin coat of engine oil NOTICE ECA13390 Make sure the O ring 3 is positioned cor rectly in the groove of the oil filter cartridge c Tighten the new oil filter cartridge to specifi cation with an oil filter wrench 6 Install Engine oil drain bolt along with the gasket 7 Fill Oil pan with the specified amo...

Page 144: ...he engine is cold the engine oil will have a higher viscosity causing the engine oil pressure to increase Therefore be sure to measure the engine oil pressure after warming up the engine 4 Remove Main gallery bolt 1 WARNING EWA12980 The engine muffler and engine oil are ex tremely hot 5 Install Oil pressure gauge 1 Adapter 2 6 Measure Engine oil pressure at the following conditions Out of specific...

Page 145: ...several min utes and then turn it off 4 Check Coolant level TIP Before checking the coolant level wait a few minutes until it settles EAS30812 CHECKING THE COOLING SYSTEM 1 Check Radiator 1 Radiator inlet hose 2 Radiator outlet hose 3 Oil cooler 4 Oil cooler inlet hose 5 Oil cooler outlet hose 6 Water jacket joint 7 Water jacket joint inlet hose 8 Thermostat cover 9 Thermostat 10 Water pump inlet ...

Page 146: ...nd radiator 7 Install Coolant drain bolt Copper washer 8 Install Collar Coolant reservoir Coolant reservoir cover Coolant reservoir quick fastener Coolant reservoir bolt 9 Fill Cooling system with the specified amount of the recom mended coolant Handling notes for coolant Coolant is potentially harmful and should be handled with special care 2 1 1 4 5 3 1 2 T R Coolant drain bolt 7 Nm 0 7 m kgf 5 ...

Page 147: ...h the recommended coolant to the maxi mum level mark a 12 Install Coolant reservoir cap 13 Start the engine warm it up for several min utes and then turn it off 14 Check Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 24 TIP Before checking the coolant level wait a few minutes until the coolant has settled EAS30814 CHECKING THE FRONT BRAKE LIGHT SWITCH Refer to CHECKING THE SWITCHES o...

Page 148: ...fective part s TIP With the engine stopped turn the throttle grip slowly and release it Make sure that the throttle grip turns smoothly and returns properly when released Repeat this check with the handlebar turned all the way to the left and right 3 Check Throttle grip free play a Out of specification Adjust 4 Adjust Throttle grip free play TIP Prior to adjusting the throttle grip free play throt...

Page 149: ...adjusting nut is covered com pletely by the rubber cover EAS30816 CHECKING AND CHARGING THE BATTERY Refer to CHECKING AND CHARGING THE BATTERY on page 8 128 EAS30662 CHECKING THE FUSES Refer to CHECKING THE FUSES on page 8 127 EAS30665 REPLACING THE HEADLIGHT BULB 1 Remove Headlight assembly bolts 1 TIP Lift up the headlight unit 2 and then remove it from the headlight bracket 3 2 Disconnect Headl...

Page 150: ...will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 7 Hook Headlight bulb holder 8 Install Headlight bulb cover 9 Connect Headlight coupler 1 10 Install Headlight assembly 1 TIP Fit the projections a on the headlight bracket into the holes b in the headlight assembly 11 Install Headlight assembly bolts 1 TIP When t...

Page 151: ... 2 Adjust Headlight beam horizontally TIP To adjust the headlight beam horizontally in sert a crosshead screwdriver into the hole a in the headlight assembly and turn the adjusting screw a Turn the adjusting screw 1 in direction b or c Direction b Headlight beam is raised Direction c Headlight beam is lowered a 1 c b a Direction b Headlight beam moves to the right Direction c Headlight beam moves ...

Page 152: ...PERIODIC MAINTENANCE 3 31 ...

Page 153: ... CHASSIS 4 4 11 REMOVING THE FUEL TANK TOP COVER 4 12 INSTALLING THE FUEL TANK TOP COVER 4 12 REMOVING THE FUEL TANK COVERS 4 12 INSTALLING THE FUEL TANK COVERS 4 12 REMOVING THE FUEL TANK CENTER COVER 4 13 INSTALLING THE FUEL TANK CENTER COVER 4 13 GENERAL CHASSIS 5 4 14 REMOVING THE ECU engine control unit 4 17 INSTALLING THE ECU engine control unit 4 17 INSTALLING THE ELECTRICAL COMPONENTS TRAY...

Page 154: ...ECKING THE FRONT BRAKE MASTER CYLINDER 4 46 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 46 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 47 REAR BRAKE 4 49 INTRODUCTION 4 55 CHECKING THE REAR BRAKE DISC 4 55 REPLACING THE REAR BRAKE PADS 4 55 REMOVING THE REAR BRAKE CALIPER 4 57 DISASSEMBLING THE REAR BRAKE CALIPER 4 57 CHECKING THE REAR BRAKE CALIPER 4 57 ASSEMBLING THE REAR BRAKE CALIPER 4 58 IN...

Page 155: ...ORBER 4 93 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 93 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 93 CHECKING THE RELAY ARM 4 93 INSTALLING THE RELAY ARM 4 93 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 94 SWINGARM 4 95 REMOVING THE SWINGARM 4 98 CHECKING THE SWINGARM 4 98 CHECKING THE CONNECTING ARM 4 98 INSTALLING THE CONNECTING ARM 4 99 INSTALLING THE SWINGARM 4 99 CHAIN DRIVE 4 101 REMOV...

Page 156: ...enger seat 1 2 Owner s tool kit band 1 3 Owner s tool kit 1 4 Pouch 1 5 Rider seat 1 6 Rider seat bracket 1 7 Negative battery lead 1 Disconnect 8 Positive battery lead 1 Disconnect 9 Battery band 1 10 Battery 1 5 4 2 3 4 10 1 9 8 7 6 2 2 Nm 0 22 m kgf 1 6 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 157: ...er seat bracket as shown and then place the seat in the original position EAS31126 INSTALLING THE PASSENGER SEAT 1 Install Passenger seat 1 TIP Insert the projections a on the front of the pas senger seat into the grooves b as shown and then push the rear of the seat down to lock it in place T R Rider seat bolt 7 Nm 0 7 m kgf 5 1 ft lbf b 1 a a 1 b ...

Page 158: ...ail cover 1 3 Lower tail cover 1 4 Rear side cover left 1 5 Rear side cover right 1 6 Lining cover left 1 7 Lining cover right 1 8 Tail brake light coupler 1 Disconnect 2 4 3 1 5 7 8 LT 4 6 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 3 3 Nm 0 33 m kgf 2 4 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 16 Nm 1 6 m kgf 12 f...

Page 159: ...License plate light coupler 1 Disconnect 12 Rear turn signal light coupler 2 Disconnect 13 Mudguard assembly 1 4 LT 13 10 9 12 11 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 3 3 Nm 0 33 m kgf 2 4 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R ...

Page 160: ...LING THE UPPER TAIL COVER 1 Install Upper tail cover 1 a Fit the projections a on the upper tail cover into the holes b in the rear side covers and then slide the cover forward while fitting the projection c on the tail brake light assembly into the slots d in the cover ribs and then slide the cover forward b Tighten the upper tail cover screws EAS31098 REMOVING THE REAR SIDE COVERS The following ...

Page 161: ...en the bolts to spec ification EAS31127 INSTALLING THE LOWER TAIL COVER 1 Install Lower tail cover 1 a Fit the projection a on the tail brake light as sembly into the hole b in the lower tail cover b Installing the quick fastener EAS31100 REMOVING THE LOWER FENDER COVER 1 Remove Lower fender cover 1 a Remove the quick fastener 2 b Slide the lower fender cover rearward and re move it EAS31101 INSTA...

Page 162: ...GENERAL CHASSIS 2 4 7 a Fit the projections a on the lower fender cover into the holes b in the battery box b Install the quick fastener a b a 1 ...

Page 163: ...ont turn signal light coupler right 1 Disconnect 5 Auxiliary light coupler 1 Disconnect 6 Headlight coupler 1 Disconnect 7 Headlight side cover left 1 8 Headlight side cover right 1 9 Headlight center cover 1 10 Headlight 1 1 8 5 6 10 9 4 7 1 2 3 1 3 Nm 0 13 m kgf 0 94 ft Ibf T R 0 8 Nm 0 08 m kgf 0 58 ft Ibf T R 0 8 Nm 0 08 m kgf 0 58 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft...

Page 164: ... Remarks 11 Meter assembly bracket 1 12 Meter assembly coupler 1 Disconnect 13 Meter assembly 1 1 3 Nm 0 13 m kgf 0 94 ft Ibf T R 0 8 Nm 0 08 m kgf 0 58 ft Ibf T R 0 8 Nm 0 08 m kgf 0 58 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 12 13 11 ...

Page 165: ...bolts 2 TIP Fit the projections a on the headlight bracket into the holes b in the headlight assembly When the headlight assembly bolts are tight ened to specification there may be gaps a between the washers and the grommets as shown in the illustration T R Headlight assembly bolt 7 Nm 0 7 m kgf 5 1 ft lbf b a 1 2 a ...

Page 166: ... 1 3 Fuel tank cover right 1 4 Fuel tank center cover 1 5 Fuel tank front cover 1 6 Air scoop inner panel left 1 7 Air scoop left 1 8 Air scoop inner panel right 1 9 Air scoop right 1 8 7 6 7 2 9 1 4 5 3 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T ...

Page 167: ...e fuel tank covers 1 Remove Fuel tank cover 1 a Remove the fuel tank cover bolts 2 and quick fastener 3 b Remove the projections a on the fuel tank cover from the fuel tank center cover and re move the fuel tank cover c Pull the fuel tank cover outward to remove the projections b from the grommets EAS31105 INSTALLING THE FUEL TANK COVERS The following procedure applies to both of the fuel tank cov...

Page 168: ...rojections a on the fuel tank center cover from the fuel tank front cover and remove the fuel tank center cover EAS31107 INSTALLING THE FUEL TANK CENTER COVER 1 Install Fuel tank center cover 1 a Fit the projections a on the fuel tank center cover into the holes b in the fuel tank front cover b Install the fuel tank center cover bolts and quick fastener and then tighten the bolts to specification ...

Page 169: ... front cover Refer to GENERAL CHASSIS 4 on page 4 11 Hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYS TEM on page 4 62 Fuel tank Refer to FUEL TANK on page 7 1 1 Stator coil coupler 1 2 Rectifier regulator coupler 1 Disconnect 3 Rectifier regulator 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8...

Page 170: ...sconnect 9 Intake air pressure sensor 1 10 Joint coupler 1 11 Crankshaft position sensor coupler 1 12 Fan motor coupler 1 13 Electrical components tray 1 1 14 Fuel tank cover bracket 1 15 ECU coupler 1 Disconnect 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 6...

Page 171: ...ngine control unit 1 18 Sub wire harness coupler 1 19 Intake solenoid 1 20 Surge tank 1 21 Electrical components tray 2 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 18 20 19 21 16 17 ...

Page 172: ...ll Electrical components tray 2 1 TIP Tighten the electrical components tray 2 nuts and bolt in the proper tightening sequence as shown 2 Install Fuel tank cover bracket 1 Electrical components tray 1 2 TIP Make sure that the projection a on the fuel tank cover bracket contacts the frame 3 Install Intake air pressure sensor 1 TIP Make sure that the intake air pressure sensor contacts the frame T R...

Page 173: ...h bolt 1 Loosen 6 Front wheel axle 1 7 Collar 2 8 Front wheel 1 9 Front brake disc 2 10 Front wheel sensor rotor 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 65 Nm 6 5 m kgf 47 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R LT LT LT LT New...

Page 174: ...FRONT WHEEL 4 19 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 New New LS LS New New 1 1 2 2 3 ...

Page 175: ...ply the brake lever when remov ing the brake calipers Be sure not to contact the sensor electrode to any metal part when removing the front wheel sensor from the outer tube 3 Elevate Front wheel TIP Place the vehicle on a suitable stand so that the front wheel is elevated EAS30146 DISASSEMBLING THE FRONT WHEEL 1 Remove Oil seal Wheel bearings a Clean the surface of the front wheel hub b Remove the...

Page 176: ...hock the wheel sensor or the wheel sensor rotor 1 Check Front wheel sensor 1 Cracks bends distortion Replace Iron powder dust Clean 2 Check Front wheel sensor rotor 1 Cracks damage scratches Replace the front wheel sensor rotor Iron powder dust solvent Clean TIP The wheel sensor rotor is installed on the inner side of the wheel hub When cleaning the wheel sensor rotor be careful not to damage the ...

Page 177: ... new wheel bearing right side NOTICE ECA18110 Do not contact the wheel bearing inner race 1 or balls 2 Contact should be made only with the outer race 3 TIP Use a socket 4 that matches the diameter of the wheel bearing outer race b Install the spacer c Install the new wheel bearing left side TIP Place a suitable washer 1 between the socket 2 and the bearing so that both the inner race 3 and outer ...

Page 178: ...est at the same spot g The spot where all the marks come to rest is the front wheel s heavy spot X 3 Adjust Front wheel static balance a Install a balancing weight 1 onto the rim ex actly opposite the heavy spot X TIP Start with the lightest weight b Turn the front wheel 90 so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d ...

Page 179: ... wheel rota tion 5 Tighten Front wheel axle Front wheel axle pinch bolt NOTICE ECA19760 Before tightening the wheel axle push down hard on the handlebars several times and check if the front fork rebounds smoothly TIP First tighten the wheel axle then the wheel axle pinch bolt 6 Install Front wheel sensor NOTICE ECA21020 Make sure there are no foreign materials in the front wheel sensor rotor and ...

Page 180: ...ces in one rotation of the front wheel Do not turn the front wheel while the thickness gauge is installed This may damage the front wheel sen sor rotor and the front wheel sensor 8 Install Front wheel sensor lead holders 1 Front brake calipers Front brake hose lead holders 2 WARNING EWA13500 Make sure the brake hose is routed properly TIP Make sure that the projection a on each front wheel sensor ...

Page 181: ...chain adjusting nut 2 Loosen 5 Swingarm end plate left 1 6 Swingarm end plate right 1 7 Wheel axle nut 1 8 Washer 1 9 Rear wheel axle 1 10 Drive chain slack adjusting plate left 1 3 4 5 10 3 4 6 1 8 9 7 S 2 16 Nm 1 6 m kgf 12 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 105 Nm 10 5 m kgf 76 ft lbf T R 22 Nm 2 2 m kgf 16 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R LT 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 182: ...te right 1 12 Chain puller 2 13 Rear wheel 1 14 Brake caliper bracket 1 15 Collar left 1 16 Collar right 1 13 16 12 12 14 15 11 S 16 Nm 1 6 m kgf 12 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 105 Nm 10 5 m kgf 76 ft lbf T R 22 Nm 2 2 m kgf 16 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R LT 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 183: ...ket assembly 1 3 Rear wheel sprocket 1 4 Rear wheel drive hub 1 5 Rear wheel drive hub damper 6 6 Collar 1 7 Oil seal 1 8 Bearing 1 9 Rear brake disc 1 10 Rear wheel sensor rotor 1 11 Rear wheel 1 LT 5 9 11 5 6 4 3 2 8 7 1 10 3 LS LS LS New New LT 6 30 Nm 3 0 m kgf 22 ft Ibf T R 80 Nm 8 0 m kgf 58 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R ...

Page 184: ...REAR WHEEL 4 29 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Wheel bearing 2 3 Spacer 1 New New 1 3 LS New 2 2 ...

Page 185: ... not to contact the sensor electrode to any metal part when removing the rear wheel sensor from the rear brake caliper bracket 3 Loosen Chain puller locknuts 1 Drive chain adjusting nuts 2 4 Remove Wheel axle nut 1 Washer Rear wheel axle 2 Drive chain slack adjusting plates Rear wheel TIP Push the rear wheel forward and remove the drive chain from the rear wheel sprocket EAS30158 DISASSEMBLING THE...

Page 186: ...components with care since they have been accurately adjusted Keep them away from dirt and do not sub ject them to shocks The rear wheel sensor cannot be disassem bled Do not attempt to disassemble it If faulty replace with a new one Keep any type of magnets including mag netic pick up tools magnetic screwdrivers etc away from the rear wheel sensor or rear wheel sensor rotor Do not drop or shock t...

Page 187: ...r sub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off immediately Replace the brake disc bolts and wheel sensor bolts with new ones TIP Install the wheel sensor rotor with the stamped mark a facing outward Install the brake disc so that the recessed por tions of the bolt holes b face away from the hub Tighten the brake disc bolts in stages and in a crisscross pattern 2...

Page 188: ... 2 8 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 17 9 Tighten Wheel axle nut Rear brake caliper retaining bolt Rear brake caliper bolt WARNING EWA13500 Make sure the brake hose is routed properly 10 Install Rear wheel sensor NOTICE ECA21080 Make sure there are no foreign materials in the rear wheel sensor rotor and rear wheel sensor Foreign materials cause damage to...

Page 189: ...ting surface of the rotor deformation caused by an impact during ser vice and caught foreign materials If there is any defective part repair or replace the de fective part TIP Measure the distance between the rear wheel sensor rotor and rear wheel sensor in several places in one rotation of the rear wheel Do not turn the rear wheel while the thickness gauge is installed This may damage the rear wh...

Page 190: ...ke calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Front wheel sensor lead holder 2 Right side only 6 Front brake caliper 1 7 Brake caliper bleed screw 1 Left side only 8 Brake caliper bleed screw 1 Right side only 3 6 4 2 7 8 1 5 New 4 LS 40 Nm 4 0 m kgf 29 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R ...

Page 191: ... reservoir cap 1 2 Brake master cylinder reservoir diaphragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Brake lever 1 5 Front brake light switch connector 2 Disconnect 6 Front brake light switch 1 7 Front brake hose union bolt 1 S 1 2 3 4 5 6 7 New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 0 Nm 0 10 m kgf 0 72 ft Ibf T R 1 2 Nm 0 12 m kgf 0 87 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 6 Nm...

Page 192: ...ont brake master cylinder to hy draulic unit 1 10 Front brake master cylinder holder 1 11 Front brake master cylinder assembly 1 S 8 9 10 11 New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 0 Nm 0 10 m kgf 0 72 ft Ibf T R 1 2 Nm 0 12 m kgf 0 87 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R ...

Page 193: ...FRONT BRAKE 4 38 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 2 1 New BF BF S ...

Page 194: ... SYSTEM ABS on page 3 14 1 Front brake hose union bolt 1 2 Brake hose gasket 1 Left side only 3 Brake hose gasket 2 4 Brake hose hydraulic unit to left front brake cal iper 1 Left side only 5 Brake hose left front brake caliper to right front brake caliper 1 6 Front wheel sensor lead holder 2 Right side only 7 Front brake caliper 1 1 2 7 3 5 4 New New 6 30 Nm 3 0 m kgf 22 ft Ibf T R 40 Nm 4 0 m kg...

Page 195: ...Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston dust seal 4 7 Brake caliper piston seal 4 8 Brake caliper bleed screw 1 Left side only 9 Brake caliper bleed screw 1 Right side only 7 5 5 5 5 6 2 8 6 7 7 7 6 1 6 3 4 4 S S BF BF New New New New New New New New 9 New LS 5 Nm 0 5 m kgf 3 6 ft Ibf T R ...

Page 196: ... Check Front 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 brake disc deflection turn the handlebar to the left or right to ensure that the front wheel is stationary c Remove the brake caliper d Hold ...

Page 197: ...iper 1 Remove Brake pad clips 1 Brake pad pin 2 Brake pad spring 3 2 Remove Brake pads 1 Front brake caliper 2 Front wheel sensor lead holders right side only 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 plastic hose 1 tightly to the b...

Page 198: ...or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 EAS30724 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 Brake hose union bolt 1 Brake hose gaskets 2 Brake hose hydraulic unit to left front brake ca...

Page 199: ...aliper EAS30173 CHECKING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Check Brake caliper pistons 1 Rust scratches wear Replace the brake caliper pistons Brake caliper cylinders 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruc...

Page 200: ...the brake hose onto the brake caliper 1 make sure the brake pipe a touches the projection b on the brake caliper There should be 0 5 1 5 mm 0 020 0 059 in of clearance between the brake pipes Left side only 2 Install Brake pads Brake pad spring Brake pad pin Brake pad clips Refer to REPLACING THE FRONT BRAKE PADS on page 4 42 3 Fill Brake master cylinder reservoir with the specified amount of the ...

Page 201: ...emove Brake hose union bolt 1 Brake hose gaskets 2 Brake hose front brake master cylinder to hydraulic unit 3 TIP To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS30725 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder Damage scratches wear Replace Brake fluid delivery passages brake master cylinder body Obstruct...

Page 202: ... tighten the union bolt as shown Turn the handlebar to the left and right to make sure the brake hose does not touch other parts e g wire harness cables leads Correct if necessary 3 Fill Brake master cylinder reservoir with the specified amount of the specified brake fluid WARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leak...

Page 203: ...um level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 15 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 a ...

Page 204: ...er retaining bolt 1 4 Rear brake caliper bolt 1 5 Rear brake caliper 1 6 Brake pad 2 7 Brake pad shim 2 8 Brake pad insulator 2 9 Brake pad spring 1 10 Brake caliper bleed screw 1 S LT S S S 1 2 4 3 5 10 9 8 8 7 6 7 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 22 Nm 2 2 m kgf 16 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R ...

Page 205: ...r 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Rear brake hose union bolt 1 8 Brake hose gasket 2 2 1 3 4 6 7 8 5 LT LS New New 22 Nm 2 2 m kgf 16 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ib...

Page 206: ... Footrest assembly right 1 12 Rear brake light switch 1 13 Rear brake master cylinder 1 14 Brake pedal 1 15 Rear brake hose lead holder 1 16 Rear brake hose lead guide 1 15 16 9 13 11 12 10 14 LT LS New New 22 Nm 2 2 m kgf 16 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 23 Nm 2 3 ...

Page 207: ...brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder yoke 1 2 Brake master cylinder kit 1 3 Hose joint 1 4 Bushing 1 5 Brake master cylinder body 1 1 2 2 3 4 5 S BF BF New New New 18 Nm 1 8 m kgf 13 ft Ibf T R ...

Page 208: ...AKE SYSTEM ABS on page 3 14 1 Rear brake hose union bolt 1 2 Brake hose gasket 2 3 Brake hose hydraulic unit to rear brake caliper 1 4 Rear brake caliper retaining bolt 1 5 Rear brake caliper bolt 1 6 Rear brake caliper 1 LT LT LT S S 1 2 3 4 5 6 22 Nm 2 2 m kgf 16 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R New ...

Page 209: ...1 3 Brake pad 2 4 Brake pad shim 2 5 Brake pad insulator 2 6 Brake pad spring 1 7 Brake caliper piston 1 8 Brake caliper piston dust seal 1 9 Brake caliper piston seal 1 10 Brake caliper bleed screw 1 S New S BF S New 10 7 8 9 6 5 4 3 5 4 2 1 5 Nm 0 5 m kgf 3 6 ft Ibf T R 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R ...

Page 210: ...age 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 41 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 41 5 Adjust Brake disc deflection Refer t...

Page 211: ...pads and brake pad spring TIP The longer tangs a of the brake pad spring must point in the direction of the brake caliper piston 3 Lubricate Rear brake caliper bolt Rear brake caliper retaining bolt NOTICE ECA18210 Do not allow grease to contact the brake pads Remove any excess grease 4 Install Rear brake caliper Rear brake caliper bolt Rear brake caliper retaining bolt Brake pad retaining bolt Sc...

Page 212: ...piston dust seal 2 Brake caliper piston seal 3 a Blow compressed air into the brake hose joint opening a to force out the piston from the brake caliper WARNING EWA13550 Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston dust seal and brake calipe...

Page 213: ...on internal brake com ponents as they will cause the brake caliper piston dust seal and brake caliper piston seal to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston dust seal and brake caliper piston seal EAS30190 INSTALLING THE REAR BRAKE CALIPER 1 Install Rear brake caliper 1 temporarily Brake hose gaskets 2 Brake hose hydraulic unit to rear brake cali...

Page 214: ...E HYDRAULIC BRAKE SYSTEM ABS on page 3 14 6 Check Brake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 15 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 EAS30193 REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove B...

Page 215: ...brake hose lead holder 2 TIP Fit the projection a on the rear brake hose lead guide into the hole b in the swing arm Make sure that the projection c on the rear brake hose lead holder contacts the swingarm 2 Install Brake hose gaskets Brake hose rear brake master cylinder to hy draulic unit Brake hose union bolt Brake fluid reservoir hose WARNING EWA13530 Proper brake hose routing is essential to ...

Page 216: ...servoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 5 Check Brake fluid level Below the minimum level mark a Add the specified brake...

Page 217: ...age 3 14 Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank top cover Fuel tank cover right Refer to GENERAL CHASSIS 4 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 1 ABS ECU coupler 1 Disconnect 2 Brake hose union bolt 4 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R New New New...

Page 218: ...lic unit to left front brake cal iper 1 Disconnect 6 Brake hose front brake master cylinder to hy draulic unit 1 Disconnect 7 Brake hose rear brake master cylinder to hy draulic unit 1 Disconnect 8 Hydraulic unit assembly 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R New New New New New 3 7 3 ...

Page 219: ...he specified torque and bleed the brake system 1 Disconnect ABS ECU coupler 1 TIP Pull the lock lever a of the ABS ECU coupler in the direction of the arrow shown and then dis connect the coupler 2 Remove Brake hoses TIP Do not operate the brake lever and brake pedal while removing the brake hoses NOTICE ECA14530 When removing the brake hoses cover the area around the hydraulic unit to catch any s...

Page 220: ...nt brake master cylinder to hydraulic unit c Temporarily tighten the union bolt for the brake hose rear brake master cylinder to hy draulic unit 1 TIP Make sure that the pipe section b of the brake hose rear brake master cylinder to hydraulic unit does not contact the hydraulic unit d Position the brake hose hydraulic unit to left front brake caliper 3 so that its projection c contacts the brake h...

Page 221: ...te the fault codes Refer to B 3 DE LETING THE FAULT CODES on page 8 116 9 Perform a trial run Refer to CHECKING THE ABS WARNING LIGHT on page 4 69 EAS31040 HYDRAULIC UNIT OPERATION TESTS The reaction force pulsating action generated in the brake lever and brake pedal when the ABS is activated can be tested when the vehicle is stopped The hydraulic unit operation can be tested using the following t...

Page 222: ...econds The operation of the hydraulic unit can be con firmed using the indicator On The hydraulic unit is operating Flashing The conditions for operating the hy draulic unit have not been met Off The brake lever and brake pedal are not being operated 9 Check Hydraulic unit operation Click Action a single pulse will be generat ed in the brake lever 1 brake pedal 2 and again in the brake lever 1 in ...

Page 223: ...at Rider seat Refer to GENERAL CHASSIS 1 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 ABS reaction force confirmation 5 Removing the protective cap 1 and then connect the Yamaha diagnostic tool to the Yamaha diagnostic tool coupler 4P 6 Start the Yamaha diagnostic tool and dis...

Page 224: ...e tool screen indicate when the brakes are being applied and re leased respectively NOTICE ECA18280 Check that the pulse is felt in the brake le ver brake pedal and again in the brake le ver in this order If the pulse is felt in the brake pedal before it is felt in the brake lever check that the brake hoses and brake pipes are connected correctly to the hydraulic unit assembly If the pulse is hard...

Page 225: ...5 Handlebar switch right 1 6 Throttle cable housing 1 7 Throttle cable 2 Disconnect 8 Grip end 2 LT LS LS LS LS 1 1 2 4 6 6 7 7 5 8 3 5 8 11 Nm 1 1 m kgf 8 0 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 17 Nm 1 7...

Page 226: ...dlebar holder 2 18 Handlebar 1 19 Lower handlebar holder 1 LT LS LS LS LS 11 9 17 18 17 14 16 15 12 13 10 19 11 11 Nm 1 1 m kgf 8 0 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 17 Nm...

Page 227: ...rface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Lower handlebar holder Handlebar 1 Upper handlebar holders 2 NOTICE ECA18300 First tighten the bolts on the front side of the handlebar holder and then on the rear side TIP The upper handlebar holders should be in stalled with the punch marks a facing for ward Align the punch mark b on the h...

Page 228: ...ot touch the handlebar grip until the rub ber adhesive has fully dried TIP There should be 1 3 mm 0 04 0 12 in of clear ance a between the handlebar grip and the grip end 5 Install Handlebar switch left 1 TIP Align the projection a on the left handlebar switch with the hole b in the handlebar 6 Install Throttle grip 1 Throttle cables Grip end right Throttle cable housings 2 TIP Align the projectio...

Page 229: ...ends of the holder are pointing rearward Align the throttle cable holder 2 2 with the edge a of the front brake master cylinder 9 Install Front brake master cylinder assembly Refer to INSTALLING THE FRONT BRAKE MASTER CYLINDER on page 4 47 10 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP OPERATION on page 3 27 11 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVE...

Page 230: ...overs Fuel tank center cover Fuel tank front cover Refer to GENERAL CHASSIS 4 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 Front wheel Refer to FRONT WHEEL on page 4 18 1 Front fender side cover left 1 1 New LT LT LT LT LT LT 21 Nm 2 1 m kgf 15 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 26 Nm 2 6 m kgf 19 ft Ibf T R 26 Nm 2 6 m kgf 19 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf ...

Page 231: ...2 Loosen 9 Upper bracket pinch bolt center 1 Loosen 10 Main switch coupler 2 Disconnect 11 Immobilizer unit coupler 1 Disconnect 12 Upper bracket 1 13 Front fork cover 1 8 8 12 11 10 13 9 7 4 3 6 2 5 New 6 LT LT LT LT LT LT 21 Nm 2 1 m kgf 15 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 26 Nm 2 6 m kgf 19 ft Ibf T R 26 Nm 2 6 m kgf 19 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf ...

Page 232: ...oosen 16 Front fork leg 1 14 15 15 16 New LT LT LT LT LT LT 21 Nm 2 1 m kgf 15 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 26 Nm 2 6 m kgf 19 ft Ibf T R 26 Nm 2 6 m kgf 19 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 233: ...edure applies to both of the front fork legs 1 Protector 1 2 Front fork cap bolt 1 3 O ring 1 4 Spacer 1 5 Spring seat 1 6 Fork spring 1 7 Dust seal 1 8 Oil seal clip 1 9 Front fork damper rod bolt 1 10 Copper washer 1 2 3 4 5 7 1 8 10 9 6 New New New New New New LS New LS LT LT 30 Nm 3 0 m kgf 22 ft Ibf T R ...

Page 234: ... 1 12 Damper rod ring 1 13 Rebound spring 1 14 Inner tube 1 15 Oil seal 1 16 Washer 1 17 Outer tube bushing 1 18 Inner tube bushing 1 19 Oil flow stopper spring 1 20 Oil flow stopper 1 21 Outer tube 1 14 15 16 17 21 18 19 20 12 11 13 New New New New New New LS New LS LT LT 30 Nm 3 0 m kgf 22 ft Ibf T R ...

Page 235: ...13120 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 3 Loosen Front fork cap bolt 1 Upper bracket pinch bolts left and right 2 Upper bracket pinch bolt center 3 Lower bracket pinch bolts 4 WARNING EWA13640 Before loosening the upper and lower brack et pinch bolts support the front fork leg EAS...

Page 236: ... the front fork legs 1 Check Inner tube Outer tube Bends damage scratches Replace WARNING EWA13650 Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure Fork spring free length a Out of specification Replace 3 Check Damper rod Damage wear Replace Obstruction Blow out all of the oil passag es with compressed air Oil flow stopper Damage Replace NOTICE ECA14200 Th...

Page 237: ... that the oil flow stopper spring is in stalled securely into the grooves a in the oil flow stopper b Install the damper rod ring onto the damper rod TIP Fit the damper rod ring into the damper rod groove so that the side of the ring with the pro jections is facing in the direction shown in the il lustration c Install the damper rod and rebound spring to the inner tube TIP Allow the damper rod to ...

Page 238: ...e outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag 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 T R Front fork damper rod bolt 30 Nm 3 0 m kgf 22 ft lbf LOCTITE Damper rod holder 90890 01460 T handle 90890 01326 T hand...

Page 239: ...ing the front fork cap bolt lubri cate its O ring with grease Temporarily tighten the front fork cap bolt Tighten the front fork cap bolt specified torque when installing the front fork with upper brack et 13 Install Protector 1 TIP Align the projection a on the protector with the slot b in the outer tube EAS31111 INSTALLING THE FRONT FORK LEGS AND FRONT FENDER SIDE COVERS The following procedure ...

Page 240: ...t bolts to specification 5 Install Front fender Front fender side cover 1 a Fit the projections a on the front fender side cover into the holes b in the front fender and then slide the cover rearward b Fit the projection c on the front fender side cover into the hole d in the front fender c Install the front fender side cover bolt and then tighten the bolts to specification 2 1 3 a 2 2 1 T R Lower...

Page 241: ...FRONT FORK 4 86 d b a c 1 ...

Page 242: ...sembly Refer to GENERAL CHASSIS 3 on page 4 8 Handlebar Front fork legs Refer to FRONT FORK on page 4 75 1 Front brake hose lower holder 1 2 Front brake hose upper holder 1 3 Headlight bracket 1 4 Front brake hose holder bracket 1 5 Cap nut 1 4 1 2 3 5 LS LS LS 1st 52 Nm 5 2 m kgf 38 ft lbf 2nd 18 Nm 1 8 m kgf 13 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 243: ... Order Job Parts to remove Q ty Remarks 6 Lower bracket 1 7 Lower bracket cap 1 8 Bearing cover 1 9 Lower bearing dust seal 1 10 Upper bearing 1 11 Lower bearing 1 11 9 6 7 10 8 LS LS LS 1st 52 Nm 5 2 m kgf 38 ft lbf 2nd 18 Nm 1 8 m kgf 13 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 244: ...rom the steering head pipe 1 with a long rod 2 and hammer b Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer c Install a new dust seal and new bearing rac es NOTICE ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged TIP Always replace the bearings and bearing races as a set Whenever the steering head is disassembled repla...

Page 245: ...er bracket and cap nut 4 Install Front brake hose holder bracket 1 Headlight bracket Front brake hose upper holder 2 Front brake hose lower holder 3 TIP Make sure that the front brake hose holder bracket contacts the projection a on the lower bracket Make sure that the projection b on the front brake hose lower holder fits into the hole in the front brake hose upper holder T R Front brake hose hol...

Page 246: ... 2 Rear shock absorber assembly nut bolt front side 1 1 3 Spacer 1 4 Rear shock absorber assembly nut bolt rear side 1 1 5 Rear shock absorber assembly 1 6 Relay arm rubber cover 1 7 Spacer 1 8 Oil seal 2 7 Nm 0 7 m kgf 5 1 ft Ibf T R 2 4 7 8 8 4 5 2 3 1 6 LS LS New New New New New New 44 Nm 4 4 m kgf 32 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R ...

Page 247: ...nut bolt 1 1 11 Spacer 1 12 Oil seal 2 13 Bearing 1 14 Connecting arm nut bolt relay arm side 1 1 15 Relay arm 1 16 Spacer 1 17 Oil seal 2 18 Bearing 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 13 15 17 17 18 16 9 12 12 11 10 14 14 10 LS LS New New New New New New 44 Nm 4 4 m kgf 32 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R ...

Page 248: ...ber at a point 20 25 mm 0 79 0 98 in from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS30219 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 a suitable stand so that the rear wheel is...

Page 249: ...SORBER ASSEMBLY 1 Install Rear shock absorber assembly 1 TIP Make sure that the label a on the rear shock absorber assembly faces down 2 Tighten Rear shock absorber assembly nut front side Rear shock absorber bolt rear side A Left side B Right side a a 1 2 4 3 A B New 2 New b b a a 1 2 3 New 2 New b b a a 1 2 3 New 2 New b b T R Connecting arm nut relay arm side 40 Nm 4 0 m kgf 29 ft lbf Relay arm...

Page 250: ...BLY on page 4 91 Drive chain sprocket cover Refer to CHAIN DRIVE on page 4 101 1 Pivot shaft protector left 1 2 Pivot shaft protector right 1 3 Sidestand switch coupler 1 4 Sidestand 1 4 3 1 2 LT LT LT LT LS LS LS LS LS New New New New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 52 Nm 5 2 m kgf 38 ft Ibf T R 63 Nm 6 3...

Page 251: ...uide 1 12 Dust cover 2 13 Oil seal 2 14 Spacer 2 15 Oil seal 2 16 Bearing 3 6 7 8 5 12 13 10 9 11 12 13 14 15 16 16 14 LT LT LT LT LS LS LS LS LS New New New New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 52 Nm 5 2 m kgf 38 ft Ibf T R 63 Nm 6 3 m kgf 46 ft Ibf T R 110 Nm 11 m kgf 80 ft lbf T R 45 Nm 4 5 m kgf 33 ft I...

Page 252: ...pacer 1 20 Oil seal 2 21 Bearing 2 17 17 19 18 20 20 21 LT LT LT LT LS LS LS LS LS New New New New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 52 Nm 5 2 m kgf 38 ft Ibf T R 63 Nm 6 3 m kgf 46 ft Ibf T R 110 Nm 11 m kgf 80 ft lbf T R 45 Nm 4 5 m kgf 33 ft Ibf T R ...

Page 253: ... up and down If the swingarm vertical movement is not smooth or if there is binding check the pivot shaft collars bearings and dust covers 3 Remove Swingarm EAS30227 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash Pivot shaft Dust cover...

Page 254: ...INSTALLING THE SWINGARM 1 Lubricate Spacers Pivot shaft Bearings 2 Install Bearings 1 Oil seals 2 to the swingarm TIP Install the oil seals to the swingarm so that they are facing in the directions shown in the illustra tion Recommended lubricant Lithium soap based grease A Left side B Right side Installed depth a 3 5 4 5 mm 0 14 0 18 in Installed depth b 8 0 9 0 mm 0 31 0 35 in T R Connecting arm...

Page 255: ...INGARM 4 100 3 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 17 A Left side B Right side Drive chain slack 51 0 56 0 mm 2 01 2 20 in A B 1 1 New 2 New 2 New 2 New 2 b c a b d ...

Page 256: ...ARM on page 4 95 1 Shift rod locknut shift arm side 1 2 Shift rod locknut shift pedal side 1 Left hand threads 3 Shift rod 1 4 Shift rod joint 1 5 Shift arm 1 6 Drive sprocket cover 1 7 Drive chain guide 1 1 2 3 4 5 6 7 New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R 95 Nm 9 5 m kgf 69 ft Ibf T R 110 Nm 11 m kgf 80 ft lb...

Page 257: ...ut 1 Loosen 9 Drive chain 1 10 Drive sprocket nut 1 11 Washer 1 12 Drive sprocket 1 9 10 11 12 8 New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R 95 Nm 9 5 m kgf 69 ft Ibf T R 110 Nm 11 m kgf 80 ft lbf T R E LS LT LT LT LT ...

Page 258: ...s 4 d Move the footrest bracket 5 rearward and then remove the drive chain EAS31115 REMOVING THE DRIVE SPROCKET 1 Straighten the drive sprocket nut ribs a 2 Loosen Drive chain sprocket nut TIP Loosen the drive sprocket nut while pressing the brake pedal EAS30230 CHECKING THE DRIVE CHAIN 1 Measure 15 link section a of the drive chain Out of specification Replace the drive chain a Measure the length...

Page 259: ...s Never use high pressure water or air steam gasoline certain sol vents e g benzine or a coarse brush to clean the drive chain High pressure meth ods could force dirt or water into the drive chain s internals and solvents will deterio rate the O rings A coarse brush can also damage the O rings Therefore use only kerosene to clean the drive chain Do not soak the drive chain in kerosene for more tha...

Page 260: ... sprocket 1 Washer 2 Drive sprocket nut 3 TIP While applying the rear brake tighten the drive sprocket nut Install washer with the OUT mark a facing out Stake the drive sprocket nut at cutouts b in the drive axle EAS30234 INSTALLING THE DRIVE CHAIN 1 Install Drive chain 1 TIP Make sure that the drive chain is positioned above the portion a of the footrest bracket 2 2 Tighten Footrest bracket bolts...

Page 261: ...tain the correct shift pedal position c Tighten both locknuts TIP The shift rod locknut shift pedal side has left hand threads d Make sure the installed shift rod length is within specification Make sure that the in stalled shift rod length is within specification and that the angle between the shift arm and the shift rod is 90 T R Shift arm pinch bolt 14 Nm 1 4 m kgf 10 ft lbf Installed length a ...

Page 262: ... 3 17 NOTICE ECA13550 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its Drive chain slack 51 0 56 0 mm 2 01 2 20 in 90 ...

Page 263: ...EMOVING THE CYLINDER HEAD 5 29 CHECKING THE TIMING CHAIN GUIDES 5 29 CHECKING THE CYLINDER HEAD 5 29 INSTALLING THE CYLINDER HEAD 5 30 VALVES AND VALVE SPRINGS 5 31 REMOVING THE VALVES 5 32 CHECKING THE VALVES AND VALVE GUIDES 5 32 CHECKING THE VALVE SEATS 5 34 CHECKING THE VALVE SPRINGS 5 35 CHECKING THE VALVE LIFTERS 5 36 INSTALLING THE VALVES 5 36 GENERATOR AND STARTER CLUTCH 5 39 REMOVING THE ...

Page 264: ...FT SHAFT 5 62 OIL PUMP 5 63 CHECKING THE SPROCKET AND CHAIN 5 65 CHECKING THE OIL PUMP 5 65 CHECKING THE RELIEF VALVE 5 65 ASSEMBLING THE OIL PUMP 5 65 INSTALLING THE OIL PUMP 5 66 OIL PAN 5 67 REMOVING THE OIL PAN 5 68 CHECKING THE OIL STRAINER 5 68 INSTALLING THE OIL PAN 5 68 CRANKCASE 5 69 DISASSEMBLING THE CRANKCASE 5 71 CHECKING THE CRANKCASE 5 71 ASSEMBLING THE CRANKCASE 5 71 INSTALLING THE ...

Page 265: ...ER SHAFT ASSEMBLY 5 87 CHECKING THE CRANKSHAFT 5 89 INSTALLING THE CRANKSHAFT 5 91 INSTALLING THE BALANCER SHAFT ASSEMBLY 5 91 TRANSMISSION 5 92 REMOVING THE TRANSMISSION 5 97 CHECKING THE SHIFT FORKS 5 97 CHECKING THE SHIFT DRUM ASSEMBLY 5 97 CHECKING THE TRANSMISSION 5 98 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 98 INSTALLING THE TRANSMISSION 5 99 ...

Page 266: ...ECA13340 Before removing the spark plugs use com pressed air to blow away any dirt accumulat ed in the spark plug wells to prevent it from falling into the cylinders 7 Install Extension 1 Compression gauge 2 8 Measure Compression pressure Out of specification Refer to steps c and d TIP Due to the engine characteristics the compres sion pressure is different for cylinder 1 and cyl inder 2 a Turn th...

Page 267: ...o standard and then adjust the exhaust gas volume To adjust the exhaust gas volume use the CO adjustment mode of the Yamaha diagnostic tool For more information refer to the opera tion manual of the Yamaha diagnostic tool 1 Connect the Yamaha diagnostic tool to the coupler For information about connecting the Yamaha diagnostic tool refer to YAMAHA DIAGNOSTIC TOOL on page 8 36 EAS31133 CHECKING THE...

Page 268: ...el tank Refer to FUEL TANK on page 7 1 Fuel tank front cover Fuel tank center cover Fuel tank cover left Fuel tank cover right Fuel tank top cover Refer to GENERAL CHASSIS 4 on page 4 11 Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 ...

Page 269: ...ler 1 Disconnect 2 Muffler assembly 1 3 Exhaust gasket 2 4 Muffler bracket 2 5 Muffler cover 1 6 O2 sensor 1 Remove the O2 sensor only when neces sary 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 25 N...

Page 270: ... Refer to REAR BRAKE on page 4 49 Fuel tank top cover Fuel tank covers Fuel tank center cover Fuel tank front cover Refer to GENERAL CHASSIS 4 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 Air duct bracket Refer to AIR FILTER CASE VALVE on page 7 6 Throttle bodies Air filter case Cylinder head breather hose Refer to THROTTLE BODIES on page 7 9 1 2 3 4 5 6 11 10 7 8 9 13 12 10 Nm 1 0 m kgf ...

Page 271: ... hose Oil cooler inlet hose Refer to OIL COOLER on page 6 4 Water pump inlet pipe Water pump outlet pipe Refer to WATER PUMP on page 6 9 Drive chain Drive sprocket Refer to CHAIN DRIVE on page 4 101 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 22 1 Clutch cable 1 Disconnect 2 Negative battery lead 1 Disconnect 1 2 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 2 Nm 0 22 m kgf 1 6 ft Ibf T R 7 Nm ...

Page 272: ...ct 7 Gear position switch coupler 1 Disconnect 8 Starter motor lead 1 Disconnect 9 Coolant temperature sensor coupler 1 Disconnect 10 Stator coil coupler 1 Disconnect 11 Crankshaft position sensor coupler 1 Disconnect 12 Ignition coil coupler 2 Disconnect 13 Oil pressure switch connector 1 Disconnect 3 4 5 6 11 10 7 8 9 13 12 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 2 Nm 0 22 m kgf 1 6 ft Ibf T R 7 Nm 0 7...

Page 273: ...pper side 1 8 Engine bracket left 1 9 Engine bracket bolt right 2 10 Engine mounting bolt right upper side 1 11 Engine bracket right 1 2 9 9 6 10 7 11 3 8 1 3 5 4 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T...

Page 274: ...1 16 Engine 1 17 Plate 1 Install the plate only for frames that have a stamped 1 mark at the location a 12 13 14 14 15 15 16 17 a 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 75 Nm 7 5 m kgf 54 ft Ibf T R ...

Page 275: ... rear upper side NOTICE ECA21181 Do not move the rear brake hose joint brack et more than necessary Otherwise the brake hoses could bend and break EAS30251 INSTALLING THE ENGINE 1 Install for models with a stamped 1 mark on the frame Plate 1 TIP Install the plate only for frames that have a stamped 1 mark at the location a Fit the projections b on the plate into the slots c in the frame 2 Install ...

Page 276: ...ake hose joint bracket contacts the projection a on the frame 8 Install Clutch cable guide 1 TIP Make sure that the projection a on the clutch cable guide contacts the frame T R Engine mounting nut rear upper side 55 Nm 5 5 m kgf 40 ft lbf Engine mounting nut rear lower side 55 Nm 5 5 m kgf 40 ft lbf Engine mounting bolt left front side 75 Nm 7 5 m kgf 54 ft lbf T R Engine mounting bolt left upper...

Page 277: ...ENGINE REMOVAL 5 12 a 1 ...

Page 278: ...r to CHANGING THE COOLANT on page 3 24 Radiator inlet hose Radiator Refer to RADIATOR on page 6 1 Surge tank Intake solenoid Refer to INTAKE SOLENOID on page 7 19 Clutch cable guide Refer to ENGINE REMOVAL on page 5 4 1 Cylinder head breather hose 1 Disconnect 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R New New LT S ...

Page 279: ...gnition coil 2 4 Spark plug 2 5 Cylinder head cover 1 6 Cylinder head cover gasket 1 7 Breather plate 1 8 Breather plate gasket 1 9 Timing chain guide upper side 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R New New LT S S 7 6 4 3 3 4 4 8 5 2 6 9 ...

Page 280: ...el pin 4 8 Intake camshaft 1 9 Exhaust camshaft 1 10 Intake camshaft sprocket 1 11 Exhaust camshaft sprocket 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R M M M E E E E ...

Page 281: ...ressor lever pin 2 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R M M M E E E E E LS New New New 6 6 13 12 14 14 ...

Page 282: ...nto the timing chain tension er b Remove the timing chain tensioner 4 Remove Intake camshaft cap 1 Exhaust camshaft cap 2 NOTICE ECA13720 To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a criss cross pattern working from the outside in 5 Remove Intake camshaft 1 Exhaust camshaft 2 TIP To prevent the timing chain from falling into the...

Page 283: ... b Out of specification Replace the camshaft 3 Measure Camshaft runout Out of specification Replace 1 2 2 1 1 Camshaft lobe dimensions Lobe height Intake 35 610 35 710 mm 1 4020 1 4059 in Limit 35 510 mm 1 3980 in Base circle diameter Intake 27 950 28 050 mm 1 1004 1 1043 in Limit 27 850 mm 1 0965 in Lobe height Exhaust 35 710 35 810 mm 1 4059 1 4098 in Limit 35 610 mm 1 4020 in Base circle diamet...

Page 284: ...e 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 Replace the camshaft Within specification Replace the cylinder head and camshaft caps as a set EAS30936 CHECKING THE CAMSHAFT SPROCKETS 1 Check Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprockets and timing chain as a ...

Page 285: ...the decompressor cams 2 and de compressor lever pins 1 moves smoothly EAS30269 INSTALLING THE CAMSHAFTS 1 Align Mark a on the generator rotor with the slot b in the generator rotor cover a Turn the crankshaft counterclockwise b When piston 1 is at TDC align the TDC mark a on the generator rotor with the slot b in the generator rotor cover 2 Install Intake camshaft sprocket 1 NOTICE ECA19980 Be sur...

Page 286: ...aligned with cam lobe 1 b as shown in the illustration While holding the exhaust camshaft with a suit able tool tighten the exhaust camshaft sprock et bolts Tighten the camshaft sprocket bolts in the tightening sequence as shown 5 Install Timing chain 1 onto the exhaust camshaft sprocket 2 Exhaust camshaft Exhaust camshaft cap NOTICE ECA20930 Lubricate the camshaft cap bolts with the engine oil Th...

Page 287: ... the camshaft to avoid damage or improper valve timing a Install the timing chain onto intake camshaft sprocket and then install the intake camshaft onto the cylinder head TIP Make sure the match mark a on the intake camshaft sprocket is aligned with the cylinder head edge b b Tighten the intake camshaft cap bolts TIP Temporarily tighten the intake camshaft cap bolts and then tighten the bolts to ...

Page 288: ...bolt and gasket and then tighten the timing chain ten sioner cap bolt to specification 8 Turn Crankshaft several turns counterclockwise 9 Check Mark a Make sure the mark a on the generator rotor is aligned with the slot b in the generator ro tor cover Camshaft sprocket match mark Make sure the match marks c on the cam shaft sprockets are aligned with the cylinder head mating surface d Out of align...

Page 289: ...ead cover gasket 1 to the cylinder head cover cut off the a section Make sure that the projection b on the cylin der head cover gasket is positioned on the ex haust side of the rib c on the cylinder head cover 2 Install Spark plugs Ignition coils 1 TIP Install the ignition coils 1 in the direction shown in the illustration T R Cylinder head cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf Yamaha bond No 1215...

Page 290: ...acket Refer to AIR FILTER CASE VALVE on page 7 6 Throttle bodies Refer to THROTTLE BODIES on page 7 9 Footrest assembly right Refer to REAR BRAKE on page 4 49 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 75 Nm 7 5 m kgf 54 ft Ibf T R...

Page 291: ...ch cover Refer to CLUTCH on page 5 50 Thermostat Refer to THERMOSTAT on page 6 7 1 Coolant temperature sensor coupler 1 Disconnect 2 Coolant temperature sensor 1 3 Engine bracket bolt left 2 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T...

Page 292: ...t side 1 11 Timing chain bolt right side of cylinder head 1 12 Timing chain guide exhaust side 1 13 Cylinder head 1 14 Cylinder head gasket 1 15 Dowel pin 2 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 75 Nm 7 5 m kgf 54 ft Ibf T R 7...

Page 293: ...10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 75 Nm 7 5 m kgf 54 ft Ibf T R 75 Nm 7 5 m kgf 54 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf 20 Nm 2 0 m kgf 14 ft Ibf 40 Nm 4 0 m kgf 29 ft Ibf 1st 2nd T R 3rd Sp...

Page 294: ...s are fully loosened remove them M6 45 mm 1 2 M10 100 mm 3 8 EAS30278 CHECKING THE TIMING CHAIN GUIDES 1 Check Timing chain guide exhaust side Timing chain guide intake side Damage wear Replace EAS30277 CHECKING THE CYLINDER HEAD 1 Eliminate Combustion chamber carbon deposits with a rounded scraper TIP Do not use a sharp instrument to avoid damag ing or scratching Spark plug bore threads Valve sea...

Page 295: ... bolt M10 6 Cylinder head bolt M6 2 TIP Pass the timing chain through the timing chain cavity Lubricate the cylinder head bolt M10 threads and mating surface with engine oil 2 Tighten Cylinder head bolts 1 6 Cylinder head bolts 7 8 Following the tightening order loosen the bolt one by one and then retighten it to the specific torque TIP Tighten the cylinder head bolts in the tightening sequence as...

Page 296: ...emove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 25 1 Valve lifter 8 2 Valve pad 8 3 Valve cotter 16 4 Valve spring retainer 8 5 Valve spring 8 6 Exhaust valve 4 7 Intake valve 4 8 Valve stem seal 8 9 Valve spring seat 8 10 Valve guide 8 New New New New E E S S M M M M 2 2 3 3 4 4 5 5 10 10 8 8 9 1 1 9 7 6 ...

Page 297: ... 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 attachment 2 4 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4 Valve spring seat 5 TIP Iden...

Page 298: ...2 and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit ...

Page 299: ...ting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width TIP Where the valve seat and valve face contacted one another the bluein...

Page 300: ... forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply blue layout fluid b onto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear impres ...

Page 301: ...f the valves and related components 1 Deburr Valve stem end with an oil stone 2 Lubricate Valve stem 1 Valve stem end with the recommended lubricant 3 Lubricate Valve stem seal 2 with the recommended lubricant Installed compression spring force intake 144 00 166 00 N 14 68 16 93 kgf 32 37 37 32 lbf Installed compression spring force exhaust 149 00 171 00 N 15 19 17 44 kgf 33 50 38 44 lbf Installed...

Page 302: ...ing compressor attachment 2 6 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve 7 Lubricate Valve lifter with the recommended lubricant 8 Install Valve pad Valve lifter TIP The valve lifter must move smoothly when ro tated with a finger b Smaller pitch M S 2 1 New 3 1 4...

Page 303: ...VALVES AND VALVE SPRINGS 5 38 Each valve lifter and valve pad must be rein stalled in their original position ...

Page 304: ...ge 4 11 Drive chain sprocket cover Refer to CHAIN DRIVE on page 4 101 Coolant reservoir Refer to RADIATOR on page 6 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 22 1 Stator coil coupler 1 Disconnect 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R ...

Page 305: ...r 1 7 Generator cover gasket 1 8 Bearing 1 9 Dowel pin 2 10 Stator coil lead holder 1 11 Stator coil assembly Stator coil Crankshaft po sition sensor 1 12 Torque limiter 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R 70 Nm 7 0 m kgf 51 ft Ibf T R LT LT LT LT LT...

Page 306: ...ff key 1 17 Starter clutch idle gear shaft 1 18 Starter clutch idle gear 1 19 Starter clutch gear 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R 70 Nm 7 0 m kgf 51 ft Ibf T R LT LT LT LT LT LT LT LT LS LS New New New New E E E E E E 3 8 3 14 15 19 16 18 17 13 ...

Page 307: ...r rotor EAS30868 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts 1 Starter clutch TIP While holding the generator rotor 2 with the ro tor holding tool 3 loosen the starter clutch bolts EAS30869 CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers Damage wear Replace 2 Check Starter clutch idle gear Starter clutch gear Burrs chips roughness wear Replace the defective part s 3 Check ...

Page 308: ...rd the generator rotor 2 While holding the generator rotor with the rotor holding tool 3 tighten the starter clutch bolts 4 EAS30872 INSTALLING THE GENERATOR 1 Install Woodruff key Generator rotor Washer Generator rotor bolt TIP Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure the woodruff key is properly seated in the key way of...

Page 309: ... gasket Generator cover TIP Tighten the generator cover bolts in stages and in a crisscross pattern Apply LOCTITE to the threads of only the generator cover bolts 1 shown in the illustra tion 7 Connect Stator coil coupler Crankshaft position sensor coupler TIP To route the stator coil lead refer to CABLE ROUTING on page 2 41 Yamaha bond No 1215 90890 85505 Three bond No 1215 1 3 2 1 1 a T R Genera...

Page 310: ...k center cover Fuel tank front cover Refer to GENERAL CHASSIS 4 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 Pivot shaft protectors Refer to SWINGARM on page 4 95 Air duct bracket Refer to AIR FILTER CASE VALVE on page 7 6 Throttle bodies Air filter case Refer to THROTTLE BODIES on page 7 9 1 2 3 4 5 6 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf...

Page 311: ...arks 1 Gear position switch coupler 1 2 Fuel tank overflow hose 1 3 Fuel tank breather hose 1 4 Coupler and hose bracket 1 5 Starter motor lead 1 Disconnect 6 Starter motor 1 1 2 3 4 5 6 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R LS New ...

Page 312: ...move Q ty Remarks 1 O ring 1 2 Starter motor front cover 1 3 Starter motor yoke 1 4 Armature assembly 1 5 Gasket 2 6 Brush holder set 1 7 Starter motor rear cover 1 8 Lead guide 1 5 5 2 7 8 6 1 3 4 LS New New New New 5 Nm 0 5 m kgf 3 6 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R ...

Page 313: ...rmature assembly resistances with the digital circuit tester b If any resistance is out of specification re place the starter motor 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 6 Check Gear teeth Damage wear Replace the starter motor Mica undercut depth 0 70 mm 0 03 in Digital circuit teste...

Page 314: ...n in the illustration 2 Install Starter motor yoke 1 Starter motor front cover 2 Starter motor rear cover 3 TIP Align the match marks a on the starter motor yoke with the match marks b on the front cover and rear covers EAS30327 INSTALLING THE STARTER MOTOR 1 Install Coupler and hose holder bracket 1 TIP Make sure that the tab a on the coupler and hose holder bracket contacts the projection b on t...

Page 315: ...HE ENGINE OIL on page 3 22 Water pump housing Refer to WATER PUMP on page 6 9 1 Clutch cable 1 Disconnect 2 Clutch cable holder 1 3 Holder O2 sensor lead and oil pressure switch lead 2 4 Clutch cover 1 5 Clutch cover gasket 1 1 2 8 4 5 3 3 LS New New E E LT LT 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 316: ...ty Remarks 6 Dowel pin 2 7 Circlip 1 8 Pull lever 1 9 Pull lever spring 1 10 Circlip 1 11 Pull lever shaft 1 12 Oil seal 1 13 Bearing 1 14 Bearing 1 8 6 6 7 9 8 11 10 12 13 14 LS New New E E LT LT 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 317: ...Pull rod 1 4 Bearing 1 5 Friction plate 1 2 6 Clutch plate 6 7 Friction plate 2 5 8 Clutch boss nut 1 9 Conical spring washer 1 10 Washer 1 11 Clutch boss 1 LT LT E E E LS New E 8 9 5 5 6 6 6 6 6 6 11 10 1 6 6 2 3 4 7 7 7 7 7 10 Nm 1 0 m kgf 7 2 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 95 Nm 9 5 m kgf 69 ft Ibf T R ...

Page 318: ...2 Thrust plate 1 13 Spacer 1 14 Bearing 1 15 Clutch housing 1 16 Thrust plate 1 17 Oil pump drive chain 1 18 Oil pump drive chain guide 1 LT LT E E E LS New E 6 6 18 13 14 17 16 15 12 10 Nm 1 0 m kgf 7 2 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 95 Nm 9 5 m kgf 69 ft Ibf T R ...

Page 319: ...tages and in a crisscross pattern 3 Remove Friction plates 1 Clutch plates Friction plates 2 4 Straighten the clutch boss nut rib a 5 Loosen Clutch boss nut 1 TIP While holding the clutch boss 2 with the univer sal clutch holder 3 loosen the clutch boss nut 6 Remove Spacer 1 Bearing 2 Clutch housing 3 a Remove the spacer and bearing b Remove the oil pump drive chain 4 from the oil pump driven spro...

Page 320: ... with a surface plate and thickness gauge 1 Out of specification Replace the clutch plates as a set EAS30351 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs 1 Check Clutch spring Damage Replace the clutch springs as a set 2 Measure Clutch spring free length a Out of specification Replace the clutch springs as a set Friction plate 1 thickness 2 90 3 10 mm 0 ...

Page 321: ...ration EAS30354 CHECKING THE PRESSURE PLATE 1 Check Pressure plate 1 Cracks damage Replace Bearing 2 Damage wear Replace EAS30356 CHECKING THE PRIMARY DRIVE GEAR 1 Check Primary drive gear Damage wear Replace the crankshaft and clutch housing as a set Excessive noise during operation Replace the crankshaft and clutch housing as a set EAS30357 CHECKING THE PRIMARY DRIVEN GEAR 1 Check Primary driven...

Page 322: ...away from the vehicle While holding the clutch boss 1 with the uni versal clutch holder 3 tighten the clutch boss nut Stake the clutch boss nut at a cutout a in the main axle 3 Install Friction plates 1 1 Friction plates 2 2 TIP First install a friction plate and then alternate between a clutch plate and a friction plate Align a projection on friction plate 1 with the punch mark a on the clutch ho...

Page 323: ...hium soap based grease Install the bearings until they contact the sur faces a and install the oil seal until it contacts the surface b as shown in the illustration 6 Install Pull lever TIP Install the pull lever with the UP mark a fac ing toward upper side When installing the pull lever push the pull le ver and check that the punch mark b on the pull lever aligns with the mark c on the clutch cov...

Page 324: ...on Tighten the bolts in stages and in a crisscross pattern 8 Connect Clutch cable 1 TIP Install the clutch cable so that the clutch cable length a is 51 6 62 2mm 2 03 2 45 in as shown in the illustration In addition make sure that the vehicle is positioned upright when measuring the clutch cable length After installing the clutch cable bend the pro jection b on the pull lever 9 Adjust Clutch lever...

Page 325: ... Order Job Parts to remove Q ty Remarks Clutch housing Refer to CLUTCH on page 5 50 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4 Washer 1 5 Circlip 1 6 Washer 1 7 Stopper lever 1 8 Stopper lever spring 1 9 Collar 1 22 Nm 2 2 m kgf 16 ft Ibf T R E E LS New New New LT E 2 1 3 4 5 6 7 8 9 ...

Page 326: ...ng the shift shaft and stopper lever Order Job Parts to remove Q ty Remarks 10 Shift shaft spring 1 11 Shift shaft spring stopper 1 12 Oil seal 1 13 Bearing 1 22 Nm 2 2 m kgf 16 ft Ibf T R E E LS New New New LT E 12 13 11 10 ...

Page 327: ... bearing does not protrude past the line b shown in the illustration Lubricate the oil seal lips with lithium soap based grease 2 Install Shift shaft spring stopper Washer Shift shaft assembly Stopper lever spring TIP Hook the end of the shift shaft spring 2 onto the shift shaft spring stopper 1 Hook the ends of the stopper lever spring 3 onto the stopper lever 4 and the stopper lever spring hook ...

Page 328: ...moving the oil pump Order Job Parts to remove Q ty Remarks Clutch housing Refer to CLUTCH on page 5 50 1 Oil pump assembly 1 2 Holder 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R LT 1 2 ...

Page 329: ... 2 Oil pump rotor assembly 1 3 Oil pump inner rotor 1 4 Oil pump outer rotor 1 5 Pin 1 6 Oil pump driven sprocket 1 7 Circlip 1 Hold down the washer when removing the circlip 8 Washer 1 9 Spring 1 10 Relief valve 1 11 Dowel pin 2 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R New E E E 2 3 4 5 10 11 11 8 1 9 7 6 ...

Page 330: ... defec tive part s 2 Measure Inner rotor to outer rotor tip clearance a Outer rotor to oil pump housing clearance b 3 Check Oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAS30338 CHECKING THE RELIEF VALVE 1 Check Relief valve 1 Spring 2 Damage wear Replace the oil pump as sembly EAS30342 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor with the r...

Page 331: ...e grooves a in the inner rotor 4 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 65 EAS30343 INSTALLING THE OIL PUMP 1 Install Oil pump 1 Oil pump bolts 2 NOTICE ECA20940 After installing the oil pump drive chain and driven sprocket make sure the oil pump turns smoothly Recommended lubricant Engine oil T R Oil pump cover screw 3 8 Nm 0 38 m kgf 2 8 ft lbf T R Oil pump bolt 12 Nm ...

Page 332: ... assembly right Refer to REAR BRAKE on page 4 49 Muffler assembly Refer to ENGINE REMOVAL on page 5 4 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 22 1 Engine oil drain bolt 1 2 Oil pan 1 3 Oil pan gasket 1 4 Oil strainer 1 4 1 3 2 11 10 Nm 1 0 m kgf 7 2 ft Ibf T R 43 Nm 4 3 m kgf 31 ft Ibf T R LT LT New New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 333: ...ver into the slots a in the oil pan to remove the oil pan EAS31069 CHECKING THE OIL STRAINER 1 Check Oil strainer Damage Replace Contaminants Clean with solvent EAS31070 INSTALLING THE OIL PAN 1 Install Oil pan gasket Oil pan TIP Tighten the oil pan bolts in stages and in a criss cross pattern 2 Install Gasket Engine oil drain bolt T R Oil pan bolt 10 Nm 1 0 m kgf 7 2 ft lbf T R Engine oil drain b...

Page 334: ...r to ELECTRIC STARTER on page 5 45 Clutch housing Refer to CLUTCH on page 5 50 Oil strainer Refer to OIL PAN on page 5 67 2 6 6 3 8 2 1 2 3 4 6 7 7 8 5 E E E E New New New New LT LT LT LT LT LT LS LS LS 24 Nm 2 4 m kgf 17 ft Ibf 17 Nm 1 7 m kgf 12 ft Ibf 1st 2nd Final Specified angle 60 T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf...

Page 335: ...5 Main gallery bolt 1 6 Crankcase 1 7 Dowel pin 3 8 Blind plate 1 2 6 6 3 8 2 1 2 3 4 6 7 7 8 5 E E E E New New New New LT LT LT LT LT LT LS LS LS 24 Nm 2 4 m kgf 17 ft Ibf 17 Nm 1 7 m kgf 12 ft Ibf 1st 2nd Final Specified angle 60 T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 24 Nm 2 4 ...

Page 336: ...mmer Tap only on reinforced por tions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves sepa rate evenly EAS30390 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstru...

Page 337: ...olts 13 27 threads and mat ing surfaces with engine oil M9 80 mm bolt 6 bolts with washers 1 6 M8 70 mm bolt 6 bolts with new O rings 7 12 M8 65 mm bolt 2 13 14 M6 65 mm bolt 2 15 16 M6 40 mm bolt 8 17 18 21 24 26 27 M6 60 mm bolt 3 19 20 25 7 Tighten Crankcase bolts 1 6 Following the tightening order loosen the bolt one by one and then retighten it to the specific torque WARNING EWA16610 If the b...

Page 338: ... 2 2 Apply Sealant onto the oil pressure switch threads TIP Apply Three bond No 1215 to the threads a of the oil pressure switch However do not ap ply Three bond No 1215 to the portion b of the oil pressure switch Install the oil pressure switch lead so that it is routed within the range shown in the illustra tion T R Crankcase bolts 7 14 24 Nm 2 4 m kgf 17 ft lbf Crankcase bolts 15 27 10 Nm 1 0 m...

Page 339: ...CRANKCASE 5 74 a 1 2 2 b 45 10 1 ...

Page 340: ... The following procedure applies to all of the connecting rods and pistons Refer to CRANKCASE on page 5 69 1 Connecting rod cap 1 2 Big end lower bearing 1 3 Big end upper bearing 1 4 Piston pin clip 2 5 Piston pin 1 6 Piston 1 7 Connecting rod 1 2 1 3 4 4 6 7 5 1st 20 Nm 2 0 m kgf 14 ft Ibf 2nd Specified angle 180 T R New New New New E E E E E M M ...

Page 341: ...TONS 5 76 Removing the connecting rods and pistons Order Job Parts to remove Q ty Remarks 8 Top ring 1 9 2nd ring 1 10 Oil ring 1 9 10 8 1st 20 Nm 2 0 m kgf 14 ft Ibf 2nd Specified angle 180 T R New New New New E E E E E M M ...

Page 342: ...pin out TIP For reference during installation put identifica tion marks on the piston crown Before removing the piston pin deburr the pis ton pin clip groove and the piston pin bore ar ea If both areas are debarred and the piston pin is still difficult to remove remove it with the piston pin puller set 5 3 Remove Top ring 2nd ring Oil ring TIP When removing a piston ring open the end gap with your...

Page 343: ...G THE PISTON RINGS 1 Measure Piston ring side clearance Out of specification Replace the piston and piston rings as a set TIP Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings Bore 80 000 80 010 mm 3 1496 3 1500 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in Cylinder bore maximum of D1 D6 Taper limit...

Page 344: ...k the lubrication sys tem 2 Measure Piston pin outside diameter a Out of specification Replace the piston pin 3 Measure Piston pin bore inside diameter b Out of specification Replace the piston 4 Calculate Piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set Top ring End gap installed 0 15 0 25 mm 0 0059 0 0098 in Limit 0 50 mm 0 0197 in 2nd ring ...

Page 345: ... Assemble the connecting rod halves NOTICE ECA18390 Tighten the connecting rod bolts using the plastic region tightening angle method Al ways install new bolts TIP Clean the connecting rod bolts and lubricate the bolt threads and seats with molybdenum disulfide oil Make sure that the projection a on the con necting rod cap faces the same direction as the Y mark b on the connecting rod After instal...

Page 346: ...e left side of the crank shaft g Tighten the connecting rod bolts with a torque wrench h Put a mark 1 on the corner of the connecting rod bolt 2 and the connecting rod cap 3 i Tighten the connecting rod bolts further to reach the specified angle 175 185 WARNING EWA16610 If the bolt is tightened more than the speci fied angle do not loosen the bolt and then re tighten it Instead replace the bolt wi...

Page 347: ...he crankshaft web P1 numbers are 5 and 2 respectively then the bearing size for P1 is EAS30751 INSTALLING THE CONNECTING ROD AND PISTON The following procedure applies to all of the con necting rods and pistons 1 Install Big end bearings Connecting rod cap onto the connecting rod TIP Be sure to reinstall each big end bearing in its original place Align the projections a on the big end bear ings wi...

Page 348: ...are should be taken not to install it at an angle and the position should not be out of alignment e Loosen the connecting rod bolt remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in the current condition 3 Install Oil ring expander 1 Lower oil ring rail 2 Upper oil ring rail 3 2nd ring 4 Top ring 5 TIP Be sure to install the ...

Page 349: ...2 install the connecting rod assembly into the cylinder with the other hand Make sure the Y marks a on the connecting rods face towards the left side of the crank shaft Make sure that the projection b on the con necting rod cap faces the same direction as the Y mark a on the connecting rod Apply Molybdenum disulfide oil to the threads and seats of the connecting rod bolt 9 Tighten Connecting rod b...

Page 350: ...bolt and then re tighten it Instead replace the bolt with a new one and perform the procedure again NOTICE ECA20890 Do not use a torque wrench to tighten the bolt to the specified angle d After the installation check that the section shown a is flush with each other by touching the surface WARNING EWA17120 If the connecting rod and cap are not flush with each other remove the connecting rod bolts ...

Page 351: ...ankcase Refer to CRANKCASE on page 5 69 Connecting rod Refer to CONNECTING RODS AND PIS TONS on page 5 75 1 Balancer shaft assembly 1 2 Balancer shaft journal lower bearing 3 3 Balancer shaft journal upper bearing 3 4 Crankshaft assembly 1 5 Crankshaft journal lower bearing 3 6 Crankshaft journal upper bearing 3 1 2 3 3 3 2 4 6 6 6 5 5 5 2 E E E E E E E E E ...

Page 352: ...aft assembly Cracks damage wear Replace the balanc er shaft assembly and journal bearings Dirt Clean Bearings Damage wear Replace 4 Measure Balancer shaft journal to balancer shaft jour nal bearing clearance Out of specification Replace the balancer shaft journal bearings NOTICE ECA18400 Do not interchange the balancer shaft jour nal bearings To obtain the correct balancer shaft journal to balance...

Page 353: ...RANKCASE on page 5 69 f Remove the crankcase and the balancer shaft journal lower bearings g Measure the compressed Plastigauge width e on each balancer shaft journal If the balancer shaft journal to balancer shaft journal bearing clearance is out of specification select replacement balancer shaft journal bearings 5 Select Balancer shaft journal bearings J1 J3 TIP The numbers A stamped into the cr...

Page 354: ...nal bearings NOTICE ECA13920 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crank shaft journal bearings must be installed in their original positions a Clean the crankshaft journal bearings crank shaft journals and bearing portions of the cyl inder and crankcase b Install the cranks...

Page 355: ...idth g on each crankshaft journal If the crankshaft journal to crankshaft jour nal bearing clearance is out of specification select replacement crankshaft journal bear ings 5 Select Crankshaft journal bearings J1 J3 TIP The numbers A stamped into the crankcase and the numbers B stamped into the crank shaft web are used to determine the replace ment crankshaft journal bearing sizes J1 J3 refer to t...

Page 356: ...nstall Balancer shaft journal upper bearings into the upper crankcase Balancer shaft journal lower bearings into the lower crankcase TIP Align the projections a on the balancer shaft journal bearings 1 with the notches b in the crankcase Be sure to install each balancer shaft journal bearing in its original place 2 Install Balancer shaft 1 TIP Align the punch mark a in the balancer drive gear with...

Page 357: ...ks Crankcase Refer to CRANKCASE on page 5 69 1 Drive axle assembly 1 2 Shift drum retainer 1 3 Shift fork guide bar 2 4 Shift fork L 1 5 Shift fork R 1 6 Shift drum assembly 1 7 Shift fork C 1 8 Bearing retainer 1 9 Main axle assembly 1 LT LT E LT E E E E E 1 2 3 3 6 4 5 7 9 8 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R ...

Page 358: ...remove Q ty Remarks 1 2nd pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Collar 1 6 Washer 1 7 Circlip 1 8 3rd pinion gear 1 9 Circlip 1 10 Washer 1 11 5th pinion gear 1 12 Collar 1 M M M M M M M New New 8 10 11 12 9 7 6 5 4 3 1 2 ...

Page 359: ...TRANSMISSION 5 94 Disassembling the main axle assembly Order Job Parts to remove Q ty Remarks 13 Main axle 1 M M M M M M M New New 13 ...

Page 360: ...Q ty Remarks 1 1st wheel gear 1 2 Collar 1 3 5th wheel gear 1 4 Circlip 1 5 Washer 1 6 3rd wheel gear 1 7 Collar 1 8 Toothed lock washer 1 9 Toothed lock washer retainer 1 10 4th wheel gear 1 11 Collar 1 12 Washer 1 10 11 12 1 2 3 4 5 6 7 8 9 LS M M M M M M M M M New New New New New ...

Page 361: ...Job Parts to remove Q ty Remarks 13 Circlip 1 14 6th wheel gear 1 15 Circlip 1 16 Washer 1 17 Collar 1 18 2nd wheel gear 1 19 Oil seal 1 20 Circlip 1 21 Bearing 1 22 Collar 1 23 Drive axle 1 13 14 15 16 17 18 20 19 21 22 23 LS M M M M M M M M M New New New New New ...

Page 362: ...KING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WARNING EWA12840 Do not attempt to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide ...

Page 363: ...r s 4 Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies 5 Check Transmission gear movement Rough movement Replace the defective part s 6 Check Circlips Bends damage looseness Replace EAS30435 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1 Install Toothed washer 1 Circlip 2 TIP Be sure the circlip sharp edged corner a i...

Page 364: ...s the cylinder 2 Install Shift fork C Shift drum assembly Shift fork guide bar TIP The embossed marks on the shift forks should face towards the right side of the engine Install shift fork C into the groove in the 3rd pinion gear on the main axle 3 Install Shift fork L 1 Shift fork R 2 Shift fork guide bar Shift drum retainer Drive axle assembly 3 TIP Install shift fork L into the groove in the 6t...

Page 365: ...TRANSMISSION 5 100 4 Check Transmission Rough movement Repair TIP Oil each gear shaft and bearing thoroughly 3 2 1 c b a ...

Page 366: ...TRANSMISSION 5 101 ...

Page 367: ...KING THE OIL COOLER 6 6 CHECKING THE WATER JACKET JOINT 6 6 INSTALLING THE OIL COOLER 6 6 THERMOSTAT 6 7 CHECKING THE THERMOSTAT 6 8 INSTALLING THE THERMOSTAT 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 CLUTCH COVER 6 13 ...

Page 368: ...left Refer to GENERAL CHASSIS 4 on page 4 11 1 Radiator cap 1 2 Coolant reservoir hose 1 3 Coolant reservoir cap 1 4 Coolant reservoir cover 1 5 Coolant reservoir 1 1 0 Nm 0 10 m kgf 0 72 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 2 3 4 5 1 ...

Page 369: ...n 1 10 Radiator fan motor coupler 1 Disconnect 11 Radiator outlet hose 1 12 Radiator inlet hose 1 13 Radiator 1 14 Radiator fan 1 1 0 Nm 0 10 m kgf 0 72 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 11 14 10 12 7 13 6 9 8 ...

Page 370: ... Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 29 EAS30440 INSTALLING THE RADIATOR 1 Install Coolant reservoir cap 1 TIP Point the tab a on the coolant reservoir cap in the direction shown in the illustration 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 24 3 Check Cooling system Leak...

Page 371: ...ge 3 24 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 22 Coolant reservoir Refer to RADIATOR on page 6 1 1 Oil filter cartridge 1 2 Water jacket joint 1 3 Water jacket joint inlet hose 1 LS New New E E LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 3 2 1 ...

Page 372: ...emarks 4 Oil cooler inlet hose 1 5 Oil cooler outlet hose 1 6 Oil filter cartridge union bolt 1 7 Oil cooler 1 8 Gasket 1 LS New New E E LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 4 5 6 7 8 ...

Page 373: ...ling the oil cooler apply engine oil lightly to the oil filter cartridge union bolt Align the projection a on the oil cooler with the slot b in the crankcase 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 24 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 22 4 Check Co...

Page 374: ...Drain Refer to CHANGING THE COOLANT on page 3 24 1 Coolant temperature sensor coupler 1 Disconnect 2 Coolant temperature sensor 1 3 Radiator inlet hose 1 Disconnect 4 Thermostat cover 1 5 Thermostat 1 New 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 3 4 2 1 5 ...

Page 375: ...ulty thermostat could cause serious overheating or overcooling 2 Check Thermostat cover Cracks damage Replace EAS30939 INSTALLING THE THERMOSTAT 1 Install Thermostat TIP Install the thermostat with its breather valve a facing inward 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 24 3 Check Cooling system Leaks Repair or replace a...

Page 376: ...1 Clutch cable 1 Disconnect 2 Water pump outlet hose 1 Disconnect 3 Oil cooler outlet hose 1 Disconnect 4 Radiator outlet hose 1 Disconnect 5 Water pump inlet pipe 1 LT LT LS LS LS New New New New New New New E LS LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R...

Page 377: ... cover 1 9 Impeller shaft 1 10 Water pump seal assembly 1 11 Oil seal 1 12 Bearing 1 LT LT LS LS LS New New New New New New New E LS LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 10 12 11 6 8 10 7 9 ...

Page 378: ...eller shaft Cracks damage wear Replace 2 Check Bearing Rough movement Replace 3 Check Water pump outlet pipe Water pump inlet pipe Cracks damage wear Replace EAS30448 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 Bearing into the clutch cover 2 TIP Install the oil seal with a socket 3 that matches its outside diameter 2 Install Mechanical seal housing side 1 into the clutch cover 2 NOTICE ECA2033...

Page 379: ...contacts the mechanical seal housing side is dirty clean it 5 Install Impeller shaft 1 Circlip 2 TIP Be sure the circlip sharp edged corner a is positioned opposite side to the bearing After installation check that the impeller shaft rotates smoothly Mechanical seal installer 90890 04132 Water pump seal installer YM 33221 A Middle driven shaft bearing driv er 90890 04058 Middle drive bearing insta...

Page 380: ...the clutch cover make sure that the alignment mark d on the clutch cover is aligned with the punch mark e on the pull le ver 6 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 24 3 Check Cooling system Leaks Repair or replace the faulty part 4 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator c...

Page 381: ... THROTTLE BODIES 7 9 CHECKING THE INJECTORS BEFORE REMOVING 7 12 REMOVING THE INJECTORS 7 12 CHECKING THE INJECTORS 7 12 CHECKING THE THROTTLE BODIES 7 12 CLEANING THE ISC IDLE SPEED CONTROL VALVE 7 12 CHECKING THE THROTTLE BODY JOINTS 7 14 ADJUSTING THE THROTTLE POSITION SENSOR 7 15 INSTALLING THE FUEL INJECTORS 7 15 CHECKING THE INJECTOR PRESSURE 7 16 CHECKING THE FUEL PRESSURE 7 16 INSTALLING T...

Page 382: ...RAL CHASSIS 4 on page 4 11 1 Air temperature sensor coupler 1 Disconnect 2 Fuel tank overflow hose 1 Disconnect 3 Fuel tank breather hose 1 Disconnect 4 Fuel pump coupler 1 Disconnect 5 Fuel hose 1 6 Fuel tank 1 1 2 4 3 6 5 4 New 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m k...

Page 383: ...re sensor 1 8 Fuel pump 1 9 Front fuel tank bracket 1 10 Rear fuel tank bracket 1 4 New 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 7 8 9 10 ...

Page 384: ...re it will be removed 3 Remove Fuel tank TIP Do not set the fuel tank down on the installation surface of the fuel pump Be sure to lean the fuel tank against a wall or the like EAS30451 REMOVING THE FUEL PUMP 1 Remove Fuel pump NOTICE ECA14720 Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender EAS30454 CHECKING THE FUEL PUMP BODY 1 Check Fuel pump ...

Page 385: ...tank bracket bolt 2 Install Fuel hose NOTICE ECA18420 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed TIP Install the fuel hose securely onto the fuel rail and fuel pump until a distinct click is heard To install the fuel hose slide the fue...

Page 386: ...e air temperature sensor 4 Tighten Rear fuel tank bracket bolts 5 Tighten Front fuel tank bracket bolt T R Rear fuel tank bracket bolt 10 Nm 1 0 m kgf 7 2 ft lbf T R Front fuel tank bracket bolt 30 Nm 3 0 m kgf 22 ft lbf ...

Page 387: ...emarks Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank top cover Fuel tank covers Fuel tank center cover Refer to GENERAL CHASSIS 4 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 1 Intake solenoid vacuum hose intake solenoid to air filter case valve 1 Disconnect 2 Air duct bracket 1 A B 1 2 4 New 1 6 Nm 0 16 m kgf 1 2 ft Ibf T R 1 6 Nm 0 16 m kgf 1 2 ft Ibf T R ...

Page 388: ...valve and air filter element A 1XB1 1XB5 1XB6 B 1XB2 1XB7 1XB8 Order Job Parts to remove Q ty Remarks 3 Air duct 1 4 Plug 1 5 Air filter case valve 1 6 Air filter element 1 A B 4 New 3 5 6 4 1 6 Nm 0 16 m kgf 1 2 ft Ibf T R 1 6 Nm 0 16 m kgf 1 2 ft Ibf T R ...

Page 389: ...NG THE AIR FILTER CASE VALVE 1 Install Air filter case valve a Hook the end of the shaft a onto the plate 1 as shown b Align the tabs b on the air filter case valve 2 with the cutouts c in the air duct bracket 3 and then turn the air filter case valve 90 clockwise 2 Install 1XB1 1XB5 1XB6 Air duct 1 TIP Align the tab a on the air duct between the pro jections b on the air duct bracket 3 Install 1X...

Page 390: ...S 4 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 Air duct bracket Refer to AIR FILTER CASE VALVE on page 7 6 Pivot shaft protector left right Refer to SWINGARM on page 4 95 1 Cylinder head breather hose 1 2 Throttle position sensor coupler 1 Disconnect 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R 3 0 Nm 0 3...

Page 391: ...e decelerator cable 1 Disconnect 8 Throttle cable accelerator cable 1 Disconnect 9 Throttle body joint clamp screw 4 Loosen 10 Air filter case bolt 2 11 Air filter case joint clamp screw 2 Loosen 12 Throttle bodies 1 13 Throttle body joint 2 14 Air filter case 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R 3 0 Nm 0 ...

Page 392: ...Remarks 1 ISC idle speed control valve plate 1 2 ISC idle speed control valve 1 3 Spring 1 4 Throttle position sensor 1 5 Fuel rail 1 6 Fuel injector 2 New New New New New 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 6 6 3 1 2 5 4 ...

Page 393: ...ce 2 Check Injector resistance Refer to CHECKING THE FUEL INJEC TORS on page 8 141 EAS30479 CHECKING THE THROTTLE BODIES TIP Before checking the throttle bodies check the following items Valve clearance Spark plugs Air filter element Throttle body joints Fuel hose Exhaust system Cylinder head breather hose Vacuum hoses WARNING EWA17850 If the throttle bodies are subjected to strong shocks or dropp...

Page 394: ...ed solvent to the portions of the throttle valve shafts be tween the throttle bodies e Remove the carbon deposits from the inside of each throttle body in a downward direction from the air filter case side of the throttle body to the engine side NOTICE ECA18470 Do not use a tool such as a wire brush to remove the carbon deposits otherwise the inside of the throttle bodies may be dam aged Do not al...

Page 395: ...r enters the throttle bodies thoroughly wipe it off TIP Clean the area a of the ISC valve and the ISC valve installation hole b in the throttle bodies 3 Install O ring ISC idle speed control valve ISC idle speed control valve plate TIP Align the slot a in the ISC valve plate with the projection b on the ISC valve Resetting the ISC idle speed control learn ing values 1 Install Throttle bodies 2 Res...

Page 396: ...ostic tool screen g After adjusting the throttle position sensor an gle tighten the throttle position sensor bolts 2 EAS31124 INSTALLING THE FUEL INJECTORS NOTICE ECA20000 Always use new O rings When checking the injectors do not allow any foreign material to enter or adhere to the injectors fuel rail or O rings Be careful not to twist or pinch the O rings when installing the injectors If an injec...

Page 397: ... gauge and adapter Check the seals and O rings and then rein stall Replace the fuel injectors EAS30482 CHECKING THE FUEL PRESSURE 1 Remove Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank top cover Fuel tank cover left Fuel tank cover right Fuel tank center cover Fuel tank front cover Refer to GENERAL CHASSIS 4 on page 4 11 2 Check Fuel pressure a Remove the rear fuel tank bracket bolts...

Page 398: ...illustration EAS31092 INSTALLING THE AIR FILTER CASE 1 Install Air filter case joint clamps 1 TIP Align the projection a on the air filter case joint with the slot b in the air filter case joint clamp Face the screw head c of the air filter case joint clamp outward Pressure gauge 90890 03153 Pressure gauge YU 03153 Fuel pressure adapter 90890 03176 Fuel pressure adapter YM 03176 Fuel line pressure...

Page 399: ...THROTTLE BODIES 7 18 a b c a b c 1 ...

Page 400: ... tank top cover Fuel tank covers Fuel tank center cover Fuel tank front cover Refer to GENERAL CHASSIS 4 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 1 Intake solenoid coupler 1 Disconnect 2 Intake solenoid vacuum hose throttle body to one way valve 1 3 Intake solenoid vacuum hose intake solenoid air filter case valve 1 1 3 2 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R ...

Page 401: ...intake solenoid Order Job Parts to remove Q ty Remarks 4 One way valve 1 5 Intake solenoid vacuum hose one way valve to intake solenoid 1 6 Surge tank hose 1 7 Intake solenoid 1 8 Surge tank 1 6 8 7 4 5 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R ...

Page 402: ...tank Cracks damage Replace 3 Check One way valve Cracks damage faulty Replace TIP Check that air flows smoothly only in the direc tion of the arrow shown in the illustration 4 Check Intake solenoid Damage Replace 5 Check Intake solenoid resistance Refer to CHECKING THE INTAKE SOLE NOID on page 8 140 6 Check Surge tank Cracks damage Replace ...

Page 403: ...TING 8 19 SIGNALING SYSTEM 8 21 CIRCUIT DIAGRAM 8 21 TROUBLESHOOTING 8 23 COOLING SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 TROUBLESHOOTING 8 31 FUEL INJECTION SYSTEM 8 33 CIRCUIT DIAGRAM 8 33 ECU SELF DIAGNOSTIC FUNCTION 8 35 TROUBLESHOOTING METHOD 8 35 YAMAHA DIAGNOSTIC TOOL 8 36 TROUBLESHOOTING DETAILS 8 39 FUEL PUMP SYSTEM 8 73 CIRCUIT DIAGRAM 8 73 TROUBLESHOOTING 8 75 IMMOBILIZER SYSTEM 8 77 CIRCUIT D...

Page 404: ...HE SWITCHES 8 123 CHECKING THE BULBS AND BULB SOCKETS 8 126 CHECKING THE FUSES 8 127 REPLACING THE ECU engine control unit 8 128 CHECKING AND CHARGING THE BATTERY 8 128 CHECKING THE RELAYS 8 131 CHECKING THE TURN SIGNAL HAZARD RELAY 8 132 CHECKING THE RELAY UNIT DIODE 8 133 CHECKING THE IGNITION COILS 8 134 CHECKING THE IGNITION SPARK GAP 8 134 CHECKING THE CRANKSHAFT POSITION SENSOR 8 135 CHECKIN...

Page 405: ......

Page 406: ...W Y Y L R L R L R L W L W L W L W L R R R R R R R Lg R W G B R G Y L B G B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb L G B B B B B Gy B Gy B L L B L P W L B B W L B R W Gy G B L P B B L W B L B B B L Br W B B L G W L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P...

Page 407: ... Joint coupler 26 Sidestand switch 27 Crankshaft position sensor 30 Ignition coil 1 31 Ignition coil 2 32 Spark plug 37 ECU engine control unit 41 Lean angle sensor 63 Gear position switch 64 Handlebar switch right 67 Start engine stop switch A Wire harness C Sub wire harness gear position switch coolant temperature sensor fuel injector ...

Page 408: ...n gine continues to run under the following conditions The transmission is in gear the neutral circuit of the gear position switch is open and the sidestand is up the sidestand switch circuit is closed The transmission is in neutral the neutral circuit of the gear position switch is closed and the side stand is down the sidestand switch circuit is open 10 11 9 1 4 5 7 2 6 3 8 1 Battery 2 Main fuse...

Page 409: ...o CHECKING AND CHARGING THE BATTERY on page 8 128 Clean the 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 plug s 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 134 Ignition system is OK 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 1...

Page 410: ...ch 10 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 123 Replace the sidestand switch 11 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 133 Replace the relay unit 12 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 135 Replace the lean angle sensor 13 Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM on p...

Page 411: ...IGNITION SYSTEM 8 6 ...

Page 412: ... W R W R W Y Y L R L R L R L W L W L W L W L R R R R R R R Lg R W G B R G Y L B G B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb L G B B B B B Gy B Gy B L L B L P W L B B W L B R W Gy G B L P B B L W B L B B B L Br W B B L G W L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y ...

Page 413: ...y 20 Starter motor 22 Relay unit 23 Starting circuit cut off relay 25 Joint coupler 26 Sidestand switch 37 ECU engine control unit 63 Gear position switch 64 Handlebar switch right 67 Start engine stop switch 69 Handlebar switch left 70 Clutch switch A Wire harness C Sub wire harness gear position switch coolant temperature sensor fuel injector ...

Page 414: ...otor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the side of the start engine stop switch 12 1 11 4 6 6 6 6 a b 8 6 9 7 5 2 3 10 10 a WHEN...

Page 415: ... page 8 128 Clean the battery terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 136 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 48 Repair or replace the starter motor 5 Check the relay unit st...

Page 416: ...fer to CHECKING THE SWITCHES on page 8 123 Replace the sidestand switch 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 123 Replace the clutch switch 12 Check the start engine stop switch Refer to CHECKING THE SWITCHES on page 8 123 The start engine stop switch is faulty Replace the right handlebar switch 13 Check the entire starting system wiring Refer to CIRCUIT DIAGRAM on pa...

Page 417: ...ELECTRIC STARTING SYSTEM 8 12 ...

Page 418: ... W Y Y L R L R L R L W L W L W L W L R R R R R R R Lg R W G B R G Y L B G B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb L G B B B B B Gy B Gy B L L B L P W L B B W L B R W Gy G B L P B B L W B L B B B L Br W B B L G W L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B ...

Page 419: ...CHARGING SYSTEM 8 14 13 AC magneto 14 Rectifier regulator 15 Battery 16 Engine ground 18 Main fuse ...

Page 420: ...eck the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 128 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 stator coil assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 136 Replace the rectifier regulator 5 Check the entire charging system wiring...

Page 421: ...CHARGING SYSTEM 8 16 ...

Page 422: ... W Y Y L R L R L R L W L W L W L W L R R R R R R R Lg R W G B R G Y L B G B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb L G B B B B B Gy B Gy B L L B L P W L B B W L B R W Gy G B L P B B L W B L B B B L Br W B B L G W L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B ...

Page 423: ...6 Engine ground 18 Main fuse 25 Joint coupler 37 ECU engine control unit 49 Meter assembly 52 Meter light 58 High beam indicator light 69 Handlebar switch left 71 Dimmer switch 72 Pass switch 79 Headlight assembly 80 Auxiliary light 81 Headlight 82 License plate light 83 Tail brake light assembly 84 Tail brake light 87 Headlight relay ...

Page 424: ...lb s and bulb socket s 2 Check the fuses Ignition signaling system head light fuel injection system and main Refer to CHECKING THE FUS ES on page 8 127 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 128 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...

Page 425: ... LAYS on page 8 131 Replace the headlight relay 8 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 8 17 Properly connect or replace the wiring har ness Replace the ECU meter assembly or tail brake light Refer to REPLACING THE ECU engine control unit on page 8 128 ...

Page 426: ...R W Y Y L R L R L R L W L W L W L W L R R R R R R R Lg R W G B R G Y L B G B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb L G B B B B B Gy B Gy B L L B L P W L B B W L B R W Gy G B L P B B L W B L B B B L Br W B B L G W L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B...

Page 427: ...ator light 53 Tachometer 54 Multi function meter 55 Oil pressure warning light 57 Coolant temperature warning light 59 Turn signal indicator light left 60 Turn signal indicator light right 62 Horn 63 Gear position switch 64 Handlebar switch right 65 Front brake light switch 66 Hazard switch 68 Turn signal hazard relay 69 Handlebar switch left 73 Turn signal switch 74 Horn switch 75 Rear turn signa...

Page 428: ...nit ignition signaling system fuel in jection system backup and main Refer to CHECKING THE FUS ES on page 8 127 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 128 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 sig...

Page 429: ...e the rear brake light switch 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or replace the wiring har ness Replace the tail brake light 1 Check the turn signal light bulbs and sockets 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 THE SW...

Page 430: ...r position switch 2 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 133 Replace the relay unit 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or replace the wiring har ness Replace the meter assembly 1 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or replace the wiring h...

Page 431: ... oil viscosity oil seal oil filter or oil pump Replace the oil pressure switch 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 8 137 Replace the fuel pump assembly 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or replace the wiring har ness Replace the meter assembly 1 Check the coolant temperature sen sor Refer to CHECKING THE ...

Page 432: ...joint coupler and ECU coupler blue black blue black blue red blue red Between joint coupler and meter assembly coupler blue black blue black blue red blue red 1 Check the rear wheel sensor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 31 Replace the rear wheel sensor 2 Check the entire rear wheel sensor wiring Refer to TIP Properly connect or replace the wiring har ness ...

Page 433: ...SIGNALING SYSTEM 8 28 ...

Page 434: ...W Y Y L R L R L R L W L W L W L W L R R R R R R R Lg R W G B R G Y L B G B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb L G B B B B B Gy B Gy B L L B L P W L B B W L B R W Gy G B L P B B L W B L B B B L Br W B B L G W L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P...

Page 435: ...Radiator fan motor fuse 15 Battery 16 Engine ground 18 Main fuse 25 Joint coupler 37 ECU engine control unit 39 Coolant temperature sensor 85 Radiator fan motor 86 Radiator fan motor relay A Wire harness C Sub wire harness gear position switch coolant temperature sensor fuel injector ...

Page 436: ...tery Refer to CHECKING AND CHARGING THE BATTERY on page 8 128 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 CHEC...

Page 437: ... 8 32 NG OK 7 Check the entire cooling system wiring Refer to CIRCUIT DIAGRAM on page 8 29 Properly connect or replace the wiring har ness Replace the ECU Refer to REPLAC ING THE ECU engine control unit on page 8 128 ...

Page 438: ... R W R W Y Y L R L R L R L W L W L W L W L R R R R R R R Lg R W G B R G Y L B G B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb L G B B B B B Gy B Gy B L L B L P W L B B W L B R W Gy G B L P B B L W B L B B B L Br W B B L G W L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R ...

Page 439: ...eed control unit 36 Intake solenoid 37 ECU engine control unit 38 Intake air temperature sensor 39 Coolant temperature sensor 40 Intake air pressure sensor 41 Lean angle sensor 43 Rear wheel sensor 44 ABS ECU electronic control unit 45 Yamaha diagnostic tool coupler 47 Fuel pump 49 Meter assembly 54 Multi function meter 56 Engine trouble warning light 63 Gear position switch 64 Handlebar switch ri...

Page 440: ...ing light comes on for around 2 seconds after the main switch has been set to ON and it comes on while the side of the start engine stop switch is being pushed If the warning light does not come on under these conditions the warning light LED may be defective ECU detects an abnormal signal from a sensor If the ECU detects an abnormal signal from a sensor while the vehicle is being driven the ECU i...

Page 441: ...ion is detected in the sensors and actuators check and repair the inner parts of the engine EAS30951 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions For information about using the Yamaha diagnostic tool refer to the operation manual that is included with the tool Features of the Yamaha diagnostic tool You can use the Yamaha diagnostic tool to identify ma...

Page 442: ...a malfunction was detected This data can be used to identify when the malfunction occurred and check the engine conditions and running conditions when it occurred Function diagnostic mode Check the operation of the output value of each sensor and actuator Inspection mode Determine whether each sensor or actuator is functioning properly CO adjustment mode Adjust the concentration of CO admissions d...

Page 443: ...f the malfunction currently occurred are displayed 3 Code The following icons and the fault code numbers for the detected malfunctions are displayed 4 ECU The types of the control units are displayed e g FI ABS 5 Item The item names of the detected malfunction are displayed 2 3 1 4 5 6 7 8 9 10 11 12 A B A Detected malfunction B Recovered malfunction ...

Page 444: ...the probable cause of the malfunction following the order given After the check and service of the malfunctioning part have been completed reset the meter display according to the reinstatement method Fault code No Fault code number displayed on the meter when the engine failed to work normally Diagnostic code No Diagnostic code number to be used when the diagnostic mode is operated Refer to SELF ...

Page 445: ...ensor Check for looseness or pinch ing Check the gap between the crankshaft position sensor and the pickup rotor Improperly installed sensor Reinstall or replace the sensor Refer to GENERATOR AND STARTER CLUTCH on page 5 39 Crank the engine Fault code number is not dis played Service is finished Fault code number is displayed Go to item 5 5 Defective crankshaft position sensor Check the crankshaft...

Page 446: ...rely or re place the wire harness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between intake air pressure sensor coupler and ECU cou pler pink white pink white blue blue Between intake air pressure sensor coupler and joint cou pler black blue b...

Page 447: ...cranking Check the intake air pressure sensor Replace if defective Refer to CHECKING THE IN TAKE AIR PRESSURE SEN SOR on page 8 139 Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 128 Fault code No 13 Item Intake air pressure s...

Page 448: ...x 80 kPa 600 0 mmHg 23 6 inHg 3000 m 9800 ft above sea lev el Approx 70 kPa 525 0 mmHg 20 7 inHg When engine is cranking Make sure that the indication value changes The value does not change when engine is cranking Check the intake air pressure sensor Replace if defective Refer to CHECKING THE IN TAKE AIR PRESSURE SEN SOR on page 8 139 Fault code No 14 Item Intake air pressure sensor hose system m...

Page 449: ...ler black blue black blue Between joint coupler and ECU coupler black blue black blue Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Installed condition of throttle po sition sensor Check for looseness or pinch ing Improperly installed sensor Reinstall or adjust the sensor Refer to ADJUSTING THE THROTTLE POSITION SEN...

Page 450: ... 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON and then extend and retract the sidestand Fault code number is not dis played Service is finished Fault code number is...

Page 451: ...nt temperature Procedure Compare the actually measured coolant temperature with the meter dis play value Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of coolant tempera ture sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins I...

Page 452: ...5 5 Defective coolant temperature sensor Execute the diagnostic mode Code No 06 When engine is cold Displayed temperature is close to the ambient temperature The displayed temperature is not close to the ambient temper ature Check the coolant tem perature sensor Replace if defective Refer to CHECKING THE COOLANT TEMPERATURE SENSOR on page 8 138 Turn the main switch to ON Fault code number is not d...

Page 453: ...temperature sensor coupler and joint cou pler black blue black blue Between joint coupler and ECU coupler black blue black blue Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Installed condition of intake air temperature sensor Check for looseness or pinch ing Improperly installed sensor Reinstall or replace the sens...

Page 454: ...3 Fault code number is not dis played Service is finished Fault code number is displayed Go to item 3 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Start the engine warm it up and then race it o...

Page 455: ... sensor no normal signals are received from the O2 sensor Fault code No 30 Item Latch up detected Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No 08 Meter display Lean angle sensor output voltage 0 4 1 4 upright 3 7 4 4 overturned Procedure Remove the lean angle sensor and incline it more than 65 degrees Item Probable cause of malfunc tion and check Maintenance j...

Page 456: ...eck Maintenance job Confirmation of service com pletion 1 Connection of cylinder 1 igni tion coil coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Start the engine and let it idle for approximately 5 seconds Fault cod...

Page 457: ...gine depending on the number of faulty cylinders Able to drive vehicle depending on the number of faulty cylinders Diagnostic code No 31 Actuation Actuates the cylinder 2 ignition coil five times at one second intervals The CHECK indicator and on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated Procedure Check that a spark is generated five times Connect an igniti...

Page 458: ...primary coil resis tance of the cylinder 2 ignition coil Replace if out of specification Refer to CHECKING THE IG NITION COILS on page 8 134 Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is displayed Go to item 6 6 Malfunction in ECU Execute the diagnostic mode Code No 31 No spark Replace the ECU Refer to REPL...

Page 459: ...ed Fault code number is displayed Go to item A 4 A 4 ISC valve is not moving correct ly Replace the ISC valve Start the engine and let it idle for approximately 10 seconds Fault code number is not dis played Service is finished Fault code number is displayed Go to item A 5 A 5 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 128 Fault code No 37 Item A Co...

Page 460: ...he fault code ISC operating sound is not heard Go to item B 4 B 4 Wire harness continuity Open or short circuit Replace the wire harness Between ISC idle speed con trol unit coupler and sub wire harness coupler red green red green pink blue pink blue white green white green brown blue brown blue Between sub harness and ECU coupler red green red green pink blue pink blue white green white green bro...

Page 461: ...ted Procedure Check that fuel injector 1 is actuated five times by listening for the oper ating sound 37 Actuation Actuates fuel injector 2 five times at one second intervals The CHECK indicator and on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated Procedure Check that fuel injector 2 is actuated five times by listening for the oper ating sound Item Probable cau...

Page 462: ...blue red blue Fuel injector 2 green black green black red blue red blue Between sub wire harness cou pler and ECU coupler Fuel injector 1 red black red black red blue red blue Fuel injector 2 green black green black red blue red blue Execute the diagnostic mode Code Nos 36 37 No operating sound Go to item 6 Operating sound Go to item 7 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE EC...

Page 463: ...e wire harness Between lean angle sensor cou pler and ECU coupler blue blue yellow green yellow green Between lean angle sensor cou pler and joint coupler black blue black blue Between joint coupler and ECU coupler black blue black blue Turn the main switch to ON then to OFF and then back to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 De...

Page 464: ...e No 07 Rotate the rear wheel by hand and check that the indicated val ue increases Value increases Go to item A 8 and delete the fault code Value does not increase Go to item A 3 A 3 Connection of ABS ECU cou pler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler...

Page 465: ...vehicle speed signals by operat ing the vehicle at 20 to 30 km h 12 to 19 mph Check that the fault code num ber is not displayed The fault code can also be de leted by activating the diagnos tic mode and selecting diagnostic code number 63 Fault code No 42 Item A Rear wheel sensor no normal signals are received from the rear wheel sensor B Gear position switch open or short circuit is detected C C...

Page 466: ...the coupler securely or re place the wire harness Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever re leased OFF Correct indication Go to item B 9 and delete the fault code Incorrect indication Go to item B 3 B 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check t...

Page 467: ...o to item B 9 and delete the fault code Incorrect indication Go to item B 6 B 6 Defective gear position switch Check the gear position switch Replace if defective Refer to CHECKING THE GEAR POSITION SWITCH on page 8 140 Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever re leased OFF Correct indication Go to item B 9...

Page 468: ...when the clutch lever is squeezed with the transmission in gear and when the sidestand is extended Procedure Operate the transmission clutch lever and sidestand Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion C 1 Locate the malfunction Execute the diagnostic mode Code No 07 Rotate the rear wheel by hand and check that the indicated val ue increases...

Page 469: ...n the sidestand is retracted OFF When the clutch lever is squeezed with the transmission in gear and when the sidestand is retracted ON Correct indication Go to item C 9 and delete the fault code Incorrect indication Go to item C 4 C 4 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the...

Page 470: ...IT DIODE on page 8 133 Execute the diagnostic mode Code No 21 When the clutch lever is re leased with the transmission in gear and when the sidestand is retracted OFF When the clutch lever is squeezed with the transmission in gear and when the sidestand is retracted ON Correct indication Go to item C 9 and delete the fault code Incorrect indication Go to item C 7 C 7 Defective clutch switch Check ...

Page 471: ... and then compare the actually measured battery voltage with the meter display value If the actually measured battery voltage is low recharge the battery 50 Actuation Actuates the relay unit five times at one second intervals The CHECK indicator and on the Yamaha diagnostic tool screen come on each time the relay is actuated When the relay is on the CHECK indicator and on the Yamaha diagnostic too...

Page 472: ...inal red red Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Defective relay unit Execute the diagnostic mode Code No 50 No operating sound Replace the relay unit Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault...

Page 473: ...d Fault code number is displayed Repeat item 1 If the same number is indicated go to item 5 3 02 is indicated in diagnostic mode code No 60 EEP ROM data error for adjustment of CO concentration of cylinder 2 Change the CO concentration of cylinder 2 and rewrite in EE PROM Refer to ADJUSTING THE EX HAUST GAS VOLUME on page 5 2 After this adjustment is made turn the main switch to OFF Turn the main ...

Page 474: ...l 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 display Fail safe system Able Unable to start engine Able Unable to drive vehicle Diagnostic code No Meter display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Malfunction in ECU Replace the ECU R...

Page 475: ...t Replace the wire harness Between meter assembly cou pler and joint coupler blue black blue black blue red blue red Between joint coupler and ECU coupler blue black blue black blue red blue red Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Defective meter assembly Replace the meter assembly Turn the main switch to ...

Page 476: ...ch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between meter assembly cou pler and joint coupler blue black blue black blue red blue red Between joint coupler and ECU coupler blue black blue black blue red blue red Turn the main switch to ON Fault code number is no...

Page 477: ...FUEL INJECTION SYSTEM 8 72 ...

Page 478: ...R W Y Y L R L R L R L W L W L W L W L R R R R R R R Lg R W G B R G Y L B G B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb L G B B B B B Gy B Gy B L L B L P W L B B W L B R W Gy G B L P B B L W B L B B B L Br W B B L G W L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B...

Page 479: ...tch 7 Ignition fuse 10 Fuel injection system fuse 15 Battery 16 Engine ground 18 Main fuse 22 Relay unit 24 Fuel pump relay 25 Joint coupler 37 ECU engine control unit 47 Fuel pump 64 Handlebar switch right 67 Start engine stop switch ...

Page 480: ...the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 128 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 start engine stop switch Refer to CHECKING THE SWITCHES on page 8 123 The start engine stop switch is faulty Replace the right handlebar switch 5 Che...

Page 481: ... 8 76 NG OK 7 Check the entire fuel pump system wiring Refer to CIRCUIT DIAGRAM on page 8 73 Properly connect or replace the wiring har ness Replace the ECU Refer to REPLAC ING THE ECU engine control unit on page 8 128 ...

Page 482: ...W R W Y Y L R L R L R L W L W L W L W L R R R R R R R Lg R W G B R G Y L B G B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb L G B B B B B Gy B Gy B L L B L P W L B B W L B R W Gy G B L P B B L W B L B B B L Br W B B L G W L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R...

Page 483: ...gnition fuse 10 Fuel injection system fuse 11 Backup fuse 15 Battery 16 Engine ground 17 Immobilizer unit 18 Main fuse 25 Joint coupler 37 ECU engine control unit 49 Meter assembly 50 Immobilizer system indicator light 54 Multi function meter ...

Page 484: ...ering key is lost regis tering 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 immobilizer system must be replaced Therefore it is highly rec ommended to use either standard key for driving and to keep the code re registering key in a sa...

Page 485: ... Standby mode To enable the immobilizer system turn the ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours After that time the indicator light will stop flashing but the immobilizer system is still enabled Parts to be replaced Key registration re quirement Main switch immobi lizer unit Standard key ECU A...

Page 486: ...ch then turn 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 activated When the key registration mode is activated the immobilizer system indicator light flashes rapidly 4 While the indicator light is flashing turn the main switch to OFF remove the key and within 5 sec onds insert th...

Page 487: ... 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 488: ...128 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 wiring Refer to CIRCUIT DIAGRAM on page 8 77 Properly connect or replace the wiring har ness Check the condition each of the im mobilizer system circuits Refer to SELF DIAGNOSIS FAULT COD...

Page 489: ...witch immobiliz er unit 3 Replace the ECU Refer to REPLAC ING THE ECU en gine control unit on page 8 128 54 IMMOBILIZER UNIT Codes transmitted be tween the ECU and the immobilizer unit do not match Noise interference or dis connected lead cable 1 Interference due to ra dio wave noise 2 Disconnected commu nication harness 3 Immobilizer unit mal function 4 ECU failure The ECU or immobiliz er unit wa...

Page 490: ...IMMOBILIZER SYSTEM 8 85 a Light on b Light off ...

Page 491: ...IMMOBILIZER SYSTEM 8 86 ...

Page 492: ...W R W R W R W Y Y L R L R L R L W L W L W L W L R R R R R R R Lg R W G B R G Y L B G B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb L G B B B B B Gy B Gy B L L B L P W L B B W L B R W Gy G B L P B B L W B L B B B L Br W B B L G W L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W...

Page 493: ...Main fuse 21 Rear brake light switch 25 Joint coupler 37 ECU engine control unit 42 Front wheel sensor 43 Rear wheel sensor 44 ABS ECU electronic control unit 45 Yamaha diagnostic tool coupler 49 Meter assembly 54 Multi function meter 61 ABS warning light 64 Handlebar switch right 65 Front brake light switch 83 Tail brake light assembly 84 Tail brake light A Wire harness B Positive battery sub wir...

Page 494: ...KE SYSTEM 8 89 EAS30990 ABS COUPLER LOCATION CHART W B Gy W Gy W B W L R L B R W B B R W R L W B B W G G R W Y Y G G Br W L R L B B L B B G G R G W L R L B Sb W Y Dg Ch G R Gy O W R Y W P W R W R G G B B W Gy 2 5 3 1 4 ...

Page 495: ...ABS ANTI LOCK BRAKE SYSTEM 8 90 1 ABS ECU coupler 2 Rear wheel sensor coupler 3 Yamaha diagnostic tool coupler 4 Meter assembly coupler 5 Front wheel sensor coupler ...

Page 496: ...ha diagnostic tool For information about using the Yamaha diagnostic tool refer to B 2 DIAG NOSIS USING THE FAULT CODES on page 8 95 For troubleshooting items other than the following items follow the normal service method WARNING EWA16710 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 T...

Page 497: ...bjecting 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 ser vice is finished This is because the past fault codes will be displayed again if another malfunction occurs EA...

Page 498: ...inal checks Were all of the final checks completed normally Finished Yes No A Turn the main switch to ON and check the ABS warning light Fails to come on Comes on The ABS control unit fuse is blown The ABS ECU coupler is disconnected The wire harness is defective The hydraulic unit assembly is defective The connection with the Yamaha diagnostic tool is defective The wire harness is defective Canno...

Page 499: ...he meter assembly If the ABS warning light comes on the ABS ECU is defective Replace the hydraulic unit assembly EAS30997 A 2 ALL INDICATOR LIGHTS FAIL TO COME ON 1 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES on page 8 123 If there is no continuity replace the main switch immobilizer unit 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGIN...

Page 500: ...CANH Check for continuity between blue black terminal of the ABS ECU coupler and blue black terminal of the Yamaha diagnostic tool coupler CANL 4 ABS ECU malfunction Replace the hydraulic unit assembly EAS31136 A 5 ABS ECU AND FI ECU FAIL TO COMMUNICATE Cannot connect due to a tool error 1 Yamaha diagnostic tool Check that the Yamaha diagnostic tool is properly connected 2 Wire harness Open circui...

Page 501: ...n ing the main switch off Operation of the Yamaha diagnostic tool Fault diagnosis mode Malfunction results are displayed in the top part of the window area 1 Recovered The item list of the malfunction detected in the past already recovered are displayed 2 Detected The item list of the malfunction currently occurred are displayed 3 Code The following icons and the fault code numbers for the detecte...

Page 502: ...s or no pulses Front wheel sensor signal is not received properly Puls es are not received or are re ceived intermittently while the vehicle is traveling Foreign material adhered around the front wheel sen sor Incorrect installation of the front wheel Defective sensor rotor or incorrect installation of the rotor Defective front wheel sen sor or incorrect installation of the sensor 12 Rear wheel se...

Page 503: ...cuit is de tected in the front wheel sen sor Defective coupler between the front wheel sensor and the hydraulic unit assembly Open or short circuit in the wire harness between the front wheel sensor and the hydraulic unit assembly Defective front wheel sen sor or hydraulic unit as sembly 16 Rear wheel sensor open or short circuit Open or short circuit is de tected in the rear wheel sen sor Defecti...

Page 504: ...r brake light switch and the hydraulic unit as sembly Defective hydraulic unit as sembly 31 Hydraulic unit assembly ab normal ABS solenoid power supply Power is not supplied to the solenoid circuit in the hy draulic unit assembly Blown ABS solenoid fuse Defective coupler between the battery and the hydrau lic unit assembly Open or short circuit in the wire harness between the battery and the hydra...

Page 505: ...ulses Front wheel sensor signal is not received properly Miss ing pulses are detected in the signal while the vehicle is traveling Foreign material adhered around the front wheel sen sor Incorrect installation of the front wheel Defective sensor rotor or incorrect installation of the rotor Defective front wheel sen sor or incorrect installation of the sensor 44 Rear wheel sensor missing pulses Rea...

Page 506: ...Open or short circuit in the wire harness between the battery and the hydraulic unit assembly Defective charging system Defective hydraulic unit as sembly 55 Hydraulic unit assembly de fective ABS ECU Abnormal data is detected in the hydraulic unit assembly Defective hydraulic unit as sembly 56 Hydraulic unit assembly ab normal internal power sup ply Abnormality is detected in the power supply cir...

Page 507: ...ensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Repair or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 21 Fault code No 12 Item Rear wheel sensor intermittent pulses or no pulses Symptom Rear wheel sensor signal is not received properly Pulses are not re ceiv...

Page 508: ...r damage Re place the sensor rotor if there is visible damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 21 4 Defective front wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Repair or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on...

Page 509: ...nd the hydraulic unit assembly 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 cou pler securely See TIP 2 Open or short circuit in the wire harness between the front wheel sensor and the hydraulic unit assembly Check for continuity between the white terminal 1 and the white terminal 4 and between ...

Page 510: ... hydraulic unit assembly 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 cou pler securely See TIP 2 Open or short circuit in the wire harness between the rear wheel sensor and the hydraulic unit assembly Check for continuity between the white terminal 1 and the white terminal 4 and between the bla...

Page 511: ...tom Open or short circuit is detected in the rear wheel sensor Order Item components and probable cause Check or maintenance job Fault code No 17 45 Item Front wheel sensor missing pulses Symptom Front wheel sensor signal is not received properly Missing pulses are detected in the signal while the vehicle is traveling Order Item components and probable cause Check or maintenance job 1 Foreign mate...

Page 512: ...nd the installed condition of the sensor Repair or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 31 Fault code No 21 Item Hydraulic unit assembly defective solenoid drive circuit Symptom Solenoid drive circuit in the hydraulic unit assembly is open or short circuited Order Item components and probable cause Check or maintenance job 1...

Page 513: ...or rear brake light switch circuit Order Item components and probable cause Check or maintenance job Fault code No 31 Item Hydraulic unit assembly abnormal ABS solenoid power supply Symptom Power is not supplied to the solenoid circuit in the hydraulic unit as sembly Order Item components and probable cause Check or maintenance job 1 Blown ABS solenoid fuse Check the ABS solenoid fuse If the ABS s...

Page 514: ...er to CHECKING THE FUSES on page 8 127 2 Defective coupler between the battery and the hydraulic unit assembly 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 cou pler securely See TIP 3 Open or short circuit in the wire harness between the battery and the hydraulic unit assembly Replace if there i...

Page 515: ...nsmit ted to the brake caliper when the brake lever is operated and that the pressure decreases when the lever is re leased Refer to CHECKING THE FRONT BRAKE DISCS on page 4 41 4 Defective hydraulic unit assembly If the above items were performed and no malfunctions were found replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 62 Fault code No 42 47 Item Rear wheel A...

Page 516: ...lt code No 43 Item Front wheel sensor missing pulses Symptom Front wheel sensor signal is not received properly Missing pulses are detected in the signal while the vehicle is traveling Order Item components and probable cause Check or maintenance job 1 Foreign material adhered around the front wheel sensor Check the surface of the sensor rotor and wheel sensor for foreign material such as metal pa...

Page 517: ...visible damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 31 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Repair or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 31 Fault code No 51 52 Item Vehicle system...

Page 518: ...ARGING SYSTEM on page 8 13 Fault code No 54 Item Hydraulic unit assembly defective ABS solenoid and ABS motor power supply circuits Symptom Abnormality is detected in the solenoid or motor power supply circuit in the hydraulic unit assembly Order Item components and probable cause Check or maintenance job 1 Defective battery Recharge or replace the battery Refer to CHECKING AND CHARGING THE BATTER...

Page 519: ... job 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 62 Fault code No 63 Item Front wheel sensor power supply voltage of power supply is low Symptom Power voltage supplied from the ABS ECU to the front wheel sensor is too low Order Item components and probable cause Check or maintenance job 1 Short circuit in the wire harness be...

Page 520: ... probable cause Check or maintenance job B W Gy W R W R L W B B W G G R W Y Y G G Br W L R L B B L B B G 1 2 3 4 Fault code No 64 Item Rear wheel sensor power supply voltage of power supply is low Symptom Power voltage supplied from the ABS ECU to the rear wheel sensor is too low Order Item components and probable cause Check or maintenance job 1 Short circuit in the wire harness between the rear ...

Page 521: ...start again from the beginning 2 Defective rear wheel sensor Check that there is no short circuit between the gray terminal 1 and the white terminal 2 If there is a short circuit the wheel sensor is defective Repair or replace the wheel sensor 3 ABS ECU 4 Rear wheel sensor 3 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 62 Yamah...

Page 522: ... 66 If it does not have reaction force properly the brake hose is not properly routed or connected 4 Delete the fault codes Refer to B 3 DELETING THE FAULT CODES on page 8 116 5 Checking the ABS warning light Refer to CHECKING THE ABS WARNING LIGHT on page 4 69 If the ABS warning light does not turn off the possible causes are following The problem is not solved Open circuit between the ABS ECU an...

Page 523: ...ABS ANTI LOCK BRAKE SYSTEM 8 118 ...

Page 524: ...ELECTRICAL COMPONENTS 8 119 EAS20089 ELECTRICAL COMPONENTS 1 2 3 4 5 5 6 7 8 9 11 12 13 14 10 15 16 17 18 ...

Page 525: ...ch switch 4 Rectifier regulator 5 Ignition coil 6 Battery 7 Fuse box 1 8 Fuse box 2 9 Main fuse 10 Starter relay 11 Rear brake light switch 12 Sidestand switch 13 O2 sensor 14 Gear position switch 15 Oil pressure switch 16 Horn 17 Radiator fan motor 18 ECU engine control unit ...

Page 526: ...ELECTRICAL COMPONENTS 8 121 1 3 4 5 6 8 9 13 14 15 16 7 2 12 10 10 11 ...

Page 527: ...enoid 4 Intake air pressure sensor 5 Fuel pump 6 Lean angle sensor 7 Rear wheel sensor 8 Coolant temperature sensor 9 Crankshaft position sensor 10 Fuel injector 11 Throttle position sensor 12 Front wheel sensor 13 Radiator fan motor relay 14 Headlight relay 15 Relay unit 16 Turn signal hazard relay ...

Page 528: ...549 CHECKING THE SWITCHES Dg Br W L B B Y B R Ch G B W Y Br R W L W B B L B L Br W R B Dg Ch Br Y B B 11 10 9 8 7 6 5 4 3 2 1 Y L B G L B Y Br W Ch Dg Br B W B R B Y Br R ON OFF P R W Br L Br R B L W R B R W Ch Dg Br W R W Br L B L B L ...

Page 529: ...TS 8 124 1 Start engine stop switch 2 Hazard switch 3 Front brake light switch 4 Rear brake light switch 5 Sidestand switch 6 Main switch 7 Clutch switch 8 Horn switch 9 Turn signal switch 10 Pass switch 11 Dimmer switch ...

Page 530: ... 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 pos...

Page 531: ...owing procedure applies to all of the bulbs 1 Remove Bulb WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down NOTICE ECA14380 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of the head...

Page 532: ...ester to the fuse and check the continuity TIP Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit WARNING EWA13310 Never ...

Page 533: ...F BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion NOTICE ECA13661 This is a VRLA Valve Regulated Lead Acid battery Never remove the sealing caps be cause the balance between cells will not...

Page 534: ... cle disconnect the negative battery lead from the battery terminal To reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal and ...

Page 535: ...a lapse of 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging current g Measure the battery open circuit voltage after leaving the battery unused for more than 30 minutes Charging method using a constant volt age charger a Measure the open circuit voltage prior to charging TIP Voltage should be measured 30 minutes after the engine is stopped b Conne...

Page 536: ...relay from the wire harness 2 Connect the pocket tester Ω 1 and battery 12 V to the relay terminal as shown Check the relay operation Out of specification Replace Starter relay Relay unit starting circuit cut off relay Relay unit fuel pump relay Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog pocket tester YU 03112 C 2 1 1 Positive battery terminal 2 Negative battery termi...

Page 537: ...of specification Replace a Connect the pocket tester DC 20 V to the turn signal hazard relay terminal as shown 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 tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative ba...

Page 538: ...ester 90890 03112 Analog pocket tester YU 03112 C Continuity Positive tester probe Sky blue 1 Negative tester probe Black yellow 2 No continuity Positive tester probe Black yellow 2 Negative tester probe Sky blue 1 Continuity Positive tester probe Sky blue 1 Negative tester probe Blue red 3 No continuity Positive tester probe Blue red 3 Negative tester probe Sky blue 1 Continuity Positive tester p...

Page 539: ...SPARK GAP 1 Check Ignition spark gap Out of specification Perform the ignition system troubleshooting starting with step 5 Refer to TROUBLESHOOTING on page 8 4 TIP If the ignition spark gap is within specification the ignition system circuit is operating normally a Remove the ignition coil from the spark plug b Connect the ignition checker 1 as shown Primary coil resistance 1 19 1 61 Ω Pocket test...

Page 540: ...ENSOR 1 Remove Lean angle sensor from the battery box 2 Check Lean angle sensor output voltage Out of specification Replace a Connect the test harness lean angle sensor 6P 1 to the lean angle sensor and wire harness as shown b Connect the pocket tester DC 20 V to the test harness lean angle sensor 6P 2 Ignition coil Crankshaft position sensor resis tance 228 342 Ω Pocket tester 90890 03112 Analog ...

Page 541: ...duce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAS30566 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the stator coil a Connect the digital circuit tester to the stator coil coupler as shown b Measure the stator coil resistance EAS30680 CHE...

Page 542: ...l is equipped with a self diagnosis de vice for the fuel level detection circuit 1 Check Fuel meter fuel level warning light 1 Turn the main switch to ON Warning light comes on for a few seconds then goes off Warning light is OK Warning light does not come on Replace the meter assembly Warning light flashes eight times then goes off for 3 seconds in a repeated cycle mal function detected in fuel s...

Page 543: ...pped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 1 k to the coolant temperature sensor as shown b Immerse the coolant temperature sensor 1 in a container filled with coolant 2 TIP Make sure the coolant temperature 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 ...

Page 544: ...0593 CHECKING THE INTAKE AIR PRESSURE SENSOR 1 Check Intake air pressure sensor output voltage Out of specification Replace a Connect the test harness S pressure sensor 3P 1 to the intake air pressure sensor and wire harness as shown NOTICE ECA20920 Pay attention to the installing direction of the test harness S pressure sensor 3P cou pler b Connect the digital circuit tester DCV to the test harne...

Page 545: ...t it cool down to the specified temperature e Measure the intake air temperature sensor resistance 3 Install Intake air temperature sensor EAS31087 CHECKING THE INTAKE SOLENOID 1 Check Intake solenoid resistance Out of specification Replace a Disconnect the intake solenoid coupler from the intake solenoid b Connect the pocket tester Ω 10 to the in take solenoid terminal as shown c Measure the inta...

Page 546: ...egative tester probe Switch terminal a 1st position Continuity Positive tester probe Pink 2 Negative tester probe Switch terminal b 2nd position Continuity Positive tester probe White 3 Negative tester probe Switch terminal c 3rd position Continuity Positive tester probe Gray 4 Negative tester probe Switch terminal d 4th position Continuity Positive tester probe Orange 5 Negative tester probe Swit...

Page 547: ... 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 SELF DIAGNOSTIC FUNCTION TABLE 9 5 COMMUNICATION ERROR WITH THE METER 9 6 DIAGNOSTIC CODE SENSOR OPERATION TABLE 9 6 DIAGNOSTIC CODE ACTUA...

Page 548: ...mp Faulty fuel pump Faulty relay unit fuel pump relay 3 Throttle body ies 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 spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 4 Ignit...

Page 549: ...n a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS30605 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS308...

Page 550: ... brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS30610 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 assembly bolt Damaged damper rod assembly bolt copper...

Page 551: ...ife expired Tail brake light does not come on Faulty brake light switch Too many electrical accessories Incorrect connection Faulty tail brake light assembly Turn signal does not come on Faulty turn signal switch Faulty turn signal hazard relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse T...

Page 552: ...linder 2 ig nition coil 37 Component other than ISC idle speed control unit is defective ISC operating sound is heard Defective ISC idle speed control unit ISC operating sound is not heard 39 Injector open or short circuit detected 41 Lean angle sensor open or short circuit detected 42 Rear wheel sensor no normal signals are received from the rear wheel sensor Gear position switch open or short ci...

Page 553: ...ue changes the performance is OK 05 Air temperature Displays the air temperature Compare the actually mea sured air temperature with the meter display value 06 Coolant temperature When engine is cold Dis plays temperature closer to air temperature When engine is hot Displays current coolant temperature Compare the actually mea sured coolant temperature with the meter display value 07 Rear wheel ve...

Page 554: ... display No history 00 No malfunctions detected If the self diagnosis fault code 44 is indicated the ECU is defective History exists 01 02 Cylinder fault code If more than one cylinder is defective the display al ternates every two seconds to show all the detected cylinder numbers When all cylinder numbers are shown the display re peats the same process 11 Data error for ISC idle speed control lea...

Page 555: ...own the display repeats the same process Save the malfunction history to the computer and then delete the fault codes 67 ISC idle speed control learning condition display ISC idle speed control learning data erasure 00 ISC idle speed control learning data has been erased 01 It is not necessary to erase the ISC idle speed control learning data 02 It is necessary to erase the ISC idle speed control ...

Page 556: ...the operating sound 49 Intake solenoid Actuates fuel intake sole noid five times at one sec ond intervals The CHECK indicator and on the Yamaha diag nostic tool screen come on each time the intake sole noid is actuated Check fuel operating sound of the intake solenoid five time 50 Relay unit Actuates the relay unit five times at one second inter vals The CHECK indicator and on the Yamaha diag nost...

Page 557: ...s actuat ed Check that the headlight re lay is actuated five times by listening for the operating sound 54 ISC valve Fully closes the ISC valve and then opens the valve This operation is performed 3 times and takes approxi mately 6 seconds each time The CHECK indicator and on the Yamaha diag nostic tool screen come on during the operation The ISC unit vibrates when the ISC valve operates Diagnosti...

Page 558: ...maintenance jobs for fault code number 22 203 Lean angle sensor Brief abnormality de tected in lean angle sensor Same as for fault code number 41 Perform the checks and maintenance jobs for fault code number 41 240 O2 sensor Correction value re mains at upper limit Correction value re mains at upper limit during O2 feedback Open or short circuit in the wire harness between the sensor and the ECU G...

Page 559: ...clutch cable Defective fuel injec tion system Dirty or worn spark plug Defective battery Defective ECU If a fault code is indi cated perform the checks and mainte nance jobs for the fault code first Event code number 243 may be indicated even if the system is normal 244 Difficult unable to start engine Engine starting diffi cult unable condition detected Empty fuel tank Defective fuel injec tion s...

Page 560: ...nal indicator light right 61 ABS warning light 62 Horn 63 Gear position switch 64 Handlebar switch right 65 Front brake light switch 66 Hazard switch 67 Start engine stop switch 68 Turn signal hazard relay 69 Handlebar switch left 70 Clutch switch 71 Dimmer switch 72 Pass switch 73 Turn signal switch 74 Horn switch 75 Rear turn signal light right 76 Front turn signal light right 77 Rear turn signa...

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Page 563: ... L B L B L B L B L B L B L R W R W R W R W Y Y L R L R L R L W L W L W L W L R R R R R R R Lg R W G B R G Y L R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb L G B B B B B Gy B Gy B L L B L P W L B B W L B R W Gy G B L P B B L W B L B B B L Br W B B L G W L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G...

Page 564: ...A A B A B B B B Gy B B B B Gy B B O O B B B B B Gy Gy Gy Gy B B B B B B B B B B B Gy Gy B B B B B B B L B B B B B B 1 2 3 6 5 4 7 8 9 17 13 14 15 16 18 19 20 21 22 23 24 25 25 26 25 25 27 40 41 28 29 38 39 30 31 32 32 33 34 35 36 45 25 25 25 25 46 47 48 49 50 51 52 52 53 54 55 56 57 58 59 60 63 62 64 65 66 67 70 72 73 74 75 76 77 78 79 80 81 82 68 83 84 85 87 88 86 37 69 71 10 11 12 43 44 42 61 ...

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